Boletin Competitivo Camiones Mineros Caterpillar - TEJB8063-01

Caterpillar Product Information
Competitive Bulletin
September 2006
Cat Mining Trucks

785C, 789C, 793D, 797B
For Dealer Sales Personnel
Table of Contents
Machine Positioning Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Structures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Mechanical Versus Electric Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Caterpillar Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Steering and Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Operators Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Truck Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Manufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cat Mining Trucks 785C, 789C, 793D, 797B
September 2006
Machine Positioning Strategy
Caterpillar undertakes extensive field research to ensure customer needs are understood. High on the list
of mining customer priorities are:
Lower cost-per-ton
Lower risk due to machine performance and operator safety
Less capital tied up in assets
Fewer liabilities
Caterpillar has responded with: research and development; continuous product improvement; superior
support, including MARC Contracts and Power-by-the-Hour; and tools such as Mine EIA (Equipment
Investment Analysis).
Today, as miners seek to reduce cost-per-ton, manufacturers are pushed to increase the payload capacity
of haul trucks. New tire, electronic and engine technologies have been developed to deliver a more powerful,
yet fuel efficient and environmentally friendly range of trucks. Caterpillar entered the ultra-truck market
with the introduction of the largest mechanical drive mining truck in the world, the 797.
September 2006
Competitive Situation
Field Population
785
789
793
797
Total Units
2,300+
1,800+
1,900+
190+
Fleet Hours
71 million
67 million
70 million
3.9 million
Highest Hour Unit

(As of June 2006)
127,000
106,000
105,400
49,000
Caterpillar clearly leads the Mining Truck market with over 5,780 mining trucks shipped since 1985.
Today, of every ten mining trucks sold worldwide, more than half bear the Cat brand. The remaining
sales are shared between four major competitors:
Komatsu
Liebherr
Terex-Unit Rig
Euclid-Hitachi
The Caterpillar global dealership network is comprised of 182 Dealers with 59 in the United States and
123 outside the U.S. Caterpillar dealers worldwide provide an unsurpassed level of personalized customer
service through more than 3,492 facilities (defined as main stores 182, branch stores 1,741 and rental
stores 1,569) in 182 countries.
There are 135 Caterpillar manufacturing centers worldwide with around 57 located in the U.S. and 78 located
outside the U.S. With 14 remanufacturing centers, 12 technical centers, 4 proving grounds and 16 training
centers, Caterpillar applies more resources than any of its competitors to developing, testing and producing
innovative, high quality products that are supported by the best quality technical and service personnel in
the industry.
The Caterpillar parts distribution network features 22 distribution centers in eleven countries with 11 located
in the United States. No matter where in the world customers are located, a Caterpillar dealer is within reach
and has the most replacement parts in stock. On rare instances when a part is not found at the local level,
the ANTARESSM Parts Order System can locate it in seconds. A dedicated Emergency Floor handles rush
requests and is on call 24 hours a day, seven days a week. Many Emergency orders are routinely shipped
in less than four hours. This level of support differentiates Caterpillar from all the competitors and adds
tangible value to the Cat product.
September 2006
Competitive Situation Caterpillar
Target Payload Capacity*

(91-363 Metric Tonne Size Class)
(100-400 Short Ton Size Class)
CATERPILLAR
785C
EH3000
789C
793D
EH3500
797B
EH4500-2
EH5000
EUCLID/HITACHI
HD 1500
730E
KOMATSU
MT3000
TEREX/UNIT RIG
MT3300
MT3300AC
MT3600B MT3700B
MT3700AC
T252
830E
930E-3
830E - AC
930E-3SE
MT4400
MT5500B
MT4400AC
T262
MT5900AC
T282B
LIEBHERR
Metric Tons 91 100 109 118 127 136 145 154 163 172 181 191 200 209 218 227 236 245 254 263 272 281 290 299 308 318 327 336 345 354 363 372 381
Short Tons 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420
* Approved weights as of 2005.

Note: Caterpillar models represent recommended target payloads for both standard body and
MSD body configurations.
Competitors may approve higher payloads than indicated by using lighter weight bodies.
Caterpillar offers a range of mining truck models in the 136 to 363 tonne (150 to 400 ton) size class.
Caterpillars trucks are all mechanical drive with Caterpillars 797B being the largest mechanical drive
truck in the world. The Cat mining truck line-up includes:
785C: 136+ tonne (150+ ton) mechanical drive
789C: 176+ tonne (195+ ton) mechanical drive
793D: 218+ tonne (240+ ton) mechanical drive
797B: 345+ tonne (380+ ton) mechanical drive
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:
Standard (MA1) for balanced all-around performance
Extra Retarding (MA2) for long, downhill-loaded hauls
Extra Top Speed (MA3) for long, flat hauls
Extended Life Wheel Groups (MA4) for long, uphill hauls
High Altitude Arrangement (MA5) for operations above 2750 m (9,000 ft)
September 2006
Competitive Situation Komatsu
General Observations. Due to the strong mining market, Komatsu and other suppliers have reported record
sales and profits driven by the huge increase in demand for mining equipment. Komatsu is the principal
mining machine competitor with a full-line of products.
Model Line-Up and Recent Introductions.
HD1550-5: 136 to 149 tonne (150- to 164-ton) mechanical drive
730E: 184 tonne (230-ton) DC electric drive
830E: 223 tonne (246-ton) DC electric drive
830E-AC: 221 tonne (244-ton) AC electric drive.
930E-3: 290 tonne (320-ton) AC electric drive.
930E-3SE: 290 tonne (320-ton) AC electric drive.
In 2004, Komatsu introduced the 930E-3 and 930E-3S in the 290 tonne (320-ton) class, which replaced
the 930E-2. The 930E-3, powered by the Cummins QSK60 engine, is rated at 2013 kW (2,700 hp), and
the 930E-3SE, powered by the Cummins QSK78 engine, is rated at 2610 kW (3,500 hp), which appear
to be offered predominantly for high altitude applications in locations such as Chile.
Komatsu also introduced the 830E-AC in 2004 that among other features, is capable of speeds up to
64 km/h (40 mph), an increase of 13 km/h (8 mph) versus the standard 830E DC that seems likely will
continue in the market.
It appears Komatsu is promoting the 930E over the 830E, as the market in the 290 tonne (320 short-ton)
class appears to offer more opportunities.
September 2006
Product Issues and Known Problems. Feedback gathered indicated Komatsu has encountered the following
issues in the filed:
Komatsu trucks are bigger and heavier than Caterpillar trucks. With slightly higher GMW, Komatsu
trucks have a significantly higher EMW, which translates into payload disadvantage. For example,
several Cat 789C versus Komatsu 730E studies have shown at least 10-15 metric tons (11-17 tons)
payload advantage for Cat 789C. A similar situation is found for the Komatsu 830E versus Cat 793C.
Additional weight represents tires and fuel consumption disadvantage. Mine records estimate that the
average tire life on Komatsu 830E is at least 12 percent shorter compared to tires on Cat 793C. Also, field
study data indicates the Cat 793C is in average 17 percent-20 percent more fuel efficient than
Komatsu 830E on a metric tons per liter basis.
Significant problems with Komatsu 730E DC wheel motor armatures when working in downhill
hauling applications. Replacements were required with low operating hours.
Komatsu 730E are experiencing numerous disc brake pad failures due to excessive downhill speeds.
Successes and Selling Points.
Komatsu 930E is promoted as being a perfect three pass-match with cable shovels swinging 100 tonnes
(110 short tons).
Selling downhill hauling speed and braking capabilities, leveraging AC drive system that provide
significant performance and safety improvements over the DC drive system.
Developing commercial alliances with mining companies with a long history of operating electric
drive trucks, such as Rio Tinto and Cleveland Cliffs, Codelco and Grupo Mexico.
Building a strong alliance with Cummins for the design and development of engines. The joint venture
agreement, effective in 1997, nominates Cummins as preferred engine supplier for Komatsu Mining
Equipment.
Targeting emerging markets in India and Indonesia, at reduced prices with a global product.
Future Developments. Komatsu announced the development of the new 960E (327-345 tonnes
[360-380 short tons]) and the new 860E (254 tonnes [280 short tons]). August 2006 Komatsu started the
field trial of 2 960E trucks. It has a 222 m3 (290 yd3) wider lower profile body and the truck has a rated
payload of 327 tonnes (360 tons). One is running in the Canadian Oil Sands and the second is running in
Wyomings Powder river basin. It is rumored the truck is one year late from the proposed in the dirt date
from Komatsu due to frame problems.
The 960E appears to have two different drive systems; for oil sands or hard rock mines.
The 960E has a 20 cylinder Cummins engine with 12 turbo chargers, and it is rated at 2759 kW (3,700 hp)
but de-rated to 2535 kW (3,400 hp) in the oil sands. It has high torque Siemens AC drives. The truck shares
930E elements and the same front end, but it is built slightly heavier. It has the same tire scuffing on the
outside fronts. The machine has bladder style steering accumulators that are very tall, and bladder change
is considered to be difficult.
September 2006
Initial timing studies in the oil sands, de-rated 960E, indicate the 797B is significantly faster (10 percent)
in High RR (> 9 percent).
Speculation is high the company also is developing the 730E-AC.
It also announced the development of a new manufacturing facility in Japan for off-highway trucks
scheduled for January 2007.
Five autonomous Komatsu trucks are being tested in Codelco, Chile.
Komatsu announced the co-development of hybrid drive systems with GE.
September 2006
Competitive Situation Liebherr
General Observations. Liebherr has increased its participation rate and is indicating a strong
desire to compete. However, it appears Liebherr it is not willing to entertain high risk deals.
Model Line-Up and Recent Introductions.
T252: 181 tonne (200-ton) DC electric drive
T262: 218 tonne (240-ton) DC electric drive
T282B: 363 tonne (400-ton) AC electric drive
Liebherr offers three mining truck models, with the T282B being the largest size at 363 tonne (400 short-ton)
capacity. Liebherr focuses heavily on the T282B and does not actively market the other machine models.
Product Issues and Known Problems. Limited manufacturing capacity (80-100 units per year)
The T282B truck was successfully promoted as an ultra lightweight truck. However, it has many product
problems that tremendously affect its availability, and there is a big concern the lighter weight of the truck
will generate frame issues in the long term.
Unsuccessful introduction of its ultra light truck design concept, TI272, because of safety issues with
rear tire changes.
A special sound attenuation package targeted in sound sensitive areas such as Hunted Valley
in Australia is a strong selling point.
It offers the best GMW/HP ratio in the industry.
Future Developments. Liebherr developed its own drive system, which will eventually integrate into the T282B.
There are speculations that Liebherr will reintroduce the TI-272 and also a second-generation machine,
the TI-264, that will replace the current T262.
September 2006
Competitive Situation Terex/Unit Rig
General Observations. After the collapse in failure of the negotiations with Caterpillar, Terex has reorganized
its Unit Rig and created more distance from O&K. Due to Terex reporting structure, it is difficult to establish
Unit Rigs profitability contribution to Terex. It is however generally understood that Unit Rig contribution
is probably under par and O&K sales carried the Mining dealerships.
Model Line-Up and Introductions.
MT3000: 109 tonne (120-ton) DC electric drive
MT3300: 136 tonne (150-ton) DC electric drive
MT3300 AC: 136 tonne (150-ton) AC electric drive
MT3600B: 154 to 172 tonne (170- to 190-ton) DC electric drive
MT3700B: 172 to 186 tonne (190- to 205-ton) DC electric drive
MT3700 AC: 186 tonne (205-ton) AC electric drive
MT4400: 218 to 236 tonne (240- to 260-ton) DC electric drive
MT4400: 218 to 236 tonne (240- to 260-ton) DC electric drive
MT4400 AC: 218 to 236 tonne (240- to 260-ton) AC electric drive
MT5500B: 326 tonne (360-ton) AC electric drive
Since 2002, Terex has added three new AC drive trucks in its wide range of truck product offering,
the MT3700AC (186 tonnes [205 tons]), the MT4400AC (up to 236 tonnes [260 tons]) and the
MT5900AC (327-354 tonnes [360-390 tons]).
Product Issues and Known Problems. Terex has limited manufacturing capacity.
The company lacks infrastructure for product support and is considered weak in many territories.
The General Atomic AC system on MT5500B has experienced serious problems, particularly wheel motors
overspeed.
Field study data indicates Terex MT4400 AC (793 class) weighs much more than what is documented
in their publications, which affects tire and fuel consumption negatively.
Terex/Unit Rig is successful with Rio Tinto through the HME agreement.
North Hauler Lt. (NHL) is a joint venture with Terex for the manufacture and distribution in China
of 20-92 metric tons (22-101 tons) mechanic OHT and 154-340 metric tons (170-375 tons) electric
OHT. Recently, the joint venture has been awarded an order for MT4400AC and MT5500B/MT5900
AC trucks by a state-owned Chinese company for coal application.
Future Developments. Persistent rumors indicate Terex will exit the large off-highway truck business.
10
September 2006
Competitive Situation Hitachi
General Observations. Hitachis focus appears to be in system selling, matching shovels to trucks.
Hitachi has decided to move large off-highway trucks manufacturing facilities to Japan away from
its traditional truck production facility in the U.S.
Model Line-Up and Introductions.
EH3000: 154 tonne (170-ton) DC electric drive
EH3500: 172 to 181 tonne (190- to 200-ton) DC electric drive
EH4500: 254 tonne (280-ton) AC electric drive
EH5000: 284 tonne (312-ton) AC electric drive
Hitachi has four mining truck sizes. EH5000 is the largest with a nominal payload of 283 tonnes (312 tons).
It also introduced the new EH4500-2, which provides a higher maximum gross machine weight than its
predecessor EH4500 in response to a nominal rated payload, not maximum.
In 2005, Siemens AC drive system was upgraded with EGBT technology only for EH4500 and EH5000.
Product Issues and Known Problems. Feedback gathered indicated Hitachi encountered the following
issues in the filed:
Very weak distribution, except for good Euclid dealers (Rudd, Colombia)
Overheating of AC drive motors and frame cracking on EH4500
Weight distribution on EH4500 creates serious safety concern related to front tire overloading
and steering system operation.
In some sites, average availability of EH4500 is 15 percent lower than that of the Cat 793s.
Operators note rear axle tire spinning in wet conditions on EH4500.
September 2006
11
Competitive Situation Hitachi

In downhill haul applications at high speed. The recent introduction of the Cat 793D MA2
(Extra Retarding) has narrowed or eliminated the AC drive advantage in this application.
EH5000 and EH4500-2 are relatively strong products.
Selling shovel/truck system.
Future Developments. There are speculations the company is designing two new trucks, a 191 tonne-truck
(210 ton-truck) and the largest of its range with a capacity of at least 363 tonnes (400 tons) that could be
the EH5500 or EX6000.
12
September 2006
Other Competition: Truck Manufacturers
Belaz.
Belaz offers a range of rigid dump trucks from 30- to 220-tonnes (33-243 tons) capacity.
Considering upsizing
Developing the first 320 tonne (354 short ton) capacity prototype with a 2610 kW (3,500 hp)
Cummins engine and an electromechanical transmission.
Following is the 2006 line up of Belaz (all are equipped with a Cummins engine).
7514
120 metric tonnes (132 short tons)
895 kW (1,200 hp)
7513
1193 kW (1,600 hp)
7530
1790 kW (2,400 hp)
September 2006
13
Other Competition: Components
General Electric (GE).

Co-developed the OHT hybrid drive system with Komatsu.
Transitioning to IGBT technology in all AC systems in the future.
Market share of 92 percent, but OEMs moving away from GE.
Siemens.
Adding Komatsu to their OEM portfolio, along side Liebherr and Hitachi.
Speculations indicate they are working with Belaz on 354T truck.
Transitioning to IGBT technology in all AC systems in the future.
Active in less than 200T trolley systems.
Recently acquired Flender Gear for $1.4 billion.
General Atomics.
Joint development with Terex on MT5500 and MT5900 models.
Cummins.
Tier 2 engines: QSK50 (1044-1566 kW [1,400-2,100 hp]) and QSK60 (1342-2237 kW [1,800-3,000 hp]).
Tier 1 engine: QSK78 (2610 kW [3,500 hp]) is experiencing reliability problems.
Detroit Diesel.
Tier 2 engines: 12V4000 (1193-1678 kW [1,600-2,250 hp]), 16V4000 (1491-2237 kW [2,000-3,000 hp])
and 20V4000 (2375-2796 kW [3,185-3,750 hp]).
Routinely demonstrating 24,000-hour life.
14
September 2006
Structures
Structures. Caterpillar main frames are the backbone of the mining trucks durability.
Caterpillar integral ROPS cab frame.

Caterpillar truck frame with castings shown in red.
Caterpillar Truck Frames. Cat frames are built

for strength and durability and incorporate the
following key features:
Finite Element Analysis. Proprietary computer
generated method of showing stress concentration
areas under load based on empirical data from actual
trucks. Castings are used for added strength and
durability in these high stress locations.
Controlled Weld Quality. Weld quality is strictly
controlled. All welders are trained and certified.
The use of rollover fixtures ensures all welding is
done horizontal not overhead. All critical welds
are 100 percent ultrasonically tested to find
subsurface defects. All defective welds are
immediately repaired and then rechecked.
Integral ROPS Cab. Frame is designed for an

integral ROPS cab and provides increased strength
in the front frame supports. Durable design provides
added operator protection.
Caterpillar Castings. Caterpillar uses castings
because of their proven strength and capacity to
produce design flexibility. Castings eliminate the
need for a lot of high quality welding that is
expensive and hard to achieve consistently. With
more than 50 percent of the mining truck market,
Caterpillar is the only truck manufacturer that can
achieve economies of scale needed to make castings
affordable. For competitors, castings are less
affordable due to lower volumes.
Mild Steel Construction. The high strength low

alloy (mild) steel used in Caterpillar OHTs offers
superior fatigue resistance and outstanding
weldability characteristics. The weakest link in any
frame is in the welds. For that reason Caterpillar
has designed the frame using mild steel because of
its ability to produce the strongest welds. In addition
large castings are used to move the welds away from
the high stress areas. Mild steel is easily repaired
in the field with standard welding techniques and
equipment.
No Horse Collar. Easy in-frame engine access
allows quick repairs with less downtime.
September 2006
15
Structures
Crack propagation rates are much higher,

rendering in-field service inspection and repair
very difficult. As a result, the structures become
much more prone to catastrophic failures.
Caterpillar Field Testing. Caterpillar and its
customers learned of this trade-off through
extensive field experience and testing.
Caterpillar Integral Four-Post ROPS Cab.
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. Caterpillar has
chosen to meet the toughest standards and then go
beyond test certification requirements. Caterpillar
cabs are designed to offer maximum operator
protection in the event of a rollover accident.
Competitive Designs. Although the competition
promotes their use of relatively high yield strength
parent plate in their structures with implications
that this provides lighter weight and longer life,
catastrophic field failures at multiple sites have
proven otherwise. In fact, their structures
seriously compromise field supportability.
High yield strength provides increased resistance
to gross plastic deformation and fatigue strength
of the parent material. However, it does not improve
fatigue life of full-scale welded structures, because:
The full scale fatigue testing conducted by

Caterpillar was corroborated by laboratory
testing of welded specimens by the British
Welding Institute.
An optimum balance of yield and toughness
needs to be maintained. Caterpillars weld
joints reflect this balance of yield strength
and maximized toughness.
In field applications, toughness and ability to
locally deform plastically provides a significant
benefit in case of accidents involving
extraordinary strains. Events that can be absorbed
through plastic deformation rather than crack
initiation are less likely to result in subsequent
fractures.
Rolled section steel in frame rails allows
J-groove welds for better penetration.
Castings transition weld location to areas
of lower stress.
While these mechanisms have their limits,
Caterpillar Mining Trucks are much better
configured for tolerance of abnormal events
than competitors.
Increasing yield strength comes at the expense

of toughness and results in increased sensitivity
to inherent notches at the weld joints.
Localized plastic deformation, which occurs at
these notches, is much more damaging to high
yield strength steels due to reduced toughness.
16
September 2006
Structures
Mild steel provides a balance of medium yield

strength and high toughness for:
Ease of welding. No pre-heat or post-heat.
Impact resistance.
Slow crack propagation.
Ease of weld repair, if required.
Long life.
High quality control during manufacturing.
797B frame. Extensive use of castings and
new weld technology results in longer life.
Caterpillar Frame Design Versus Competition.

Cat frames are backed by years of design experience
using same design philosophy since 1963, resulting
in a superior structure. Caterpillar has control over
quality by manufacturing its own frames.
Frames are designed using the latest static and
dynamic analysis techniques.
Frame design incorporates the loads and
deflections required by the integral ROPS cab.
Front superstructure eliminates the need for
a horse collar, providing superior engine
access and increased front frame strength.
Critical welds are 100 percent ultrasonically

tested for weld integrity.
Komatsu Frame Design.
Fabricated horse collar surrounds engine,
increasing repair and service time.
930E is an upgraded 830E frame with thicker
main rail plates with an unoptimized modulus.
930E uses 4921 kg/cm2 (70,000 psi) yield
strength plate material and difficult to weld
repair 6328 kg/cm2 (90,000 psi) casting material.
Terex/Unit Rig Frame Design.
All fabricated. No castings used. More vulnerable
to cracking failures.
Castings are used in areas of high stress.

Weld joints are located in areas of lower stress.
September 2006
17
Structures
Euclid/Hitachi truck frame.
Euclid/Hitachi Frame Design.
Liebherr truck frame.
Liebherr Frame Design.
All fabricated. No castings used. More vulnerable

to cracking failures.
Fabrication and welding in high stress areas,

which is more vulnerable for cracking failures.
No consistent frame design among various

models.
Nickel copper combination steel frame.
Material yield strength varies among models.

