 |  | Power Train - Engine
The Cat 3516B engine delivers the power and reliability necessary to perform in the most demanding applications. Designed for efficient operation, the 3516B offers excellent fuel efficiency, lower emissions, reduced engine noise and lower operating costs. |
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Engine
The Cat 3516B EUI twin turbocharged and aftercooled diesel engine delivers high power and reliability in the world's most demanding mining applications. |
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Design
The 3516B is a 16-cylinder, four-stroke design that uses long, effective power strokes for more complete fuel combustion and optimum efficiency. |
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EPA Compliant
The 3516B engine is compliant with U.S. Environmental Protection Agency Tier I emissions standards. |
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Altitude Compensation
Designed for maximum operating efficiencies at altitudes under 2300 m (7,500 ft). |
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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. |
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Enhanced Life
High displacement, low rpm rating and conservative horsepower ratings mean more time on the haul roads and less time in the shop. |
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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. |
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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. |
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Electronic Control Module (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. |
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Separate Circuit Aftercooler
Allows the aftercooler circuit to operate cooler than jacket water temperature for a denser air charge and greater combustion efficiency. |
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Oil Renewal System
Optional oil renewal system extends engine oil change intervals from 500 hours to 4000 hours or more to increase machine availability and reduce costs. |
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Engine Protection
Computerized system electronically protects the engine during cold starts, high altitude operation, air filter plugging, and high exhaust temperature. |
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 | | Power Train - Transmission
The Cat six-speed power shift transmission and mechanical power train, matched with the electronic unit injection 3516B engine, provides consistent power and efficiency for peak power train performance. |
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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. |
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 | | 1) Transmission
The Cat six-speed planetary power shift transmission is matched with the direct-injection 3516B diesel engine to deliver constant power over a wide range of operating speeds. |
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Robust Design
Designed for the higher horsepower of the 3516B engine, the proven planetary power shift transmission is built tough for long life between overhauls. |
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Long Life
A dedicated oil tank and circuit provides cooler, cleaner oil for maximum performance and longer component life. |
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Transmission Chassis Control (TCC)
Transmission/Chassis Control (TCC) module communicates over the CAT Data Link with the engine ECM to manage engine speed during shifts for increased clutch life and operator comfort. When the transmission is in sixth gear, the engine is allowed to run out to 2000 rpm, so the truck can achieve speeds up to 55 km/h (34 mph). The shift points are set at the factory for optimal performance, efficiency and component life.
- TCC monitors and records key operating conditions and parameters for later downloading and diagnostic troubleshooting by service personnel.
The integrated system features:
- Programmable top gear limit
- Control throttle shifting
- Directional shift management
- Neutral coast inhibitor
- Economy shift mode
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| | 2) Lock-Up Torque Converter
Lock-up Torque Converter combines the maximum rimpull and cushioned shifting of torque converter drive with the efficiency and performance of direct drive. The lock-up clutch engages at approximately 7.2 km/h (4.5 mph). During shifts the lock-up clutch quickly releases and re-engages to reduce power train torque loads. This action provides for smoother shifting, extended component life, and increased operator comfort.
