Power Train - Engine
The Cat 3516B High Displacement engine is built for power, reliability and efficiency for superior performance in the toughest applications. The field–proven engine delivers high horsepower, superior fuel efficiency, lower emissions, reduced engine noise and lower operating costs. |
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 | | Engine
The Cat 3516B High Displacement EUI quad turbocharged and aftercooled diesel engine produces 5% greater power with enhanced power management capability for maximum hauling performance in the most demanding mining applications. |
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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 Cat 3516B High Displacement 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 2750 m (9,000 ft). Power is automatically derated as altitude increases to help prevent excessive combustion temperatures and subsequent component damage. |
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High Altitude Arrangement (HAA)
The optional Cat 3516B quad and series turbocharged aftercooled short stroke engine provides full power with no deration at altitudes greater than 2750 m (9,000 ft). |
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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 skirts 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)
The engine is controlled by the new engine-mounted ADEM™ III engine controller, which provides integration of the engine with other systems, incorporates the latest technology for additional monitoring functions and increases input output capability.
The ADEM III engine controller uses advanced engine management software to monitor, control and protect the engine using self-diagnosing electronic sensors. The computerized system senses operating conditions and power requirements, and adjusts engine for peak performance and most efficient operation at all times. The engine controller:
- Automatically derates power by limiting fuel when elevation reaches 2750 m (9,000 ft), which prevents excessive exhaust gas temperatures and related damage.
- Disables acceleration on startup for two seconds after the engine attains low idle, which gives all machine lubrication and cooling systems time to achieve full pressure and flow.
- Detects when engine coolant temperature is below 20° C (68° F) and signal the engine to operate in “cold mode,” which retards timing until the engine reaches operating temperature, reducing peak cylinder pressure and the rate at which cylinder pressure rises.
- Indicates when engine coolant temperature dips to 70° C (158° F), and low idle is elevated to 1,600 rpm from the standard 700 rpm, which prevents engine overcooling.
- Matches injection timing and duration with the transmission’s demand allows fuel to be optimized not only during steady state operation, but also during transient acceleration.
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• ECM Engine Monitoring
The ECM monitors and adjusts for overspeed, acceleration delay on start-up, elevated low idle, cold mode start, throttle lock, air filter restriction, altitude compensation, fuel use, multi-point pressure sensing, ether aid, starter protection, electrical connections and diagnostics. |
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• Transmission/Chassis Monitoring
The ECM monitors and adjusts for transmission shift control, lock-up clutch control, controlled throttle shift, directional shift management, top gear limit, shift counter, transmission lockout and transmission oil level. |
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• Brake System Monitoring
The ECM monitors and adjusts for Hydraulic Automatic Retarder Control (HARC), Traction Control System (TCS), brake lights, brake cooling system, engine cooling system, continuous rear axle lubrication, brakes, brake overstroke, service brake pressure, secondary brake pressure, parking brake filter bypass switch, retarder pressure switch, brake system pressure sensor, differential filter bypass switch, differential oil level switch, differential pressure sensor, differential oil temperature sensor. |
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Separate Circuit Aftercooler
Allows the aftercooler circuit to operate at a cooler temperature than the jacket-water temperature for a denser air charge and greater combustion efficiency. Eliminates the stress, weakness and cracking produced by frequent thermal cycles, and accommodates the additional heat load of the higher horsepower engine. |
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 | | Cooling System
Modular high-density cooling system with a 2130 mm (84 in) fan, which promotes more efficient cooling with lower fuel consumption and noise levels. It is also easily serviceable. The fan and drive motor are removed with the radiator, as one unit, headlights are no longer on the radiator module, and the surge tank/radiator is one self-contained unit. |
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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, from 500 hours to 4,000 hours or more, and reduce oil disposal labor and costs. Engine oil from the crankcase is injected into the engine’s fuel return line, and new oil is added manually as a part of daily maintenance. |
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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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Intake and Exhaust System
Performance and efficiency are optimized by side-mounted turbochargers that are carefully matched to each engine rating. The new bearing system offers longer life and improves aerodynamics for better response, altitude compensation and lower emissions. The intake and exhaust valves are designed to prevent seizures via chrome-plated stems, which promotes more even wear and heat distribution. |
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Cylinder Block
Cat 3500 engines use only stress relieved, high tensile strength, cast iron alloy for the cylinder block, which allows increased resistance to stress cracking. Strength and rigidity, which keep crankshafts and cylinders aligned, are added to the block by a deep-skirted structure and heavy, internal ribbing. The block is also designed to resist twisting and flexing, eliminate the need for block liner counterbores, and allow for longer head and head gasket life. |
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Crankshaft and Bearings
The high fatigue strength of the material used to craft the crankshaft allows it to be reground up to three times. The bearings resist the scuffing and are designed for lower bearing loads and longer life. |
