Caterpillar® 793D Mining Truck
NameVenue
Date
OverviewCaterpillar® 793D Mining Truck
Safety Reminders
Emergency Contacts
Fire•Building: <Phone #>•Municipal: <Phone #>
Medical•Building: <Phone #>•Municipal: <Phone #>
First Responders•Room <Identify>•Building <Location and name>
Emergency Information
Alarm Description• Evacuate• Take cover• All clear
Unique Hazards•Room•Floor/Building
Emergency Procedures•Equipment locations•Evacuation routes
Overview
• History• Product Development Manufacturing & Distribution• Specifications• Features & Benefits• Safety Health & Environment• Equipping Your Truck• Productivity• Serviceability• Product Support
Mining Truck Evolution
• Over 50,000 construction and mining trucks (769-797) delivered since 1963• Over 18,000 large mining trucks (777-797) delivered since 1984
Caterpillar’s mining truck experience dates back over 40 years and includes the world’s largest truck
Cat ModelYear
Introuced
770 2004772 1971773 1970775 1992777 1975785 1984789 1986793 1991797 1998
Update Yearly
Field Population
Truck Model
Total Units
Fleet Hours
Highest Hour Unit(As of December 2008)
777 10000+ 350 million 150,000785 2900+ 108 million 139,700789 2200+ 91 million 116,703793 2700+ 100 million 106,891797 350+ 6.6 million 69,755
Large Mining Truck Worldwide Fleet
Over 18,900 Shipments* (as of Feb. 31st 2009)
38%North
America
20%Latin
America
28%Asia
Pacific, Indonesia & Australia
14%Europe, Africa & Middle East
*Shipments leaving factory (Percentages reflect 777,785, 789, 793,797, distribution)
Update Bi-Yearly
793 Worldwide Deliveries
Over 2,700 Shipments* (as of Dec. 2008)
36%North
America
32%Latin
America
28%Asia
Pacific, Indonesia & Australia
4%Europe, Africa & Middle East
*Shipments leaving factory (Percentages reflect 793B, 793C and 793D distribution)
Update Bi-Yearly
Short TonsMetric Tons
777 D / F
DP905
TR100
HD785-7
EH1700-3
HD985-5**
* Pre Production** Japan Only*** India Only
7757 7514 - Electric
72 77 82 86 100 109 127 132 136 141 14590 104 11895 113 122
80 85 90 95 110 120 140 145 150 155 160100 115 130105 125 135
BH85-1 BH90 BH100
TR100
SRT95*
SF31904
100 -150 ton Product Strategy Cont.
Short TonsMetric Tons
795F-AC785C / D
100 109 1188 127 154 172 209 218 2277 236 245 254 2722633
281 290 299 308 318 327136 163 191145 181 200 354336 345 372363 381
110 120 130 140 170 190 230 240 250 260 270 280 300290 310 3200 330 340 350 360150 180 210160 200 220 390370 380 410400 420
T252
Unit Rig
MT300 MT3600 MT5500
T262 T282
789 793D / F 797B / F
HD 1500 -7 730E 930E-4830E - AC
930E-4SE
EH3000 EH3500-AC EH4500-2 EH5000
MT6300AMT4400ACMT3700ACMT3300A
TI274
960E860E
7513 7530 7560
SF32601SF31904
150 – 400 ton Product Strategy
793 History
• Cat® 793– 1991 - 1992– Over 50 sold
• B-Series– 1992 - 1996– Over 500 sold
• C-Series – 1996 - 2005– Over 1,300 sold
• D-Series– Introduced 4Q 2005– Five arrangements for
specific applications
The 793 has continuously evolved to remain the leader in its class
D-Series Application Arrangements
Standard Arrangement – Balanced all-around performance
Extended Life Wheel Groups – For long uphill hauls
Extra Top Speed – For long flat hauls
Extra Retarding – For long downhill loaded hauls
High Altitude Arrangement – For operations above 2590 m (8,500 ft)
The 793D is offered in five machine arrangements to match the application conditions found in your mine
793D Standard Arrangement
• Exceptional all-around performance• Three factors combine to produce
up to 9% more power at the wheels than the 793C:
– 5% more engine horsepower than 793C
– Common rail hydraulic system provides improved power train efficiency compared to 793C
– Hydraulically driven demand fan reduces parasitic load by operating only when needed
• Power at the wheels is a primary driver of cost per ton since it reduces cycle time
793D Extended Life Wheel Group Arrangement - Rear
• For long uphill hauls
Differences from Standard Arrangement• Larger wheel bearings • Wider wheel bearing spacing• 29% increase in braking surface• Larger spindle• Spline-on brake group
Benefits• Longer brake life• Extended life to overhaul• Lower cost per ton Standard (Rear)
Extended Life (Rear) Brakes Bearings
793D Extended Life Wheel Group Arrangement - Front
• For long uphill hauls
Differences from Standard Arrangement• Larger wheel bearings • Larger spindle, wider wheel
bearing spacing• Larger brakes, 94 cm (37 in) vs 86 cm
(34 in)• Repositioned duo-cone seal• Bottom mount steering arm fits
either side
Benefits• Longer brake life and duo-cone
seal life• Extended life to overhaul• Lower cost per ton Spindle bolts
(outer pattern) Strut bolts(inner pattern)
Bottom mountsteering arm
Extended Life (Front)
Standard (Front)
793D Extra Top Speed Arrangement
• For the long flat haul
Differences from Standard Arrangement• New transfer gear with lower gear ratio• Hydraulic rear axle cooler• Includes Extended Life Wheel Groups
Benefits• Top speed of 60 km/h (37 mph)• 10% higher top speed than the other