• Rimpull at stall is 840.6 kN (189,127 lb) - 32 percent gradeability at maximum operating weight. |
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Lock-Up Clutch
Quickly releases and re-engages to reduce power train torque loads for smoother shifting, long life and a more comfortable ride. |
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Smooth Shifting
Individual clutch modulation provides smooth clutch engagements to optimize performance and extend clutch life. |
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| | 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. |
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Steering System
Hydraulic steering control system is designed for exceptional smoothness and precise control. A separate circuit prevents cross contamination for long life. |
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Supplemental Steering
Supplemental steering system uses pressure accumulators and allows up to three 90 degree turns in case of engine failure. |
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Wheels and Rims
Center mounted rims and cast rear wheels are mounted using studs and nuts to minimize maintenance and provide outstanding durability. |
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 | | Engine/Power Train Integration
The Cat Data Link electronically combines engine, transmission, brake and operational information to optimize overall truck performance. Stored diagnostic data can be accessed via the Electronic Technician (Cat ET) to improve troubleshooting and reduce downtime. |
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Cat Data Link
Electronically integrates machine computer systems to optimize overall power train performance, increase reliability and component life, and reduce operating costs. |
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Controlled Throttle Shifting
Regulates engine rpm during shifting to reduce power train stress and clutch wear by controlling engine speed, torque converter lock-up and transmission clutch engagement for smoother shifts and longer component life. |
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Directional Shift Management
Regulates engine speed during directional shifts to prevent damage caused by high speed directional changes. |
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Neutral Coast Inhibitor
Prevents transmission from shifting to neutral at speeds above 6.5 km/h (4 mph) to protect the transmission from operating with insufficient lubrication. |
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Body-up Reverse Neutralizer
Automatically shifts the transmission to neutral if the hoist lever is activated while transmission is shifted in reverse. |
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Body-up Shift Inhibitor
Prevents the transmission from shifting above the pre-programmed gear without the body fully lowered. |
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Overspeed Protection
The transmission control electronically senses engine conditions and automatically up-shifts one gear to prevent overspeeding. If overspeeding occurs in top gear, the lock-up clutch is disengaged. |
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Programmable Top Gear
Transmission top gear maximum can be set using the Cat Electronic Technician service tool to help the operator maintain speed limits. |
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Anti-Hunt Function
Minimizes shifting by not allowing the transmission to up or down shift immediately after a shift has occurred. This prevents gear hunting when operating near a shift point and minimizes transmission shifting for increased component life. |
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Downshift Inhibitor
Prevents engine overspeeding by keeping transmission from downshifting until engine speed reaches the downshift point. |
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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. |
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Diagnostic Capability
Critical data from the electronic engine and transmission controls, including transmission shifting, engine speed and fuel consumption, provides service technicians with enhanced diagnostic capability to reduce downtime and operating costs. |
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Integrated Braking Control (IBC)
Integrates Hydraulic Automatic Retarder Control and Traction Control into one system for optimum performance and efficiency. |
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 | | 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. |
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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. |
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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. |
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 | | 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. |
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Optional 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. |
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| | 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. Oil cooled brakes provide superior performance and service life in comparison to shoe-type and dry disc brake systems. |
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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. |
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Pistons
Caterpillar's patented, two-piece piston design combines the service, secondary, parking brake and retarding functions in the same robust system.
- The primary piston is hydraulically actuated and provides both service and retarding functions.
- The secondary piston is spring-applied and is held in the disengaged position by hydraulic pressure.
- The brake system is designed so that, in the event hydraulic system pressure drops below a specified level, the spring-applied secondary piston automatically applies the brakes.
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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. |
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 | | 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. |
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HARC vs. ARC
- Less chance for engine overspeed
- Smoother engagement
- No loping
- Less demand on air system
- Reduces operating costs
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 | | HARC Production Advantages
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Faster Speeds
HARC allows the operator to maintain optimum engine speeds for faster downhill hauls and greater productivity. |
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Superior Control
Automatic brake modulation offers a smoother ride and better control in slippery conditions, allowing the operator to concentrate on driving. |
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Ease of Operation
HARC increases operating ease, resulting in greater operator confidence with less fatigue. |
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Engine Overspeed Protection
Automatically activates HARC when engine speed exceeds factory preset levels, regardless of operator inputs, to avoid potentially damaging engine overspeeds. |
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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. |
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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. |
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Differential Action