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Liner
Designed for maximum oil control, wear resistance and reusability at overhaul. |
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Turbocharger
The new turbocharger allows for higher compressor speeds and has a decreased area-to-radius ratio, which increases response and lowers exhaust temperatures. Turbo life is improved by a titanium compressor wheel, an improvement from the forged aluminum 793C compressor wheel and a feature that results in lower operating costs via less maintenance. |
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Vibration Reduction
The 793D has retained the dual, fluid-filled damper system that reduces engine vibration and noise. |
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 | | Fuel Tanks
Two new optional fuel tank sizes are available for the 793D:
- 4350 L (1,150 gal)— Provides 24-hour operation at normal duty operation at 38% load factor
- 4920 L (1,300 gal) — Provides 24-hour operation in heavy duty operation at 43% load factor
Both are fitted with a larger inlet hose diameter — from 38 mm to 51 mm (1.5 to 2.0 in) — for faster fill capability with fast fill system. |
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Power Train - Merchandising Arrangements
The 793D is available in four different normal altitude configurations and one arrangement for high altitude operations. All configurations include key components matched to performance requirements in specific applications and conditions. |
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 | | Merchandising Arrangements
The 793D is available in four different normal altitude configurations and a high altitude arrangement. All configurations deliver increased speed on grade and include key components that are performance matched to the hauling application and site conditions. |
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 | | Standard Arrangement
The standard arrangement is designed for exceptional, all-around performance. More power at the wheels reduces cycle times and lowers cost-per-ton.
Enhancements incorporated into all normal altitude configurations include:
- 5% increase in engine horsepower (2,300 to 2,415 hp)
- Common rail hydraulic system improvements with reduction of up to 4% in parasitics
- Up to 9% effective horsepower increase means more speed on grade
- Modular high-density cooling system with a 2130 mm (84 in) fan
— The new modular higher density cooling system with larger fans is hydraulically driven for more efficient cooling with lower fuel consumption and noise levels.
- Continuous rear axle filtration
— A new filtration system provides cooler, cleaner oil and parasitic power loss management via a constant oil flow to the final drives for longer component life.
- New wear- and fade-resistant brake friction material
— 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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 | | Extended Life Wheel Groups
Developed for uphill hauling applications, this arrangement is designed to extend wheel life and hauling performance on long, uphill hauls. Extended life wheel groups are built with larger, more durable components, including larger spindles, wider wheel bearing spacing, a larger braking surface, and extended life friction disc material for longer brake life and more time between overhauls. The Extended Wheel Life Group is included in the optional Extra Top Speed, Extra Retarding and High Altitude arrangements; however, wheel groups for the standard configuration remain the same as in the 793C. |
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 | | Extra Top Speed
Developed for long, flat haul applications, this configuration delivers a 10% increase in maximum speed to 60 km/h (37 mph) via a new input transfer gear group. This arrangement also includes Extended Life Wheel Groups. This arrangement also includes the optional Extended Life Wheel Groups arrangement. |
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 | | Extra Retarding
Developed for downhill-loaded applications, this configuration typically delivers an extra gear of retarding capability of 35% more speed on downhill grades. Extra retarding is achieved by adding more robust wheel groups, larger brakes, extended life friction material, and additional cooling capacity. |
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 | | High Altitude Arrangement
Developed for high altitude applications, the 3516B short stroke engine delivers enhanced power management at higher altitudes — from 2750 to 1600 m (9,000 to 12,000 ft). This arrangement also includes Extra Retarding. This arrangement also includes the optional Extra Retarding. |
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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 high displacement 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 provide 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 HD 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 HD 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)
TCC uses electronically transferred engine rpm data to execute shifts at preset points for optimum performance, efficiency and clutch life. The TCC provides integrated functionality to controlled throttle shifting, directional shift management, neutral coast inhibitor, body-up shift limiter and body-up reverse neutralizer. |
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2) Lock-Up Torque Converter
Combines maximum rimpull and cushioned shifting of torque converter drive with the efficiency and performance of direct drive. The torque converter includes: an additional clutch plate to maintain power train capability for higher horsepower and top speed, a new torque converter adapter that provides extra length to house the additional clutch plate and enables the converter components to be changed without having to change the housing, and a new sump oil level switch that serves as an emergency warning if oil is lost. The lock-up torque converter engages at approximately 8 km/h (5 mph), delivering more power to the wheels. |
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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 differential and 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. They deliver superior performance and are of such high quality that they can be remanufactured for a second life. |
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• Rear Axle Filtration
A new hydraulically driven filtration system provides cooler, cleaner oil and parasitic power loss management via a constant oil flow to the final drives for longer component life. |