Euclid/Hitachi EH4500-2 and EH5000 use
3515 kg/cm2 (50,000 psi) yield strength material.
Other models use 7031 kg/cm2 (100,000 psi)
yield strength material, which is not easily
weld repairable.
18
Minimal section high stress dump

body interface.
September 2006
Engine
Engine. Cat engines are built for power, reliability and maximum operating efficiency.
Model
Engine
Configuration
785C
3512B
V-12
793D HAA*
789C
785C HAA
3516B
V-16
Bore mm (in)
170 (6.7)
170 (6.7)
170 (6.7)
170 (6.7)
190 (7.5)
51.8 (3158)
190 (7.5)
69 (4211)
215 (8.5)
78 (4758)
215 (8.5)
117 (7146)
Stroke mm (in)
Displacement L (in3)
789C HAA 797B HAA*

793D
797B
3516B HD 3524B HD**
V-16
V-24
*Two Stage Turbo charging

**3524 is a tandem unit with two 3512B HD engines.
Cat 3500B Engine Enhancements. The improvements

to the Caterpillar 3500B engine, as compared to
earlier 3500 Caterpillar engine models, include
higher injection pressure, electronically controlled
fuel injection timing and duration, enhanced
combustion chamber design, improved air system
management, and electronic engine protection and
monitoring. Design enhancements have met specific
objectives for reduced fuel consumption, increased
power capability, transient response, smokeless
operation, and lower emissions.
Caterpillar Truck Engines. The Caterpillar 3500B

Series EUI engine design focuses on performance,
reliability and durability. Parameters are established
to maximize engine performance while protecting
the engine from damage and undue wear. Success
of this philosophy is evidenced by the 3500s
dominance of its market segment.
Caterpillar has shipped more than 105,000 units
over the past 25 years.
High quality manufacturing of the 3500B Series
engines is ensured by the Caterpillar Engine Center
in Lafayette, Indiana, an ISO9001 Certified Facility.
September 2006
Electronic Unit Injection (EUI). The Cat 3500B Series

Engines feature an electronic governor with
Electronic Unit Injection (EUI). The brain of
the EUI system is the Electronic Control Module
(ECM). The ECM performs much like a mechanical
governor, but has no moving parts. The ECM sends
signals to the injectors to regulate the fuel supply
to control engine speed and power.
Electronic Unit Injection eliminates complex
hydraulic governor linkages resulting in fewer
moving parts. That means EUI provides customers
significant improvements in reliability and durability.
EUI offers the following advantages:
Reduced Exhaust Smoke. EUI reduces smoke by
electronically adjusting the fuel limits to maintain
correct air/fuel ratio.
Reduced Emissions. EUI reduces gaseous and
particulates emissions. Through electronic injection
timing control, deep crater piston design and
increased injection pressure, fuel burn is optimized.
19
Engine
Improved Fuel Efficiency. The ECMs ability

to match injection timing and duration with the
transmissions demand and a host of other sensed
parameters allows fuel to be optimized not only
during steady state operation but also during transient
acceleration fuel consumption is maximized over
the entire engine operating range.
Fuel Consumption History. The ECM stores
information on machine fuel consumption.
This can be used as a management tool to
ensure maximum life to overhaul.
Diagnostics and Troubleshooting. EUI offers a
new generation of diagnostic and troubleshooting
features. Advanced, easy-to-use diagnostic systems
provide easy reference to vital machine information
and quick solutions if problems arise.
Automatic Altitude Compensation. Power is
automatically derated as altitude increases to help
prevent excessive combustion temperatures and
subsequent component damage. An on-board
atmospheric pressure sensor derates the engine
at the optimal cutoff point for each model.
Cold Start Protection. When temperature dictates,
the engine is automatically put into cold mode
to protect it from unequal distribution of load at
start-up and to eliminate piston scuffing and seizure.
If the parking brake is on and the transmission is
in neutral, low idle speed will rise to 1,600 rpm and
timing will be retarded until the engine is warmed
up or until the transmission is put in gear. If the
transmission is put into gear before the engine has
reached operating temperature, the engine reduces
the amount of injection advance upon acceleration,
to provide continuing protection.
Injector Diagnostics. Using an electronic service

tool, each injector can be tested to determine which
injector requires service without taking exhaust port
temperature readings or picking up a wrench.
Engine Design Limits. Caterpillar performance
engineers impose an exhaust temperature limit,
because exceeding that limit negatively affects fuel
burn to overhaul goals. Damage, including warped
or burnt exhaust valves and turbocharger damage
would result if temperatures were allowed to get
too high.
Cat engineers also maintain peak cylinder pressure,
turbo speed, and turbo surge limits to ensure that
the engine will not only meet the performance goals
but also meet the expected life to overhaul goals.
With many years of experience in the mining
industry, Caterpillar has been able to establish
physical material limitations specifically for
demanding mining applications to achieve
maximum engine life.
Long Engine Life. Caterpillar truck engines are
designed to provide the highest customer value over
the life of the machine. The expense of unplanned
downtime has a tremendous impact on cost per ton.
This reality has played an important role in making
decisions on how to design and apply the 3500 Series
engine. Thermal stress, pressure and vibration
stresses caused by high BMEP are major factors
in reducing engine life.
Air Filter Restriction Indicator. By calculating

pressure drop across the filter, restriction can be
detected and the engine automatically derates if
the allowable limit is exceeded.
20
September 2006
Engine
Engine BMEP in Truck and Other Applications
D11R (3508B)
789C (3516B)
785C (3512B)
777D (3508B)
994F (3516B HD)
500
797B (3524B HD)
1000
793D (3516B HD)
MTU DDC
1500
QSK60
2000
QSK78
Standby EPG
BMEP (kPa)
2500
0
To calculate Brake Mean Effective Pressure (BMEP):
BMEP =
Power rev/cycle
Displacement Speed
P (kW) rev/cycle 60,000

BMEP
=
(Metric)
D (L3) N (rpm)
BMEP
P (Bhp) rev/cycle 396,000
=
(English)
D (in3) N (rpm)
Rev/cycle =
number of crank rotations per cycle

(2 stroke or 4 stroke)
Brake Mean Effective Pressure (BMEP).

Brake Mean Effective Pressure is a measure of
how hard an engine is being worked for its given
displacement. This calculated parameter, expressed
in units of pressure, could be used to compare
engines of greatly different displacements and
applications.
September 2006
Caterpillar BMEP Versus Competition.

Recognizing that BMEP is critical in determining
engine life, Caterpillar designs engines to run at
a much lower BMEP than the competition.
Although diesel engine technology is the same
across the industry, Caterpillar consistently
applies engines with a lower BMEP.
BMEP figures for competitive engines are more
comparable with figures for standby power
generators. Due to high early hour failure rates,
some competitors have abandoned the use of high
BMEP engines in mining trucks. Most of the
available alternatives have substantially higher
BMEP than Caterpillar, as clearly indicated on
the graphic.
21
Engine
Cat High Displacement Engine. The physical limits

established by Cat performance engineers are not
static limits. Caterpillar is always conducting research
to develop materials, manufacturing techniques and
designs that allow increases in engine capability.
One example of how this has benefited customers
is the 3500 HD (High Displacement) program.
Piston technology had improved to the point where
Caterpillar was confident that piston speed increases
could be put into production. An evaluation of the
3500B showed an increased stroke was possible.
Applying this change has greatly benefited
customers of the 793D and 797B. With increased
displacement, and superior injection timing control,
engine temperatures and pressures dont need to
be as high to produce the same amount of power.
The High Displacement 3500 engine optimizes
fuel consumption for a more fuel-efficient engine.
Customers in the field have experienced higher fuel
efficiencies due to, among others, the machines
ability to hold gears longer with the High
Displacement engine.
Brake Specific Fuel

Consumption (Improvement)
BSFC Comparison
793D 3516B HD vs 793C 3516B SS
8%
793D 3516B HD fuel consumption

advantage in the engine operating range
6%
4%
2%
0%
1250
1350
1450
1550
1650
1750
Engine Speed (RPM)
High Displacement Versus Standard Stroke.

A plot of fuel consumption versus engine speed
demonstrates one of the benefits of a high
displacement versus standard stroke engine.
Engine Combustion. The 3500B engine offers

world-class fuel economy. The combustion system
on the 3500B engine has increased valve lift and
improved combustion efficiency when compared
to early 3500 series engines. The 3500B fuel system
produces high injection pressures over short
injection duration resulting in enhanced in-cylinder
combustion and better fuel burn. Internal iron
changes that provide these results include
modifications to the camshaft, rocker arms, camshaft
followers, push rods, rear gear train, and pistons.
As a result of camshaft changes, the 3500B engine
has increased valve lift for both the intake and
exhaust valve. The new lobe design yields 13%
more lift, allowing the combustion chamber to fill
and exhaust with greater efficiency and without
compromises for engine overspeed.
Design changes to the piston provide significant
improvements in combustion efficiency of the
air/fuel mixture within the cylinder. The shape has
a deep bowl crown that reduces crevice volume and
increases air compression. This change results in
improved fuel efficiency and lower emissions.
The piston uses a proven, two-piece high
performance design with an aluminum
skirt and forged steel crown.
Engine Cooling. The Caterpillar cooling system is
incorporated into the total design of the truck and
consists of two parts, which include the jacket
cooling system and the Separate Circuit Aftercooler
(SCAC) system. It is built for efficiency and
designed to take up no more space than necessary
in order not to diminish payload capacity. Use of
separate cooling circuits enables Caterpillar to
achieve effective cooling without excessive
radiator size or horsepower loss.
The 797B and 793D cooling system employs
hydraulics rather than belt drive, allowing the use
of a demand fan. The demand fan reduces parasitic
losses when cooling requirements are less than
maximum.
22
September 2006
Engine
For most efficient combustion, highest density

charge air (coolest air) is required in the
combustion chamber. The lower the aftercooler
water temperature needs to be, the bigger the
radiator required.
Competitors tend to need more cooling to achieve
the same emissions as Caterpillar. Because they
need cooler water, theyre not nearly as well
positioned to meet emissions requirements.
Some competitors already face difficulty meeting
emissions requirements and customers need to
ascertain how these companies plan to deal with
new emissions standards.
Caterpillar has a single aftercooler, or a double
cooler, depending on the model.
Cat Electronics. Cat 3500B engine performance is
optimized by an integrated electronic control system.
The electronics optimize the fuel injection timing
to improve power characteristics and fuel economy.
Overall, the 3500B and 3500B HD series engines
offer 6 percent to 20 percent lower fuel consumption
than competitors mechanical engines, and in most
cases identical to or better than competitors
electronic engines. It is important to note that often
competitors use a fuel consumption tolerance of
5 percent tolerance compared with 3 percent
on Caterpillar engines.
Electronic Control Module (ECM). The ECM uses

industry leading control algorithms (software) and
hardware to ensure peak engine performance over
the entire operating range. The 3500B engine
controls consist of an engine-mounted Advanced
Diesel Engine Management (ADEM) ECM.
With the exception of the 797B, which has a master
control and two slave units, the 3500 engines use
only one ECM. The ADEM control facilitates
integration of the engine with other Caterpillar
controls on board the truck. Electronic unit injectors,
sensors and the ECM regulate and monitor the
operation and health of the engine.
September 2006
23
Engine
The ECM consists of two components: the control

computer and the control software. The control
software contains the operating maps defining
horsepower, torque curves, air/fuel ratio, injection
timing and transmission shift information. The ECM
controls the injectors using feedback from various
engine sensors. Based on this input, the ECM
determines fuel injection timing and duration
to use for optimum performance.
Fuel injection timing depends on engine speed, load,
throttle and other sensor inputs. The speed/timing
calibration sensor signals the location of top dead
center of each cylinder, enabling ECM to control
timing and length of injection to maximize
performance. The ECM will deliver only enough
fuel to reach Caterpillars limit on exhaust
temperature, turbo speed, peak cylinder pressure and
other key factors in maintaining a healthy engine,
which will reach its expected life and beyond.
The ECM controls the variable horsepower settings
on the Cat 797B (3524B) engine, to improve
production. By exchanging information over the
Cat Data Link, the ECM allows the engine to
accelerate up to 1,950 rpm when the transmission
is in 7th gear, achieving top speed of 64 km/h
(40 mph). When in torque converter drive, the
ECM allows the engine to limit its speed and the
torque to the drive train to extend component life.
These features yield an increase in production and
a decrease in cost per ton.
Monitoring and Diagnosis. The ECM performs
two engine health related tasks. First, it monitors
engine parameters such as oil pressure, engine
speed, filter differential, and boost, and determines
if these parameters are consistent with acceptable
engine limitations. If not, the ECM records an
engine event and initiates an alarm, a derate or a
shutdown depending on the severity of the problem.
Recorded events, including the nature of the event,
the number of occurrences and service hour of
first and last occurrences, can be reviewed and
investigated via the Electronic Technician (ET)
service tool.
24
Second, the 3500B engine ECM has the ability to

diagnose itself, its electronic sensors, and wiring.
Diagnostic codes are generated and stored in
memory, as active or non-active, to reflect current
and intermittent or repaired problems. The codes
provide event description, number of occurrences,
hour of first and last occurrence and total hours.
In the 3524B, the codes also indicate which engine
has a fault. Logged diagnostic codes are helpful in
troubleshooting and are accessed via the Caterpillar
Electronic Technician (ET) service tool. To further
enhance serviceability of the system, sensors used
to monitor the engine are consolidated with the
Vital Information Management Systems (VIMS)
sensors to reduce redundancy and complexity.
Caterpillar Electronic Technician (ET) Service tool

is used to diagnose the Cat 3500B engine.
Cat Data Link. The ECM is a critical component of

the Caterpillar Integrated Power Train Management
System. Information is shared between smart
components over the Cat Data Link, allowing
onboard microprocessors to communicate with
each other and access stored information for
troubleshooting. Most competitive machines lack
such an integrated control and monitoring system.
September 2006
Engine
Electronics Integration Features. The Cat integrated

control and monitoring system offers the following
electronic control features:
Engine Overspeed Protection. If the engine
reaches 2,100 rpm, a warning horn and check
engine message will activate in the message center
of the VIMS. At 2,300 rpm the transmission will
automatically upshift one gear regardless of cane
position. If the transmission is in top gear, the
torque converter lock up will disengage.
An overspeed upshift event will be logged in
memory. The Automatic Retarder Control (ARC)
computer will automatically activate in an overspeed
condition to control engine speed to 2,180 rpm.
Acceleration Delay on Start Up. To reduce wear
on lubricated components, engine acceleration is
disabled for two seconds after low idle has been
attained, on start-up only. This allows time for all
machine lubrication and cooling systems to achieve
pressure and flow before operating at higher speeds.
An engine pre-lubrication attachment is available
to pre-pressurize oil galleries within the engine
prior to cranking the engine during start-up.
Elevated Low Idle. In cold weather conditions,
low idle is elevated to allow the engine to achieve
operating temperature quicker and maintain
temperature. Certain conditions must be met for
elevated low idle to be enabled: transmission must
be in neutral, parking brake set and engine coolant
temperature below 75 C (167 F). Standard low
idle is 700 rpm.
Cold Mode Start Capability. The ability to start
and to perform is improved in cold weather by
retarding timing when the engine is below operating
temperature. Retarded timing reduces peak cylinder
pressure and cylinder pressure rate. The engine
operates in cold mode when engine coolant
temperature is below 70 C (158 F). The ECM
also modifies the amount of advance on acceleration
when in cold mode to further protect the engine.
September 2006
Air Filter Restriction. An air filter restriction

indicator monitors the air intake system. When the
air inlet restriction is too high, the system will
activate a warning and record the event in system
memory. The system will automatically derate as air
intake restriction increases. When restrictions reach
660 mm (26 in) of water, fuel is limited 1 percent.
For higher restriction, fuel is limited 2 percent per
102 mm (4 in) of water up to a maximum of
20 percent.
Altitude Compensation. When operating at high
altitudes, the system automatically derates power
by limiting fuel to prevent excessive exhaust gas
temperatures and related damage. The ECM uses
atmospheric pressure to determine the engines
altitude. High Altitude Arrangements (HAA)
are available and they use either additional
displacement or two stage turbocharging to get
full truck performance even at the highest mine
sites in the world.
Diagnostics. The ECM is compatible with the
Electronic Technician (ET) service tool, and
interfaces with Electronic Programmable
Transmission Control II (EPTC) and ARC via
the Cat Data Link. ET plugs into a connector port
located on the fuse panel behind the operators
seat. ET can retrieve and display boost pressure,
fuel flow rate, engine rpm, logged diagnostics,
logged engine events, overspeed events, air filter
restriction, oil pressure, overheating and other sensor
input. ET provides numerous service features
including individual cylinder cut out, crank without
injection, and injector solenoid test. ET is the
primary troubleshooting tool for the 3500B engine.
25
Engine
Fuel Use Record. The ECM provides a cumulative

record of fuel consumed. This record is accessible
via ET and VIMS.
Multi-Point Pressure Sensing. The engine oil
pressure alarm will be activated if pressure falls out
of spec. Oil pressure is monitored as a function of
engine speed and the information is passed on
to VIMS. If a condition falls outside of normal
operating parameters, the operator will be alerted
to decrease the risk of piston scuffing and engine
damage.
3500
Engine
Engine Fuel
System
Oil
Supply
(Injectors)
Transfer
Pump
Engine
ECM
Engine
2u Fuel
Filter
Mixed Return
ORS
Electronic
Metering
Valve
Fuel Tank
Diesel Fuel
Ether Starting Aid. The ECM automatically

controls ether injection by determining if ether
starting aid is necessary based on engine coolant
temperature. Automatic ether injection control
prevents the possibility of the operator damaging
the engine by using too much ether during engine
start-up.
Oil Renewal System (ORS). ORS is an optional

system, which increases machine availability and
productivity by extending oil change intervals and
reducing oil disposal and labor costs. ORS meters
and injects used engine oil from the crankcase
into the engines return fuel line, within carefully
controlled parameters. The ECM performs control
of the ORS. No additional electronic modules
are required.
Oil Degradation versus Time

Oil Degradation
Starter Protection. The starter is protected from

damage in two ways. First, the control feature will
not allow starter engagement if the engine speed is
above 0 rpm. Second, the starter is disengaged by
a solenoid after the engine speed reaches 300 rpm.
This prevents the starter from remaining engaged
if an operator continues to hold the key in the start
position after the engine has started.
Oil Renewal System
1000
2000
3000
4000
5000
Hours
Oil Degradation Versus Time.
26
September 2006
Engine
Electrical Connections. To improve reliability

and serviceability, over 80 percent of the electrical
connections used are Deutsch connectors. VIMS
and ECM sensors were combined to reduce
redundant sensors on the engine. Additionally, the
wiring harness and clipping of the harness on the
engine and within the engine compartment is
designed to facilitate easier and faster engine
removal and installation.
At Komatsu, for example, integration of three

different systems is required. Engine control
systems from Cummins and GE must be integrated
with operating systems from Komatsu. All are
developed separately and with different performance
parameters. While GE might want the operating
system to protect the engine, Komatsu may want
the system to operate differently to meet customer
demands.
Caterpillar Engine Design Versus Competition.