793D arrangements
New transfer gear
Hydraulic rear axle cooler
Extra Retarding Arrangement
• For long downhill loaded hauls
Differences from Standard Arrangement• Higher flow brake cooling• Higher capacity cooling system• Includes Extended Life Wheel Groups
Benefits• 35% increase in downhill speed over the
standard 793D
High Altitude Arrangement
• For operations above 2590 m (8,500 ft)
Differences from Standard Arrangement• 69 L (4,760 in 3 ) 3516B vs 78 L (4,211 in 3 )
3516B HD used in other 793D arrangements• Includes Extra Retarding arrangement
Benefits• Rated at 1715 kW (2,300 hp) to
3600 m (12,000 ft)
Product Development, Manufacturing & DistributionCaterpillar® 793D Mining Truck
6 Sigma & CPS
6 Sigma CPI• Enhances processes to enhance product quality• Maintains quality during production and when
product is in the field • Keeps all accountable to deliver a superior product
at all levels
Caterpillar Production System (CPS)• 6 Sigma based method for relentless improvement• Focuses on 3 processes:
– Core– Governing – Enabling
A methodology that improves product quality, processes throughout the company, and customer satisfaction
Design & Engineering
• New Product Introduction (NPI) process• Concurrent Product and Process Design
(CPPD)• 6 Sigma methodology improves processes
and product quality• Collaborates with Cat design and
manufacturing resources worldwide• Designed at the same facility where
it’s assembled
The 793D was developed by the truck engineering group in Decatur, Illinois using the latest design technologies and methodologies
Research & Testing
• Largest and most sophisticated research and development facility in the industry
• State-of-the-art laboratories, testing facilities, and simulators
• Interacts with design teams at each product facility
Innovation begins at the Caterpillar Technical Center in Mossville, Illinois
… and hits the ground at the Tucson Proving Grounds
• Complete machine cooling evaluations • On-machine structural evaluations• Complete machine noise evaluations• Brake, steering, visibility & government standards• Performance & machine productivity comparisons• Machine endurance & reliability evaluations
Manufacturing & Assembly
• Close tolerance machining centers• Automated material handling systems• Extensive welder training• Nondestructive weld testing• Highly trained, experienced
assemblers
From machine shop to assembly line, the 793D and its components are produced using the latest machining technology and highly skilled workforce
Manufacturing Quality Assurance
• Engineered using computer-generated stress modeling
• Steel castings used in high stress locations
• Rollover fixtures ensure all welding is done horizontally, not overhead
• Ultrasonic weld inspection of all frames• Caterpillar build cell quality certification• Precise coordinate measuring• Contamination control, for the entire
process• Laser hardened wheel spindles
Quality control practices have long been built into the Caterpillar manufacturing process, from machining to assembly
Distribution & Support
• Caterpillar’s Global Distribution network maintains over 20 parts centers worldwide
• Dealer branch facilities, service trucks,
trained technicians, and operator training programs provide customers with full-scale customer support
• Cat Product Support Center offers global training for dealer service technicians
• Global Mining’s Field Assembly Group commissions 793 trucks worldwide
When Cat products reach the field, they are supported by an advanced network of parts distribution facilities, dealer service centers, and technical training facilities
793D Component Sources
Caterpillar designs and manufactures all major components of the 793D
Bodies also manufactured in Australia & South Africa
Completely Caterpillar
• Complete design control over entire truck
• Single-point accountability • Enables Cat to optimize the truck as a
whole rather than by individual component
• Ensures compliance with the high quality standards expected
Design and manufacturing control ensures that the 793D operates as a complete and balanced unit
May 2004 – Decatur Plant
SpecificationsCaterpillar® 793D Mining Truck
12 862 mm42.2 ft
5584 mm18.3 ft
5905 mm19.4 ft
12 862 mm42.2 ft
1005 mm3.3 ft
3772 mm12.4 ft
13 113 mm43.0 ft
Body Raised
5871 mm19.3 ftEmpty
1364 mm4.5 ft
7680 mm25.2 ft
5610 mm18.4 ft
1294 mm4.2 ft
7680 mm25.2 ft
6940 mm22.8 ft
6500 mm21.3 ft
6494 mm21.3 ft
1128 mm3.7 ft 4963 mm
16.3 ft
7605 mm24.9 ft
793D Dimensions
Shown with MSD II body Dimensions are with dual slope body
793D Specifications (Metric)
1 Approximate clean chassis with full fuel, hoist, body mounting group and tires. Excludes body weight. Dependent on optional attachments. 2 Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with the 69 liter 3516B.3 Approximate altitude only. Changes with barometric pressure variations. Derate above this altitude is 1% per 1kPa- Data not available