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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
Cast rear wheels and Cat center-mount rims are mounted using studs and nuts to minimize maintenance and maximize durability. |
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 | | • Front Wheel Assembly
Larger higher capacity wheel bearings are designed to increase durability. Wheel bearings have a wider spread for even load distribution. And an increased spindle diameter allows for a more robust wheel mounting. |
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Input Transfer Gear and Transmission
There are two new groups: one for the Standard configuration, and one with extra teeth to accommodate the Extra Top Speed configuration. Both have features that reduce transmission noise and that are designed to house standard and high–speed gears. |
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Differential Drives
Cat differential and final drives work as a system with the planetary power shift transmission to deliver maximum power to the ground. The differential carrier divides the power between the right and left axle shafts, turns the power 90 degrees so that it can turn the wheels, and adjusts the speed of the axle shafts for vehicle cornering. These enhancements improve the service life of the differential and wheel station components. |
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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
Reduces driveline torque spikes and transmission clutch energy spikes. When an operator changes direction without stopping, the transmission sends a signal to the ECM to momentarily reduce engine speed while the transmission shifts, reducing the potential for damage and related driveline component failures. |
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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 preprogrammed gear without the body being fully lowered. This allows the machine to move forward but limits speed to avoid excessive racking when pulling away from a dump site.
An indicator light on the dash notifies the operator when the body is up. It serves as a reminder that the body is up to help prevent unsafe operation of high-speed travel with the body raised. The shift inhibitor is set to first gear at shipping but can be programmed up to third gear. |
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Overspeed Protection
The transmission control electronically senses engine conditions and automatically upshifts one gear to prevent overspeeding. If overspeeding occurs in top gear, the lock-up clutch is disengaged. Overspeed protection is controlled via the Cat Data Link, and warnings are displayed on the VIMS monitoring system. |
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Programmable Top Gear
Transmission top gear maximum can be set using the Cat ET service tool to help the operator maintain speed limits. |
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Anti-Hunt Function
Minimizes shifting by not allowing the transmission to upshift or downshift 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 the transmission from downshifting until engine speed reaches the downshift point. |
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Economy Shift Mode
Engine speed in third gear and above is reduced to improve fuel consumption, lower noise levels and potentially lengthen engine life. Economy Shift Mode is best used when a customer has extra truck capacity and wants to lower cost-per-ton. A customer who effectively uses Economy Shift Mode can reduce operating costs without sacrificing production. |
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Rapid Downshift Function
The TCC will override the turnaround time delay when the operator applies either the brake or the retarder. Downshifts are able to occur immediately as the decreasing transmission output speed dictates. This function allows the operator to make a sudden stop while the turnaround time delay is in effect. |
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Reverse Speed Inhibitor
Another feature of the TCC is the protection it provides from high-shock loads created by abusive directional shifts. This feature prevents shifts into reverse when forward ground speeds are greater than 3 mph. |
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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. Cat ET is beneficial because of how it displays the status of all engine parameters, including throttle position, timing and fuel flow. 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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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)
IBC integrates Hydraulic Automatic Retarder Control and Traction Control into one system for optimum performance and efficiency. |
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 | | Hydraulic Power Management System
The system, also known as common rail hydraulics, reduces parasitic — unused or wasted — losses in the power management system components and the new hydraulic fan drive system. The system is operated by two new variable displacement piston pumps. These pumps primarily provide for the steering and cooling functions, and are independent of the brake and hoist circuit. One pump is dedicated to a new on-demand hydraulic fan drive system that is designed to increase available power and improve sound management. The other pump feeds a new priority valve and provides hydraulic pressure and flow to feed steering, brake cooling, rear axle filtration (RAX), and the optional RAX cooler systems. The system continues to allow priority for the steering system while using an improved power management scheme for brake cooling and RAX functions. By reducing the losses, the system is able to provide more horsepower to the ground. |
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 | | 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 ease of troubleshooting, and extend component life. All the information from these controls can be accessed through the VIMS monitoring system message center or a laptop computer with Cat ET or VIMS PC software. |
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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. With proper attention to oil temperatures, the brakes experience virtually no wear, and most mines have had service lives of more than 10,000 hours. |
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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. |
