CAT Mining Trucks 793D

Caterpillar Brake System

Integrated Braking System

The Cat oil-cooled braking system delivers reliable performance and control in the most extreme haul road conditions. The integrated system combines the service, secondary, parking brake and retarding functions in the same robust system for optimum braking efficiency.

Cat Data Link

All control modules communicate via the Cat Data Link and work together as an integrated system to maximize production efficiency and extend component life.

Oil-Cooled Multiple Disc Brakes

Caterpillar four-wheel, forced oil-cooled, multiple disc service brakes are continuously cooled by water-to-oil heat exchangers for exceptional, non-fade braking and retarding performance.

Extended Life Disc Brakes

Extended life friction material has double the wear life of standard brakes and is twice as resistant to glazing for more consistent braking power with less noise.

Brake Design

Cat oil-cooled disc brakes are designed with large discs and plates for reliable, adjustment-free operation and performance. Brakes are completely enclosed and sealed to prevent contamination and reduce maintenance.

Long Life

An oil film prevents direct contact between the discs. This design absorbs the braking forces by shearing the oil molecules and carrying heat away to extend brake life.

Pistons

The Caterpillar two-piece piston design combines the service, secondary, parking brake and retarding functions in the same system. The primary piston hydraulically actuates both service and retarding functions. The secondary piston is spring-applied and held in the disengaged position by hydraulic pressure. If hydraulic system pressure drops below a specified level, the spring-applied secondary piston automatically applies the brakes.

Parking Brake

Oil-cooled, spring-applied, hydraulically released parking brake is applied to all four wheels for superior parking capability on all grades up to 15 percent.

Hydraulic Automatic Retarder Control (HARC)

Hydraulically activated automatic retarder control system electronically controls retarding on grade to maintain optimum engine rpm and oil cooling. Additional braking may be applied using the manual retarder or the brake pedal. HARC is deactivated when the operator applies the brake or accelerator controls.

HARC Production Advantages

Faster Speeds

HARC allows the operator to maintain optimum engine speeds for faster downhill hauls and greater productivity.

Superior Control

Automatic brake modulation offers a smoother ride and better control in slippery conditions, allowing the operator to concentrate on driving.

Ease of Operation

HARC increases operating ease, resulting in greater operator confidence with less fatigue.

Engine Overspeed Protection

Automatically activates HARC when engine speed exceeds factory preset levels, regardless of operator inputs, to avoid potentially damaging engine overspeeds.

Four Corner Retarding

Four corner retarding with 60/40 percent split (rear/front) in braking effort provides superior control in slippery conditions. Balanced front to rear brake torque provides exceptional braking performance and minimizes wheel lock-up, especially during retarding.

Traction Control System (TCS)

Electronically monitors and controls rear wheel slippage for greater traction and enhanced truck performance in poor underfoot conditions. If slippage exceeds a set limit, the oil-cooled disc brakes engage to slow the spinning wheel. Torque is then automatically transferred to the wheel with better traction.

Differential Action

Normal differential action provides superior maneuvering and control in slippery conditions.

Integrated Braking Control (IBC)

Combines Hydraulic Automatic Retarder Control (HARC) and Traction Control System (TCS) into one integrated brake control system for optimum efficiency, performance and reliability.

Fuel Efficiency

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.

Truck Body Systems

Cat Truck Bodies

Caterpillar offers three specific body styles and custom body options to help customers obtain the lowest cost-per-ton hauling solution.

• Dual-Slope
• Flat Floor
• Mine Specific Design (MSD II)

Body Selection

Selection of the right body depends on material and haul road conditions. The better the match of body to application, the greater the efficiency. Your Cat dealer can help you select the right body system for your site specific applications.

Body/Chassis Integration

Caterpillar truck bodies are designed and matched with the integrated chassis system for optimum structural reliability, durability and long life.

Electronic Hoist Control

Provides the operator with better control of the load when dumping, including over-center load control and modulated control throughout the operating range. The automatic body snubbing feature reduces impact on the frame, hoist cylinders and operator.

Fast Hoist Cycle Times

Two-stage hoist cylinders provide fast dump cycle times of 20.25 seconds for raise and 17.5 seconds for lower.

Body Liners

A variety of liner options are available to save weight and extend the body system's life. Wear surfaces and liners are equipped to handle tough impact loads while resisting abrasion. Wear plates deliver long life in high wear areas. Modular liner plate packages:

• Smooth plate
• Rock box
• Zipper grid
• Mechanically Attached Wear Plate System (MAWPS)

Custom Body Options

Tail extensions, sideboards, tumblebars, rock boxes and rock shedders are available to maintain rated payload, reduce spillage, and improve hauling efficiencies.