793D Standard
793D Extra Life Wheel
Groups
793D Extra Top
Speed
793D Extra
Retarding
793D Extra
Retarding793C2
Maximum GMW (kg)Chassis weight1 (kg) 119 597 121 539 121 632 121 583 122 196 118 284
Engine model 3516 B3516B
HDDisplacement (L) 69 78Gross power (kW)Flywheel power (kW) 1615Rated speed (rpm)Engine derates above altitude3 (m) 3658 2743Transmission speedsTop speed (km/h) 59.954.2 54.2
17431,750
25916 Forward – 1 Reverse
383 739
3516B HD78
1801 1715
793D Specifications (Metric)
(1) Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with 3516B short stroke engine.(-) Data not available
793D Standard
793D Extra Life Wheel
Groups
793D Extra Top Speed
793D Extra Retarding
793D Extra Retarding
793C2
Fuel tank capacity (L) 4467Optional fuel tank (L) -Brake discs per side - front
10 10
Brake area - front (m2) 8.98 8.98
Brake discs per side - rear
Brake area - rear (m2) 13.46 13.46
Brake disc outside diameter (mm) 876.3 876.3
Total brake area (m2) 22.44 22.44
15
15.54
939.829.01
43534921
13
13.47
793D Specifications (English)
1 Approximate clean chassis with full fuel, hoist, body mounting group and tires. Excludes body weight. Dependent on optional attachments. 2 Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with the 69 liter 3516B.3 Approximate altitude only. Changes with barometric pressure variations. Derate above this altitude is 1% per 1kPa- Data not available
793D Standard
793D Extra Life Wheel
Groups
793D Extra Top
Speed
793D Extra Retarding
793D Extra Retarding 793C2
Maximum GMW (lbs)Chassis weight1 (lbs) 263,666 267,947 268,153 268,045 269,396 260,771Engine model 3516 B 3516B HD
Displacement (in3) 4,211 4,760Gross power (hp)Flywheel power (hp) 2,166Rated speed (rpm)
Engine derates above altitude3 (ft) 12,000 9,000Transmission speedsTop speed (mph) 37.233.7 33.7
2,3371,750
8,5006 Forward – 1 Reverse
846 000
3516B HD
4,7602,415 2,300
793D Specifications (English)
(1) Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with 3516B short stroke engine.(-) Data not available
793D Standard
793D Extra Life Wheel
Groups
793D Extra Top
Speed
793D Extra
Retarding
793D Extra
Retarding793C2
Fuel tank capacity (gal) 1,180Optional fuel tank (gal) -Brake discs per side - front 10 10Brake area - front (in2) 13,912 13,912Brake discs per side - rearBrake area - rear (in2) 20,869 20,869Brake disc outside diameter (in) 34.5 34.5Total brake area (in2) 34,781 34,781
1524,084
3744,958
1,1501,300
1320,874
Features & BenefitsCaterpillar® 793D Mining Truck
793D Features & Benefits
• Frame & Structures• Suspension• Hydraulic System• Power Train• Cooling System• Brakes & Retarding• Operator Station• System Integration• Bodies & Liners • Tires & Rims
The 793D is the premier machine in its class, designed and built by Caterpillar using components and systems that have evolved through years of rugged mining applications
793D Frame
• Engineered using computer-generated
stress modeling• Forgings and castings used in high
stress locations• Rollover fixtures ensure all welding is
done horizontally, not overhead• All critical welds are
ultrasonically tested• High strength low alloy (mild) steel is
highly durable, easy to weld
Caterpillar frames are designed to deliver long service life in rugged mining applications
Structures
Fabrications
Castings
Integral 4-post ROPS
Integrated Steering & Suspension
• Four-corner independent, nitrogen- over-oil cylinders offer superior performance and ease of service
• Front & rear struts have built-in rebound control to improve ride
• Front cylinders act as axle mounting group
• Turning radius designed to minimize tire wear
Cat designed for excellent maneuverability, safe operation, lower operating costs, and a comfortable ride
Front Axle Steering Components
• Separate steering hydraulic system prevents cross contamination
• Secondary steering meets ISO 5010 up to 120% of target payload
• Twin double-acting cylinders• Steering arm pin retention plate
provides redundant pin retention• Front suspension cylinders serve
as kingpins• Serviceable bracket assembly on
steering box casting saves time at rebuild
• Two tie-rods allow optimum steering geometry
The 793D front suspension is a field proven design with dual tie-rods for optimum steering geometry to help extend tire life
Hydraulic Power Management
• Delivers up to 4% additional power to the ground rather than to functions that are not needed at the time
• Provides priority to supply functions required for safe operation
• Very controllable; provides flexible power management
Common rail hydraulics improve system efficiency by better sharing and controlling power needs for hydraulically-driven functions
Hydraulic pump
Common Rail Hydraulics
Optional Rear Axle
Common Rail Valve
Brake Cooling Pumps
Common Rail Pump
Fan/Common Rail Cooler
Common Rail and Fan Tank
Return Filter
Fan Pump
Brake Cooling Drive Motor
Solid Connection
MainEngineFan
Steering Cylinders