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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
The Caterpillar two-piece piston design combines the service, secondary, parking brake and retarding functions in the same system. The primary piston hydraulically actuates both service and retarding functions. The secondary piston is spring-applied and held in the disengaged position by hydraulic pressure. If hydraulic system pressure drops below a specified level, the spring-applied secondary piston automatically applies the brakes. |
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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%. |
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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. It is designed to modulate the brake system in order to maintain a constant engine speed, and it also promotes smoother engagement, better responsiveness, loping removal, less air system demand and fewer air system parts. 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
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- Less chance for engine overspeed
- Smoother engagement
- No loping
- Less air system demand
- 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 maneuvering and control in slippery conditions. |
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Integrated Braking Control (IBC)
Combines HARC and 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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Brake Oil Cooling System
A new brake cooling system is used to control the cooling of the brakes. The IBC controls the solenoid for the brake cooling pump to adjust the flow of oil used for brake cooling. The IBC also directs the flow of oil through extra coolers via a diverter during HARC operation. |
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Fan Cooling System
The new water cooling system is controlled by the IBC, which controls the cooling fan. The IBC varies the speed after analyzing various inputs. |
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Continuous Rear Axle Lubrication
The IBC also controls the new continuous rear axle lubrication system. The system delivers a more consistent oil supply to wheel bearings and final drive assemblies providing longer life. An optional cooler and fan reduces the temperature of the rear axle lubricating oil. |
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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 793D frame uses a box-section design, incorporating two forgings and 24 castings in high-stress areas with deep penetrating and continuous wrap-around welds to resist damage from twisting loads without adding extra weight. Cat frames have shown superior durability and have resulted in trucks with more than 100,000 operating hours. |
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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. It also allows for superior fatigue resistance, outstanding weldability and 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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 | | 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 structure provides “five-sided protection” for the operator and is ROPS- and FOPS-certified to ISO standards. |
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Suspension System
Designed to dissipate haul road and loading impacts for longer frame life and a more comfortable ride. The improvements are designed to reduce the potential for pressure leaks and to improve the accuracy of the payload measurement system. |
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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 use 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 uneven and rough haul roads rather than transmitting them to the main frame. |
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 | | Monitoring System
The VIMS™ monitoring system provides operators, service technicians and mine personnel with vital machine health and payload data to keep the 793D 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 793D performing at top production levels. In addition to the usual VIMS monitoring system functionality, the system also monitors torque converter screen switch, torque converter inlet filter, brake oil temperature, fuel level, ambient air temperature, ‘R’ terminal, front aftercooler temperature, aftercooler coolant level, jacket-water level, high steering pressure switch, steering oil temperature, steering oil bypass switch and payload. |
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Integrated System Monitoring
Sensors located throughout the machine systems enable the VIMS monitoring system to quickly exchange and monitor information from all machine systems for efficient, high-performance operation. |
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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 for analysis. Data can be accessed through the message center, transmitted via optional radio or downloaded onto a computer 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
- Gear indicator
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 | | Gauge Cluster
Conveniently located gauge cluster maintains a constant display of vital machine functions, including:
- Engine coolant temperature
- Brake oil temperature
- Air system pressure
- Fuel level
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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. The keypad can also be used by service personnel to access diagnostic information. |
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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. |
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• Category I
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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 | | Production Management
Production management enhances truck/loading tool effectiveness, improves fleet productivity and helps extend the life of truck frames, tires, rims and power train components while lowering operating and maintenance cost. |
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 | | Payload Management
Max Payload Speed Manager is a feature that aids in managing the Caterpillar 10/10/20 Overload Policy. Based on target payload weight and overload settings, the VIMS monitoring system logs and warns the operator when the truck reaches overload after second gear reweigh. The truck will be limited to second gear at 1,750 rpm, and the automatic retarder speed setting is reduced to 1,750 rpm until the load is dumped.
