Caterpillar Product Information

Salesgram
August 1998

Cat 785C/789C/793C Mining Truck Introduction

Caterpillar mining trucks have become the industry standard for efficiency, productivity and durability since their introduction in 1984, with over 3,300 trucks shipped. With the introduction of the C-Series mining trucks the 793C in late 1996, and the 785C/789C models scheduled for late 1998, additional enhancements have been made to the entire mining truck product line to help increase machine life and reduce operating costs. Major enhancements include: Cat 3500 B-Series engine Redesigned operators station Integration and improvements to electronic controls Improved serviceability

For Dealer Sales Personnel

3500 B-Series Engine

Designed and manufactured by Caterpillar, the durable and reliable 3500 B-Series engine is the result of proven technology and performance. The 3500B engine is the heart of the C-Series power train, providing customers with the lowest cost-per-ton hauling alternative.

The Cat 3500 B-Series engine offers the following improvements to the 785 and 789 C-Series mining trucks (these improvements were made to the 793C when it was introduced in late 1996): Higher Horsepower Ratings Horsepower ratings increased by five percent for the 785C and 789C. Engine power for the 785C increased from 1380 hp (1029 kW) to 1450 hp (1082 kW), while the 789C increased from 1800 hp (1342 kW) to 1900 hp (1417 kW). Horsepower for the 793C remains unchanged at 2300 hp (1715 kW). Improved Fuel Injection System Brake Specific Fuel Consumption has improved 3 to 4 percent as a result of 22 percent higher fuel injection pressures and shorter injection cycles. Emissions (NOx) and oil sooting have also been reduced as a result of these enhancements to the fuel injection system. Camshafts, cam followers, push rods, rocker arms, and gear train components were all strengthened in response to these system changes.

Improved Air System B-Series engines breathe easier due to the following improvements: Improved inlet and exhaust system for streamlined air flow through the combustion chamber. Redesigned Separate Circuit Aftercooler System (SCAC). Redesigned camshaft for increased valve lift and improved inlet/exhaust air exchange. Electronic Control Module (ECM) The 3500Bs Electronic Control Module (ECM) stores and selects the appropriate injection timing and air/fuel ratio mixture for any operational situation by monitoring sensors throughout the engine, torque converter, transmission, and operators control station. The ECM has been enhanced with the following additional features: Exhaust temperature derating for extended component life. Automatic ether injection protects engine componentry. Flash programmable ECM memory for efficient system updates. Expanded system sensing, including: coolant flow, rear aftercooler temperature, engine oil level, engine oil filter pressure/restriction, turbo exhaust temperature, engine fan speed, air conditioner compressor pressure and engine crankcase pressure. Overspeed monitoring, warning and self-protection. Acceleration delay on start-up for extended component life. Elevated low idle boosts efficient operating temperatures. Air filter restriction deration protects operating components. Fan clutch control (optional). Oil Renewal System control (optional). Pre-lubrication control (optional). Radiator Shutter control (optional). Extended Service Intervals Service intervals have been extended from 250 to 500 hours for oil, oil filter, and fuel filter changes, reducing service time and increasing machine availability.

Operators Station

Major design improvements have been made to the operators station on all three C-Series trucks to enhance operator comfort, minimize fatigue, and maximize productivity. Improved Ergonomics Electronically controlled body hoist control provides better modulation and ease of operation. This hoist control is hydraulically snubbed for improved comfort. Operators seat adjustments improved for better comfort. New telescopic/tilt steering column provides improved access and operator comfort. Repositioned pedal controls provide easier, more natural actuation. New integrated electronic control for intermittent windshield wiper, washer and turn signal for improved reliability. Enhanced instrument layout with backlit rocker switches for improved visibility. Electric horn control mounted on steering wheel for easier access. Enhanced Operator Comfort More powerful heating and air conditioning system provides enhanced reliability and performance. Secondary brake control moved from column lever to floor pedal for easier access. Operators seat redesigned and armrests added for improved comfort. Increased operator and passenger space provides more leg room and storage space. Power window added to drivers side for ease of operation. Cab is radio ready with provision for add-on communication packages for added versatility. Soft grey interior color reduces glare and adds to operators perception of spaciousness.

Updated Electronic Control Module (ECM) The Electronic Control Module (ECM) on 3500 B-Series engines has been enhanced and updated with a number of new features. (See engine improvements for more details). A new Electronic Control Module, Transmission and Chassis Control (TCC), replaces EPTCII and incorporates several new system improvements. TCC communicates over the CAT Data Link with the engine ECM to manage engine speed during shifts for increased clutch life and operator comfort. TCC also controls body hoist, neutral start, rear axle filtration, and automatic lubrication functions. Brake Circuits Brake circuits have been integrated on all three C-Series trucks to provide operators with the brake system confidence and performance they have come to expect from Cat trucks through the new Integrated Braking Control (IBC) system. This system incorporates all the advantages of the proven Traction Control System (TCS), Automatic Retarder Control (ARC) system, and normal brake control systems into one simplified control module located in the rear of the operator station. Vital Information Management System (VIMS) Caterpillars Vital Information Management System (VIMS), an intelligent machine management tool, provides operators, service personnel, and managers with information on a wide range of machine functions. VIMS has been redesigned to relocate sensor modules in the rear of the operators station on all three C-Series trucks for improved reliability and serviceability.