Caterpillar has a very real advantage in being able
to design and develop a fully integrated engine and
power train control system.
The Lafayette engine group employs engine

software specialists to develop a system that
will control specific parameters for optimal
engine efficiency, reliability and durability.
Based on extensive experience using the control
system on engines in different applications,
Caterpillar has the expertise to integrate engine
and power train specifically for the requirements
of mining.
Through the Mining Truck Engineering Group
in Decatur, IL, Caterpillar ensures system design
and manufacturing suppliers work together to
offer a fully integrated system.
Competitive Engine Design. Competitors are
challenged when it comes to system integration
because they join together with up to three different
companies, each with their own performance
criteria. Cat doesnt face these difficulties with
integration.
Typically the engine manufacturer develops software
to control and protect the engine, but the truck
manufacturer and the customer may have different
operating parameters in mind. To reach agreement
is a compromise, not likely to be ideal for any of
the three parties.
September 2006
17
16
1. 12 Holset Turbos
2. Belt drive alternator
3. Jacket water pump
4. Coolant filters
5. Centrifugal oil filtration system

6. 3 electric starters
7. Auto prelube
Cummins QSK78 Engine.
Komatsu-Cummins Engine Design. In a joint

venture with Komatsu, Cummins has formed a new
company (Industrial Power Alliance (IPA), and
added the 2610 kW (3,500 hp) QSK78 (alternatively
named the Komatsu SSDA18V170), to its range of
engines for mining trucks, which also includes the
QSK45 and QSK60. The joint venture agreement
nominates Cummins as exclusive engine supplier
for Komatsu Mining Equipment.
27
Engine
Reducing product development and manufacturing

time, while minimizing development capital, IPA
sourced off-the-shelf components for the QSK78.
In an unprecedented union, the design team had
to accommodate ideas from both Cummins and
Komatsu engineers. On-going development, specific
manufacturing and operational requirements were
to be achieved in the shortest possible time.
Komatsu-Cummins Engine Performance.
Although the negative impact of increasing
peak cylinder pressures and specific power was
acknowledged, the BMEP of the QSK78 is more
than a third higher than the Cat 3524B. QSK60
and QSK78 ratings exceed MTU/DDC 4000, and
are similar to ratings for Cat Standby GenSets.
Based on information available, the predicted life
of the QSK78 would be significantly less than the
published 20,000 hours. To date, there appears to
be no site where a QSK78 engine can be found
operating and reaching expected parameters.
The QSK78 has a peak torque of 13,770 Nm
(10,156 lb-ft) at 1,500 rpm while the Cat 3524B
peaks at 17,220 Nm (12,701 lb-ft) at 1,300 rpm.
At 1,900 rpm rated speed, the QSK78 produces
13,100 Nm (9,662 lb-ft) versus 14,444 Nm
(10,653 lb-ft) at 1,750 rpm for the Cat 3524B,
a torque rise of 5% versus 19% for the 3524B.
Performance curves show 2610 ekW (3,500 BHP) at
rated 1,900 rpm and BSFC of less than 201 g/kW/h,
looks good versus Cat BSFC of 211 g/kW/h, but
there is no indication of tolerances.
2
4
5
3
6
1. 2 Intercoolers
2. Belt fan drive
3. Inter/Aftercooler pump
4. Balance tubes
5. 6 Aftercoolers (3 per side)
6. Fuel/water separators
Cummins Quantum Engine was

the basis of the QSK78 design.
Komatsu-Cummins QSK Family. Cummins opted

for a mono-block construction with added stiffness
and chose the power cylinder components (head,
piston, ring pack and liner) from the Komatsu
inline SAA6D170 family, which fit, with some
adjustments. QSK78 uses a one-piece nitride
hardened iron piston design.
Components for the QSK60 were derived from
the Komatsu SAA6D170 family, but the extended
crank length and additional crank throws required
modification to the piston crank. Concerns about
reliability of the front gear train resulted in design
changes to accommodate wider, high-contact
ratio gears.
Accommodating new performance criteria and the
engineering philosophies of both Cummins and
Komatsu required a clean sheet approach in many
areas, but longevity of the QSK78 is yet to be tested
in field applications.
28
September 2006
Engine
The QSK60 is a 60 L (16 gal) (2 m3 [3,672 in3]),

159 mm bore and 190 mm stroke (6.26 x 7.48 in)
2013 kW (2,700 hp) engine. The engine can be
configured with one or two stage aftercooling
and with serial or parallel turbochargers.
Approximately 25% of QSK60 production
is placed in mining applications.
Terex/Unit Rig also uses the Cummins QSK60
engine in its larger mining trucks while Hitachi
uses Cummins engines in some of its smaller
mining trucks.
MTU/DDC Engine Design. In a joint effort by DDC
and MTU, Series 4000 MTU/DDC engines were
developed to provide fuel economy, reduced service
time and promise of a 20,000 hour life to overhaul
(in most applications). Since their introduction in
1999, attention has been required to address issues
with injector seals, high-pressure pump failures,
cooling system performance, charge air intake
system and, most recently, main bearings.
MTU/DDC engines are used in Liebherr,
Terex/Unit Rig and some Euclid models.
MTU/DDC Versus Cat. The MTU/DCC engine
requires a much colder SCAC temperature and still
has higher cycle emissions than the Cat 3500 engine.
The MTU pushes the turbochargers harder to get
its performance and it requires a higher BMEP
to get to its rating.
Durability of MTU/DDC 4000 in the 830E and
930E has been reported to be less than expected.
There is evidence that some MTU/DDC 4000
engines were stripped out due to disappointment
with performance and serviceability in mining
applications. By comparison, with the very
serviceable Cat 3500 series engine, the
MTU engine presents some challenges:
In tests conducted by Caterpillar, at mid-load and

at high speed, the MTU had better fuel consumption,
but throughout the entire load range produced
much more smoke than the Cat 3500 engines.
The MTU had higher NOx limits and particulates
emission than the Cat engine. The Cat 3500 engine
also has a better NOx/BSFC trade-off than the
MTU/DDC 4000.
The MTU/DDC 4000 engine was found to have
some advantages over Cat 3500 series engines:
Slightly better Brake Specific Fuel Consumption
(BSFC) than the Cat 3500 engines.
More efficient two-pass aftercooler.
Low and high idle engine noise.
Caterpillar offers the following advantages over
the MTU/DDC engine:
Lower installation costs. MTU requires
26 percent more SCAC flow. More stringent
inlet and exhaust restriction requirements.
Better tested emissions capability.
Higher injection pressure.
Slightly less engine noise at rated point.
Lower cost rebuild as cylinder head has better
reman potential and flush bottom deck is
cheaper to refinish.
Less expensive pistons.
Longer engine life.
Very high levels of liquid nitrogen are involved.

Flangeless couplings are more complicated
and time consuming to deal with.
September 2006
29
Drive Train
Drive Train. Cat mechanical drive train delivers more power to the ground.
Precise planet gear tooth profiles are achieved
by CBN grinding after heat treat. This reduces
sound and provides exceptional bending
fatigue life.
Planet gear teeth also are designed and
manufactured with crown to ensure correct
load distribution across the tooth face.
Caterpillar Planetary Powershift Transmission.
Cat planet shafts are stone polished.

This provides superior resistance to frosting
and pitting compared to more common
centerless-grind finished shafts. They also
are more likely to be reusable at rebuild.
Proven Cat technology uses durable large

diameter clutch packs. Clutches and controls
are designed to provide smooth, automatic
shifting while limiting clutch energy input
to give long clutch life.
Routine maintenance and most control repairs

can be made in-chassis. Modular design allows
quick transmission removal. Electronic controls
eliminate linkage adjustments and lessen the
chance of mechanical failures.
The Cat patented design for rotating clutch

pressure seals minimize drag losses and make
rotating clutches as reliable as stationary clutches.
At rebuild, bearings, seals, gaskets, seal rings

and thrust discs are expected to be replaced
regardless of condition; other components,
including clutch discs and gears, may be
inspected and reused.
Gears are made from bearing-quality steel to

avoid inclusions that can cause tooth breakage.
High Contact Ratio Helical transfer gears
designed by Cat to control sound and give
long life.
On the new 793D, the extra top speed
arrangement provides an input transfer
gear with lower gear ratio.
30
Modular design allows quick transmission

removal. When the transmission must be
exchanged, it can be done by two mechanics
in a half-shift or less.
September 2006
Drive Train
Controlled throttle shifting reduces torque

created by the engine during shifts for smooth
clutch engagement and improved component
life. Ability to select any gear with cane.
Programmable top gear limit with any gear
from 4 to 7 as top limit.
Directional shift management automatically
reduces engine throttle before shifting from
neutral, reverse to forward and forward to
reverse to protect driveline components.
No operator input change required.
Neutral coast prevention will not allow the
transmission to shift to neutral if the ground
speed is above 6.4 km/h (4.0 mph). It only
down-shifts to the proper gear for that
ground speed.
Caterpillar Transmission Design. Electronically
controlled planetary transmission features:
Smart shifting with no gear hunting.
Downshift inhibitor prevents engine overspeed.
On-board alphanumeric diagnostic display

records intermittent and active faults.
On-board memory records shift histograms
and lock-up clutch engagements.
Optimum performance with minimum wear.

6 and 7 speeds forward, 1 speed reverse.
Top speeds: 785C in F6 = 54.8 km/h (34.0 mph);
789C in F6 = 52.6 km/h (32.7 mph); 793D in
F6 = 54.3 km/h (33.7 mph); 797B in F7 =
67.6 km/h (42.0 mph)
35 percent ratio steps in all ranges.
Torque converter lockup in first gear with
torque converter drive in reverse and first
gear below 7.2 km/h (4.5 mph).
Low torque design with most reduction in
final drives.
Transmission mounted directly to differential
housing.
September 2006
31
Drive Train
A new hydraulically driven filtration system on

793D and 797B provides cooler, cleaner oil and
parasitic power loss management via a constant
oil flow to the final drives for longer
component life.
The VIMS Monitoring System monitors the
rear axle system to notify the operator of low
lubrication levels, high temperatures and low
lubrication flow caused by plugged filters.
Caterpillar Final Drives. Transmission and final
drive parts work together to put more power on
the ground. Cat final drives are designed to work
as a system to withstand the forces of high torque
and impact loads. They are manufactured and tested
for precise fit and heat-treated to ensure durability
and long life. They deliver superior performance
and are of such high quality that they can be
remanufactured for a second life.
Spindle bearing journals are laser-hardened.
The differential bearings utilize newly developed
steel for increased resistance to fatigue failures.
Extended Power Train Life. Cat final drives, wheels,

and differential are designed and built for long
power train life.
Final Drive Features.
Flat deck carrier improves the ability to cast
and assemble; planet loads are equalized.
Higher capacity planet bearings for improved
reliability.
Improved heat treatment with an exclusive
finish and higher precision.
Wheel Features.
Forged and ground crowned gear teeth prevent

excessive stress on mating teeth and ensure
correct load distribution across the face.
Pitting, scoring and breakage is reduced
to extend component life.
Optimized structure. High casting quality, high

yield strength steel, can be re-manufactured
and repaired.
Cat mining trucks are equipped with a one-piece

cast rear wheel to accommodate high-capacity
wheel bearings.
Rear wheel splined brake to spindle connection;

improved stress distribution.
Cat Duo-Cone seal mountings within the

wheel station prevent brake hub wear and
increase service life.
Direct lubrication of differential bearings is
provided through use of ground driven gear
pump on 785C and 789C or continuous,
hydraulically driven gear pump on 793D
and 797B. The lubrication is filtered prior
to being directed to the components.
32
Front wheel spindle is forged or cast with laser

hardened journals.
Increased capacity wheel bearings for better

load distribution.
Sealing designed to minimize debris
accumulation.
September 2006
Drive Train
Differential Features.
Structure designed to maintain optimum gear
and bearing alignment.
Optimized effective bearing spread.
Spider bearing sleeves eliminated; new spider
bearings eliminate cage wear.
Pressure lubrication.
Rear Axle Lube System.
Continuous driven lubrication pump on 793D
and 797B. Ground driven lubrication pump
on 785C and 789C.
Parasitic power loss management.
Caterpillar wheel station with laser hardened journals.
Caterpillar Rim to Wheel Mountings. To mount rims

to wheels, Caterpillar uses a flange type mounting
with sufficient quantity of torqued bolts to
accommodate both vertical loads and tractive loads.
A single torquing of the bolts is sufficient to prevent
slip or loosening of the joint. If, in the unlikely
event the rim were to slip, the multiple bolts act as
dowels to stop any further slippage. For more than
30 years, Caterpillar has successfully used the
flange-type mounting system in off-highway trucks.
Cat Duo-Cone Seals. Since the introduction of
oil-cooled disc brakes on Caterpillar mining trucks,
Cat Duo-Cone seals have been an integral part of
the design. Duo-Cone seals were developed in the
late 1950s to provide a new type of seal to improve
lubricant retention in hostile, abrasive and corrosive
environments where elastomeric shaft seals wore
out quickly.
The design of a Caterpillar metal-faced seal
compensates for many manufacturing and operating
variables. Two metal sealing rings float in position;
two elastomeric toric rings exert uniform pressure
to accurately position the metal rings and serve as
the static seal between the housing and the seal ring.
The load rings also transmit the turning torque from
the driven housing to the seal ring. Positive sealing
contact is provided, regardless of assembly tolerance
build up, deflections or end play.
Power Train Reliability. Caterpillar builds the best

drive train parts on the market and achieves the
highest availability in the industry. Backed by
excellent maintenance and repair options, the result
is maximum productivity and lower costs. Cat offers
effective drive train maintenance, including
Preventive Maintenance (PM) programs, Oil
Analysis, Inspections, Training, Scheduling, and
Recordkeeping, which result in fewer failures and
less unexpected downtime. Operating costs decrease,
as machine life and availability increase.
September 2006
33
Drive Train
Metal-faced seals feature:

Corrosion resistant seal rings.
Precision lapped, self-renewing seal surface.
Minimum face load variations.
Long life.
Good performance across a wide range
of face loads.
34
Service Support. Cat dealers can restore system

performance and get machines back to work fast,
helping to evaluate repair indicators and determine
the lowest cost repair option. Dealer service is
guaranteed, with professional service people who
have the training and technology to handle all levels
of repairs. Even in remote areas, Caterpillar dealers
have access to the worldwide expertise and support
of Caterpillar. Cat dealers also offer an unmatched
Exchange or Cat Remanufactured parts service
providing parts that carry a same as new parts
warranty but cost far less than new.
September 2006
Mechanical Versus Electric Drive

Mechanical Versus Electric Drive. Cat mechanical drive trucks are built for superior control in the most
severe applications.
Caterpillar trucks are used in relatively more
severe applications than competitive DC drive
trucks, but with the advent of newer AC trucks,
the application ranges are now more comparable.
Caterpillar mechanical drive systems offer the
following benefits:
Efficiency... more power getting to the ground
and thus more useful work done.
Reduced fuel cost per ton... less fuel burned
per ton of material moved.
Power Train Efficiency. Power train efficiency
quantifies how much of the engine power generated
gets to the ground to do the work... moving material
efficiently from point A to point B. Engine power
that doesnt get to the ground is wasted.
Caterpillar Mechanical Drive. Caterpillar entered the
mining market with the introduction of the 77 tonnes
(85-ton) 777 in 1975. Prior to the introduction of
the 777, all trucks in the 77 tonnes (85-ton) class
were electric drive. No competitor had attempted
a mechanical drive with a power shift transmission
in larger trucks. The mechanical drive 777 with
power shift transmission soon became the dominant
leader in the 77-91 tonnes (85- to 100-ton) class
construction/mining trucks. Because of the greater
efficiency, rimpull, gradeability and durability,
mechanical drive quickly replaced the electric
drive in the 77-91 tonnes (85- to 100-ton) class.
Today, no competitor offers an electric drive
in the size classes below 91 tonnes (100 tons).
September 2006
35
Gross Power Train Efficiency

100%
Peak
12%
95%
90%
797B
88
86.7
85%
793D
88
85.4
80%
AC
83
79
75%
DC
81.5
72.2
70%
65%
60%
55%
50%
793D
797B
AC Drive
DC Drive
45%
40%
35%
30%
0%
5%
10%
15%
20%
25%
30%
Effective Grade
Mechanical drive systems are the most efficient over a broad operating range
Mechanical Drive. The mechanical drive system

is more efficient than both the DC or AC electric
drive system. A comparison of efficiencies on a
typical mine haul grade of 10 percent shows the
793 to be about 8 percent more efficient than an
830E. Under the same conditions, the 797 is about
6 percent more efficient than a 930E.
As effective adverse grades increase, the electric

drive becomes less efficient while the mechanical
drive has a relatively constant efficiency as adverse
grades change. For example, the efficiency of the
830E truck drops from 81 percent on a 5 percent
effective grade to 66 percent on a 15 percent grade.
The efficiency of the 793 truck actually increases
slightly from 81 percent on the 5 percent grade to
83 percent on a 15 percent grade.
Higher efficiency of the drive train system results
in less fuel burned per ton of material moved, which
translates into lower cost per ton operating costs.
36
September 2006
Peak
12%
797B
88
86.7
100%
793D
88
85.4
95%
AC
83
79
DC
81.5
72.2
90%
85%
80%
75%
70%
65%
60%
55%
793D
797B
AC Drive
DC Drive
50%
45%
40%
35%
30%
0
10
20
30
40
50
Ground Speed-mph
Mechanical drive systems are the most efficient over a broad operating range
Electric Drive. The efficiency losses in an

electric drive system are caused by losses in
power conversion.
For DC systems:
Engine power to alternating current.
Alternating current to direct current.
Direct current to mechanical motion at the
wheel motor.
Additional accessory losses to support the
electric drive system.
For AC systems:
Engine power to alternating current.
Alternating current to direct current.
Direct current back to multiphase alternating
current.
Alternating current to mechanical motion
at the wheel motor.
Additional accessory losses to support the
electric drive system.
September 2006
Because electric drive systems are less efficient,

competitors with electric drives must increase
gross engine power to have grade power equivalent
to mechanical drive. For example, the 830E has
1864 kW (2,500 gross horsepower) compared to
the 793D at 1801 kW (2,415 gross horsepower).
Mechanical Drive Advantages.
Miners acknowledges that mechanical drive trucks
offer the following advantages:
Broader application range, steeper grades,
good performance in poor underfoot conditions
and superior performance in high rolling
resistance in tar sands.
Few thermal limitations on grade. The insulation
in the Electric Drive wheel motor breaks down
under high heat and load conditions experienced
over long periods of time.
No high voltage electric support required.
High voltage safety.
Potential to use mechanical drive in more
severe conditions.
Better controllability retarding and driving.
37
High stall rimpull.

Environmental tolerance mechanical drive
is less affected by wet conditions.
Lower fuel costs per ton.
Conclusion. Caterpillars field research concluded

Cat mechanical drive trucks have functional
capabilities that promote their use in a broader range
of applications than the DC and AC drive trucks.
Competitive DC trucks perform well in light
duty applications.
Fewer electrical parts.
Competitive AC trucks have a wider range

of applications than the DC drive trucks.
Electric Drive Advantages.

Less maintenance time is required to change
oil and filters.
Trolley compatibility.
Less oil volume.
Fewer gears and mechanical parts, although
mechanical drive has no high voltage lines
or control cabinets.
Faster downhill hauling speeds.
No wearing of brake parts during retarding,
but mechanical systems have no blowers
or heat rejection grids.
Electric Drive Disadvantages.
Efficiency.
The 218 tonnes (240-ton) AC drive trucks were

preferred in severe downhill hauling until the
recent introduction of the Cat 793D MA2 (Extra
Retarding), which has narrowed or eliminated
the AC drive advantage in this application.
The responsiveness of power electronic
traction control software in electric trucks is
slightly inefficient when compared to the Cat
mechanical drive Traction Control System.
Some competitors market machines with
lower prices for repair and maintenance
contracts falsely, creating the perception that
electric drive is a lower cost-per-ton option.
Maintenance costs and conditions need
to be compared carefully.
Support multiple suppliers.

System integration multiple software systems.
Complex to trouble shoot.
Stall torque capability.
Thermal capacity.
High voltage lines and control cabinets.
Traction control.
38
September 2006
Operating Cost Comparison. Miners acknowledge

cost per hour (or ton) varies widely between mine
sites depending on a number of variables, and
Caterpillars studies confirmed this variation is far
greater than the variation between mechanical and
electric drive systems. For mature systems operating
under similar conditions, there is no significant
difference in operating costs for the electric vs.
mechanical power transmission system in mining
trucks. The difference in drive type impacts on
only 16.5 percent of the total cost-per-ton.
Cost-per-hour of the total propulsion system
averaged:
Engine: 46 percent
Power Transmission: 16.5 percent
Product Support. Every element of Caterpillars

mechanical drive train is performance-matched
and built to take the abuse of haul truck applications.
From the heavy-duty design of the 3500 series engine
to the six/seven speed transmission, through double
reduction planetary final drives and the all-wheel,
oil-cooled disc brakes, each component in every
system is designed for maximum durability.
The result is a mining truck that performs better,
breaks down less and lasts longer. And just as
important is an unmatched product support team
Repair Before Failure programs, remanufactured
components and reusable parts, Scheduled Oil
Sampling, regular maintenance options,
worldwide parts inventories and an extensive
parts distribution system.
Wheel Station: 37.5 percent
September 2006
39
Caterpillar Brake System

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.
1
2
3
4
5
6
7
Parking/Secondary Piston
Service/Retarding Piston
Friction Discs
Steel Plates
Actuating Springs
Cooling Oil In
Cooling Oil Out
Caterpillar Brake System. Caterpillar oil-cooled

multiple disc brakes for off-highway trucks have a
long development history. When Caterpillar began
development of an off-highway truck in the late
1950s, oil-cooled brakes were an integral part of
the design. Improvement of the brake has been an
on going process since those early days. For many
years only Caterpillar offered the superior oil-cooled
braking system on off-highway trucks. Several
competitors have since tried to copy the Cat system,
but have not kept up with the advances and
innovations offered by Caterpillar.
40
Integrated Design. The Caterpillar designed and

developed non-fade, oil-cooled braking system is
an integral part of the overall truck design, not an
add-on or afterthought.
The integrated design serves four braking systems:
service
retarding
secondary
parking
The service and retarding functions are actuated
by modulated hydraulic pressure on the brake piston
that in turn applies a load or force on the brake rotors
and stators. The secondary and parking functions
are actuated by multiple springs acting on the
secondary/parking piston. The springs are released
by modulated hydraulic pressure. Hence, brakes are
always available even in the event of a complete
hydraulic failure very important safety feature.
No other manufacturer has ever offered an oil-cooled
brake with the safety feature of spring applied/oil
released secondary/parking brake.
September 2006
Four-Wheel Braking. The large Cat trucks have

four-wheel braking for superior retarding control
with wet haul road conditions. Single axle retarding
limits controllability during slippery road conditions.
Operator security is much greater with the fourwheel brake system, resulting in greater productivity.
Trucks with two-wheel or single axle retarding must
cease operations during conditions of slick haul
roads while Cat trucks can continue to operate.
The parking brake is applied to all four wheels
to give superior parking capability. The parking
system provides parking capability on grades up
to 15 percent with worn brakes at the targeted gross
machine weight. No competitor provides four-wheel
parking brakes. Since the parking brake system also
is oil-cooled, inadvertent application while moving
will not burn-up the brakes, which is the case
for competitors.
Brake System Design. The Cat oil-cooled disc brake
system delivers exceptional performance due to
superior design features.
The large frictional area is determined by the
gross machine weight to give low retarding
hp/in2 and high wheel torque for short
stopping distances.
Front to rear brake torque split is balanced
to give the best braking performance and
to minimize wheel lock-up especially
when in the retarding mode.
The friction material has been improved from

the original sintered bronze to a cellulose fiber
material. To be more environmentally friendly,
asbestos ras eliminated from the friction material
in the 1980s. The friction material is continually
being modified to improve frictional, wear and
heat resistance characteristics.
The energy absorbed by the brakes during
retarding is dissipated by high flow of oil
through the discs and separator plates. The oil
is cooled by water-to-oil heat exchangers to
give good retarding capability.
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.
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.
The non-fade characteristic of oil-cooled brakes

enables reduced stopping distances compared
to systems using either dry caliper disc or drum
type brakes. As trucks became larger, retarding
grades steeper and regulatory requirements
more stringent, only the Cat trucks were able
to meet legal braking requirements without
modifications.
September 2006
41
HARC
1
1
2
3
4
5
6
7
8
Traction Control System (TCS). Caterpillar trucks

also use the rear oil-cooled brakes for traction
control. The exclusive Caterpillar system improves
performance in poor underfoot conditions by
electronically monitoring and controlling wheel
slippage. Sensors monitor wheel speed and if the
difference exceeds a preset limit, the oil-cooled
brake is actuated on the faster spinning wheel.
With a standard differential output, torque to the
two wheels is always equal. Applying brake torque
to the faster spinning wheel (the one with least
traction) will then give additional torque to the
slower wheel and provide additional tractive
effort. Normal steering maneuvers do not
actuate the system.
TCS
Service Brake Sensor

Engine Sensor
HARC
HARC Switch
Brakes
Service Brakes
Axle Speed Sensor
TCS
6
7
8
3
7
5
HARC vs. ARC.