Payload management enables the manager to enhance truck/loading tool effectiveness and productivity levels by preventing overloads that can cause damage to component life and affect operator safety.
The Payload Weight Distribution chart illustrates the benefit of managing payloads with VIMS monitoring system production management tools. |
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Data Storage
The VIMS monitoring system stores payload information that is used to manage production. The system stores up to 2,400 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, using the efficiency of Preventative Maintenance. |
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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 display with digital numeric monitor are available to replace the standard red/green indicator lamps. |
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Road Analysis Control (RAC)
Customers can more effectively and efficiently manage haul roads with this optional advanced solution. By measuring frame, rack and pitch levels, RAC precisely tracks haul-road conditions and communicates the information in real time via a radio network. The data and reports generated can be used to improve haul-road maintenance and, in turn, cycle times, component life and fuel efficiency. VIMS monitoring system stores the RAC events and creates a summary measurement, called a Fatigue Equivalent Load Analysis (FELA), that allows management to track severity and benchmark road conditions. When used with a telemetry system such as the MineStar® information management system, RAC events can be transmitted in near real time to the mine control office for immediate action by haul-road maintenance crews. RAC is designed to help all Cat truck users derive more value from their owning and operating experience. |
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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 personnel to generate health and payload reports for more effective machine management. |
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VIMS Supervisor
Optional software allows mine personnel to easily manage and interpret VIMS monitoring system data for optimum fleet management and productivity. The easy-to-use analysis tool has the ability to read the VIMS monitoring system database and generate custom reports based on customer preferences. |
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MineStar® Information Management System
The Caterpillar union of mine planning, business management and advanced on-board information systems is unparalleled. MineStar information management system helps meet the challenges of the mining industry by linking the machines in the field with business and operating systems to ensure peak performance of mining assets at the lowest possible cost. These products deliver customers everything from real-time machine health information to GPS-guided production aids. The 793D is equipped for quick and easy installation of MineStar information management system products. Specific Minestar information management system products include:
- MineStar Machine Tracking — Monitors machine locations and fleet movement via GPS, alerting controllers to delays against expected arrival times. Provides position analysis of machine operational and health events
- MineStar Material Tracking — Tracks and manages material types and grades, improving overall ore recovery by ensuring material is moved to correct destinations. Includes material stockpile tracking. Allows for real-time ore-grade determination at the excavation face.
- MineStar Production — Monitors and reports mine production information in real time. Manages production and delay codes for accurate machine utilization tracking.
- MineStar Fleet Commander — Advanced optimization algorithm increases truck/shovel fleet use. Maximizes shovel production and minimizes truck wait time, while simultaneously meeting mine production plan requirements for material blending.
- MineStar Health — Monitors and communicates machine vital sign information in real time, enabling remote maintenance/service diagnostics and advanced prognostic analysis. Enhances the entire maintenance and repair process, allowing higher machine availabilities to be attained.
- MineStar Business Enterprise — Provides IT infrastructure platform for seamless integration of MineStar information management system with other mine planning and enterprise resource planning systems.
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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
Caterpillar offers three specific body styles and custom body options to help customers obtain the lowest cost-per-ton hauling solution.
- Dual-Slope
- Flat Floor
- Mine Specific Design (MSD II)
The flat floor and dual slope bodies offer a heavy-duty structure for long life, impact durability and excellent wear characteristics. The MSD II bodies are customized to suit specific mining applications and provide for a more efficient haul and easier dumping.
The MSD II body delivers unsurpassed durability while maintaining excellent payload performance.