SteeringControl
Rear AxleLubricator Motor
Cooler Fan
3516B High Displacement EUI Engine
• 25 mm (1 in) longer stroke than 69 L engine
• 2,415 gross horsepower from 78 L (4,760 in 3 )
• Electronic Unit Injection (EUI)• Turbocharged and aftercooled• No waste gate• 5% horsepower increase
over the 793C • Enhanced diagnostics with Electronic
Technician (Cat ET)• Electronic monitoring of key functions
and logging critical indicators• Me ets US EPA Tier I
A proven performer for over 20 years, the 3500 series engine now has over 80,000 units worldwide working in a variety of applications
High Displacement Engine
Metric English
Ratings @ 1,750rpm Gross Power 1801 kW 2,415 hp Net Power 1743 kW 2,337 hpDimensions Bore 170 mm 6.7 in Stroke 215 mm 8.5 in Displacement 78 L 4,760 in3
3516B EUI Engine for High Altitude
• 25 mm (1 in) shorter stroke than 78 L engine
• 2,300 gross horsepower from 69 L (4,211 in 3 )
• Electronic Unit Injection (EUI)• Turbocharged and aftercooled• Enhanced diagnostics with Electronic
Technician (Cat ET)• Electronic monitoring of key functions
and logging critical indicators
A proven performer for over 20 years, the 3500 series engine now has over 80,000 units worldwide working in a variety of applications
High Altitude Arrangement Engine
Metric English
Ratings @ 1,750rpm Gross Power 1715 kW 2,300 hp Net Power 1615 kW 2,166 hpDimensions Bore 170 mm 6.7 in Stroke 190 mm 8.5 in Displacement 69 L 4,211 in3
Engine Comparisons
793C793C
(Tier 1)793D
(Tier 1)793D
High Altitude
Engine 3516B 3516B HD 3516B HD 3516B
Gross Power 1715 kW2,300 hp
1715 kW 2,300 hp
1801 kW 2,415 hp
1715 kW 2,300 hp
Displacement 69 L
4,211 in3
78 L
4,760 in3
78 L
4,760 in3
69 L
4,211 in3
BSFC g/kW-hr (lb/hp-hr)
211 (0.347)
201 (0.330)
206 (0.339)
221 (0.363)
BMEP 1704 kPa 247 psi
1508 kPa 219 psi
1583 kPa 230 psi
1704 kPa 247 psi
12
3
4
56
79
10
11
8
Power Train Integration
1. Gauge cluster module
2. Message center module
3. Integrated Braking Control
4. Transmission/Chassis Control
5. Brakes
6. Wheel sensor
7. Transmission
8. Cat data link
9. Engine Control Module
10.Sensors
11. Electronic Unit Injector
Brake Mean Effective Pressure (BMEP)
• BMEP measures how hard anengine is working
• Lower BMEP = longer life• Cat engines’ low BMEP
improves availability, extends service life and reduces overall costs
Cat engines have low BMEP, which means the 3500 works easier and lasts longer
0
500
1000
1500
2000
2500
793C
HD
793D
793B
793C
DDC16V40
00
QSK60
DDC16V40
00
QSK60
1715
kW
1715
kW
1801
kW
1611
kW
1864
kW
1864
kW
2051
kW
2013
kWE
ng
ine
BM
EP
(kP
a)
Oil supply from crankcase
Oil sent to tank via fuel return line
Oil metered via electronic controls
Oil Renewal System (ORS)
• Eliminates regular oil changes and oil disposal costs
• Improves average engine oil quality• Lessens environmental impact• Decreases service downtime• Exclusive integrated Caterpillar
controls • US EPA Tier I compliant
On 3500 engines, ORS meters used crankcase oil into the fuel system to be burned, replaced by new oil as the system is regularly topped off
Because ORS constantly replaces old oil with new, the quality level remains consistent and free of the quality degradation experienced in oil during a typical 500-hour life cycle
Superior Engine Oil Quality with ORS
Oil Degradation vs Time
Oil
Deg
rad
atio
n
Hours
0 1000 2000 3000 4000 5000
Non-ORS
ORS
Mechanical Power Train
Lock-up Torque Converter
Six-speed planetary power shift transmission
Differential and double reduction final drive
Transmission has internal changes to accommodate increased horsepower & top speed
Dual transmission output speed sensors
New two-piece transmissionharness for redundant
speed sensors
Oil level switch
Adapter to provide spacefor additional disc & platein lock-up clutch
Torque converter & lock-up clutch(additional clutch disc & plate added)
New input transfer case to accommodate increased top speed gears
Rear axle filtrationis now continuous(no longer ground driven)
Transmission input speed sensor
Lock-up Torque Converter
• Increased power train efficiency• High reliability from proven
design components • 28% stall torque• Broad converter performance band• Lock-up clutch engages at
7.3 km/h (4.5 mph)
Combines the advantages of direct drive and converter drive to achieve high component reliability and maximum output performance
Controlled Throttle Shift
• Regulates engine rpm during shifts• Reduces torque spikes and
extends transmission life • Smoother ride and less spillage • Lowers operator fatigue • Possible only through electronic
integration of components
Reduces driveline torque stress for smoother shifts, extended component life and improved operator comfort
Controlled Throttle Shift (CTS)
Tra
nsm
issi
on
Ou
tpu
t T
orq
ue
C
lutc
h P
ow
er
Time
Precise Transmission Control
• Microprocessor controls hydraulics for smoother clutch transition during shifts
• Reduces torque spikes and extends transmission life