Less chance for engine overspeed
Smoother engagement
No loping
Less air system demand
Reduces operating costs
HARC Production Advantages.
2500
Engine Speed (rpm)
2000
1500
1000
Integrated Brake Control (IBC). The HARC and

TCS are combined into an Integrated Brake Control
(IBC) System to enhance Cat truck performance
and increase productivity.
500
0
10
20
30
40
50
Time (Seconds)
60
70
With Hydraulic Automatic Retarder Control

(average speed, 1950 rpm)
With Manual Retarder Control
(average speed, 1730 rpm)
42
Serviceability. Maintenance of the oil-cooled

brake is minimal since the brake is enclosed and
sealed. Additionally, brake material wear condition
can be determined without disassembly of the brake.
By removal of a service plug and insertion of a
simple service tool, wear of the disc pack is easily
determined.
September 2006
Regulations. All brake tests to determine

compliance with regulatory requirements are run
with the truck at the maximum allowable gross
machine weight and not at nominal gross machine
weight as in the past. Seldom will the truck weight
be at the nominal because of variations in loading
tool fill factors, material density variations, and
loading tool operator skill. It is imperative then
that the truck has adequate brakes when loaded
to the maximum allowable gross machine weight.
Komatsu Brake System. The brake system features:
Caterpillar Brake System Versus Competition.

The brake system on Caterpillar mining trucks
has been designed for optimum braking efficiency
and safety.
Spring applied, hydraulically released parking

brake on high speed motor armature develops
high torque but almost no dynamic capability.
Oil cooled multiple disc brakes provide nonfade braking and retarding on all four corners.
Braking force is applied in a ratio of 40 percent
front, 60 percent rear for better handling and
controllability.
Hydraulically applied front and rear dry caliper

disc brakes are subject to dirt and moisture entry,
which can cause premature wear and/or
malfunction.
Rear brake discs on the high-speed motor
armature develops high torque but very limited
dynamic capability. Small disc diameter of
635 mm (25 in) provides limited frictional area.
Dynamic electric retarding through traction

motors and grid system.
The 930E-3 and 930E-3SE brake system features:
Hydraulically applied front and rear brakes are
oil cooled multi-disc brakes.
Automatic electronics control the retarding

function.
Retarding capability with the oil-cooled brakes

is limited since oil flow is low.
Rear brakes provide traction aid.

brake on the high-speed motor armature develops
Service and retarding brakes are hydraulically

applied for greater efficiency.
Secondary and parking brakes are spring applied
for added safety.
The application of emergency brakes can
be modulated for a brief period before they
remain applied.
The brake system exceeds legal/regulatory
requirements at maximum allowable gross
machine weight.
Completely sealed system is not affected
by environment, including water and dust
contaminants.
Brake wear measurement can be undertaken
without disassembly.
September 2006
Dynamic electric retarding through traction

motors and grid system.
Terex/Unit Rig Brake System. The brake system
features:
disc brakes are subject to dirt and moisture entry
malfunction.
armature develop high torque but very limited
dynamic capability. Small disc diameter of
508 mm (20.2 in) on the MT3000, 635 mm
(25 in) on the MT4400 and 787 mm (31 in)
on the MT5900 provides limited frictional area.
43

brake on high-speed motor armature develops
Accumulators that require routine pressure
checks and maintenance provide secondary
brake power.
Service and secondary brakes share the same
brake circuit and are more complex. Circuit
includes: pump, shuttle valves, pressure reducing
valve, relief valves, accumulators, pilot-operated
control valves, steering versus brakes priority.

brake on high-speed motor armature develops
The EH4500-2 and EH5000 brake system features:
Hydraulically actuated dry caliper disc front
brakes are subject to dirt and moisture entry,
malfunction.
Hydraulically actuated oil cooled rear disc
brakes.
brake on high-speed armature has almost no
dynamic capability.
Liebherr Brake System. The brake system features:
Standard service brakes use wheel speed discs
on the front with three calipers on the T252,
four on the T262 and five on the T282B.
Rear brakes use dual disc armature speed discs
with one caliper.
Multiple calipers cause high heat production.
Euclid/Hitachi EH3500 front and rear dry disc brakes.
Euclid/Hitachi Brake System. The brake system

on the Euclid/Hitachi EH3000 and EH3500 features:
disc brakes are subject to dirt and moisture entry,
malfunction.
armature develop high torque but very limited
dynamic capability. The small disc diameter of
EH3000 and EH3500 provides limited
frictional area.
44
September 2006
Steering and Suspension System

Steering and Suspension System. Cat designed for excellent maneuverability, superior control
and a comfortable ride.
Steering Geometry. The three steering geometry
features kingpin inclination, caster and camber
are permanently designed and built into the truck
and require no adjustments during the life of the
truck. The only steering linkage adjustment required
is toe-in which is achieved simply by adjusting the
two tie-rods.
Kingpin Inclination. The front suspension cylinder
serves as the steering kingpin.
The kingpin is rigidly attached to the mainframe
by bolts and shear keys and is inclined in the
front elevation view 3 degrees from vertical.
This kingpin inclination reduces the torque
required to steer the front tires by moving the
center of rotation nearer to the tire than would
be the case if the kingpin were vertical.
Caterpillar Design. Cat steering and suspension
system design, first introduced on a 769 in 1963,
are simple integrated designs, built rugged for
minimal maintenance and long life.
Caster.
From the side view the kingpin is set at
2-1/2 degrees to the vertical to provide caster
or self-alignment for the front wheels.
Camber.
The front axle is designed and manufactured
to have one-half degree of camber, which is
reduced to near zero by the load deflections.
Maximum Tire Life. Good tire life is dependent
upon having minimal tire scuffing. Caterpillar trucks
are designed to maintain near zero toe-in/toe-out,
which is essential to minimize tire scuffing and
extend tire life.
When either loaded or empty, Cat steering
linkage/ suspension systems are designed to
have near zero toe-in/toe-out when the tie-rods
and front suspension cylinders are properly
adjusted.
September 2006
45
Having two tie-rods that pivot with the center

tee-bar minimizes the amount of toe-in/toe-out
that occurs during all conditions of loading
and steering.
Systems with a single tie-rod inherently have
greater toe-in/toe-out variations.
Maneuverability. Caterpillar trucks have a
balanced design to give good maneuverability and
yet minimize tire wear. If the turning circle is too
small, extreme tire wear occurs during tight turns.
Some competitors claim smaller turning circles
than Caterpillar, but pay for those claims with
increased tire wear.
The Caterpillar truck steering geometry is
designed for Ackerman steering with minimal
steering error even at extreme steering angles.
Nitrogen
Rebound
Chamber
Cylinder
Housing
Piston
The two tie-rod design enables the steering

error to be less than can be achieved with
a single tie-rod.
Ride Control. The rear suspension geometry is
designed to allow sufficient rear axle oscillation in
conjunction with large front suspension travel to
reduce frame racking while traveling over rough
terrain. Both front and rear struts have built-in
rebound control to improve ride. To further enhance
the operators ride the cab is strategically located
relative to the front axle to minimize the effects of
pitch and bounce.
Competitors frequently locate the cab in a position
that exacerbates the effects of pitch and bounce.
The Caterpillar suspension is located and tuned to
maximize ride qualities and yet give a stable feel
of the road for the operator. Because of the superior
ride qualities of Caterpillar trucks, the operators
have less fatigue and a more secure feeling that
results in greater productivity.
Design Features. The steering and suspension

system offers advanced design features:
Caterpillar steering systems have top priority
for the control of the machine in case of a
hydraulic failure. This is critical to ensure
the highest possible safety for the operator.
To further protect the operator, the main steering
hydraulic system is backed by a supplemental
system using pressure accumulators in the
unlikely event the steering pump should
malfunction. The secondary steering system
is more than adequate to meet SAE J1511 and
ISO 5010 standards at the maximum allowable
gross machine weight.
Twin, double-acting hydraulic cylinders provide
the force necessary to provide precise steering
during all loading and underfoot conditions.
46
September 2006
The suspension system is comprised of nitrogen

over oil cylinders at each of the four corners.
Improvements have continued to be
implemented since introduction in 1963 to
provide a highly reliable, long life system.
Nitrogen and oil are readily available world
wide for easy maintenance and adjustment.
The front and rear cylinders are of sufficient
diameter that the nominal pressure is low
(less than 141 kg/cm2 [2,000 psi]).
The front cylinders are attached to the front
spindles by tapered joints that can be separated
for repairs and maintenance.
Caterpillar Steering and Suspension System Versus
Competition. The Caterpillar integrated steering and
suspension system is designed for safer operation
and lower operating cost.
Front suspension cylinders, which serve as
steering kingpins, are rigidly mounted to the
main frame with built-in adjustment to save
maintenance time and tire wear.
Toe-in/toe-out can be adjusted for varying
conditions but is kept near zero, minimizing
tire wear.
Design simplicity and balance gives good
maneuverability and minimizes tire wear.
Twin, double-acting hydraulic cylinders provide
precise steering during all loading and underfoot
conditions.
The steering/fan/common rail control system
is fully hydraulic and completely separate from
the other systems to prevent cross contamination
and heat from other sources.
Accumulators provide pressure/flow source for
the supplemental steering system. The secondary
steering system exceeds requirements of
SAE J1511 and ISO 5010 standards at the
maximum allowable gross machine weight.
September 2006
Four nitrogen over oil cylinders (one at each

corner) provide a highly reliable, long life
suspension system. Nitrogen and oil are
readily available worldwide.
Strategically located cab relative to the front
axle minimizes the effects of pitch and bounce,
resulting in reduced operator fatigue, greater
security and higher productivity.
Nominal internal pressure in the suspension
cylinders is low (less than 141 kg/cm2
[2,000 psi]) because of the large diameter
cylinders.
The rear suspension geometry allows sufficient
axle oscillation in conjunction with large front
suspension travel to reduce mainframe racking
while traveling over rough terrain.
Built-in rebound control improves ride.
Komatsu Steering/Suspension System.
Steering hydraulic system shares oil with hoist
system, increasing the potential for crosscontamination.
Single tie-rod for steering.
Additional wear points in the Komatsu steering
and suspension system make it more vulnerable
to hysteresis or slop. This may eventually
result in transverse tire oscillations or wobble,
increased tire wear and reduced stability.
As turning radius gets tighter, it becomes more
difficult to achieve correct Ackerman steering
angles, and lateral forces on the tires increase.
Ackerman error leads to tire scrubbing during
turns, and high lateral forces increase tire flex,
which can cause sidewall damage.
Serviceability of Komatsu suspension and
steering system requires more downtime.
47
Euclid/Hitachi Steering/Suspension System.

Front steering and suspension system is complex
using trailing arms. The large number of joints
increases susceptibility to wear and need for
periodic maintenance. Loose joints can cause
excessive tire wear.
Field evidence indicates that at less than
20,000 hours, the steering and suspension
system can require major restorative work,
including build-up and line boring to front
end. With 10 wear points per side, heavy
reliance is placed on the integrity of the
lubrication system.
Suspension cylinders are charged with expensive,
hard-to-obtain Neocon X and Helium.
Terex/Unit Rig suspension cylinder.
Terex/Unit Rig Steering/Suspension System.

Front suspension and steering system is very
complex and heavy with numerous joints
subject to wear and periodic maintenance.
Loose joints can cause excessive tire wear.
Steering hydraulic system shares oil with the
hoist system, increasing the potential for
cross-contamination.
48
Small diameter strut rods result in:

Dramatically increased strut pressures
Struts that are difficult to seal
Leakage possibility under high loads
Steering hydraulic system is combined with
the brake system, increasing the potential for
cross-contamination.
Suspension system is very serviceable.
September 2006
Terex/Hitachi independent trailing arm suspension.
Euclid/Hitachi frame with trailing

arm suspension system.
Euclid/Hitachi suspension
cylinder charged with Neocon.
September 2006
49
Hydraulics
Hydraulics. Cat hydraulics are designed for dependable performance and precise control.
Brake System. With the changing demands of
brake systems, Caterpillar is continuously working
to increase the speed of brake response through
improved valving capabilities.
Hydraulically controlled valves support the
braking system.
Specifically crafted and precision tested valves
provide superior operator control.
Steering System. Caterpillar variable pump
steering systems perform with higher efficiency
and greater reliability.
Increased flow rates provide faster hydraulics
and greater lift force.
Cylinders are induction hardened to Caterpillar
specifications for greater longevity.
Integrated Design. Cat hydraulics are integrated
throughout the truck design, including:
Hoist Systems
Brake System
Strut cylinder rod eyes are inertia welded for

superior strength and reliability, allowing low
stress concentration, bonds as strong as base
material, and twice the fatigue life.
Steering System
Suspension System
Hoist Systems. Hoist systems offer superior
controllability and reliability of cylinders:
End of stroke control for hoist cylinders is
achieved through a proprietary EH valve system,
which automates the use of electronic snubbers.
Electronic dampening of cylinders restricts
flow of fluids to reduce the speed of cylinder
positioning, thus eliminating sudden shocks
to the system.
Cylinder rods are induction hardened to Cat
specifications. Case depth typically exceeds
industry standards and extends cylinder life.
50
Suspension System. Caterpillar suspension system

is designed for excellent maneuverability, superior
control, and a comfortable ride.
Caterpillar mining truck suspension cylinders

are charged with Nitrogen gas.
Unlike competitive systems, which typically
use air or other gases, nitrogen systems respond
quickly to absorb a rapid series of shocks.
The nitrogen gas system cushions better (loaded
or unloaded), controls rebound, helps eliminate
truck pitching and provides superior ride quality
when loaded.
Cat suspension systems operate effectively
at 1/3 lower pressure than some competitors,
which helps minimize seal leakage.
September 2006
Hydraulics
Fan Drive System. Caterpillar offers a state of the

art hydraulic demand fan on certain applications,
which increases available power and improves
sound management. The hydraulically driven
fan is standard on the 793D and 797B.
Because it is more efficient, the Caterpillar fan
drive system uses less horsepower and consumes
less fuel than the conventional engine driven
fan system utilized by the competition.
For customers with a focus on sound
management of large mining trucks,
Caterpillar offers the lowest dBA in the industry.
Sound reduction trucks offer a significant
reduction in spectator sound level.
Hydraulic Components. Components are designed
and manufactured to strict specifications to ensure
the reliability and longevity expected of Caterpillar
machines. Each component is part of an integrated
system and must meet exacting performance
standards.
Pumps and Motors. Cat pumps and motors are
designed to respond quickly to hydraulic system
demands.
Built to tight tolerances with heavy-duty
bearings and shafts.
Field repairable for ease of maintenance.
Cylinders. A robust cylinder design ensures

excellent durability.
Cat induction hardened rods provide higher
surface hardness for increased fatigue strength.
Induction hardened at a slightly higher depth
of case than the competition (3 mm [0.12 in])
for greater durability.
Rod assemblies are inertia (friction) welded
for cylinder longevity.
Cylinders are bore honed and roller burnished
for superior finish. Cylinder walls are honed to
remove minor scratches and other hard to see
imperfections that can cause damage to the
cylinder seals. This process produces a highly
symmetrical bore with a surface finish that
provides a longer seal life.
Caterpillars proprietary sealing system includes
an inboard sealing design in the head, for a more
robust design and improved performance.
Cat hydraulic rod seals feature a proprietary
urethane material and patented design
improvement.
Valves. Caterpillar valves offer precise control,
quicker response of the hydraulic system, and
reduced operator effort to meet the most exacting
application requirements.
Proprietary solenoid valves offer greater
performance and reliability through superior
design and process manufacturing.
Sophisticated software controls are available
for electro-hydraulic valves. This allows for
programmable features customized to
customer requirements.
September 2006
51
Hydraulics
Filters. All filters are custom built to Cat

specifications for optimization of system and
efficiency of application requirements
Unique Cat filter design features fiberglass
spiral roving and acrylic beads, which maintain
optimum pleat spacing and prevent bunching,
collapse and loss of capacity.
High efficiency hydraulic filters are available for
systems requiring extra cleanliness with tighter
system tolerances and higher operating pressure.
Cat high efficiency filters reduce the risk of
exposing critical components to abrasives, thus
extending component wear life. These high
efficiency filters trap a higher percentage of
fine particles in comparison with some of
competitive standard filters.
Tanks. Caterpillar hydraulic tanks are designed

to ensure hydraulic oil stays in and contaminants
stay out of the hydraulic system.
For applications requiring smaller tanks, Cat
offers tanks formed from a single sheet of steel
by using a deep-drawn process in manufacturing.
This allows Cat to stamp out a shape of the tank
in one piece of metal thus manufacturing a
stronger tank and eliminating potential leaks.
For applications requiring larger tanks, Cat
has greater flexibility by utilizing sheet metal
weldments in manufacturing for fewer
restrictions in the design process.
All tanks are subject to air testing to ensure
system reliability.
Cat filters will clean the system faster, thus

increasing component life and system efficiency.
Hoses and Couplings. Caterpillar offers a wide
range of hoses for high, low, medium pressure
and special applications.
Cat XT hose line is impulse tested to one
million cycles twice the industry standard.
Cat XT hose has superior construction for
longer life.
The fabric on Cat XT hoses is impregnated,
not wrapped, around the liner. This unique
process helps prevent pinhole failures.
Reliable components reduce the risk of leaks
and blown lines.
52
September 2006
Operators Station
Operators Station. Ergonomically designed for operator comfort, superior control and high productivity.
The cabs have been widened to provide an
increase in interior volume and an increase
in glass area.
Electronically controlled body hoist control
provides better modulation and ease of operation.
Hoist control is hydraulically snubbed for
improved comfort.
Integrated electronic control for intermittent
windshield wiper, washer and turn signal for
improved reliability.
Operator Efficiency. Ergonomic cab design allows
operators to direct their full attention to machine
control.
Caterpillar Operators Station. As the world leader

in mining trucks, Caterpillar has designed its cabs
to provide unsurpassed comfort, control and safety.
Cat advanced electronics and ergonomic
enhancements set a new standard for information
management, operator efficiency and productivity.
Designed for Productivity. Every aspect of the
operator station has been refined to ensure that
operator efficiency contributes fully to machine
productivity.
Actual gear, engine speed and VIMS status are
visible at a glance.
Controls are ergonomically designed and located

for intuitive reach to guarantee easier operation
and maximum convenience.
Gearshift lever is contoured to fit the hand.
Narrower shift control console contains the
parking brake control.
Secondary brake is a pedal control, conveniently
located on the floor for easy operator control.
Pedal control positioning provides easier, more
natural actuation.
Tilt and telescoping steering wheel adds to ease
of operation and comfort.
Transmission console has backlit gear indicators

and ergonomic shift knob.
VIMS display and operator keypad provide
precise machine status information.
Exceptional all-round visibility allows confident
maneuvering and increased productivity with
less fatigue.
With clear sight lines toward the haul road and
to the instrument panel in front, strain on the
operator and fatigue are reduced.
September 2006
53
Operators Station
Comfort and Control. The cab has everything the

operator needs for superior comfort and control,
including:
ROPS/FOPS Cab. Caterpillar has its own requirements

for ROPS testing that surpass the toughest ISO
guidelines.
Fingertip controls.
Integral four-post ROPS is standard.
Ergonomically designed, fully adjustable air

suspension seat with adjustable armrests
provides optimal driving comfort.
Cab is resiliently mounted to the mainframe

and is sound suppressed to isolates the operator
from sound and vibration.
A wide, retractable three-point seat/shoulder

belt provides a secure, comfortable restraint
with three height adjustments and six vertical
adjustment positions.
Cab operator sound levels are less than

80 dB(A).
Trainer seat has wide hip and shoulder room,

with a backrest and seat belt.
Integral, adjustable armrests for added comfort
and lumbar support adjustment are standard.
Powered operator window with sliding window
on trainers side.
Reliable large capacity air conditioning and
heating provides efficient, high volume airflow
though more vents. Controls have been relocated
to the dash. 9576 kilocalorie (38,000 Btu)
heater, optional A/C rated at 7056 kilocalorie
(28,000 Btu).
Radio ready cab is pre-wired for a 12-volt
entertainment radio. Cab is equipped with two
speakers, antenna, 5-amp converter, and radio
mount recessed in the headliner. Includes a
provision for add-on communication systems.
Under seat storage compartment.
Caterpillar integral ROPS frame.
Cat Operators Station Versus Competition.

Caterpillar Mining Truck cabs are designed to
maximize operator control, safety and productivity.
Cat cabs provide a comfortable and convenient
environment that minimizes fatigue. Caterpillar has
its own requirements for ROPS testing that surpass
the toughest ISO guidelines.
Komatsu Operators Station.
Komatsu mining trucks, from the HD1500-5
to the 930E-3, have integral four-post ROPS,
which means the frame of the cab is the ROPS
structure. The integral ROPS cab mounts directly
to the frame at all four corners and offers rollover
protection on all sides of the operators station.
54
September 2006
Operators Station
Terex/Unit Rig Operators Station.

Integral ROPS cab with 180-degree vision
meets SAE J1040 May 94 criteria.
Room for two full-size seats.
Sound abatement package reduces in cab noise
to 82 dB(A).
Liebherr Operators Station.
Integral ROPS is standard.
Room for two full-size seats.
Cab set back for protection in case of a rearend collision.
Euclid/Hitachi cab frame.
Euclid/Hitachi Operators Station.