- Deliver superior abrasion and impact resistance
- Provide significant weight savings of up to 21%
- Deliver 20,000+ service hours before major rebuild or repair
- Feature a trademark grid floor texture
- Promote enhanced material flow and shedding
- Have superior impact distribution
- Have enhanced floor plate support
- Promote easier inspection and maintenance
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Body Selection
Selection of the right body depends on material and haul road conditions. The better the match of body to application, the greater the efficiency. Your Cat dealer can help you select the right body system for your site specific applications. |
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Body/Chassis Integration
Caterpillar truck bodies are the only truck bodies designed and matched with the integrated chassis system for optimum structural reliability, durability and long life. |
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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 20.25 seconds for raise and 17.5 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. Modular liner plate packages:
- Smooth plate
- Rock box
- Zipper grid
- Mechanically Attached Wear Plate System (MAWPS)
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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
Your Caterpillar Dealer can help you manage to target payload to maximize equipment use, ensure safe operation, increase productivity and lower cost-per-ton.
- Underloading increases costs due to lost payloads, underuses equipment, and drives cost-per-ton.
- Overloading, or surpassing maximum gross machine weight, causes excessive wear on vehicle components such as brakes, tires and drivetrain, reducing component life and increasing maintenance costs and repairs.
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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) 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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3) Mine Specific Design (MSD II) Body
The lightweight MSD II body is based on the flat floor design and is customized to maximize payload potential and minimize cost-per-ton. Each MSD II body design begins with a detailed mine site profile to develop a body suitable for a mine's individual needs. |
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Manufacturing Processes
Bodies are produced using the latest technology, such as solid modeling graphics, plasma burners, robotic welding and special welding specifications for higher strength steels. Manufacturing sources throughout the world enable Caterpillar to meet local needs. |
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 | | Customer Support
Caterpillar dealers provide unmatched product support, anywhere in the world. With the best part availability in the world and a wide range of maintenance and service options, Cat dealers have what it takes to keep your mining machine productive. |
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| | Commitment Makes the Difference
Cat dealers offer a wide range of solutions, services and products that help you lower costs, enhance productivity and manage your operation more efficiently. Support goes far beyond parts and service. From the time you select a piece of Cat equipment until the day you rebuild, trade or sell it, the support you get from your Cat dealer makes the difference that counts. |
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Dealer Capability
Cat dealers will provide the level of support you need, on a global scale. Dealer expert technicians have the knowledge, experience, training and tooling necessary to handle your repair and maintenance needs, when and where you need them.
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. When Cat products reach the field, they are supported by a worldwide network of parts distribution facilities, dealer service centers, and technical training facilities to keep your equipment up and running. Cat customers rely on prompt, dependable parts availability and expertise through our global dealer network, ready to meet your needs 24/7. |
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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, including:
- Preventive Maintenance Programs
- Diagnostic Programs, such as Scheduled Oil Sampling and Technical Analysis
- Rebuild and Reman Options
- 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
With today’s complex products, equipment operators must have a thorough understanding of machine systems and operating techniques to maximize efficiency and profitability. Your Cat dealer can arrange training programs to help operator's improve productivity, decrease downtime, reduce operating costs, enhance safety and improve return on the investment you make in Cat products. |
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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 complete, detailed information on all Cat products, dealer services and industry solutions, visit us on the Web at www.cat.com. Specializing in fast, accurate and up-to-date information, the Cat Web site delivers the information needed for 24-hour-a-day operation. |
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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 793D operator station is ergonomically designed for total machine control in a comfortable, productive and safe environment. All controls, levers, switches and gauges are positioned to maximize productivity and minimize operator fatigue. |
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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
A toggle link based suspension system with new high-back upper cushion and adjustable rake lower cushion combine to cushion the ride on the most rugged haul roads. Ergonomically designed, fully adjustable air suspension seat with adjustable armrests provides optimal driving comfort. A wide, retractable three-point seat/shoulder belt provides a secure, comfortable restraint with three height adjustments and six vertical adjustment positions. With a 10,000-hour life expectancy the seat is designed for long life and durability. These seats have proven to be up to 80 percent more cost effective than that of the competition. |
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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. The hoist system offers superior control and reliability of cylinders. |
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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 monitoring 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 gearshift lever with backlit gear indicators optimize efficiency. |
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7) Parking Brake Reset Valve
Parking brake cannot be released when air system is drained until valve button is 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
The operator station features a four-speed fan for greater airflow control. A total of 11 vents are used to direct airflow throughout the cab. The automotive–style heating and air conditioning controls on the dash panel are within easy reach of the operator. The air conditioning is electronically controlled and has an electronically operated water valve. This provides the operator with a constant cab temperature. A more robust air compressor offers greater durability and longer life for the system. |
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Communication Systems Ready
Cab is prewired with power converter, speakers, wiring harness, antenna and mounting locations for add-on radio, closed circuit TV, and MineStar® systems.