• Possible only through electronic integration of components
• Together with Controlled Throttle Shifting provides:
- Smoother ride and less spillage
- Lower operator fatigue
Electronically controlled individual clutch modulation reduces driveline torque stress for smoother shifts, extended component life and improved operator comfort
Pre
ssu
re
Time (in fractions of a second)
Electronic Control Example ofdepressurization of one clutch and pressurization ofanother during atransmission shift
With Hydraulic Control
Six-Speed Planetary Transmission
• Torque converter lock-up in first gear• Smart shifting eliminates gear hunting• Downshift inhibitor prevents
engine overspeed• Clutch packs mounted outside of gear sets
for ease of service• Directional shift management automatically
reduces engine throttle before shifting
Large diameter clutch packs are controlled to provide smooth shifting and to limit clutch energy input for extended component life
Rear Wheel Group
• Laser-hardened spindle• One-piece cast wheel• Large bearings• Continuous rear axle filtration• Oil cleanliness to ISO 16/13
Benefits of Continuous Filtration
Bearings with kidney looping and 4,000-hour oil changes showed
little wear after 18,000 hours
Images magnified 50x
Bearings with oil changes at 1,200-hour intervals, but without kidney looping, showed pitting at
13,000 hours
Caterpillar's success with kidney looping resulted in the continuous filtration system now found in the rear axle of the 793D
New Generation Modular Radiator
Hydraulically driven, variable speed fan is matched to a new generation modular radiator with serpentine fins to improve cooling over the 793C system
• Improved heat rejection• Greater cooling density• Modular core design for ease
of service• Hydraulic fan, 198 cm (78 in) or
213 cm (84 in), operates on demand to reduce parasitic loads
1
6
2
3
5
7
4
Brakes and Retarding
1. Parking/secondary
piston
2. Service/retarding
piston
3. Friction discs
4. Steel plates
5. Actuating springs
6. Cooling oil in
7. Cooling oil out
Oil-cooled multiple disc brakes on all four wheels provide exceptional braking and retarding
• Forced oil cooling for fade resistance
• Spring applied, hydraulic released secondary/parking brake for added safety
• Braking & retarding on all four wheels
• Redundant systems• Sealed from contaminants• Extended Life brake discs
standard on all arrangements
Integrated Braking Control
Integrates the Hydraulic Automatic Retarding Control and the Traction Control System into one electronically controlled braking system
1
6
2
3
5
7
4
6
7 8
1. Service brake sensor
2. Engine sensor
3. HARC
4. HARC switch
5. Brakes
6. Service brakes
7. Axle speed sensor
8. TCS
Hydraulic Automatic Retarding Control:• Increases production due to faster
downhill speeds • Excellent controllability and reduced
operator effort • Less operator fatigue • Engine overspeed protection• New hydraulic engagement offers
smoother, more responsive operation than 793C pneumatic design
Traction Control System:• Improved traction in poor underfoot
conditions• Less slippage means less tire wear
Operator Station
1. Ergonomically designed, air suspension seat
2. Electric hoist control
3. Secondary brake pedal
4. VIMS ® displays and operator keypad
5. Tilt and telescoping steering wheel
6. Transmission console
7. Large storage compartment
8. Trainer seat
9. Powered operator window
10. Operator controls
11. Standard heater and air conditioner
The integral, sound-suppressed ROPS/FOPS cab gives the operator a comfortable and safe working environment
1 8
2
5
7
3
4
6
9 10 11
Cab Visibility
Electric truck visibility Cat 793D visibility
Cat Comfort Seat
The new Cat Comfort Seat with three-point restraint offers operators added safety and comfort
Ride zone indicator
Three-point restraint • High-back seat supports head
and neck• Ride zone indicator adjusts seat
suspension to operator’s weight• Adjustable rake lower cushion• Washable seat cover• Dual retractor lap and shoulder
belt system• Adjustable shoulder belt has six
vertical height settings for optimum fit
VIMS
1. Gauge Cluster2. Message Center and Keypad3. ADEM III Engine Control Module4. CAT Data Link5. Action Alarm6. Action Lamp7. Payload Lamps8. Payload Display (optional)9. Radio System (optional)10. Data Port (VIMS-PC)11. Service Lamp12. Diagnostic Connector (Cat ET)13. Integrated Brake Control (IBC) Module14. Transmission/Chassis Control (TCC)
Module15. Road Analysis Control (RAC) Module
(optional)
CatET
VIMS Speed Manager
• VIMS MAX Speed Manager • VIMS TKPH (TMPH) Speed Manager • VIMS MAX Payload Speed Manager
Fully integrated with VIMS, Speed Manager consists of three features that help optimize truck safety and performance, lower costs, and extend service life
MineStar® – Integrated Mine Information System
Radio Network
Rep
ort
ing
KPIs/Graphing
BusinessIntelligence
Reports
Assignment Health Production Monitoring
MachineTracking
MaterialTracking