Integral ROPS/FOPS in accordance with
J/ISO 3471 standard.
Double-wall construction made of 11-gauge
inner and outer steel panels.
Foam rubber lining and foam backed carpet
with multiple layered floor to improve sound
suppression and climate control.
Closed cab, operating sound level equivalent
to 81 dB(A).
Three-point rubber isolation-mounted
arrangement to the deck surface minimizes
vibration to the operator compartment.
September 2006
55
Monitoring System
Monitoring System. The VIMS monitoring system provides operators, service technicians and mine
personnel with vital machine health and payload data to keep the large mining trucks performing at
peak efficiency and top production levels while lowering cost-per-ton.
11
2
10
12
13
9
14
6
1
2
3
4
5
6
7
8
9
10
11
12
13
Gauge Cluster
Message Center and Keypad
ADEM III Engine Control Module
CAT Data Link
Action Alarm
Action Lamp
Payload Lamps
Payload Display (optional)
Radio System (optional)
Data Port (VIMS-PC)
Service Lamp
Diagnostic Connector (ET)
Integrated Brake Control (IBC)
and Cooling Fan Control Module
14 Transmission/Chassis Control (TCC) Module
15 Road Analysis Control (RAC) Module (optional)
5
8
15
VIMS Monitoring System. Intelligent, Caterpillar

designed machine monitoring system provides
critical machine health and payload data in realtime to keep the large mining trucks 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.
Data Access. Monitoring and diagnostic information

is stored on-board until it can be downloaded for
analysis. Data can be accessed through the message
center, transmitted via optional radio or downloaded
onto a computer for detailed analysis.
Machine Management. Service technicians or mine
personnel can download data and generate reports
for better machine management. Data can be used
to improve effectiveness of scheduled maintenance
programs, maximize component life, improve
machine availability, and lower operating costs.
Integrated System Monitoring. Sensors located

throughout the machine systems enable the
VIMS system to quickly exchange and monitor
information from all machine systems for efficient,
high performance operation.
Advanced Diagnostics. VIMS system simplifies
troubleshooting, reduces downtime and lowers
operating costs by identifying abnormal conditions
before they cause extensive damage.
56
September 2006
Monitoring System
Speedometer/Tachometer Module. Monitors three

systems:
Engine speed
Ground speed
Gear indicator
Gauge Cluster. Conveniently located gauge cluster

maintains a constant display of vital machine
functions, including:
Engine coolant temperature
Brake oil temperature
Air system pressure
Fuel level
September 2006
57
Monitoring System
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.
Percentage of Total Loads
Payload Weight Distribution
Payload Weight (Tons)
Keypad. Provides operator or service technician

immediate access to current machine information,
gauge values and stored data through the message
center display. Service personnel also can use the
key pad to access diagnostic information.
Message Center. Displays messages requested
by operator and advises operator of abnormal
machine conditions.
Recommended Payload Range
With Production Management
Inefficient Payload Ranges
Without Production Management
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.
Alert System. Three-category warning system alerts

operator of abnormal machine health conditions.
Category I. No action is required at this time.
Inform service personnel of the alerted condition
as soon as possible.
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.
58
September 2006
Monitoring System
Payload Management. Max Payload Speed

Manager is a feature that aids in managing the
Caterpillar 10/10/20 Payload Guidelines. Based on
target payload weight and overload settings, the
VIMS 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.
Data Storage. The VIMS monitoring system stores
payload information, which 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, utilizing the efficiency
of Preventative Maintenance.
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 is available to replace
the standard red/green indicator lamps.
September 2006
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 haulroad 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.
VIMS PC. VIMS PC, the off-board reporting software
program, allows service personnel to download a
complete record of machine health and productivity
data to a laptop computer for diagnosis and analysis.
Easy-to-use software enables service technicians
and mine personnel to generate health and payload
reports for more effective machine management.
VIMS Supervisor. Optional software allows mine
personnel to easily manage and interpret VIMS
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.
59
Monitoring System
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 large mining trucks are 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 oregrade determination at the excavation face.
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.
Competitive Monitoring Systems Komatsu.
Komatsus Vehicle Health Monitoring System
(VHMS) mimics the diagnostic capability of the
Caterpillar VIMS hardware and software. It monitors
30-health items and stores a total of 600 records
of event histories. Data can be accessed via personal
computer or satellite link. The website database is
called WebCARE and stores VHMS and other
monitored diagnostic data. This web-based
application is only available to Komatsu and
Distributor personnel, not the customer.
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.
60
September 2006
System Integration
System Integration. System Integration. Electronically combines virtual power train components to work
more intelligently and optimize overall truck performance.
1
2
3
4
5
6
7
8
9
Integrated Electronics System. The electronic

control modules (ECMs) and electronic and
electrical components on Caterpillar mining trucks
form an integrated system, a control network.
These ECMs are designed and developed by
Caterpillar to withstand the punishment of rugged
mining applications. They are not automotive
controls or automotive-grade components adapted
for mining applications. Cat electronics are designed
to work with each other as a system. The sensors,
switches, wiring, connectors and all of the other
electronic and electrical components on Cat mining
trucks have been developed for the same demanding
applications.
Engine Control Module (ECM)

Sensors
Electronic Unit Injector (EUI)
Integrated Braking Control (IBC)
Transmission/Chassis Control (TCC)
Transmission
Wheel Sensor
Brakes
CAT Data Link
The Cat Data Link allows the transmission and the

engine to communicate to optimize overall power
train performance and reliability, and reduce
operating costs. The Transmission and Chassis
Control (TCC) communicates over the Data Link
with the engine Electronic Control Module (ECM)
to manage engine speed during shifts for increased
clutch life and operator comfort. The TCC also
controls body hoist, neutral start, rear-axle filtration
and automatic lubrication functions.
Basic
Diagnostics
SENSORS
SENSORS
SENSORS
ECM
IBC
Traction
Retarding
ET
TCC
Smooth Shifting
Abuse Prevention
Emissions
Altitude Capability
Auto De-rating
Electronic Systems. Cat Mining Trucks feature

advanced electronic systems for superior machine
intelligence.
September 2006
61
System Integration
Electronic Control Module (ECM). The engine

ECM utilizes advanced engine management
software to monitor, control and protect the
engine utilizing self-diagnosing electronic sensors.
The module controls a wide spectrum of engine
functions, providing infinitely variable injection
timing to maintain peak performance. It provides
additional features of electronic protection of the
engine during cold starts, high altitude operations,
air filter plugging and high exhaust temperature
conditions. It stores information to permit quick
diagnosis of engine conditions to enable effective
maintenance and repairs utilizing the Caterpillar
Electronic Technician (Cat ET) service tool.
In operation, whenever the shift cane passes through
neutral and the engine speed is above 1,350 rpm,
the transmission sends a signal to the ECM to
momentarily reduce the engine throttle while the
transmission shifts. This prevents the operator
from abusing the machine and leads to improved
component life.
All of this is accomplished with one service tool.
Cummins employees a palm pilot to do some of
the diagnostics, but not all. Cummins does not
have an integrated system.
Transmission and Chassis Control (TCC). The 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 2,000 rpm, so the truck
(785-793) can achieve speeds up to 55 km/h
(34 mph). The 793D can achieve a maximum
of 60 km/h (37 mph) with the Extra Top Speed
Configuration. The 797B can reach speeds up
to 67.6 km/h (42 mph) while traveling in seventh
gear. 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.
TCC features:
Improved on-board diagnostics
Alphanumeric display
Records intermittent faults
Provides diagnostic codes
Programmable top gear selection
Cat Data Link
A two-wire connection to an optional service
tool for additional logged information
Communicates with the engine electronics
for efficient power train management
Integrated Braking Control (IBC). Hydraulically
activated electronically combines the Hydraulic
Automatic Retarder Control (HARC) and Traction
Control System (TCS) into one, integrated control
system.
62
September 2006
System Integration
Hydraulic Automatic Retarder Control (HARC).

The hydraulically activated automatic retarder
control system electronically controls retarding
on grade to maintain optimum engine rpm and oil
cooling system. HARC is a standard system on all
large mining trucks. A dash mounted push button
switch activates the HARC system via hydraulics
rather than compressed air. Settings are adjustable
from 1,850-1,950 rpm in increments of 10 rpm.
While HARC modulates the brakes, the operator
may also apply additional braking force using either
the manual retarder or the brake pedal. When the
operator applies the accelerator controls or the
brake, HARC is deactivated. An auto resume
feature reactivates the control without
additional operator input.
The precision of HARC (maintaining higher

average operating speeds) optimizes systemcooling capabilities, reduces torque fluctuations
for improved brake component life and
minimizes the potential for destructive engine
overspeed. HARC modulates the Cat designed
oil-cooled disk brakes for excellent control and
does not interfere with the manual retarder or
service brake operation.
HARC
1
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4
5
6
7
8
Service Brake Sensor

Engine Sensor
HARC
HARC Switch
Brakes
Service Brakes
Axle Speed Sensor
TCS
TCS
6
7
8
3
7
5
HARC results in:

Increased production with faster downhill
speeds. HARC can increase vehicle speed by
as much as 15 percent over manual retarder
control. The system allows trucks to operate
at maximum speeds with a consistently high
engine speed and enhanced truck handling.
Excellent controllability and reduced operator
effort. Automatic brake modulation provides
a smoother ride, better control in slippery
conditions and allows the operator to focus
more on driving.
Engine overspeed protection. HARC will
automatically activate when engine speed
exceeds factory-preset levels, regardless of
other operator inputs, including when the
system is turned off, to help ensure that
engine overspeed conditions do not occur.
September 2006
Traction Control System (TCS). The Traction

Control System improves traction and truck
performance in poor underfoot conditions by
electronically monitoring and controlling wheel
slippage. Axle sensors monitor wheel speed.
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. TCS utilizes normal differential
action to provide superior maneuvering in poor
underfoot conditions. Should the sensors fail, normal
differential action is still available to maintain
control and steering. Operators feel more confident
with the anti-slip benefits provided by the TCS.
63
System Integration
Integrated Braking Control
Message Center Module
Gauges
Transmission/Chassis
Control
Transmission
Sensors
Engine
Control
Module
Brakes
Wheel Sensor
Diagnostic
Connector
Clutch Power
(HP/Square Inch)
Transmission Output Torque

(Nm)
Integration as a Total System. All control modules,

communicating via the Cat Data Link, were
designed and developed to work together as an
integrated system to maximize production, efficiency
and extend service life of the components.
Shift without CTS
Shift with CTS
Shift without CTS
Shift with CTS
Electronic
Unit Injector
CTS reduces stress on the transmission and extends

power train life. It achieves this by briefly adjusting
engine throttle during shift change to control torque.
This allows the clutch to engage smoothly.
Smoother shifts reduce operator fatigue and
component wear.
The TCC Transmission and Chassis Controller
signals the ECM engine controller that the
transmission is preparing to change gears.
During shift changes, engine throttle is adjusted
up or down, depending on shift direction, for a
fraction of a second to alter torque created by
the engine. This allows the transmission speed
to synchronize for a smoother shift.
CTS is disabled during the braking or retarding.
Controlled Throttle Shift (CTS). Engine rpm is

regulated during a shift to reduce driveline torque
stress for smoother shifts, extended component life
and improved operator comfort. Transmission life is
a function of two things: number of shifts, and level
of stress on the transmission during each shift.
64
The benefits of Control Throttle Shifting extend

beyond the transmission. Reduced torque levels also
lead to improved driveshaft, differential, axle and
final drive life. This means lower major component
costs and therefore decreased cost per ton.
September 2006
System Integration
Directional Shift Management. Regulates engine

speed during directional shifts to prevent damage
caused by high-speed directional changes.
This prevents shifts into reverse when forward
ground speeds are in excess of 4.8 km/h (3 mph).
This protects the transmission from high shock
loads created by abusive directional shifts.
The objective of Directional Shift Management is
to reduce driveline torque spikes and transmission
clutch energy spikes. The machines driveline is
designed to withstand torque converter stall (the
maximum torque that the converter will transmit
to the transmission). If shifts are made from reverse
to forward, or if shifts are made from neutral to
reverse or forward at high engine speed, torque
spikes greater than converter stall levels can be
generated. This can result in accelerated transmission
wear and/or premature final drive or differential
failures. Directional Shift Management electronically
prevents torque levels above converter stall, reducing
the potential for abuse and related driveline
component failures.
Elevated Idle Neutral Coast Inhibitor.
Prevents the transmission from shifting to neutral
at speeds above 6.5 km/h (4 mph). This protects the
transmission against operating with insufficient
lubrication. Neutral coasting causes extremely high
relative transmission clutch speeds and inadequate
cooling oil flow, which results in accelerated wear
and the possibility of premature transmission failure.
The ECM engine controller and the TCC
transmission and chassis controller are programmed
to work together to prevent this from occurring.
A sensor on the transmission output shaft determines
ground speed. If the transmission gear selector is
placed in the neutral position, the controller will not
downshift to neutral immediately but will allow
downshifts to the proper gear for the calculated
ground speed as speed is reduced. This maintains
engine speed and oil flow through the transmission.
September 2006
After the speed for torque converter drive is reached

(approximately 6.5 km/h [4 mph]), the transmission
will shift into neutral. If coasting speed increases
to 19.4 km/h (12 mph) after the transmission has
shifted to neutral, the engine will operate in elevated
idle mode (1,300 rpm) to provide proper oil flow
to the transmission. Neutral coast events will be
logged for each occurrence over 16.1 km/h (10 mph).
These logged events can be retrieved using Cat
Electronic Technician (Cat ET).
Body-up Shift Inhibitor. Prevents the transmission
from shifting above the pre-programmed gear
without the body fully lowered.
Reverse Neutralized with Body Up. If the hoist
level is activated and the transmission is in reverse,
the transmission will automatically shift to neutral.
Engine Overspeed Protection. The transmission
control senses possible overspeed conditions and
upshifts one gear. If overspeed conditions occur
in the top gear, the lock-up clutch is disengaged.
Programmable Top Gear Selection.
The transmission top gear may be electronically set
using Cat ET. This feature helps operators maintain
speed limits. The TCC lets you electronically limit
top gear selection without the use of additional
service tooling or mechanical limiting of the shift
cane. Unlike the former method of blocking shift
cane travel, this electronic limit cannot be improperly
overridden by the operator. Reprogramming of the
top gear can only be accomplished with Cat ET.
Anti-hunt Function. The transmission will not
allow an upshift or downshift for approximately
2.3 seconds after a shift has occurred. This prevents
gear hunting when operating near a shift point and
minimizes transmission shifts to increase
component life.
Downshift Inhibitor. The transmission will not
allow a downshift to occur until engine speed
reaches the downshift point, preventing an engine
overspeed condition.
65
System Integration
Retarding Efficiency. No fuel is used during

retarding. 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.
Hydraulic Power Management System
Steering
Control
Main
Engine
Fan
Steering
Cylinders
Oil Cooler
Fan
Pump
Rear Axle
Cooler
Fan
Valve
Pump
Hydraulic Tank
Rear Axle
Lubricator Motor
Return
Filter
Brake Cooling
Pumps
Solid Connection
Brake
Cooling
Drive Motor
Steering
Tank
Hydraulic Power Management System.

Currently available on the 793D only, the system,
also known as common rail hydraulics, reduces
parasitic (unused, wasted) losses in the power
management system components and the new
hydraulic fan drive system. Two new variable
displacement piston pumps operate the system.
These pumps primarily provide for the steering
and cooling functions, and are independent of the
brake and hoist circuit. One pump is dedicated to
a new on-demand hydraulic fan drive system.
The other pump feeds a new priority valve and
provides hydraulic pressure and flow to feed steering,
brake cooling, rear axle filtration (RAX), and the
optional RAX cooler systems. The system continues
to allow priority for the steering system while using
an improved power management scheme for brake
cooling and RAX functions. By reducing the losses,
the system is able to provide more horsepower to
the ground.
66
Diagnostics and Serviceability. The electronic

engine and transmission controls provide enhanced
diagnostic capability. This useful data can be
accessed at different levels of detail using the
display panel in the cab or the Electronic Technician.
The ability to store both active and intermittent
indicators simplifies problem diagnosis and total
repair time, resulting in improved mechanical
availability and lower operating cost.
September 2006
System Integration
Diagnostic Codes. Diagnostic codes are generated

when a control computer detects an input or an
output, which is out of the ordinary, such as an
open or short circuit. Diagnostic codes are electrical
problems by nature and are identified by name
when using Cat ET. An example would be Parking
Brake Pressure Switch Short to Ground. Cat ET will
list the number of occurrences, the service hour
when the fault occurred, the first and last time.
Caterpillar Electronic Technician (Cat ET).

Allows for easy access to service diagnostic data
through the use of a single service tool. Cat ET
accesses data stored in the controls via the Cat
Data Link, which allows information on transmission
shift data, engine speed, fuel consumption and other
data to be retrieved.
Events. An event is recorded when a performance

parameter such as engine oil pressure crosses a
predetermined threshold, indicating that something
has happened out of the ordinary. Cat ET displays
the Event, the number of occurrences, the service
hours of the first and last occurrence.
The Caterpillar Electronic Technician provides a

window to the service and operational information
in the machines electronic controls. It can be used
to review logged and active diagnostic codes and
recorded events. Cat ET is an easy to use, intuitive
windows-based service tool, which significantly
reduces downtime and repair cost by providing
valuable troubleshooting aids. For example, Cat ET
can be used to individually test each injector in order
to identify an injector requiring service preventing
time-consuming exhaust port temperature readings.
Caterpillars integrated machine electronics allow the
Cat ET service tool to be used to monitor, configure,
and troubleshoot the engine, transmission and
braking system controls. Cat ETs service capability
has three major components: Review of diagnostic
and event codes, real time monitoring and data
logging, and diagnostic tests.
September 2006
67
System Integration
Monitoring. Cat ET can be used to monitor a wide

variety of machine parameters, the parameter list
being displayed can be selected from default lists
or customized.
Cat ET can also be used to data log parameters to
capture transient or intermittent problems. Data can
be retrieved and analyzed on the spot or stored for
later use. For certain parameters, data stored in the
ECM can be displayed in a histogram format using
Cat ET.
68
Diagnostic Tests. Cat ET can be used to

force certain signals to be generated to simulate
operational events and confirm functionality.
For example, Cat ET can be used to test the
High Coolant Temperature Lamp by temporarily
overriding the signal from the control computer.
This provides a quick and cost effective means
of testing electrical circuits.
Flashing. Cat ET provides a simple means of
updating a machines software by flashing in the
latest software, software files can be e-mailed and
flashed the same day they are made available from
Caterpillar.
September 2006
Truck Bodies
Truck Bodies. 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.
Caterpillar designs the bodies using the best tools
and methods backed by the most advanced analysis
approach in the industry. Caterpillar has developed
a dynamic model of the entire truck that has been
verified with extensive field-testing at a variety of
sites from around the world. Caterpillar is the only
body manufacturer that uses a full-truck dynamic
approach to body design and analysis. These tools
and methods allow our engineers to identify high
stress areas and evaluate design solutions to meet
body life goals without additional weight.
Our approach is called System Structural Analysis
and Virtual Product Environment (SSA/VPE).
This is exciting comprehensive technology that
models all load inputs to the body so our engineers
have the information necessary to design the most
efficient, durable body for the intended application.
Body/Chassis Integration and Design. Caterpillar
body and chassis are designed as one model, in
which the body forms an integral part of the
dynamic modeling and stress analysis of the
complete truck.
Because Caterpillar designs and manufactures the
entire truck from the tires to the body, Caterpillar
bodies are designed with a depth of understanding
our competitors cannot match. Our engineers look
at the body as part of a haulage system that includes
the ground interface of the wheels, tires and terrain;
suspension; chassis and structure; drive train; and
body and payload. The result of this understanding
is a suite of body offerings that fit well with the
chassis that yield expected payload and volume
requirements and proper loading front to rear for
the optimum safety and performance of the truck.
September 2006
69
Truck Bodies
With the desire to extract the most value from the

truck, Caterpillar pioneered the philosophy of Mine
Specific Design (MSD) offering more specialized
bodies to increase payload and to meet specific
application requirements. MSD is a method
we use to specify a body that meets the specific
requirements of the mine. The process starts with
an evaluation of the mines operating characteristics
and ends with a properly sized and configured body.
Along the way we evaluate the application and
determine the right combination of volume, wear
and impact liners to meet the specific requirements
of the mine.
System Structural Analysis Integration
Caterpillar Body Systems. When selecting the proper

body for a particular application, it is important to
take into consideration the material fragmentation,
density and abrasiveness as well as the loading
tool, load, dump and haul road conditions, and
maintenance practices. The better understanding
of the local conditions the better the match.
Caterpillar pioneered the introduction of lightweight
bodies, which today are well accepted in the mining
industry. The combination of better payload
performance with excellent durability is achievable
with a careful loading and maintenance strategy.
70
The MSD II and X lightweight bodies are intended

to maximize payload while still giving acceptable
life. The MSD II body yields the highest payload
but the X body gives better durability while still
giving excellent payload. Caterpillar is the worlds
leader in lightweight bodies.
Traditional dual slope and flat floor bodies find
their best fit in Greenfield sites and other heavier
duty applications.
The gateless coal body is a unique design that
achieves target payload without the need for
a heavy and maintenance intensive tailgate.
Each of the five body styles Caterpillar offers is
sized to deliver target payload with minimal spillage.
Consult your Caterpillar dealer to begin the body
selection process by filling out a site profile.
September 2006
Truck Bodies
Tail extensions are used to help retain the rear

portion of the pile and limit load spillage on
haul roads, extending tire life.
Target Payload Strategy. Your Caterpillar Dealer
can help you manage to target payload to maximize
equipment utilization, ensure safe operation, increase
productivity and lower cost-per-ton.
Underloading increases costs due to lost
payloads, underutilizes equipment and
drives cost-per-ton.
Virtual Product Environment
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.
Body Liners. A variety of liner options are available
to save weight and extend the body systems 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:
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.
Smooth plate
Rock box
Zipper grind
Mechanically Attached Wear Plate System
(MAWPS)
Custom Body Options. Tail extensions, sideboards,
tumblebars, rock boxes and rock shedders are
available to maintain payload, reduce spillage
and improve hauling efficiencies.
Sideboards are designed to maximize or attain
gross machine weight.
September 2006
Overloading or surpassing maximum gross