Normal differential action provides superior manuevering and control in slippery conditions. |
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Integrated Braking Control (IBC)
Retarder Control (HARC) and Traction Control System (TCS) into one integrated brake control system for optimum efficiency, performance and reliability. |
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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. |
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 | | Structures
Caterpillar® truck frames are built to optimize torsional load displacement. Mild steel provides flexibility, durability and resistance to impact loads. Castings and forgings in high stress areas provide exceptional strength and durability for long life. |
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Box-Section Design
The 785C 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. |
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Steel Structures
Mild steel used throughout frame provides flexibility, durability and resistance to impact loads, even in cold climates, and allows for easy field repairs. |
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Castings
Castings have large radii with internal reinforcing ribs to dissipate stress in areas of high stress concentration. Castings move welds to lower stress areas for greater frame life. |
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Serviceability
The open box-section frame design allows easy access to power train components, reducing overall removal and installation time, and lowering overall repair costs. The raised and pinned body allows excellent access to the transmission. |
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 | | 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. |
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Suspension System
Designed to dissipate haul road and loading impacts for longer frame life and a more comfortable ride. |
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 | | Cylinders
Four independent self-contained, oil pneumatic, variable-rebound suspension cylinders are designed to absorb shocks in the most severe applications. |
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 | | Durable Design
Rugged cylinders utilize large diameter bore and low pressure nitrogen/oil design for long life with minimal maintenance. |
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• Front
Front cylinders with preset caster and camber are mounted to the frame and serve as steering kingpins for a tight turning radius with excellent maneuverability and low maintenance. |
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• Rear
Rear cylinders allow axle oscillation and absorb bending and twisting stresses caused by rough, uneven haul roads rather than transmitting them to the main frame. |
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 | | Operator's Station
The ergonomic cab is designed for operator comfort and ease of operation to allow the operator to focus on production. Controls and gauges are positioned within easy reach for optimum efficiency and superior control. |
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Ergonomic Layout
The 789C 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. |
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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. |
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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. |
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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. |
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 | | 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. |
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3) Secondary Brake Pedal
Conveniently located on the floor for easy operator control. |
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4) Monitoring System
The VIMS system features an easy-to-read display and easy-to-use operator input keypad for precise machine status information. |
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5) Steering Column
Comfort wheel with tilt and telescoping steering provides a comfortable driving position. |
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6) Transmission Console
Ergonomic gear shift lever with backlit gear indicators optimize efficiency. |
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7) Parking Brake Reset Valve
When air system is drained, it will not not allow the parking brake to be released until the valve has been reset. |
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8) Storage Compartment
Large storage compartment is located under the trainer seat for a safe, uncluttered working environment. |
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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. |
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10) Operator Window
Powered operator window and sliding trainer seat window offer simple operation and an unobstructed view. |
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11) Operator Controls
Easy to reach turn signal, high beam, intermittent windshield wiper and windshield washer controls are designed for optimum efficiency and comfort. |
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12) Heating/Air Conditioning
Efficient design provides fresh, pressurized, temperature-controlled air circulation for a comfortable working environment in any climate. |
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Radio Ready
Cab is prewired with power converter, speakers, wiring harness, antenna and provision for add-on communication systems. |
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 | | Monitoring System
VIMS® monitoring system provides operators, service technicians and managers with vital machine health and payload data to keep the 789C performing at peak efficiency and top production levels while lowering cost-per-ton. |
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VIMS Monitoring System
Intelligent Caterpillar designed machine monitoring system provides critical machine health and payload data in real-time to keep the 785C performing at top production levels. |
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Integrated System Monitoring
Sensors located throughout the machine systems enable VIMS to quickly exchange and monitor information from all machine systems for efficient, high performance operation.
1)VIMS Interface Modules, 2)Transmission/Chassis Control (TCC), 3)Integrated Braking Control (IBC), 4)Engine Control Module (ECM), 5)Sensors, 6)CAT Data Link, 7)Diagnostic Connector (ET), 8)Gauge Cluster Module, 9)Message Center Module, 10)Data Port (VIMS-PC), 11)Action Lamp, 12)Action Alarm, 13)Service Lamp, 14)Payload Lamps, 15)Radio System |
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Advanced Diagnostics
VIMS monitoring system simplifies troubleshooting, reduces downtime and lowers operating costs by identifying abnormal conditions before they cause extensive damage. |
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Data Access
Monitoring and diagnostic information is stored on-board until it can be downloaded onto a computer. Data can be accessed through the message center, transmitted via optional radio or downloaded for detailed analysis. |
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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. |
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 | | Speedometer/Tachometer Module
Monitors three systems: engine speed, ground speed and gear indicator.