Electronic Controls

Improved Serviceability

Circuit Breakers Circuit breakers have replaced fuses, providing additional protection of electrical systems and improved serviceability. Consolidated Electronic Controls Electronic controls, including: Integrated Braking Control (IBC), Vital Information Management System (VIMS), and the Transmission and Chassis Control Module (TCC), have been consolidated for simpler troubleshooting. Heating and Air Conditioning System The heating and air conditioning unit has been relocated to the front of the operators station for easier serviceability, removal and installation. Turn Signals Turn signal and amber lamps have been redesigned and now feature LED lamps for improved visibility and longer life.

Improved Cooling System on 789C

Significant improvements have been made to the 789C cooling system to improve engine cooling, efficiency and emissions. Larger Radiator Capacity The capacity of the 789C cooling system has been expanded 40 percent by increasing the capacity of the radiator from 474 L (125 gal) to 663 L (175 gal). Shunt Tank A shunt tank has been added to the cooling system, providing positive pressure at the coolant pump inlet to prevent cavitation in high flow conditions. Larger Fan The fan diameter increased from 70 to 78 inches, and the number of blades increased from 8 to 11 for improved cooling efficiency.

Payload Standard Body Capacity: Struck Heaped 2:1 (SAE) Body Capacity with sideboards 460 mm (18") Struck Heaped 2:1 (SAE) Standard Empty Machine Weight (approximate) Maximum Gross Vehicle Machine Weight Engine Rated Speed Engine Power: Gross Net Wheel Base Turning Diameter Steering Angle Fuel Tank Capacity (standard) Top Speed Transmission Speeds Brake Surface Area

Metric 118-136 metric tons 57.0 m3 78.0 m3

English 130-150 U.S. tons 74.0 yd3 102.0 yd3

785C Brief Specifications

74.0 m3 91.0 m3 94 922 kg

96.0 yd3 119.0 yd3 209,302 lb

249 480 kg 550,000 lb Cat 3512B EUI 1750 rpm 1082 kW 1450 hp 1005 kW 1348 hp 5180 mm 17'0" 27.5 m 90'2" 36 degrees 1893 L 500 gal 54.8 km/hr 34.0 mph 6F - 1R 23,405 in2 150 962 cm2

789C Brief Specifications

Payload Standard Body Capacity: Struck Heaped 2:1 (SAE) Body Capacity with sideboards 460 mm (18") Struck Heaped 2:1 (SAE) Standard Empty Machine Weight (approximate) Maximum Gross Vehicle Machine Weight Engine Rated Speed Engine Power: Gross Net Wheel Base Turning Diameter Steering Angle Fuel Tank Capacity (standard) Top Speed Transmission Speeds Brake Surface Area

Metric 154-177 metric tons 73.0 m3 105.0 m3

English 170-195 U.S. tons 96.0 yd3 137.0 yd3

94.0 m3 120.0 m3 119 793 kg

123.0 yd3 157.0 yd3 264,093 lb

317 520 kg 700,000 lb Cat 3516B EUI 1750 rpm 1417 kW 1900 hp 1335 kW 1791 hp 5700 mm 18'8" 27.5 m 90'2" 36 degrees 3222 L 851 gal 54.4 km/hr 33.8 mph 6F - 1R 30,742 in2 198 338 cm2

Payload Standard Body Capacity: Struck Heaped 2:1 (SAE) Body Capacity with sideboards 500 mm (20") Struck Heaped 2:1 (SAE) Standard Empty Machine Weight (approximate) Maximum Gross Vehicle Machine Weight Engine Rated Speed Engine Power: Gross Net Wheel Base Turning Diameter Steering Angle Fuel Tank Capacity (standard) Top Speed Transmission Speeds Brake Surface Area

Metric 218 metric tons 96.1 m3 129.4 m3

English 240 U.S. tons 125.7 yd3 169.3 yd3

793C Brief Specifications

120.3 m3 147.5 m3 144 715 kg

157.4 yd3 193.0 yd3 319,050 lb

376 488 kg 830,000 lb Cat 3516B EUI 1750 rpm 1715 kW 2300 hp 1615 kW 2166 hp 5900 mm 19'4" 28.4 m 93'3" 36 degrees 3785 L 1000 gal 54.3 km/hr 33.7 mph 6F - 1R 34,769 in2 224 317 cm2

The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and is intended exclusively for their information and training. It may contain unverified analysis and facts observed by various Caterpillar or dealer employees. However, effort has been made to provide reliable results regarding any information comparing Caterpillar built and competitive machines. Effort has been made to use the latest available spec sheet and other material in the full understanding that these are subject to change without notice. Any reproduction of this release without the foregoing explanation is prohibited.

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August 1998 www.CAT.com
1998 Caterpillar Printed in U.S.A.