machine weight, causes excessive wear on
vehicle components such as brakes, tires and
drive train, reducing component life and
increasing maintenance costs and repairs.
Box section beams offer increased durability

in the floor, sidewall, top rail, corner and cab
canopy areas.
Manufacturing Processes. Caterpillar truck bodies
are built at multiple facilities across the globe
leveraging the industrys leading body manufacturing
procedures and tooling. Caterpillar owns the entire
process (cutting, forming and welding/fabrication),
all from a single design source. Both one-piece and
multi-piece shipping configuration options are
available from the factory to meet a variety of
customer needs.
71
Truck Bodies
Caterpillar truck body designs utilize materials that

provide maximum performance (balance of payload
and durability) and achieve field repairability
requirements (weld repairable anywhere in
the world).
Cat Truck Bodies. Matching the truck body to the
application is a critical part of achieving the best
value from your Caterpillar Mining Truck.
Caterpillar starts with a focus on meeting the
particular needs of the application. Caterpillar
offers five body choices to achieve the best
match of volume, payload and life.
MSD II
Mine Specific Design (MSD II) Body. The MSD II

is the standard of the industry for lightweight bodies.
Offered in a flat floor configuration, this secondgeneration MSD body combines industry-leading
payload with excellent durability. This body is
intended for mature mines using good operation
and maintenance practices that want to extract the
maximum payload from each cycle we offer the
MSD II. With a large variety of liner options
available, the MSD II can be properly configured
to meet the particular application profile of a specific
mine site. This design offers the best payload
performance with good durability. Over the life of
the truck, the MSD II body will require replacement.
X Body. The X body is more durable in design
than the MSD II expect slightly lower payload
with the X body. The intent of the X body is to
meet a heavier duty application range with greater
volume and payload than the Dual Slope of Flat
Floor body. The understructure is more substantial
than the MSD II and is better able to handle the
rigors of poorly shot material or Greenfield sites.
The X body is intended to be more general
purpose in nature than the MSD II and will fit well
with contractors who will be operating the body in
more than one site or mature mines with difficult
conditions. As with the MSD II, the X offers a
wide variety of liner configurations.
X
Dual Slope
Flat Floor
Gateless Coal
MSD II Body.
Dual Slope Body.
72
September 2006
Truck Bodies
Dual Slope and Flat Floor Bodies. For years

the strong and durable Dual Slope and Flat Floor
bodies have delivered excellent value and long life.
They are relatively heavy but strong enough to
withstand the most demanding mining conditions
such as poor material fragmentation or Greenfield
sites. The accepted standard of the industry until
the advent of the MSD family of bodies the Dual
Slope is intended for the most demanding sites and
for users who may want to operate the truck in more
than one site. A limited liner configuration is
available. The Flat Floor body is a body intended
for very demanding sites where the controlled dump
characteristics of a flat floor body are required.
It offers better payload capability than the Dual
Slope body but less than the MSD II or X bodies.
Gateless Coal Body. Due to the low material

density of coal, a larger body is required to deliver
target payload. Traditionally a compromise body
was offered that combined one of the above bodies
with a tailgate to give greater volume and control
spillage. The exclusive Caterpillar Gateless Coal
body, available for the 777 through 793 truck
models, 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. Because the tailgate
is eliminated the target payload is higher with the
Gateless Coal body than a competitive body with
a tailgate. It is intended for coal haulage only, not
for an application requiring a combination of coal
and overburden haulage.
Caterpillar Body Systems Versus Competition.
Throughout the history of Large Mining Trucks
there have been Non-Cat sources for standard Cat
bodies attachments such as liners and tailgates, etc.,
and optional truck bodies. Originally, these optional
bodies were simply specialty bodies not offered by
Caterpillar, including Coal, Fly Ash, Slag and other
niche market products. As these Non-Cat sources
became more aggressive, they began pursuing the
sale of complete truck bodies initially for Non-Cat
Chassis and then later included bodies for
Cat Chassis.
Flat Floor Body.
September 2006
Today, there are several sources Caterpillar considers

Globally Competitive and from time to time others
for specific local markets. In some cases these
competitors have an initial transaction price
advantage and a payload advantage. However, they
typically quote bodies without any liners creating
the impression of higher payload capacity and
lower price. None have the depth of engineering,
manufacturing, sales and after-market support
as provided by Caterpillar and its Dealers.
Quoting Cat bodies, we have to ensure we are
providing an apples to apples comparison
of body weight and payload capacity.
73
Truck Bodies
When challenged by customers to provide

competitive pricing against these sources, it is
necessary to gather adequate information from the
competitive proposal to create an accurate apples
to apples comparison. These sources all have new
and unique features, but not all are proven reliable.
For the most part, the concepts have not been
thoroughly analyzed from an engineering
prospective. The sources listed below have had
aggressive marketing philosophies to make the
sale now and worry about the performance issues
later, (if at all). In the beginning the sources won
business, but in many cases the customers returned
to Caterpillar after their first experience.
Today, these sources have evolved to better products
with fewer issues. The competitors include the
following:
Westech. For over 25 years, Westech has been a
body supplier to Caterpillar, building standard Cat
bodies and some specialty bodies for the 777 thru the
793 models. One result of this long-term association
is Westech, better than many sources, understands the
need for proper fit-up to the Chassis. The company
offers bodies for all trucks, a Light-Weight body
for all Cat models and also its own version of a
Gateless Coal body. Westech also provides a
Gated Coal style upon request. The company is
located in Wyoming with good access to mine sites
in the USA and Canada and is reportedly pursuing
manufacturing alliances with companies in Brazil
and Australia. It typically sells directly to the end
user, retaining part of what it considers normal
Dealer Mark-Up. So far, the company has been
the most Honest and accurate with its proposals,
technically speaking, but the question is how it will
support its products after the sale.
Minerite. A newly formed source, (just over 2-years

old) with previous background at WESTECH in
both Engineering and sales, is Minerite. This team
probably has the best background and understanding
of the basic needs of the market of all the sources.
It offers its own version of a Light-Weight body
for Cat and a Non-Cat chassis as well as its own
version of a Gateless Coal body. Recently, the
company added an automatic, hydraulic tailgate
to its Gated Coal bodies. Minerite is located in
central Wyoming and has mostly concentrated on
the market in the Rocky Mountain area, including
Canada. While initially trying to work with the
dealers, it has accepted orders directly from the
end user as well.
Phillipi-Hagenbuch. Since the early 1970s,
Phillipi-Hagenbuch has been a body and attachment
source. The companys first product was a tailgate
developed by the founder when he was still employed
at Caterpillar in the late 1960s. Phillipi-Hagenbuch
expanded its original line into a complete Gated
Coal Bodies line. As the predominate source for
Coal Bodies for over 20 years, it expanded into a
COMBO body equipped with a Flip-Over tailgate
that pivoted to the front and out of service when
handling Over Burden. The company more recently
added a version of a Semi-Light rock body,
resulting in several issues with these offerings
including:
Much heavier than proposed consequently
reduced payloads.
Poor axle splits, which in some cases, the
units could not be dumped.
Early hour failures that were not always
warranted.
While the company marketed through Dealers, it
is prone to selling direct and is a very secretive and
aggressive source. It is assumed the company is
probably working on something new at this point.
74
September 2006
Truck Bodies
Trinity. A division of a major Barge and Rail Car

builder, Trinity includes several rail car maintenance
operations nationwide. The parent is a multi-billion
dollar entity and is located in San Antonio, TX with
first and second operations (cutting and forming)
conducted at the Mexico facility. The company
offers low price bodies. Its body business began
with subcontract manufacturing for Unit Rig and
Komatsu Mining Systems (KMS) and evolved into
its own designs, which include numerous features
copied from these designs very little new or little
of its own. Early units were dimensionally larger and
heavier than stated and in several instances, load
distribution was a big problem. Loads had to be
placed well to the rear of the body in order to dump,
creating significant spillage, etc. Historically, Trinity
sales observe Caterpillar premiums of nearly
25 percent, offering bodies with similar dimensions
and payloads. However, with the issues mentioned
above, there is no doubt customers will come back
to Caterpillar.
September 2006
Dicsa. The first to develop the true Light Weight

body in the early 90s in Chile for KMS trucks was
Dicsa. At this time Dicsa was, in fact, the KMS
dealer for much of South America. In the late 90s
KMS took this dealership back, but Dicsa continued
its mining parts and service business, including the
Dicsa truck bodies. It expanded from KMS chassis
to all other OEMs, including Cat. The company
went through numerous radically new and unique
design changes and at present, is in PHASE 9.
Dicsa continues to offer the lightest bodies with
reasonable success in South America but only
limited success in other parts of the world so far.
Dicsa has several bodies in Australia in Coal
overburden and Gold Mining operations with
unclear results in the Coal Mines. The Gold Mine
only recently was commissioned. The company
experienced a drastic failure in a Labrador Iron
mine on KMS 830E chassis and has not provided
the best solution for the Canadian Tar Sands.
Current designs for the 793 are wider than our
maximum width recommendation, seemingly very
high above the frame with a questionable (and
unproven) mounting system. In South America,
Dicsa, is successful, offering a full, on-site body
maintenance program covering all the costs with
an Hourly Rate ($/HR).
75
Truck Bodies
Conymet/Duratray. Originating in Chile as

a general welding fabrication and repair shop,
Conymet/Duratray, evolved into truck body
repairs and a Body Assembly Source for the
local Caterpillar Dealers. Through this involvement,
the company next designed (copied) its own steel
bodies for Caterpillar trucks. Then it offered cheaper
bodies and a full-body maintenance program.
In 2001 the company purchased the DURATRAY
SDB (suspended dump body) product line from
Pacific Dunlop in Australia. The purchase included
orders on hand for over 20 units, mostly for the
DIVAK 830E fleet in Canada. Through a very
aggressive marketing program it won several deals
around the world, which brought the companys
total sales to date near 200 units since start up.
It so far, prices these units at near 50 percent of the
prices previously established by Pacific Dunlop and
has again included on-site maintenance programs,
which conceals the real operational costs. It seems
this business strategy is coming to an end though
in several sites where Conymets costs are so high
it is raising rental and maintenance contract costs
significantly. The customers are not accepting this
and will return to Caterpillar.
76
The SDB is a product well suited for cohesive

material sites with lots of carry-back, but our
opinion is this is not a cost-effective solution
for rock applications. The company has reduced
payloads because it is heavier than our MSD II,
and we expect the actual maintenance costs will
be quite high as well.
September 2006
Manufacturing
Manufacturing. Caterpillar manufacturing means quality.
Operator performing leak test of inner and

outer dual cone seals of rear wheel station.
Operator setting preload on differential bearings.
Caterpillar Manufacturing. All Caterpillar Mining

Trucks are produced in Decatur, IL. The Decatur
Plant is a state-of-the-art, world class manufacturing
facility, ISO-9001 certified by Det Norske Veritas.
Every manufacturing cell is certified to Mining and
Construction Equipment (MCE) Division standards
and Caterpillar corporate standards. Design control,
commercial support, and product support activities
are all located at this facility under the Cat Mining
Trucks Product Manager. Fabrication, machining,
assembly, wash, paint, test and adjust are completed
in two buildings (785-793 in building B and 797
in building D). A truck does not leave the building
until it is a finished product, ready-to-ship.
September 2006
Fabrication. Fabrication of the truck frame is of the

greatest importance in the manufacturing of trucks,
the frame being the backbone. As a consequence,
there is a weld procedure written for every weld in
the frame identifying each parameter to be controlled
to provide consistent quality. Copies of weld
procedures pertinent to each weld station are
available at that station for the ready reference
of the welder.
77
Manufacturing
Operator assembling rear axle assembly for shipping.
Welding. Welding is accomplished in three ways.

There are automatic welding machines guided by
laser beams, robot welders performing routine
welding tasks and skilled employees producing
more demanding weldments with special equipment.
All frames are produced using arc-welding processes
that conform to 1E0099 Caterpillar specifications.
Two processes are used predominately for production
purposes in the plant: flux cored arc welding (cored
wire) and gas metal arc welding (solid wire).
Computer Controlled Machining Centers.

Computer controlled machining centers incorporate
the latest technology to deliver the highest quality
components in the industry. These state-of-the-art
machining centers with automatic tool changers
allow multiple machining operations to be completed
on a single machine complex. This eliminates the
potential of relocation errors associated with moving
a piecepart from one machine and fixture to another.
Palletized, permanent setup fixtures promote better
quality and accelerate production by removing the
need to make setups between running different part
numbers. Custom designed chucks insure parts are
properly located in machining centers, increasing
dimensional accuracy. The machining centers have
tool management systems that automatically track
and compensate for tool wear, utilize redundant
tooling and alert the operator when new tooling or
servicing is required. All pieceparts are 100 percent
traceable because each part is marked with machine
operator identification and a date.
Heavy-duty tack weld fixtures are utilized to ensure

proper fit up and adequate weld joint root opening.
To achieve the best mating of parts and accuracy
of critical dimensions, weld joints and locators are
pre-machined. Weld positioners (360 rollover
fixtures) are used to position welds in a flat position
for the deepest penetration and highest quality welds
while affording the most comfort of the welder.
All welders are trained, tested, qualified and
periodically re-qualified in-house at the MCE
weld school. They are qualified according to
ANSI/AWS D1.1, D14.3 and ISO 9606.
All weldments are 100 percent visually inspected
and audited ultrasonically. All critical weldments
are 100 percent ultrasonically inspected. There is
100 percent traceability on all weldments.
78
Automated machining cell for truck repair spindles.
September 2006
Manufacturing
Assembly Highway. The assembly highway offers

the quality advantage of assembling the product
in a stationary position with the convenience of
automated movement through the assembly
process. Automatic Guided Vehicles (AGVs)
deliver trucks to each stage of assembly where
skilled personnel use proven procedures to
assemble them. Assemblers are empowered to
regulate the flow through their assembly cell to
ensure the completeness of assembly in the most
workmanlike manner.
Since customers typically order a truck optimized
for their specific mine application, the assemblers
work from assembly instructions tailored to the
specific model and serial number. Each truck is
essentially custom-built from the ground up to
the dealer/customer specification. Each assembly
instruction is signed off by the assembler performing
it giving 100% traceability.
Automatic torque control tools are utilized
throughout the assembly process to ensure every
truck shipped has been produced to specification.
All torque control tools are checked and maintained
through an auditing procedure directly linked to
the cell certification process.
Test facilities support product development at Decatur.
Quality Control. A quality team supports every

manufacturing cell. That quality teams membership
includes the cell operators, their supervisor, the
design engineer responsible for that portion of the
product design, a manufacturing and systems
engineer/processor, a welding engineer/technician,
a materials representative, a computer numerical
control programmer and a quality auditor. They are
responsible for solving any problem confronting the
cell, tracking internal and external quality indicators,
preparing the cell for certification and continuous
quality improvement.
September 2006
79
Manufacturing
Measurement accuracy is critical to quality

manufacturing. Caterpillar has invested in a
co-ordinate measurement laboratory, coordinate
measuring machines (located in the manufacturing
cells), and a large L&K co-ordinate measuring
machine (CMM) to ensure total accuracy. At the
time of its installation it was the worlds largest
single bridge CMM. The side rails, bridge and
probe rail are constructed entirely of granite to
make it less susceptible to temperature and humidity
variation and it is housed in climate-controlled room.
Its repeatability is 0.00635 mm (0.00025 in).
The CMM is capable of measuring the frames of
the 785C, 789C and 793D mining trucks. There are
150+ dimensional checks on each truck frame.
Approximately 10 percent of all mining truck
frames are checked. After any engineering changes
or repair of production machines, the first ten frames
are checked to ensure process control. A portable
laser system is used to measure critical dimensions
on the 797B mining truck.
80
Diagnostic and Functional Testing. After completion

of the assembly process every mining truck is
visually inspected, then its critical functions tested
and any required adjustment performed in a stateof-the-art test cell. Engines (all previously tested
at the Large Engine Center), transmissions (all
previously tested at the Transmission Business
Unit), hydraulics, brakes, and electrical systems
are all included in this testing. The testing is
performed utilizing computer controlled test
equipment to eliminate all subjectivity from the
test. All test results become part of the trucks
history file.
September 2006
Product Support
Product Support. Caterpillar dealers have what it takes to keep mining trucks productive.
Reman parts available for Cat Mining Trucks
include:
Axle housings
Brake Shoes
Clutch Plates
Electronic Control Modules
Engines
Engine Components
Final Drive Groups
Hydraulic Cylinders and Rods
Hydraulic Pump, Motors and Parts
Caterpillar Reman Parts. In building machines for
a lifetime, Caterpillar recognizes that keeping them
productive at the lowest cost is essential. This is one
reason why the Caterpillar remanufacturing process
is so extensive. State of the art salvage techniques,
strict re-use guidelines, advanced manufacturing
systems and unequalled quality control systems
ensure that Reman parts are as good as new and
as strong as ever. The remanufacturing process
incorporates the latest engineering design changes
ensuring components meet the latest performance
standards and carry an as-new warranty.
Reman is a way to support the Caterpillar product
and reduce operating costs over the life of the
machine. Cat Reman parts are priced at a fraction
of new and, together with the credit for the used
core, represent real savings in equipment costs.
Reaction Hubs
Torque Converters
Transmissions
Purchasing a Caterpillar Mining Truck represents
a value decision for the lifetime of the machine.
No other mining truck manufacturers provide such
an extensive line of quality, cost saving part options.
Caterpillar Certified Rebuild (CCR). A Cat Certified
Rebuild would usually be performed when a mining
truck has reached 30,000-40,000 hours and
availability and productivity are declining.
Following rebuild, a significant productive
life (20,000-30,000 hours) can be expected.
The Cat Certified Rebuild process applies to an
entire machine. The process has been developed,
promoted and is audited by Caterpillar. Only Cat
dealers perform this process. Machines are rebuilt
to like-new condition and effectively utilize their
second life.
The CCR program provides an additional purchase
option of new or used Certified Dealer Rebuilt
machines.
September 2006
81
Product Support
There also is a Cat Certified Power Train (CPT)

program available to rebuild the power train at
half the CCR life at about half the cost of a CCR
on average.
Typically about 100 engineering updates

are incorporated into rebuilds.
Extended power train coverage from Cat Insurance

is available also.
Cat Certified Rebuild benefits:
Reduced cost per ton.
Improved machine performance and
availability provided by engineering updates.
Typically 50 percent to 60 percent of new
machine cost for customer-owned machines.
New serial number.
Cat Financial Services including financing
and insurance.
Like-new appearance.
Higher resale value.
Warranty. CCR includes a warranty provided by
the Cat dealer and is the same as stated warranty
for new trucks. It does not include extended frame
repairability or MARC support from Caterpillar.
An extended power train warranty is available.
Cat Certified Rebuilds include:
Quality Processes.
Caterpillar Truck Payload Guidelines.

Specified maximum operating weights are
frequently misapplied with regards to off-highway
trucks in the marketplace. Maximum, which
means, must not exceed, which is used as the
target, results in regulatory and product support
concerns pertaining to acceptable overload.
Engineering Updates.
Mandatory Parts Replacements with over
7,000 parts are automatically replaced.
The quality of CCR is assured:
More than 350 tests and inspections have
been performed.
Highly trained experts perform rebuilds.
Technically, any overload will adversely affect

component life and potentially decertify brakes
and/or steering. In response, Caterpillar developed
a maximum operating weight and associated
payload guidelines used in support of warranty,
Maintenance and Repair Contracts (MARCs) for
mining trucks. Caterpillar paid particular attention
to specifications in light of the technical implications
of the 10/10/20 guidelines.
Caterpillar-developed procedures are used

for remanufacture.
82
September 2006
Product Support
According to the guidelines, available payload is

directly related to Empty Machine Weight, so that
reducing empty weight provides increased
payload capacity and vice versa. For example,
Gross Machine Weight (GMW) less Empty Machine
Weight (EMW) equals Target Payload. EMW
includes all attachments (installed at the factory,
by dealer and customer), full fuel and fluids,
appropriate calculations of debris, and tires.
The Caterpillar 10/10/20 Payload Guidelines state:
No more than 10 percent of payloads may exceed
1.1 times the trucks Target Payload, and no single
payload shall ever exceed 1.2 times the Target
Payload, which is the Maximum Operating Weight.
Modifications to brake service procedures are

required to maintain certification on models 785C
to 793C. Specifically, brake wear must be reduced
to 75 percent of current allowable, which enables
SAE and ISO standards to be maintained up to
target payload plus 20 percent.
Component Life Implications. The 10/10/20
payload guidelines carry significant implications
relative to component life. Data indicates that for
every 1-ton decrease in payload from maximum
target, component life will increase by
approximately 1 percent. Overload is the most
significant factor in life shortfalls of planned
component replacement goals. Haul road
conditions, machine maintenance and operation
techniques also are significant contributors. As the
10/10/20 payload guidelines may exceed tire and
rim association rating guidelines for earthmoving
vehicles, it is recommended that users of the
guidelines contact their supplier to discuss
application, site conditions, haul roads and
allowable tire loads before adopting the policy.
Specifications. The Payload Guidelines apply to

the Cat 777D, 777F, 785C, 789C, 793C, 793D and
797B trucks.
Operate within the 10/10/20 payload guidelines
requires careful attention to specifications.
Caterpillar suggests operation below the 1.2 times
Target Payload for engineering impact and safety.
The covered trucks were tested to meet ISO and
SAE steering and braking certification standards
at 20 percent over target payload.
September 2006
83
Product Support
Summary. In summary, the 10/10/20 truck

payload guidelines provide for:
Consistent payload variation benchmarking.
Basis for MARC cost/productivity adjustments.
Establishment of braking and steering
certification limits.
Competitive Payload Information. Komatsu:
Publishes a nominal payload defined by Komatsus
payload policy for its mining trucks, except for
HD1500-5 that still publishes maximum calculated
payload. Nominal payload is calculated considering
100 percent fuel, but it is unclear whether this
includes body attachments or debris.
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.
It appears that Komatsus payload policy established

that overloads between 105 percent and 110 percent
are allowed on an infrequent basis but shall not
exceed more than 10 percent of all loads in a
given month.
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.
84
September 2006
Product Support
Hitachi: Publishes a nominal payload, which

represents 90 percent of maximum payload.
Payload calculation includes 50 percent fuel
but body attachments or debris are not included.
It appears Hitachi developed Payload Guidelines
in response to the Caterpillar 10/10/20 Payload
Guidelines. Hitachis guidelines establish exceeding
maximum payload is allowed 10 percent of time,
but exceeding 110 percent maximum payload one
time voids warranty.
September 2006
Terex: Publishes maximum calculated payloads.