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 | | Gauge Cluster
A gauge cluster in the cab maintains a constant display of several, machine functions:
- engine coolant temperature
- brake oil temperature
- air system pressure
- fuel level.
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 | | Keypad
Provides operator or service technician immediate access to current machine information, gauge values and stored data through the message center display. |
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| | Message Center
Displays messages requested by operator and advises operator of abnormal machine conditions. |
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Alert System
Three-category warning system alerts operator of abnormal machine health conditions. The information is displayed when conditions in a monitored system fall outside a prescribed setting for ordinary operations. |
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• Category I
Three-category warning system alerts operator of abnormal machine health conditions. No action is required at this time. Inform service personnel of the alerted condition as soon as possible. |
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• 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. |
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• 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. |
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Data Storage
The VIMS system stores payload information, which is used to manage production. The system stores up to 2400 production cycles for a complete record of payload weight, cycle times, distances and actual dates/times. It also allows storage of maintenance data such as Events, Trends, Histograms, Cumulatives, Snapshot and Dataloggers. This data allows the user to identify potential problems before they occur, utilizing the efficiency of Preventative Maintenance. Data is accurate within ±5 percent of actual weight over a normal operating shift. |
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 | | Production Management
Maximum Payload Speed Manager is a feature within VIMS that allows the user to create an event when the truck has exceeded maximum payload based on target payload setting.
This tool provides accurate production reporting by utilizing suspension strut pressure differentials and advanced algorithm to weigh the truck after it moves away from the loading tool and shifts into second gear. Production data enhances truck and loading tool effectiveness and fleet productivity, and minimizes overloading to reduce downtime and lower operating and maintenance costs.
VIMS utilizes strut pressures and truck movements to record payload tonnage, travel distance, empty, loaded, stopped empty, stopped loaded and load time data for accurate payload reporting.
Max Payload Speed Manager is a VIMS feature that aids in managing the Caterpillar 10/10/20 payload policy by managing overloads. Based on target payload weight settings and overload settings, VIMS warns the operator when the truck is overloaded. When the overload is above the set limit, VIMS manages or limits the overload by limiting the speed of the truck.
Production management enhances truck/loading tool effectiveness and fleet productivity, helps lengthen the life of truck frames, tires, rims and power train components, and lowers operating and maintenance costs. |
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Payload Management
Max Payload Speed Manager is a VIMS feature that aids in managing the Caterpillar 10/10/20 payload policy. Based on the target payload weight and overload settings, VIMS logs and warns the operator when the truck has exceeded the overload setting after 2nd gear reweigh. The truck will be limited to 1750 rpm, 2nd Gear and the automatic retarder speed setting reduced to 1750 rpm until the load is dumped.
This payload management feature enables the manager to enhance truck/loading tool effectiveness and productivity levels, by preventing overloads that can cause damage to component lifes and affect operator safety. The chart below illustrates the benefit of managing payloads with VIMS production management tools. |
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External Payload Indicators
External lights on both sides of the truck signals loading tool operator when to cease loading for optimum payloads without overloading. Optional external payload displays with digital numeric monitors are available to replace the standard red/green indicator lamps. |
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Road Analysis Control (RAC)
Optional system monitors haul road conditions by measuring frame rack, pitch and bias to improve haul road maintenance, cycle times, tire life and fuel efficiency. |
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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 management to generate health and payload reports for more effective machine management. |
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VIMS Supervisor
Optional software allows mine management to easily manage and interpret VIMS data for optimum fleet management and productivity. |
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 | | Truck Body Systems
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. |
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Cat Truck Bodies
Matching the truck body to the application is a critical part
of achieving the best value from your 789C. Caterpillar offers five body choices to achieve the best match.