• Sideboards are designed to maximize or attain gross machine weight.
• 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 vehicle components such as brakes, tires and drivetrain, reducing component life and increasing maintenance costs and repairs.

Body Design

Cat truck bodies are designed for optimal strength, capacity and durability. Wear surfaces are equipped to handle even the toughest impact and abrasion over the long haul without diminishing capacity.

• Five-Sided Beams tie in the sidewall and floor junctions add increased body rigidity and strength.
• Wide Ribs in body floor provide increased durability and impact support.
• Full-Length Stringers create strength and rigidity throughout the bed.
• Box Section Beams offer increased durability in the floor, sidewall, top rail, corner, and cab canopy areas.

1) Dual-Slope Body

The dual-slope body design with V-shaped floor provides excellent load retention, maintains a low center of gravity, reduces shock loading, and maintains optimum load distribution on steep inclines and in challenging haul road conditions.

• Reinforced, rolled steel top rail increases body strength and protects the body from damage caused by the loading tool or falling material
• 8 degree "V" reduces shock loading and centers the load.
• 7.5 degree forward body slope and 16 degree ducktail slope helps retain loads on steep grades.

2) Flat Floor Body

The flat floor design with slight incline delivers excellent payload capacity, high dump clearances and smooth, controlled dumping.

• Flat floor design provides consistent wear characteristics on body tail.
• 12 degree forward body slope provides good load retention on better maintained haul roads.
• 400 Brinell steel on surfaces provides excellent wear.

3) Mine Specific Design (MSD II) Body

The lightweight MSD II body is based on the flat floor design and is customized to maximize payload potential and minimize cost-per-ton. Each MSD II body design begins with a detailed mine site profile to develop a body suitable for a mine's individual needs.

Structures

Box-Section Design

The 793D frame uses a box-section design, incorporating two forgings and 24 castings in high stress areas with deep penetrating and continuous wrap-around welds to resist damage from twisting loads without adding extra weight.

Integral Four-Post ROPS Cab

Resiliently mounted to the main frame to reduce vibration and sound, the integral ROPS is designed as an extension of the truck frame. The ROPS/FOPS structure provides "five sided protection" for the operator.

Suspension System

Designed to dissipate haul road and loading impacts for longer frame life and a more comfortable ride.

Serviceability

Servicing Ease

Easy access to daily service points simplifies servicing and reduces time spent on regular maintenance procedures. Enhanced serviceability and 500-hour service intervals are designed to increase machine availability and productivity.

Maintenance Platform

Provides access to engine, air filters, steering hydraulic tank and battery compartment.

In-Frame Access

Permits easy access to major components for easy servicing and removal.

Ground-Level Access

Allows convenient servicing to tanks, filters, drains, and engine shutdown. Ground-level VIMS data port permits easier downloading of information.

Autolube

Automatic lubrication system reduces maintenance time by automatically lubricating necessary components on a regular basis.

Fast Fill Service Center

Optional Wiggins fast fill service center features high speed fuel and oil exchange.

Oil Renewal System (ORS)

Optional on-board engine oil management system is designed to increase availability and productivity by extending oil change intervals and reduce oil disposal labor and costs. ORS meters and injects used engine oil from the crankcase into the engine's fuel return line. New oil is manually added as a part of daily maintenance.

Scheduled Oil Sampling

S•O•SSM sampling valves speed sampling and analysis reliability.

Pressure Test Points

Disconnect valves are conveniently located throughout the hydraulic systems for easy pressure testing.

Air Filters

Radial seal air filters are easy to change, reducing time required for air filter maintenance.

Sealed Electrical Connectors

Electrical connectors are sealed to lock out dust and moisture. Harnesses are braided for protection. Wires are color coded for easy diagnosis and repair.

Cylinder Heads

Individual cylinder heads are interchangeable for easy removal and visual inspection of internal parts.

On-Board Diagnostic Systems

The VIMS system continuously checks all critical machine functions and components, and helps locate faults quickly for faster repair. Electronic control system enables quick diagnosis of engine conditions and effective maintenance and repairs utilizing the Electronic Technician (Cat ET) service tool.

Mirrors

The left side mirror mounting bracket is more robust and allows mirror glass to be easily replaced, without the need for a new mirror assembly. New mirror glass slides in and out of the carrier, reducing downtime and maintenance costs.

Safety

Product Safety

Caterpillar has been and continues to be proactive in developing mining machines that meet or exceed safety standards. Safety is an integral part of all machine and systems designs.

SAE and ISO Standards

The 793D is designed to many national and international standards.

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.