Details about calculations are not available in
specalogs.
Liebherr: Publishes maximum calculated payloads.
Details about calculations are not available in
specalogs.
85
Safety
Safety. Caterpillar machines and systems are designed with safety as the first priority.
Brake Systems. On Cat Mining Trucks, the brake
system is designed to function under severe
conditions and to allow operators to work with
confidence. Service brakes and retarders are
actuated by modulated hydraulic pressure, while
secondary and parking functions are actuated by
multiple springs acting on the secondary/parking
piston, which is hydraulically released. This system
ensures that brakes are always available even in the
event of a complete hydraulic failure when they
would be applied automatically.
Product Safety. Caterpillar has been and continues

to be proactive in developing off-highway trucks
that meet and exceed safety standards. Caterpillar
engineers actively participate as leaders in the
development of new regulations and safety standards
and updating of existing ones. Since standards vary
from country to country and around the world, and
are sometimes even in conflict, Caterpillar has been
instrumental in the development of safety standards
that are uniform and accepted worldwide.
Safety is not an afterthought at Caterpillar, but an
integral part of all machine and systems designs.
While legislation requires that all manufacturers
must meet certain safety standards, Caterpillar
aims to deliver exceptional safety.
Caterpillar brakes are oil-cooled and have large disc

and plate surfaces to ensure more reliable faderesistant performance than shoe type and dry disc
brake systems. Four corner braking with a 60/40
(rear/front) split in braking effort provides better
control in slippery conditions. All large Cat Mining
Trucks have Integrated Braking Control (IBC),
which incorporates all the advantages of the
proven Traction Control System (TCS), Hydraulic
Automatic Retarder Control (HARC) system and
normal brake control systems into one simplified
module. These features are standard.
Steering Control Systems. Caterpillars twin
double-acting cylinder steering system is designed
to deliver precise control under all loading and
underfoot conditions.
The main steering hydraulics are backed up by a
supplemental system using pressure accumulators
that would be automatically activated in the unlikely
event of steering system failure. This supplemental
system meets SAE J1511 and ISO 5010 standards
at the maximum allowable gross machine weight.
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 and meets
SAE J1040, SAE J231, ISO 3471 and ISO 3449
standards. The cab also meets ANSI/SAE J1166
operator sound exposure requirements. The integral
ROPS cab is standard on Caterpillar mining trucks.
86
September 2006
Safety
Operator Comfort. Caterpillar has designed mining

truck cabs to provide the best in safety and comfort
while maximizing operator control and productivity.
The Caterpillar suspension system is positioned
and tuned for maximum ride qualities and yet
gives a stable feel of the road for the operator.
To further enhance the operators ride, the cab is
strategically located to minimize the effects of
pitch and bounce. Because of the superior ride
qualities of Caterpillar trucks, the operators have
less fatigue and a more secure feeling resulting
in greater productivity.
Cab design has been refined so that full attention can
be directed to machine control. Ergonomics and
visibility are given careful attention in positioning
machine controls. The location of the controls plays
a vital role in minimizing operator fatigue and
contributes to a safer operation. Clear lines of sight
toward the haul road and the instrument panel make
more information visible at a glance. Improved head
light illumination, windscreen defrosting and warning
alarms provide safer operating in adverse conditions.
Standard Safety Features. Additional standard safety
features on Caterpillar mining trucks include:
Slip resistant surfaces
Retractable, 75 mm (3 in) wide orange
three-point operator restraint.
Wide-angle mirrors
Body raised indicator
Body restraint cable
Guardrails
High-Intensity Discharge (HID) Lights.

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 percent efficient and twice as
bright compared with 20 percent to 25 percent
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.
Convenient guard rails

Reverse neutralizer when dumping
Low interior sound levels
September 2006
87
Safety
Payload Guidelines. Safety is integral to Caterpillars

approach to maintaining the highest productivity
in mining machine operation. For example, the
10/10/20 Payload Guidelines assure customers
that brakes and steering have sufficient capacity
to perform at a 20 percent overload.
Working Safely. Caterpillars holistic approach to

safety in mining means efforts are directed not only
at product design for safe performance and operation,
but also at ensuring products contribute to a safer
working environment for miners. Environmental
impacts are considered, training packages are
developed and Caterpillar actively promotes and
participates with customers in achieving ever
improving safety standards. Caterpillar operator
and service training programs reinforce the need
for safe procedures and videos and lecture materials
enable mine sites to conduct refresher courses to
ensure safety considerations are always in mind.
At Caterpillar, safety is a first priority!
88
September 2006
Technical Specifications 785C vs. Competition (109-150 tonnes [120-165 tons])
MANUFACTURER
MODEL
TEREX/
UNIT RIG
MT3000
CAT
785C
Engine Model
16V2000TA
3512B
QSK45
12V4000
Engine Manufacturer
MTU/DDC
CAT
CUMMINS
MTU/DDC
ELECT DC
MECH
ELECT DC
ELECT AC
206 300
(455,000)
249 480
(550,000)
249 480
(550,000)
249 480
(550,000)
Drive
TEREX/
UNIT RIG
MT3300
TEREX/
UNIT RIG
MT3300 AC
KOMATSU
HD1500-5
HITACHI
EH3000
CAT
785C HAA
QSK45
12V4000
3516B
CUMMINS
MTU/DDC
CAT
MECH
ELECT AC
MECH
249 476
(550,000)
278 964
(615,000)
249 476
(550,000)
OPERATING SPECIFICATIONS
Maximum Gross Vehicle Weight kg
(lb)
Chassis Weight ** kg
(lb)
77 111
(170,000)
99 448
(219,244)
77 610
(171,100)
Body without Attachments kg

(lb)
21 300
(46,958)
24 041
(53,000)
21 300
(46,958)
123 489
(272,244)
100 153
(220,800)
140
(154)
136
(150)
Empty Weight kg
(lb)
97 451
(214,880)
Payload Target/Nominal tonnes

(tons)
101 495
(223,758)
105 234
(232,000)
111 928
(246,800)
100 462
(221,481)
136+
(150+)
Payload Maximum tonnes

(tons)
109
(120)
See 10/10/20
Guidelines
136
(150)
136
(150)
136 149
(150 164)
155
(171)
Notes about Payload and Weights:
N/A
Empty weight
includes lubricants,
coolant, 100%
fuel, debris
(4% of chassis
weight), no body
attachments
N/A
Empty weight
with 50% fuel
Empty weight
with 50% fuel.
Payload based
upon the weight
of additional
equipment
such as
body liner.
Empty weight
with 50% fuel,
no body liners.
Nominal
payload
defined as 90%
of payload
with standard
equipment
Wheelbase mm
(in)
5334
(210)
5180
(204)
5334
(210)
5334
(210)
5410
(213)
5640
(222)
5182
(204)
Overall Length mm
(in)
12 167
(479)
11 022
(434)
12 167
(479)
12 344
(486)
11 379
(448)
11 550
(455)
11 024
(434)
Overall Width mm
(in)
6502
(256)
6640
(262)
6502
(256)
7112
(280)
6629
(261)
7450
(293)
6325
(249)
Tire Width mm
(in)
6121
(241)
6277
(248)
6248
(246)
6248
(246)
5994
(236)
6630
(261)
6274
(247)
Loading Height mm
(in)
4877
(192)
4968
(196)
5436
(214)
5232
(206)
4953
(195)
5380
(212)
4978
(196)
Height Body Raised mm

(in)
10 744
(423)
11 207
(442)
10 795
(425)
10 795
(425)
11 430
(450)
12 600
(496)
11 201
(441)
Front Axle Empty
49%
47%
49%
52%
46%
49%
48%
Rear Axle Empty
51%
53%
51%
48%
54%
51%
52%
Front Axle Loaded
33%
33%
33%
33%
33%
33%
34%
Rear Axle Loaded
67%
67%
67%
67%
67%
67%
66%
DIMENSIONS
WEIGHT DISTRIBUTION
September 2006
89
MANUFACTURER
TEREX/
UNIT RIG
MT3000
CAT
785C
Model
16V2000TA
3512B
QSK45
12V4000
Manufacturer
MTU/DDC
CAT
CUMMINS
MTU/DDC
Bore mm
(in)
170
(6.7)
159
(6)
165
(7)
Stroke mm
(in)
190
(7.5)
190
(7)
Displacement L
(in3)
51.8
(3,158)
Max Altitude m
(ft)
3050
(10,000)
MODEL
TEREX/
UNIT RIG
MT3300
TEREX/
UNIT RIG
MT3300 AC
KOMATSU
HD1500-5
HITACHI
EH3000
CAT
785C HAA
QSK45
12V4000
3516B
CUMMINS
MTU/DDC
CAT
159
(6)
165
(7)
170
(7)
190
(7)
190
(7)
190
(7)
190
(7)
45
(2,746)
49
(2,972)
45
(2,746)
49
(2,972)
69
(4,211)
3658
(12,000)
3048
(10,000)
ENGINE
Number of Cylinders
Rated Speed rpm
4612
(15,130)
16
12
12
12
12
12
16
1,900
1,750
1,900
1,900
1,900
1,900
1,750
High Idle rpm
1,935
Low Idle rpm
700
1,935
700
Net Power kW
(hp)
839
(1,125)
1005
(1,348)
1025
(1,375)
1171
(1,570)
1048
(1,406)
1304
(1,748)
1005
(1,348)
Gross Power kW
(hp)
899
(1,205)
1082
(1,450)
1119
(1,500)
1286
(1,725)
1108
(1,486)
1398
(1,875)
1081
(1,450)
5810
7612
6767
Net Torque Nm
6767
Torque Rise
23%
Engine Weight kg
(lb)
2540
(5,600)
6667
(14,700)
23%
5307
(11,700)
6044
(13,325)
5813
(12,815)
6668
(14,700)
OPTIONAL ENGINE
Model
Manufacturer
QSTA30
16V2000
QSK45
CUMMINS
MTU/DDC
CUMMINS
Bore mm
(in)
159
(6)
Stroke mm
(in)
190
(7)
Displacement L
(in3)
Number of Cylinders
45
(2,746)
12
16
12
Rated Speed rpm
1,900
1,900
1,900
Net Power kW
(hp)
835
(1,120)
954
(1,279)
1104
(1,480)
Gross Power
895
(1,200)
999
(1,340)
1193
(1,600)
2948
(6,500)
2540
(5,600)
5814
(12,820)
kW
(hp)
Net Torque Nm
Engine Weight kg
(lb)
90
September 2006
MANUFACTURER
MODEL
TEREX/
UNIT RIG
MT3000
CAT
785C
TEREX/
UNIT RIG
MT3300
TEREX/
UNIT RIG
MT3300 AC
KOMATSU
HD1500-5
HITACHI
EH3000
CAT
785C HAA
COOLING SYSTEM
Fan Diameter mm
(in)
1828.8
(72)
1778
(70)
TRAVEL SPEEDS
Forward 1 km/h
(mph)
12.1
(7.5)
11.0
(6.8)
12.1
(7.5)
Forward 2 km/h
(mph)
16.3
(10.2)
14.6
(9.1)
16.4
(10.2)
Forward 3 km/h
(mph)
22.2
(13.8)
19.5
(12.1)
22.2
(13.8)
Forward 4 km/h
(mph)
29.9
(18.6)
24.5
(15.2)
29.9
(18.6)
Forward 5 km/h
(mph)
40.6
(25.2)
32.6
(20.3)
40.6
(25.2)
Forward 6 km/h
(mph)
54.8
(34.0)
44.2
(27.5)
54.7
(34.0)
Forward 7 km/h
(mph)
58.0
(36.0)
Reverse 1 km/h
(mph)
Elec. Drive Max. km/h
(mph)
11.0
(6.8)
62.0
(39.0)
10.6
(6.6)
70.0
(44.0)
64.0
(40.0)
10.9
(6.8)
54.7
(34.0)
REDUCTIONS
Differential
2.10
2.647
2.100
Final Drive
10.83
7.235
10.833
TIRES
Tires
Weight kg
(lb)
30.00R51
33.00R51
33.00R51
33.00R51
33.00R51
36.00R51
33.00R51
2068
(4,560)
2304
(5,080)
2304
(5,080)
2304
(5,080)
2304
(5,080)
2152
(4,745)
2304
(5,080)
Optional Tires
36.00R51
BRAKES REAR
Discs per Side
Outside Diameter mm
(in)
Total Area
10
10
508
(20)
874.5
(34.46)
511
(20)
511
(20)
511
(20)
875
(34)
14 298
(2,216)
89 727
(13,908)
cm2
(in2)
89 729
(13,908)
79 572
(12,334)
BRAKES FRONT
9
Outside Diameter mm
(in)
715.3
(28.18)
990
(39)
990
(39)
1060
(42)
715
(28)
Total Surface Area cm2

(in2)
61 270
(9,497)
15 001
(2,325)
61 270
(9,497)
Disc per Side
Dry Disc OD
mm
(in)
September 2006
79 572
(12,334)
1016
(40)
91
MANUFACTURER
MODEL
TEREX/
UNIT RIG
MT3000
CAT
785C
TEREX/
UNIT RIG
MT3300
TEREX/
UNIT RIG
MT3300 AC
KOMATSU
HD1500-5
HITACHI
EH3000
CAT
785C HAA
2271
(600)
1893
(500)
2271
(600)
2271
(600)
2120
(560)
2839
(750)
1893
(500)
REFILL CAPACITIES
Fuel Tank 1 L
(gal)
Fuel Tank 2 L
(gal)
2500
(660)
Cooling System L
(gal)
269
(71)
379
(100)
303
(80)
454
(120)
532
(141)
323
(85)
379
(100)
Crankcase L
(gal)
(132)
35
204
(54)
215
(57)
220
(58)
193
(51)
213
(56)
204
(54)
Differential and Final Drives L

(gal)
92
2498
(660)
436
(115)
536
(142)
526
(139)
Front Wheels (Each) L

(gal)
14
(4)
14
(4)
Steering Tank L
(gal)
90
(24)
91
(24)
Steering System L
(gal)
117
(31)
Brake/Hoist/Conv Tank L
(gal)
337
(89)
576
(152)
337
(89)
Brake/Hoist/Conv System L
(gal)
641
(169)
900
(238)
641
(169)
Trans Tank L
(gal)
76
(20)
Trans System L
(gal)
248
(66)
189
(50)
117
(31)
76
(20.1)
153
(40.5)
Brake/Hoist Tank L
(gal)
564
(149)
564
(149)
564
(149)
Brake/Hoist Hydraulic System L

(gal)
814
(215)
813
(215)
813
(215)
248
(65.5)
566
(150)
September 2006
MANUFACTURER
TEREX/
UNIT RIG
MT3600B
MODEL
Engine Model
HITACHI
EH3500
CAT
789C
LIEBHERR
T252
KOMATSU
730E
TEREX/
UNIT RIG
MT3700B
TEREX/
UNIT RIG
MT3700AC
12V4000
12V4000
3516B
12V4000
K2000E
12V4000
12V4000
MTU/DDC
MTU/DDC
CAT
MTU/DDC
CUMMINS
MTU/DDC
MTU/DDC
ELECT DC
ELECT DC
MECH
ELECT DC
ELECT DC
ELECT DC
ELECT AC
297 000
(655,000)
324 324
(715,000)
317 515
(700,000)
331 120
(730,000)
324 322
(715,000)
324 263
(715,000)
335 600
(740,000)
Chassis Weight ** kg
(lb)
107 330
(236,619)
98 293
(216,700)

(lb)
26 717
(58,900)
27 045
(59,625)
134 047
(295,519)
129 238
(284,925)
131 065
(289,000)
149 660
(330,000)
171
(189)
176+
(195+)
190
(210)
See 10/10/20
Guidelines
172 186
(190 205)
186
(205)
Engine Manufacturer
Drive
(lb)
Empty Weight kg
(lb)
Payload Target/Nominal
124 700
(275,000)
tonnes
(tons)

(tons)
154 172
(170 190)
Maximum GVW
Empty weight
Empty weight
not to exceed
with 50% fuel,
includes
the following:
no body liners.
lubricants,
GE 776 Traction Nominal payload coolant, 100%
Motor 636,100 lb defined as 90%
fuel, debris
(288 480 kg)
of payload
(4% of chassis
GE 788 Traction
with standard weight), no body
Motor 655,000 lb
equipment
attachments
(297 000 kg)
25 612
(56,464)
140 320
(327,000)
140 592
(309,950)
184
(203)
181
(200)
N/A
Empty weight
with 100%
fuel, no options.
Nominal payload
defined by Komatsus
payload policy
N/A
N/A
DIMENSIONS
Wheelbase mm
(in)
5537
(218)
5640
(222)
5700
(224)
5817
(229)
5893
(232)
5639
(222)
5639
(222)
Overall Length mm
(in)
13 056
(514)
12 240
(482)
12 177
(479)
13 259
(522)
12 827
(505)
13 056
(514)
13 056
(514)
Overall Width mm
(in)
7315
(288)
8126
(320)
7674
(302)
7493
(295)
7544
(297)
7315
(288)
7341
(289)
Tire Width mm
(in)
6782
(267)
6750
(266)
6926
(272)
7188
(283)
7036
(277)
6782
(267)
7264
(286)
Loading Height mm
(in)
5436
(214)
5460
(215)
5206
(205)
5588
(220)
5613
(221)
5791
(228)
6096
(240)

(in)
11 811
(465)
12 630
(497)
11 902
(469)
12 192
(480)
12 522
(493)
11 862
(467)
11 963
(471)
Front Axle Empty
51%
49%
47%
40%
48%
47%
46%
Rear Axle Empty
49%
51%
53%
60%
52%
53%
54%
Front Axle Loaded
33%
33%
33%
33%
33%
32%
32%
Rear Axle Loaded
67%
67%
67%
67%
67%
68%
68%
WEIGHT DISTRIBUTION
September 2006
93
MANUFACTURER
TEREX/
UNIT RIG
MT3600B
MODEL
HITACHI
EH3500
CAT
789C
LIEBHERR
T252
KOMATSU
730E
TEREX/
UNIT RIG
MT3700B
TEREX/
UNIT RIG
MT3700AC
ENGINE
Model
12V4000
12V4000
3516B
12V4000
K2000E
12V4000
12V4000
MTU/DDC
MTU/DDC
CAT
MTU/DDC
CUMMINS
MTU/DDC
MTU/DDC
Bore mm
(in)
165
(7)
165
(7)
170
(6.7)
165
(7)
159
(6)
165
(7)
166
(7)
Stroke mm
(in)
190
(7)
190
(7)
190
(7.5)
190
(7)
159
(6)
190
(7)
191
(8)
Displacement L
(in3)
49
(2,972)
49
(2,972)
69
(4,211)
49
(2,972)
50
(3,070)
49
(2,972)
49
(2,972)
Max Altitude m
(ft)
3048
(10,000)
3048
(10,000)
3048
(10,000)
Manufacturer
Number of Cylinders
Rated Speed rpm
2300
(7,500)
12
12
16
12
16
12
12
1,900
1,900
1,750
1,900
1,900
1,900
1,900
High Idle rpm
1,935
Low Idle rpm
700
Net Power kW
(hp)
1175 1398
(1,575 1,875)
1414
(1,896)
1320
(1,771)
1175 1398
(1,575 1,875)
1388
(1,860)
1175 1398
(1,575 1,875)
1398
(1,875)
Gross Power kW
(hp)
1286 1510
(1,725 2,025)
1510
(2,025)
1417
(1,900)
1286 1510
(1,725 2,025)
1491
(2,000)
1286 1510
(1,725 2,025)
1510
(2,025)
8,200
8,976
4671
(10,300)
5294
(11,670)
6045
(13,325)
6045
(13,325)
Net Torque Nm
Torque Rise
23%
Engine Weight kg
(lb)
6045
(13,325)
7810
(17,225)
OPTIONAL ENGINE
Model
QSK45
QSK45
QSK45
QSK60
CUMMINS
CUMMINS
CUMMINS
CUMMINS
Bore mm
(in)
159
(6)
159
(6)
159
(6)
159
(6)
Stroke mm
(in)
190
(7)
190
(7)
190
(7)
190
(7)
45
(2,746)
45
(2,746)
45
(2,746)
60
(3,661)
Manufacturer
Displacement L
(in3)
Number of Cylinders
12
12
12
16
1,900
1,900
1,900
1,900
Net Power kW
(hp)
1084 1382
(1,454 1,854)
1084 1383
(1,454 1,854)
1084 1383
(1,454 1,854)
1603 1752
(2,150 2,350)
Gross Power kW
(hp)
1193 1491
(1,600 2,000)
1193 1342
(1,600 1,800)
1193 1491
(1,600 2,000)
1715 1864
(2,300 2,500)
5310
(11,700)
6122
(13,500)
5310
(11,700)
8852
(19,515)
Rated Speed rpm
Net Torque Nm
Engine Weight kg
(lb)
OTHER OPTIONAL ENGINE