- Dual Slope
- Flat Floor
- Mine Specific Design (MSD II)
- MSD "X"
- Gateless Coal
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Body/Chassis Integration
Caterpillar engineers have developed the most comprehensive suite of dynamic analysis tools in the industry and design the body always keeping in mind the interaction of the body with the rest of the Mining Truck System. No one in the industry today comes close to the level of analysis and application understanding as Caterpillar.
Caterpillar designs the truck body as part of the larger Mining Truck System comprised of the Body, Loading Tool and Payload, Chassis, Terrain, Suspension, Wheels and Tires, and Power Train. By controlling the design and manufacture of the entire truck – Caterpillar is able to design bodies that fit the application
and also fit the chassis to give optimum load distribution and steering and braking performance.
Our field population and balance of
payload and durability are testimony to these methods. |
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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. |
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Fast Hoist Cycle Times
Two-stage hoist cylinders provide fast dump cycle times of 15.2 seconds for raise and 16.2 seconds for lower. |
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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. |
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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. |
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Target Payload Strategy
Achieving target payload is essential to meeting cost and tonnage/volume requirements at
your operation. Caterpillar’s exclusive 10/10/20 payload guidelines help achieve a balance of excellent payload with safe operation.
The Caterpillar 10/10/20 payload
guidelines take into account the reality of running an operation by allowing overloads within limits but the guidelines also eliminate large overloads that can lead to unsafe operation of the truck. |
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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. |
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 | | 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. |
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2) Mine Specific Design (MSD II) Body
The Large Mining Truck Body Industry has focused on maximizing payload via lightweight body programs for the last eight years. During that time Caterpillar has been the leading supplier of lightweight bodies, supplying over 1500 lightweight bodies in addition to thousands of standard bodies (dual slope and flat floor bodies). Caterpillar optimizes a system, referred to as the Mine Specific Design (MSD) to create a customer/site specific body that is designed to maximize performance via an appropriate sized body with the most efficient impact and wear protection. Caterpillar has a variety of liner offerings that are key contributors to the MSD process (including Caterpillar patented products). The tailor made liner package is as essential to payload maximization as it to critical impact and wear protection requirements. |
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3) Gateless Coal
The Gateless Coal Body is an extension of the Caterpillar lightweight body design concept. These bodies are designed with large volumes to achieve target payloads in coal mining applications. The Caterpillar Gateless Coal body eliminates the heavy and maintenance intensive tailgate with a kicked up floor design that gives the volume required to meet target payload in coal haulage applications. The canopy on the Gateless Coal Body is designed to minimize the amount of material rolling onto the canopy during travel loaded. The 785 will have 4 sizes of Gateless Coal Bodies to cover the coal density range around the world. (Contact Caterpillar Truck Body Group for design and shipping availability).
Additional Caterpillar large mining truck body information:
- MSD II Sales Brochure (AEXQ0015)
- Truck Body Maintenance & Operator Guide (AEDK0627)
- Mining Truck Bodies Technical Sales Presentation CD (AEXC0613)
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4) Caterpillar "X" Body
The Caterpillar X Body is a larger volume body than the dual slope or flat floor body. The added volume comes at no extra weight because of the design improvements to the Caterpillar X body. The design improvements include a more robust understructure of which, a new body pivot system and a new generation hoist bracket are included. The sidewall plate terminates on the floor plate and the sidewall and floor ribs are aligned to improve the structural integrity of the body. The sidewall ribs are tapered to provide more flexibility and durability. The Caterpillar X Body design is a combination of everything learned from the standard bodies (dual slope and flat floor) and the new technology of the lightweight body programs. |
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5) 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.