Machine Guidance
MineStar…
GPS Infrastructure: Satellites, Repeaters, Base Station
Administration/ ManagementProduction
Engineering and Geology
SafetyMaintenanceProcessing
Data Flow
793 MSDII Body Size Options
793 MSDII Body is available in 3 sizes to meet a variety of material density ranges:
• 209 yd 3 (160 m 3 )– 2750-3000 lbs/lcy material
• 250 yd 3 (191 m 3 )– 2500-2750 lbs/lcy material
• 250 yd 3 (191 m 3 ) – 2300 – 2500 lbs/lcy material
7265 mm
6982 mm
Front to Rear Body Flare
• 1 ° flare – front interior body width to rear interior body width
• Improved material flow / release• Reduces wear on rear sidewalls (less
material contact
Front to Rear Flare
• Highly cohesive applications• Carry back reduction system• Hot surface improves material flow• Targets problem areas
Exhaust Outlet
Body Exhaust Heat
Pivot Area and Hoist Brackets
• Factory pre-assembled and installed
• Internal and external gussets provide full support
• Solid piece pivot bracket
• Internal and external gussets optimize stress distribution
• Minimizes impact damage to floor
• Analyzed and tested for optimal floor rib coverage
Understructure Gussets & Rib Coverage
793 X Body Size Options
793 X Body is available in 3 sizes to meet a variety of material density ranges:
• 195 yd 3 (149 m 3 )
– 3000+ lbs/lcy• 204 yd 3 (156 m 3 )
– 2800-3000 lbs/lcy• 210 yd 3 (160 m 3 )
– 2650-2800 lbs/lcy
Sidewall to Floor Integration • Improved structural integrity thru…
• Direct sidewall – floor integration
• Direct sidewall rib – floor rib termination
• Tapered sidewall ribs – added flexibility & durability
Cross Section
Exhaust Outlet
• Highly cohesive applications• Carry back reduction system• Hot surface improves material flow• Targets problem areas
Body Exhaust Heat
Gussets and Ribs
Internal and external gussets optimize stress distribution
• Minimizes impact damage to floor
• Analyzed and tested for optimal floor rib coverage
Understructure
Pivot Areas and hoist brackets
Factory pre-assembled and installed•Internal and external gussets provide full support•Solid piece pivot bracket
Guards, Lifting Points, & Loading Target
• Complete forward machine coverage• Canopy rock shedders• Rock ejectors
• Upper sidewall lifting eyes• Loading Target
Impact & wear protection that maximizes body life & performance
F A C L T
ragmentation
brasion
ohesion
oading
ool
Mine Specific Design (F.A.C.LT)
FACLT & Body Liner Segmentation
L 1 L 1
L 1 L 2 L 2
L 3
L 3
L 4 L 4
L 5 L 5
L 6 L 6
L 7 L 7 L 8 L 8
L 9 L 9
L 10 L 10
L 11 L 11
L 12 L 12
L 13
L 14
L 15
L 15 L 15
Body Liners
Caterpillar offers modular liner plate packages for additional impact and wear protection
Smooth Plate forcohesive materials
Rock Box for dry andnon-cohesive materials
Zipper Grid forsemi-cohesive materials
Mechanically Attached Wear Plate System (MAWPS)
for all mining conditions
793D Tires & Rims
• Cat center mount rim offers reduced stress and longer life than offset flange designs
• Stud mounted rim stays torqued while wedge mounted design require constant attention
29" rim 32" rim
Goodyear 40.00R57
Michelin 40.00R57
Bridgestone 40.00R57
Bridgestone 46/90R57
Michelin 44/80R57
793D Tire & Rim Options
Competitive
Caterpillar
Extended Tire Life
• Gross weight distribution is ideally 33/67 front-to-rear axle
• Traction Control System reduces tire slippage and wear
• Integrated VIMS Speed Manager reduces heat separation failures by monitoring tonne kilometers per hour (ton miles per hour)
• Steering geometry and turning radius are designed to minimize tire scrub
The Cat 793D is designed specifically to extend tire life and reduce costs
Sustainability
NameGlobal Mining Division
Month Year
Caterpillar® 793D Mining Truck
Sustainable Development at Caterpillar
• Our vision is a world in which all people’s basic requirements – for shelter, clean water, effective sanitation and reliable power – are not only met but provided in a way that sustains our environment.
• Our mission is to enable economic growth through infrastructure and energy development and to provide solutions that protect people and preserve the planet.
• Our strategy is to provide work environments, products, services and solutions that make wise use of the world's natural resources and reduce harmful impacts on people and nature. This means we leverage assets including technology and innovation to:
– Promote and protect individual safety – Provide employment, education, and training– Minimize the use of energy, materials, and water– Maximize recycling (remanufacturing) – Minimize harmful emissions (e.g. air, noise, etc), water discharges, waste and use of hazardous substances– Optimize the use of renewable resources
“Our commitment to being a leader in sustainable development will keep us focused on what really matters—making the intelligent choices that will drive the growth of our business and help create a more sustainable world.”
--Jim Owens, Caterpillar
Chairman and CEO .