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 | | Catwalk Extension
The catwalk has been extended at the operator’s door to allow a larger arc through which the door can open. The wider opening access platform makes movement in and out of the cab easier.
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 | | Rear Access Platforms
An optional rear access platform is available to enable easier access to the components in the rear of the cab. A handrail can be locked into place when the body is up and access is required behind the cab. The handrail folds down to enable the body to be lowered into normal loading position. The rear access platform enhances service accessibility and provides for easier movement around the truck.
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 | | Wider Stair Access
For improved ease of access, the 793D is fitted with a new 600 mm (23 in) wide stair, replacing the 400 mm (15 in) version on the 793C. The new stair provides additional comfort for operators and service personnel. To accommodate faster removal of the radiator and cowling assembly, the stairway is attached to the radiator grill. This enables a one-piece removal of the stair, radiator and platform. |
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 | | Toe Boards
Toe guards have been added to the front and side platforms to provide protection from slipping and also to prevent any tools or loose items from falling off the platform when maintenance or service work is being performed. |
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 | | Serviceability
The 793D 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 monitoring system data port permits easier downloading of information. |
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Transmission Lockout Switch
Ground-level transmission lockout switch allows the truck to be serviced with the engine running, without the risk of accidental motion. An optional indicator light is available. |
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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 monitoring system continuously checks all critical machine functions and components, and helps locate faults quickly for faster repair. Electronic control system enables quick diagnosis of engine conditions and effective maintenance and repairs using the Cat ET service tool. |
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 | | Mirrors
The left side mirror mounting bracket is more robust and allows mirror glass to be easily replaced, without the need for a new mirror assembly. New mirror glass slides in and out of the carrier, reducing downtime and maintenance costs. Also, optional heated mirrors are available for cold weather applications. |
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 | | Sight Gauges
Sight gauges make daily maintenance simple and easy. Sight gauges are provided for transmission oil, hydraulic oil and radiator coolant. All are easily visible and eliminate the risk of contamination from opening reservoirs daily. |
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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 793D 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 provides "five-sided protection" for the operator. |
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Ladder/Secondary Egress
A wide, stationary stairway allows easy access to and from the machine. The ladder on the left side of the machine permits secondary access or emergency egress. |
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Brake Systems
Four-corner, oil-cooled braking system provides excellent control in slippery conditions. The service brakes and retarding system are actuated by modulated hydraulic pressure, while secondary and parking brake functions are spring applied and hydraulic released. This system assures braking in the event of complete hydraulic failure. |
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Steering System
A twin, double-acting, variable pump cylinder steering system is designed to deliver precise control under all loading and underfoot conditions while performing with higher efficiency and greater reliability. 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. The Caterpillar 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
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- Slip-resistant surfaces
- 75 mm (3 in) wide orange three-point operator restraint
- Wide-angle mirrors
- Body raised indicator
- Body retaining cable
- Guardrails
- Reverse neutralizer when dumping
- Low interior sound level
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 | | High-Intensity Discharge (HID) Lights
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1) High Beams / Upper Low Beams
2) Lower Low Beams / Fog Lamps
3) High Beams / Upper Low Beams
4) Backup Lights
Six optional HID lights — on fender, fog and rear lights — are designed to improve operator visibility during night operations, and increase machine and operator productivity in high hour mining applications. The 35-watt, high-intensity gas discharge light produces 3,200 lumens of light. The light produced is whiter, which creates the perception of more light. HID lights are approximately 70% efficient and twice as bright compared with 20 to 25% efficiency for halogen lights because more energy is given off as light instead of heat. The life expectancy of HID lights is also four to eight times longer than halogen lights. |
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