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 | | Serviceability
The 789C is designed for quick and easy servicing. Simplified service and maintenance features reduce downtime, allowing the machine to spend less time being serviced and more time on the haul roads. |
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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. |
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Maintenance Platform
Provides access to engine, air filters, steering hydraulic tank and battery compartment. |
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In-Frame Access
Permits easy access to major components for easy servicing and removal. |
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Ground-Level Access
Allows convenient servicing to tanks, filters, drains, and engine shutdown. Ground-level VIMS data port permits easier downloading of information. |
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Autolube
Automatic lubrication system reduces maintenance time by automatically lubricating necessary components on a regular basis. |
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Fast Fill Service Center
Optional Wiggins fast fill service center features high speed fuel and oil exchange. |
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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. |
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Scheduled Oil Sampling
S•O•SSM sampling valves speed sampling and analysis reliability. |
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Pressure Test Points
Disconnect valves are conveniently located throughout the hydraulic systems for easy pressure testing. |
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Air Filters
Radial seal air filters are easy to change, reducing time required for air filter maintenance. |
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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. |
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Cylinder Heads
Individual cylinder heads are interchangeable for easy removal and visual inspection of internal parts. |
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On-Board Diagnostic Systems
The VIMS system continuously monitors all critical machine functions and components to help locate faults quickly for faster repair. Electronic Control Systems provide diagnosis of engine, transmission, brake and chassis systems. Service Technicians utilize the Electronic Technician service tool (Cat ET) to program and troubleshoot these systems. |
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 | | Safety
Caterpillar sets the standard when it comes to safety in the design and manufacturing of heavy equipment for the mining industry. Safety is not an afterthought at Caterpillar, but an integral part of all machine and systems designs. |
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 | | 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. |
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SAE and ISO Standards
The 789C is designed to many national and international standards. |
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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 provide “five sided protection” for the operator. |
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Ladder/Secondary Egress
A wide, stationary ladder with a ladder with a stairway that allows easy access to and from the machine. The ladder on the right side of the machine permits secondary access or emergency egress. |
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Brake Systems
Four corner oil-cooled braking system provides excellent control. 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. |
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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. |
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Engine Shutoff Switch
A secondary engine shutoff switch is located at ground level. |
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Electrical System Disconnect
A battery disconnect switch, located directly above the front bumper, provides ground level lockout of the electrical system. |
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Overload Policy
Safety is integral to maintaining the highest productivity in mining machine operation. Caterpillar's 10/10/20 Overload Policy assures that steering and braking systems have sufficient capacity to perform, even at 20% overload. |
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Standard Safety Features
- Additional standard safety features include:
- Slip resistant surfaces
- Retractable, 75 mm (3 in) wide orange seat/shoulder belts with three-point operator restraint
- Wide-angle mirrors
- Body raised indicator
- Body retaining cable
- Guard rails
- Reverse neutralizer when dumping
- Low interior sound level
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 | | Customer Support
Caterpillar dealers provide unmatched product support, anywhere in the world. With industry-best parts availability and a wide range of maintenance and service options, Cat dealers have what it takes to keep your mining machines productive. |
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Commitment Makes the Difference
Customer expectations, coupled with competition in a global market, continue to raise the bar for customer support. Caterpillar dealers are committed to providing customers with world-class support to meet all your equipment selection, financing, operation, parts and service needs. |
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Dealer Capability
Dealer branch facilities, trained technicians, field service trucks, and operator training programs provide customers with complete customer support on a global scale. |
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Product Support
Cat dealers believe superior products deserve superior support. Cat customers rely on prompt, dependable parts availability and expertise through our global dealer network – ready to meet your needs 24/7. |
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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, such as:
- Preventive Maintenance Programs
- Diagnostic Programs: Scheduled Oil Sampling and Technical Analysis
- Rebuild and Reman Options
- Operator Training
- Customer Support Agreements
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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. |
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Operation
Improving operating techniques can boost your profits. Your Cat dealer has training videotapes, literature and other ideas to help you increase productivity. |
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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. |
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www.cat.com
For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at www.cat.com. |
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Matched Systems
An efficient loading/hauling system starts will a perfect match. Your Caterpillar Dealer can help you evaluate and select the right system for your specific application. |
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Product Support
When Cat products reach the field, they are supported by an advanced network of parts distribution facilities, dealer service centers, and technical training facilities, worldwide. Part of that support includes training of skilled service technicians responsible for working on today’s technologically advanced equipment. |
Ag Equipment
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