Ladder/Secondary Egress

A wide, stationary stairway allows easy access to and from the machine. The ladder on the left side of the machine permits secondary access or emergency egress.

Brake Systems

Four corner oil-cooled braking system provides excellent control in slippery conditions. The service brakes and retarding system are actuated by modulated hydraulic pressure, while secondary and parking brake functions are spring applied and hydraulic released. This system assures braking in the event of complete hydraulic failure.

Steering System

A twin double-acting cylinder steering system is designed to deliver precise control under all loading and underfoot conditions. The steering hydraulic system is separate from the main hydraulic system to prevent cross-contamination and overheating from other sources.

Engine Shutoff Switch

A secondary engine shutoff switch is located at ground level.

Electrical System Disconnect

A battery disconnect switch, located directly above the front bumper provides ground level lockout of the electrical system.

Overload Policy

Safety is integral to maintaining the highest productivity in mining machine operation. The Caterpillar 10/10/20 Overload Policy assures that steering and braking systems have sufficient capacity to perform, even at 20% overload.

Standard Safety Features

• Slip resistant surfaces
• 75 mm (3 in) wide orange three-point operator restraint
• Wide-angle mirrors
• Body raised indicator
• Body retaining cable
• Guard rails
• Reverse neutralizer when dumping
• Low interior sound level

Power Train - Transmission

Mechanical Power Train

The Cat mechanical drive power train and power shift transmission provides unmatched operating efficiency and control on steep grades, in poor underfoot conditions, and on haul roads with high rolling resistance.

1) Transmission

The Cat six-speed planetary power shift transmission is matched with the direct-injection 3516B HD diesel engine to deliver constant power over a wide range of operating speeds.

• Robust Design
  Designed for the higher horsepower of the 3516B HD engine, the proven planetary power shift transmission is built tough for long life between overhauls.
• Long Life
  A dedicated oil tank and circuit provides cooler, cleaner oil for maximum performance and longer component life
• Transmission Chassis Control (TCC)
  TCC uses electronically transferred engine rpm data to execute shifts at preset points for optimum performance, efficiency and clutch life.

2) Lock-Up Torque Converter

Combines maximum rimpull and cushioned shifting of torque converter drive with the efficiency and performance of direct drive. The lock-up torque converter engages at approximately 8 km/h (5 mph), delivering more power to the wheels.

• Lock-Up Clutch
  Quickly releases and re-engages to reduce power train torque loads for smoother shifting, long life and a more comfortable ride.
• Smooth Shifting
  Individual clutch modulation provides smooth clutch engagements to optimize performance and extend clutch life.

3) Final Drives

Cat final drives work as a system with the planetary power shift transmission to deliver maximum power to the ground. Built to withstand the forces of high torque and impact loads, double reduction final drives provide high torque multiplication to further reduce drive train stress.

• Rear Axle Filtration
  A new filtration system provides cooler, cleaner oil for longer component life.
• Steering System
  Hydraulic steering control system is designed for exceptional smoothness and precise control. A separate circuit prevents cross contamination for long life.
• Supplemental Steering
  Supplemental steering system uses pressure accumulators and allows up to three 90 degree turns in case of engine failure.
• Wheels and Rims
  Cast rear wheels and Cat center-mount rims are mounted using studs and nuts to minimize maintenance and maximize durability.

Power Train - Merchandising Arrangements

Merchandising Arrangements

The 793D is available in four different normal altitude configurations, and a high altitude arrangement. All configurations deliver increased speed on grade and include key components that are performance matched to the hauling application and site conditions.

Standard Arrangement

The standard arrangement is designed for exceptional, all-around performance. Three factors combine to produce up to 9% more power at the wheels than the 793C, including: 5% more engine horsepower; a common rail hydraulic system for greater power train efficiency; and a hydraulically driven demand fan that reduces parasitic load by operating only when needed. More power at the wheels reduces cycle times and lowers cost-per-ton.

Extended Life Wheel Groups

Developed for uphill hauling applications, this arrangement is designed to extend wheel life and hauling performance on long uphill hauls. Extended life wheel groups are built with larger, more durable components, including larger spindles, wider wheel bearing spacing, a larger braking surface, and extended life friction disc material for longer brake life and more time between overhauls.

Extra Top Speed

Developed for long, flat haul applications, the extra top speed configuration delivers a 10% increase in maximum speed to 60 km/h (37 mph) via a new input transfer gear group. This arrangement also includes Extended Life Wheel Groups.

Extra Retarding

Developed for downhill loaded applications, this configuration typically delivers an extra gear of retarding capability of 35% more speed on downhill grades. Extra retarding is achieved by adding more robust wheel groups, larger brakes, extended life friction material, and additional cooling capacity.