Executive Summary
Sustainable Development & Strategic Areas of Improvement > Enterprise SD Goals…
Caterpillar Goals
SD SAI > Enterprise SD “Customer” Goals…
Customer Goals
Standard Safety Features
The 793D offers the latest safety features for the protection of the operator and mine employees
Standard Features• 4-post ROPS• Oil-cooled brakes for
fade-resistant operation• Electrical lockouts at ground level for
added safety and securityNew Standard Safety Enhancements• Three-point operator restraint• 600 mm (24 in) wide stairway and
wider railed cab access area eases operator movement
• Toe boards eliminate objects from accidentally being kicked off the deck
• Closed-circuit television ready 10/10/20 Payload Policy applies
Optional Safety Features
The 793D offers optional features to enhance safety in specific operating environments
Transmission lockout
Rear platform
• Rear cab access platform & handrail provide enhanced access to cab service panel and rear window
• High intensity discharge lighting in high beams and back-up lights improves night time visibility
• Ground level transmission lockout • Heated mirrors• External payload display• Throttle lock
Ecology Drains
• Installed on– Engine (#1)– Transmission– Torque converter– Hydraulic tank– Fuel tank– Radiator (#2)
Easily accessible drain plugs are installed in components to provide an environmentally safe and effective method to drain fluids
2
Equipping Your TruckCaterpillar® 793D Mining Truck
793D Standard Equipment Electrical• Alarm, backup• Alternator, 105 ampere• Batteries, 12 V (2), 93 amp-hour• Converter, 12 V electrical• Electrical system, 24 V, 15 amp• Directional signals (front &
rear LED)• Front stair access/Service deck• Stop/taillights (LED)• Engine compartment
Operator Environment • Air conditioner• Ashtray/Cigarette lighter• Coat hook• Diagnostic connection port• Dome courtesy light• Entertainment Radio Ready• Gauges/Indicators:
- Air cleaner service indicator
- Quad gauge panel:
Air pressure
Brake oil temperature
Engine coolant temperature
Fuel level
- Electric engine control fault indicator
- Electric hour meter/tachometer
- Speedometer
- Tachometer
- Transmission gear indicator• VIMS message center w/universal gauge• VIMS keypad• Heater/defroster (11,070 kCal/43,930
BTU) • Horn• Hoist, body control (electric)• Storage compartment• ROPS cab-insulated/sound suppressed• Seat belt, 75 mm (3 in) wide retractable• Steering wheel, tilt, padded, telescopic• Tinted glass• Window, electric powered, operator• Windshield wiper, intermittent control,
washer
Power Train • 3516B Diesel Engine• Turbocharging (4)• Aftercooled• Air cleaner w/precleaner (4)• Ground level engine shutdown• Ether starting aid (automatic)
• Elevated low idle control• Multi-point oil pressure sensing• Automatic starter protection
Braking system:
- Brake release motor (towing)
- Oil-cooled, multi-disc (front & rear)
(service, retarding, parking, secondary)
- Automatic Retarder Control
- Engine overspeed protection
Transmission :
- 6-speed, automatic power shift w/TCC
- Body-up shift inhibitor
- Controlled throttle shifting
- Directional shift management
- Neutral coast inhibitor
- Neutral start switch
- Downshift/Reverse shift inhibitor
- Individual clutch modulation
- Body-up reverse neutralizer
- Programmable top speed
- Lock-up torque converter
793D Other Standard Equipment
• Air line dryer
• Traction Control System
• Auto lubrication system (Lincoln)
• Aux "buddy" dumping quick connect
• Aux steering quick connect (towing)
• Driveline operator safety guard
• Fast fill fuel system (Wiggins)
• Ground level VIMS data port
• Ground level battery disconnect
• Hi-speed crankcase oil change (Wiggins)
• Reservoirs (3):
- Brake
- Hoist/Steering/Transmission
- Converter
• Rock ejectors
• Stairway, 600 mm
• Supplemental steering (automatic)
• Tie down eyes
• Tow hooks (front)/Tow pin (rear)
• Vandalism protection locks
Vital Information Management System (VIMS)
• Includes VIMS Payload Monitor w/MAX Payload & Speed Manager
• Recommended using download cable 127-9797 and PC based software JERD 2175
• Supplemental software "VIMS Supervisor" YERA 1403. Order separately (Computer not provided)
Antifreeze
• Extended Life Coolant to -35C (-30F)
793D Optional Equipment
• Ground level transmission lockout• Oil Renewal System (ORS)• Road Analysis Control (RAC)• External digital payload display• High intensity discharge (HID) lights
replace halogen high beams• Heated mirrors• Rear cab access platform & handrail• Rim guard
Arrangements• Extra Retarding• Extra Top Speed• Extended Life Wheel Groups• High Altitude
Bodies• Dual slope• Flat floor• MSDII
Custom Products
• Design and fabrication of specialized attachments to meet site-specific needs
• New technology retrofitted to older models
• Past custom products include:– High altitude engine arrangements– High intensity discharge (HID)
lighting for high beam retrofits
– Field installed wider stairways– Electric start
Caterpillar and your dealer work together to offer you custom attachments and retrofits to meet the specific demands of your mine site
Road Analysis Control (RAC)
• Existing suspension cylinder pressure sensors measure pitch & bias of truck, and frame rack (twist)
• System identifies haul road problem areas to avoid and correct
• Transmits real time data and GPS locations to haul road maintenance via radio, if equipped
• Improved haul roads help optimize truck component life, fuel consumption, and safety
RAC monitors and logs haul road severity to increase truck life and reduce cost/ton
ProductivityCaterpillar® 793D Mining Truck
10/10/20 Overload Policy
90 %
No loads should be above 120% of the target payload
90% of loads should fall into this range No more than 10% of loads should exceed 110% of the target payload
• No more than 10% of loads above 110%• No loads above 120%• The average payload shall not exceed the
target
793D Performance
• 5% increase in gross horsepower• New hydraulic power management
system• Optional extra retarding package
should achieve one additional gear on downhill hauls (up to 35% speed increase)
Preliminary data projects faster uphill speeds and higher productivity than its predecessors
ServiceabilityCaterpillar® 793D Mining Truck
1
6 2 7
1
5 3
4
Right Side Inspection
1. Front and rear tires – Check inflation; inspect inside of tire for damage or wear; remove large rocks from treads; check front wheel cover for bolts that are loose or missing
2. Right steering cylinder, tie rod, and front suspension cylinder
3. Power train – Check for leaks at torque converter and transmission
4. Hydraulic tank, hoist and brake oil – Check that filler cap is properly installed; check oil level sight gauge; look for leaks or damage
5. Automatic lubricant reservoir – Check oil level in sight gauge; inspect tank for leaks
6. Right hoist cylinder – Look for leaks, cracking, or marks on chrome
7. Frame and body – Inspect for cracks or damage
Front Inspection
1. Ground level controls – Make sure switch covers are down; inspect warning light and VIMS connection
2. Front operating lights – Check for damage
3. Radiator – Check for leaks; remove any debris
4. Engine – Check for oil and coolant leaks; check oil sump dipstick using the appropriate side for “low idle” or “engine stopped”; drain moisture and sediment from the air tanks
5. Ladders and platform – Make sure that the ladders and hand rails are secure
6. Check the coolant levels in the coolant tanks
7. Remove debris that may obstruct the air filters
8. Check steering system hydraulic oil levelsight gauge
9. Make sure that all of the windows are clean; make sure that the operator's vision is not impaired by dust, mud, or other foreign materials
10.Adjust the mirrors for proper vision.
1
6
2
9
58
4
10
2 7
5
37 2
10
2
Left Side Inspection
1. Front and rear tires – Check inflation; inspect inside of tire for damage or wear; remove large rocks from treads; check front wheel cover for bolts that are loose or missing
2. Left steering cylinder, tie rod, and front suspension cylinder
3. Power train – Check oil level sight gauge in torque converter sump (see Note below); check for leaks at torque converter and transmission
4. Fuel tank – Check that filler cap is properly installed; check fuel level sight gauge; look for leaks or damage
5. Left hoist cylinder – Look for leaks, cracking, or marks on chrome
6. Frame and body – Inspect for cracks or damage
1
6
2
1
5 3
4
Note: The torque converter sump oil level is checked with the body down and the engine off. There are two sight gauges. Use the lower gauge if the oil is cold. Use the upper gauge if the oil is at operating temperature.
Rear Inspection
2
1
3 4
1. Inspect lights for damage
2. Check suspension cylinders
3. Look for leaks around filter
4. Check oil level sight gauge; check grease fittings
2
Product SupportCaterpillar® 793D Mining Truck
Dealer Support
Parts and ComponentSupport
Equipment ManagementServices
Repair and MaintenanceProcess Engineering
We offer a dealer network and support system that is unparalleled by any competitor Cat dealers continue to support the customer through the entire life of the machine on every angle
Caterpillar Global Factory Support
• 23 parts distribution centers
• 13 training centers
• 107 manufacturing facilities
Caterpillar Global Dealer Network
267locally owned businesses
1,665dealer branch stores
93,000employees supporting you
$7.8 billionin assets
50+ yearsaverage tenure
More than our top 3 competitors combined
Parts & Service Support Worldwide
• Preventive maintenance programs• Diagnostic programs, such as
Scheduled Oil Sampling and Technical Analysis
• Rebuild and Reman options• Operator training• Customer support agreements
Cat dealers offer a wide range of parts and service plans that will maximize uptime and return on your investment
Caterpillar Certified Rebuild (CCR)
• Inspection• Disassembly• Reconditioning• Engineering updates• Power train testing• Reassembly• Performance testing• Repainting• New serial number/warranty• Customer evaluation
The CCR program offers a like-new machine with a renewed warranty and serial number, all at a much lower cost than a comparable new machine
Off Highway Truck Reman Components
• Engines• Engine Components• Final Drives• Torque Converter• Transmission• Electric Drive Components• Drivetrain Components
– Wheel assemblies, Spindles, Carriers, Clutch Plates
• Hydraulics– Piston Motors, Gear Pumps,
Rods / Cylinders• Electronic Components
– Starters, Alternators, ECU’s• Price 40 – 70% below new parts
We offer the following Reman components from 777-797 to decrease down time, reduce cost, and increase quality.
More information at catreman.cat.com
Percentage Commonality in Parts Numbers
793D Reduces Cost per Ton
Safety
• Key safety features you are used to on Cat trucks (oil cooled brakes, ROPS/FOPS, 10/10/20)
• Plus new enhanced safety features contribute to further lowering your costs
Production
• More rimpull, faster cycle times
• Optional +10% top speed
• Optional +35% downhill speed
• Optimized payload (with MSD bodies)
Utilization
• Traction control allows continued operation in poor underfoot conditions
Mechanical Availability
• Improved reliability, higher uptime
• 3516B HD engine has lower BMEP and no wastegate for improved durability and reliability
Owning Cost
• Long economic life
• Higher resale value than competition. Even though a customer may not resell their truck, the high resale is indicative of the remaining value in older Cat trucks
Maintenance Cost per hour
• Improvements throughout the truck (Engine, Torque Converter, Transmission, Differential, Wheel groups, brakes, frame, electrics and electronics)
• VIMS capability allows diagnostics and prognostics to extend service life of components
Tire Cost per hour
• Weight distribution and low Empty Machine Weight (EMW)
• Steering geometry
• VIMS TKPH (TMPH) Speed Manager
Operator Efficiency
• Operator station comfort and ergonomics
• Operator confidence in braking and retarding optimizes downhill speed
Fuel Cost per Ton
• Mechanical power train efficiency
• HD engine
• Zero fuel consumption while retarding
113
QuestionsCaterpillar® 793D Mining Truck
Caterpillar® 793D Mining Truck
Media Support
www.cat.comwww.safety.cat.comwww.catreman.cat.comwww.catminer.cat.com
Mining Truck BodiesBody MaintenanceGround RulesProduct Development Video
Specalog AEHQ5600-01 Show Spec Sheet AEHQ5877 VIMS AEXC0681WAVS TEKQ0647-03Virtual Operator Training TERV0101Mining Safety Brochure AEXQ0370Minestar AEHQ6017-01CPI AERV5715RAC TELQ4461Marketing Bulletin TEJB9452