High Altitude Arrangement

Developed for high altitude applications, the 3516B short stroke engine delivers enhanced power management at higher altitudes - from 2750 to 1600 m (9,000 to 12,000 ft). This arrangement also includes Extra Retarding.

Power Train - Engine

Engine

The Cat 3516B High Displacement EUI quad turbocharged and aftercooled diesel engine produces 5% greater power with enhanced power management capability for maximum hauling performance in the most demanding mining applications.

Design

The 3516B is a 16-cylinder, four-stroke design that uses long, effective power strokes for more complete fuel combustion and optimum efficiency.

EPA Compliant

The Cat 3516B High Displacement engine is compliant with U.S. Environmental Protection Agency Tier I emissions standards.

Altitude Compensation

Designed for maximum operating efficiencies at altitudes under 2750 m (9,000 ft).

High Altitude Arrangement (HAA)

The optional Cat 3516B quad and series turbocharged aftercooled short stroke engine provides full power with no deration at altitudes greater than 2750 m (9,000 ft).

High Torque Rise

The 23% net torque rise provides unequalled lugging force during acceleration, on steep grades and in rough underfoot conditions. Torque rise effectively matches transmission shift points for maximum efficiency and fast cycle times.

Enhanced Life

High displacement, low rpm rating and conservative horsepower ratings mean more time on the haul roads and less time in the shop.

Single-Piece Piston Design

New single-piece forged steel pistons with integrated forged steel skirt are more robust to withstand high engine heat and pressure and enable enhanced combustion efficiency, improved fuel efficiency and lower emissions. Corrosion resistant, stainless steel top ring reduces ring, groove and liner wear for greater reliability and longer life.

Electronic Unit Injection (EUI)

The electronically controlled unit injection fuel system senses operating conditions and regulates fuel delivery for optimum fuel efficiency. The proven high-pressure fuel system provides improved response times and more efficient fuel burn with lower emissions and less smoke.

Electronic Control Module (ECM)

ECM utilizes advanced engine management software to monitor, control and protect the engine utilizing self-diagnosing electronic sensors. The computerized system senses operating conditions and power requirements and adjusts engine for peak performance and most efficient operation and at all times.

Operator's Station

Ergonomic Layout

The 793D operator station is ergonomically designed for total machine control in a comfortable, productive and safe environment. All controls, levers, switches and gauges are positioned to maximize productivity and minimize operator fatigue.

Quiet Cab

Integral, sound-suppressed ROPS/FOPS cab is resiliently mounted to the mainframe to isolate the operator from sound and vibration for a quiet, secure and comfortable ride.

Viewing Area

Designed for excellent all-around visibility and clear sight lines to the haul road, the large viewing area enables the operator to maneuver with confidence for high productivity.

1) Air Suspension Seat w/ Three-Point Operator Restraint
Ergonomically designed, fully adjustable air suspension seat with adjustable armrests provides optimal driving comfort. A wide, retractable 3-point seat/shoulder belt provides a secure, comfortable restraint.

2) Hoist Lever
Four-position, low-effort electronic hoist control system with fingertip control is mounted next to the operator's seat for ease of operation.

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

4) Monitoring System
The VIMS system features an easy-to-read display and easy-to-use operator input keypad for precise machine status information.

5) Steering Column
Comfort wheel with tilt and telescoping steering provides a comfortable driving position.

6) Transmission Console
Ergonomic gear shift lever with backlit gear indicators optimize efficiency.

7) Parking Brake Reset Valve
Parking brake cannot be released when air system is drained until valve button is reset.

8) Storage Compartment
Located under the trainer seat for a safe, uncluttered working environment.

9) Trainer Seat
Full-size, fully padded trainer seat features a backrest, wide hip and shoulder room, and seat belt for secure travel. Air suspension, optional.

10) Operator Window
Powered operator window and sliding trainer seat window offer simple operation and an unobstructed view.

11) Operator Controls
Easy to reach turn signal, high beam, intermittent windshield wiper and windshield washer controls are designed for optimum efficiency and comfort.

12) Heating/Air Conditioning
Electronically controlled four-speed fan and eleven vents deliver temperature-controlled air circulation for a comfortable working environment in any climate. More robust air compressor offers greater durability and longer life.

Communication Systems Ready

Cab is prewired with power converter, speakers, wiring harness, antenna and mounting locations for add-on radio, closed circuit TV, and MineStar® systems.

Monitoring System

VIMS™ Monitoring System

Intelligent, Caterpillar designed machine monitoring system provides critical machine health and payload data in real-time to keep the 793D performing at top production levels.

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.

Data Access

Monitoring and diagnostic information is stored on-board until it can be downloaded for analysis. Data can be accessed through the message center, transmitted via optional radio or downloaded onto a computer for detailed analysis.

Machine Management

Service technicians or mine personnel can download data and generate reports for better machine management. Data can be used to improve effectiveness of scheduled maintenance programs, maximize component life, improve machine availability, and lower operating costs.

Speedometer/Tachometer Module

Monitors three systems: engine speed, ground speed and gear indicator.

Gauge Cluster

Conveniently located gauge cluster maintains a constant display of vital machine functions, including:

• Engine coolant temperature
• Brake oil temperature
• Air system pressure
• Fuel level

Keypad

Provides operator or service technician immediate access to current machine information, gauge values and stored data through the message center display.

Message Center

Displays messages requested by operator and advises operator of abnormal machine conditions.

Alert System

Three-category warning system alerts operator of abnormal machine health conditions.

Production Management

Production Management enhances truck/loading tool effectiveness, improves fleet productivity and helps extend the life of truck frames, tires, rims and power train components, while lowering operating and maintenance cost.

VIMS PC

VIMS-PC, the off-board reporting software program, allows service personnel to download a complete record of machine health and productivity data to a laptop computer for diagnosis and analysis. Easy-to-use software enables service technicians and mine personnel to generate health and payload reports for more effective machine management.

VIMS Supervisor

Optional software allows mine personnel to easily manage and interpret VIMS data for optimum fleet management and productivity.

Engine/Power Train Integration

Cat Data Link

Electronically integrates machine computer systems to optimize overall power train performance, increase reliability and component life, and reduce operating costs.

Electronic Technician (Cat ET)

Cat ET service tool provides service technicians with easy access to stored diagnostic data through the Cat Data Link to simplify problem diagnosis and increase machine availability.

Integrated Braking Control (IBC)

IBC integrates Hydraulic Automatic Retarder Control and Traction Control into one system for optimum performance and efficiency.

Hydraulic Power Management System

The system, also known as common rail hydraulics, reduces parasitic (unused, wasted) losses in the power management system components and the new hydraulic fan drive system. The system is operated by two new variable displacement piston pumps. 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.

Engine Protection

• Intake and Exhaust System
• Cylinder Block
• Crankshaft and Bearings
• Liner
• Turbocharger
• Vibration Reduction
• Fuel Tanks

Customer Support

Commitment Makes the Difference

Cat dealers offer a wide range of solutions, services and products that help you lower costs, enhance productivity and manage your operation more efficiently. Support goes far beyond parts and service. From the time you select a piece of Cat equipment until the day you rebuild, trade or sell it, the support you get from your Cat dealer makes the difference that counts.

Dealer Capability

Cat dealers will provide the level of support you need, on a global scale. Dealer expert technicians have the knowledge, experience, training and tooling necessary to handle your repair and maintenance needs, when and where you need them.

Product Support

Cat dealers believe superior products deserve superior support. When Cat products reach the field, they are supported by a worldwide network of parts distribution facilities, dealer service centers, and technical training facilities to keep your equipment up and running. Cat customers rely on prompt, dependable parts availability and expertise through our global dealer network, ready to meet your needs 24/7.

Service Support

Every piece of Cat equipment is designed and built to provide maximum productivity and operating economy throughout its working life. Cat dealers offer a wide range of service plans that will maximize uptime and return on your investment, including:

• Preventive Maintenance Programs
• Diagnostic Programs, such as Scheduled Oil Sampling and Technical Analysis
• Rebuild and Reman Options
• Customer Support Agreements

Application Awareness

Operating and maintenance costs are influenced by many application and site-specific factors, such as: material density, loading position, payload, grades, speeds, haul road design, and maintenance. To optimize total cost of ownership and productivity, your Cat dealer can provide you with a fundamental understanding of the effects application characteristics and operating techniques have on maintenance and operating costs.

Operation

With today's complex products, equipment operators must have a thorough understanding of machine systems and operating techniques to maximize efficiency and profitability. Your Cat dealer can arrange training programs to help operator's improve productivity, decrease downtime, reduce operating costs, enhance safety, and improve return on the investment you make in Cat products.

Technology Products

Cat dealers offer a range of advanced technology products such as VIMS® monitoring system and MineStar® information management system. These products include radio data communications, machine monitoring and diagnostics, fleet management, and haul road maintenance software - all designed to improve fleet efficiency, increase productivity, and lower costs.

WWW.TIPLINDIA.IN/CAT

For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at www.tiplindia.in/cat