Model
Manufacturer
K2000E
K2000E
CUMMINS
CUMMINS
Model
16V4000
Manufacturer
94
MTU/DDC
September 2006
MANUFACTURER
MODEL
TEREX/
UNIT RIG
MT3600B
HITACHI
EH3500
CAT
789C
LIEBHERR
T252
KOMATSU
730E
TEREX/
UNIT RIG
MT3700B
TEREX/
UNIT RIG
MT3700AC
55.7
(34.6)
54.7
(34.0)
65.0
(40.0)
COOLING SYSTEM
Fan Diameter mm
(in)
1981
(78)
TRAVEL SPEEDS
Forward 1 km/h
(mph)
11.6
(7.2)
Forward 2 km/h
(mph)
15.7
(9.8)
Forward 3 km/h
(mph)
21.3
(13.2)
Forward 4 km/h
(mph)
28.7
(17.8)
Forward 5 km/h
(mph)
38.9
(24.2)
Forward 6 km/h
(mph)
52.6
(32.7)
Reverse 1 km/h
(mph)
10.5
(6.5)

(mph)
56.4
(34.0)
55.7
(34.6)
REDUCTIONS
Differential
2.350
Final Drive
10.833
TIRES
Tires
Weight kg
(lb)
36.00R51
37.00R57
37.00R57
37.00R57
37.00R57
37.00R57
40.00R57
2152
(4,745)
3084
(6,800)
3084
(6,800)
3084
(6,800)
3084
(6,800)
3084
(6,800)
3084
(6,800)
Optional Tires
36R51
40R57
46/90R57
37.00R57
BRAKES REAR
Discs per Side
Outside Diameter mm
(in)
Total Area cm2
(in2)
13
511
(20)
635
(25)
874.5
(34.46)
635
(25)
635
(25)
635
(25)
635
(25)
14 298
(2,216)
14 298
(2,216)
116 283
(18,024)
14 298
(2,216)
14 298
(2,216)
14 298
(2,216)
14 298
(2,216)
BRAKES FRONT
Discs per Side
Outside Diameter mm
(in)
12
991
(39)
1060
(42)
715.3
(28.18)
1143
(45)
1168
(46)
1118
(44)
1118
(44)
15 001
(2,325)
81 693
(12,662)

(in2)
SUSPENSION SYSTEM
Total Stroke Rear mm
(in)
275
(11)
165
(6.5)
335
(13)
273
(11)
273
(11)
Total Stroke Front mm

(in)
355
(14)
307
(12.1)
279
(11)
355
(14)
355
(14)
September 2006
95
MANUFACTURER
TEREX/
UNIT RIG
MT3600B
MODEL
HITACHI
EH3500
CAT
789C
41
36
LIEBHERR
T252
KOMATSU
730E
TEREX/
UNIT RIG
MT3700B
TEREX/
UNIT RIG
MT3700AC
STEERING SYSTEM
Steering Angle degrees
Number of Cylinders
Turning Radius Front m
(ft)
26.8
(87.9)
25.6
(84.0)
27.5
(90.3)
24.7
(81.0)
30.2
(99.2)
30.2
(99)
18.9
20
Turning Circle Clearance Diameter m

(ft)
27.2
(89.4)
27.2
(89.4)
19
22
28.0
(91.9)
HOIST SYSTEM
Body Raise
secs
Body Float Down
19
17.9
secs
Body Power Down
17.3
secs
12
21
22
15.6
15
12
14
BODY
Body Type
Flat Floor
N/A
Dual Slope
N/A
Flat Floor
Flat Floor
Flat Floor
Capacity Struck m3
(yd3)
77
(101)
80
(105)
73
(96)
77
(100)
77
(101)
92
(121)
92
(121)
Capacity Heaped 2:1 m3

(yd3)
111
(146)
115
(151)
105
(137)
108
(141)
111
(145)
123
(161)
123
(161)
Data provided is for a representative body. Several dual slope, flat floor, coal and mine specific design (MSD) bodies are available. All weights, capacities, and
dimensions are dependent on the machine configuration (body type, attachments, tires, and optional equipment selected).
REFILL CAPACITIES
Fuel Tank 1 L
(gal)
2877
(760)
2839
(750)
Fuel Tank 2 L
(gal)
3140
(830)
3217
(850)
2877
(760)
3785
(1,000)
2877
(760)
3633
(960)
Cooling System L
(gal)
348
(92)
323
(85)
663
(175)
409
(108)
348
(92)
492
(130)
Crankcase L
(gal)
215
(57)
213
(56)
291
(77)
223
(59)
215
(57)
204
(54)
662
(175)
662
(175)
890
(235)
890
(235)

(gal)
583
(154)
Front Wheels L
(gal)
21
(6)
Steering Tank L
(gal)
130
(34)
Steering System L
(gal)
96
3222
(851)
189
(50)
189
(50)
Brake/Hoist/Conv Tank L
(gal)
531
(140)
Brake/Hoist/Conv System L
(gal)
909
(240)
Trans Tank L
(gal)
79
(21)
Trans System L
(gal)
223
(59)
Brake/Hoist Hydraulic Tank L

(gal)
662
(175)

(gal)
890
(235)
566
(150)
731
(193)
510
(135)
927
(245)
731
(193)
September 2006
Technical Specifications 793D vs. Competition (218-254 tonnes [240-280 tons])
MANUFACTURER
Engine Model
3516B
16V4000
QSK60
QSK60
QSK60
QSK60
16V4000
CAT
MTU/DDC
CUMMINS
CUMMINS
CUMMINS
CUMMINS
MTU/DDC
MECH
ELECT DC
ELECT AC
ELECT DC
ELECT DC
ELECT AC
ELECT AC

(lb)
383 749
(846,000)
390 090
(860,000)
385 848
(850,650)
385 852
(850,650)
390 930
(862,000)
392 290
(865,000)
480 362
(1,059,000)
Chassis Weight** kg
(lb)
119 597
(263,666)

(lb)
32 138
(70,832)
27 669
(61,000)
27 669
(61,000)
Empty Weight kg
(lb)
156 519
(345,045)
164 200
(362,000)
162 505
(358,259)
160 998
(355,000)
170 975
(377,000)
198 096
(436,727)
221
(244)
223
(246)
Drive
KOMATSU
830E-AC
KOMATSU
830E
TEREX/
UNIT RIG
MT4400AC
MODEL
Engine Manufacturer
LEIBHERR
T262
TEREX/
UNIT RIG
MT4400
CAT
793D
HITACHI
EH4500-2

(tons)
Payload Maximum
156 940
(346,000)
218+
(240+)
See 10/10/20
Guidelines
218
(240)
Empty weight
includes lubricants,
coolant, 100%
fuel, debris
(4% of chassis
weight), no body
attachments
N/A
Wheelbase mm
(in)
5905
(233)
6096
(240)
6350
(250)
Overall Length mm
(in)
12 862
(507)
13 335
(525)
Overall Width mm
(in)
7680
(302)
Tire Width mm
(in)
254
(280)
236
(260)
236
(260)
282
(311)
Empty weight
with 50% fuel
and autolube
capacities
Empty weight
with 50% fuel
and autolube
capacities
Empty weight
with 50% fuel,
MTU/DDC engine,
50/90 R57 tires.
Nominal payload
defined as 90%
of payload
with standard
equipment
6350
(250)
6401
(252)
6401
(252)
6150
(242)
14 148
(557)
14 148
(557)
13 894
(547)
14 072
(554)
14 300
(557)
7391
(291)
7315
(288)
7315
(288)
7976
(314)
7976
(314)
9050
(356)
7605
(299)
7214
(284)
7290
(287)
7290
(287)
7569
(298)
7976
(314)
8340
(328)
Loading Height mm
(in)
5871
(231)
5944
(234)
6706
(264)
6706
(264)
6223
(245)
6147
(242)
6220
(241)

(in)
13 113
(517)
12 649
(498)
13 411
(528)
13 411
(528)
12 776
(503)
12 700
(500)
14 300
(561)
Front Axle Empty
46%
45%
50%
50%
48%
50%
50%
Rear Axle Empty
54%
55%
50%
50%
52%
50%
50%
Front Axle Loaded
33%
33%
33%
33%
33%
33%
34%
Rear Axle Loaded
67%
67%
67%
67%
67%
67%
66%
Empty weight
Empty weight
with 100% fuel, with 100% fuel,
no options.
no options.
Nominal payload Nominal payload
defined by
defined by
Komatsus
Komatsus
payload policy payload policy
DIMENSIONS
WEIGHT DISTRIBUTION
September 2006
97
MANUFACTURER
CAT
793D
MODEL
LEIBHERR
T262
KOMATSU
830E-AC
KOMATSU
830E
TEREX/
UNIT RIG
MT4400
TEREX/
UNIT RIG
MT4400AC
HITACHI
EH4500-2
ENGINE
Model
3516B
16V4000
QSK60
QSK60
QSK60
QSK60
16V4000
Manufacturer
CAT
MTU/DDC
CUMMINS
CUMMINS
CUMMINS
CUMMINS
MTU/DDC
Bore mm
(in)
170
(6.7)
165
(7)
159
(6)
159
(6)
159
(6)
159
(6)
165
(7)
Stroke mm
(in)
215
(8.5)
185
(7)
190
(7)
190
(7)
190
(7)
190
(7)
190
(7)
Displacement L
(in3)
78
(4,760)
63
(3,863)
60
(3,661)
60
(3,661)
60
(3,661)
60
(3,661)
65
(3,967)
Max Altitude m
(ft)
2750
(9,000)
Number of Cylinders
16
16
16
16
16
16
16
Rated Speed rpm
1,750
1,900
1,900
1,900
1,900
1,900
1,900
High Idle rpm
1,960
Low Idle rpm
700
Net Power kW
(hp)
1743
(2,337)
1796
(2,409)
1761
(2,360)
1761
(2,360)
1706
(2,287)
1855
(2,487)
1939
(2,600)
Gross Power kW
(hp)
1801
(2,415)
1864
(2,500)
1865
(2,500)
1865
(2,500)
1865
(2,500)
2013
(2,700)
2014
(2,700)
Net Torque Nm
10,806
Torque Rise
10,930
23%
Engine Weight kg
(lb)
8664
(19,100)
6528
(14,391)
9608
(21,182)
9608
(21,182)
7534
(16,611)
8854
(19,515)
OPTIONAL ENGINE
Model
12V4000
16V4000
16V4000
QSK60-L
MTU/DDC
MTU/DDC
MTU/DDC
CUMMINS
Bore mm
(in)
165
(7)
165
(7)
165
(7)
159
(6)
Stroke mm
(in)
185
(7)
185
(7)
185
(7)
190
(7)
63
(3,863)
63
(3,863)
63
(3,863)
60.2
(3,674)
Manufacturer
Displacement L
(in3)
Number of Cylinders
12
16
16
16
Rated Speed rpm
1,900
1,900
1,900
1,900
Net Power kW
(hp)
1705
(2,287)
1706
(2,287)
1855
(2,487)
1920
(2,575)
Gross Power kW
(hp)
1510
(2,025)
1865
(2,500)
2014
(2,700)
2014
(2,700)
4672
(10,300)
7173
(15,813)
7173
(15,813)
Net Torque Nm
10,630
Engine Weight kg
(lb)

Model
QSK60, K2000E
Manufacturer
CUMMINS
COOLING SYSTEM
Fan Diameter mm
(in)
98
1981
(78)
September 2006
MANUFACTURER
MODEL
CAT
793D
LEIBHERR
T262
KOMATSU
830E-AC
KOMATSU
830E
TEREX/
UNIT RIG
MT4400
TEREX/
UNIT RIG
MT4400AC
HITACHI
EH4500-2
64.0
(40.0)
48.8
(30.3)
58.0
(36.0)
64.0
(40.0)
66.9
(41.6)
50/80R57
50/90R57
46/90R57
40.00R57
50/80R57
TRAVEL SPEEDS
Forward 1 km/h
(mph)
11.8
(7.3)
Forward 2 km/h
(mph)
15.9
(9.9)
Forward 3 km/h
(mph)
21.5
(13.4)
Forward 4 km/h
(mph)
29.1
(18.1)
Forward 5 km/h
(mph)
39.4
(24.5)
Forward 6 km/h
(mph)
54.3
(33.7)
Reverse 1 km/h
(mph)
10.9
(6.8)

(mph)
REDUCTIONS
Differential
1.80
Final Drive
16.00
TIRES
Tires
40.00R57
40.00R57
40.00R57
40.00R57
40.00R57
Weight kg
(lb)
3493
(7,700)
3493
(7,700)
3493
(7,700)
3493
(7,700)
3493
(7,700)
Optional Tires
44/80R57
44/95R57
46/90R57
46/90R57
46/90R57
BRAKES REAR
Discs per Side
15
Outside Diameter mm
(in)
874.5
(34.46)
635
(25)
635
(25)
635
(25)
635
(25)
635
(25)
Total Area cm2

(in2)
134 590
(20,861)
14 298
(2,216)
14 298
(2,216)
14 298
(2,216)
14 298
(2,216)
14 298
(2,216)
180 741
(28,015)
BRAKES FRONT
10
Outside Diameter mm
(in)
874.50
(34.5)
736
(29)
1213
(47.79)
1213
(47.79)
1168
(46)
1168
(46)
1213
(48)

(in2)
89 817
(13,921)
17 032
(2,640)
17 032
(2,640)

(in)
106.7
(4.2)
279
(11)
279
(11)
184
(7)
184
(7)

(in)
132.1
(5.2)
335
(13)
335
(13)
305
(12)
305
(12)
Disc per Side
17 032
(2,640)
SUSPENSION SYSTEM
September 2006
99
MANUFACTURER
CAT
793D
MODEL
LEIBHERR
T262
KOMATSU
830E-AC
KOMATSU
830E
TEREX/
UNIT RIG
MT4400
TEREX/
UNIT RIG
MT4400AC
30
(100)
30
(100)
30
(98)
HITACHI
EH4500-2
STEERING SYSTEM
36
Number of Cylinders
40

(ft)
28.42
(93.2)
29
(94)

(ft)
32.66
(107.2)
32
(106)
Body Raise secs
20.25
21
Body Float Down secs
19.26
Body Power Down secs
17.51
28
(93)
28
(93)
HOIST SYSTEM
25
25
27
27
22
14
24
24
15
22
24
BODY
Body Type
Dual Slope
N/A
Flat Floor
Flat Floor
Flat Floor
Flat Floor
Capacity Struck m3
(yd3)
96
(126)
84
(110)
117
(153)
117
(153)
100
(131)
100
(131)
108
(142)

(yd3)
129
(169)
119
(156)
147
(193)
147
(193)
144
(188)
144
(188)
159
(208)
Data provided is for a representative body. Several dual slope, flat floor, coal and mine specific design (MSD) bodies are available. All weights, capacities, and
dimensions are dependent on the machine configuration (body type, attachments, tires, and optional equipment selected).
REFILL CAPACITIES
100
Fuel Tank 1 L
(gal)
4354
(1,150)
Fuel Tank 2 L
(gal)
4922
(1,300)
3310
(875)
4542
(1,200)
4542
(1,200)
3028
(800)
3028
(800)
3785
(1,000)
4920
(1,300)
Cooling System L
(gal)
973
(257)
568
(150)
568
(150)
591
(156)
591
(156)
697
(184)
Crankcase L
(gal)
265
(70)
280
(74)
280
(74)
250
(66)
261
(69)
242
(64)
Rear Axle Housing L

(gal)
1022
(270)

(gal)
21
(5.5)
Steering Tank L
(gal)
227
(60)
Steering System L
(gal)
341
(90)
Brake/Hoist Tank L
(gal)
769
(203)
Brake/Hoist System L
(gal)
1375
(363)
TC/Trans Sump L
(gal)
102
(27)
TC/Trans System L
(gal)
189
(50)
27
(7)
901
(238)
901
(238)
473
(125)
1325
(350)
291
(77)
946
(250)
946
(250)
662
(175)
662
(175)
908
(240)
908
(240)
965
(255)
September 2006
Technical Specifications 797B vs. Competition (272 tonnes+ [300 tons+])
MANUFACTURER
HITACHI
EH5000
MODEL
Engine Model
Engine Manufacturer
Drive
KOMATSU
930E-3
KOMATSU
930E-3SE
TEREX/
UNIT RIG
MT5500B
TEREX/
UNIT RIG
MT5900AC
CAT
797B
LIEBHERR
T282B
16V4000
QSK60
QSK78
QSK60
QSK78
3524B
16V4000
MTU/DDC
CUMMINS
CUMMINS
CUMMINS
CUMMINS
CAT
MTU/DDC
ELECT AC
ELECT AC
ELECT AC
ELECT AC
ELECT AC
MECH
ELECT AC
528 208
(1,164,500)
501 974
(1,106,670)
504 400
(1,112,000)
557 823
(1,230,000)
557 823
(1,230,000)
623 690
(1,375,000)
591 939
(1,305,000)
(lb)
Chassis Weight kg
(lb)
167 865
(370,078)

(lb)
Empty Weight kg
(lb)
214 820
(473,600)
30 362
(66,936)
213 185
(469,991)
211 681
(466,672)

(tons)
284
(312)
290
(320)

(tons)
315
(347)
Empty weight
Empty weight
with 50% fuel,
with 100% fuel,
standard
no options.
MTU/DDC
Nominal payload
engine. Nominal
defined by
payload defined
Komatsus
as 90% of payload payload policy
with standard
equipment
47 264
(104,200)
212 994
(469,567)
231 332
(510,000)
231 332
(510,000)
270 677
(596,744)
229 064
(505,000)
345+
(380+)
290
(320)
326
(360)
326 353
(360 390)
See 10/10/20
Guidelines
363
(400)
Empty weight
with 50% fuel.
GVW including
options, liners,
fuel, and
payload
Empty weight
with 100% fuel
and autolube
capacities
Empty weight
with 100% fuel
and autolube
capacities
Empty weight
includes
lubricants,
coolant, 100%
fuel, debris
(4% of chassis
weight), no body
attachments
N/A
DIMENSIONS
Wheelbase mm
(in)
6150
(242)
6350
(250)
6350
(250)
6655
(262)
6655
(262)
7200
(283)
6553
(258)
Overall Length mm
(in)
14 420
(570)
15 596
(614)
15 596
(614)
15 392
(606)
15 392
(606)
14 530
(572)
14 478
(570)
Overall Width mm
(in)
9050
(356)
8687
(342)
8687
(342)
9449
(372)
9449
(372)
9154
(360)
8788
(346)
Tire Width mm
(in)
8520
(336)
8331
(328)
8331
(328)
9195
(362)
9195
(362)
9761
(384)
8712
(343)
Loading Height mm
(in)
6500
(256)
7061
(278)
7061
(278)
6858
(270)
6858
(270)
7083
(278)
6452
(254)

(in)
14 280
(562)
14 021
(552)
14 021
(552)
13 437
(529)
13 437
(529)
15 292
(602)
13 284
(523)
Front Axle Empty
49%
47%
50%
49%
49%
44%
46%
Rear Axle Empty
51%
53%
50%
51%
51%
57%
54%
Front Axle Loaded
32%
33%
33%
33%
33%
33%
34%
Rear Axle Loaded
68%
67%
67%
67%
67%
67%
66%
WEIGHT DISTRIBUTION
September 2006
101
MANUFACTURER
HITACHI
EH5000
MODEL
KOMATSU
930E-3
KOMATSU
930E-3SE
TEREX/
UNIT RIG
MT5500B
TEREX/
UNIT RIG
MT5900AC
CAT
797B
LIEBHERR
T282B
ENGINE
Model
16V4000
QSK60
QSK78
QSK60
QSK78
3524B
16V4000
MTU/DDC
CUMMINS
CUMMINS
CUMMINS
CUMMINS
CAT
MTU/DDC
Bore mm
(in)
165
(7)
159
(6)
170
(7)
159
(6)
170
(7)
170
(7)
165
(7)
Stroke mm
(in)
190
(7)
190
(7)
190
(7)
190
(7)
190
(7)
215
(8)
190
(7)
65
(3,967)
60
(3,661)
78
(4,760)
60
(3,661)
78
(4,760)
117
(7,146)
65
(3,967)
Manufacturer
Displacement L
(in3)
Max Altitude m
(ft)
2591
(8,500)
Number of Cylinders
Rated Speed rpm
16
16
18
16
18
24
16
1,900
1,900
1,900
1,900
1,900
1,750
1,800
High Idle rpm
1,950
Low Idle rpm
700
Net Power kW
(hp)
1939
(2,600)
1902
(2,550)
2558
(3,429)
1847
(2,478)
2445
(3,278)
2513
(3,370)
1848
(2,478)
Gross Power kW
(hp)
2014
(2,700)
2014
(2,700)
2611
(3,500)
2014
(2,700)
2611
(3,500)
2648
(3,550)
2013
(2,700)
Net Torque Nm
10,930
16,004
Torque Rise
22%
Engine Weight kg
(lb)
9608
(21,182)
10 100
(22,266)
8852
(19,515)
10 800
(23,810)
16 780
(37,000)
7484
(16,500)
OPTIONAL ENGINE
Model
QSK60-L
16V4000
20V4000 Tier 1
QSK78
CUMMINS
MTU/DDC
MTU/DDC
CUMMINS
Bore mm
(in)
159
(6)
165
(7)
170
(7)
Stroke mm
(in)
190
(7)
190
(7)
190
(7)
60
(3,661)
65
(3,967)
78
(4,760)
Manufacturer
Displacement L
(in3)
Number of Cylinders
16
16
20
18
Rated Speed rpm
1,900
1,800
1,800
1,900
Net Power kW
(hp)
1920
(2,575)
1848
(2,478)
2548
(3,415)
Gross Power kW
(hp)
2014
(2,700)
2013
(2,700)
2723
(3,650)
2610
(3,500)
Net Torque Nm
10,630
7173
(15,813)
10 372
(22,870)
11 294
(24,900)
QSK78
20V4000 Tier 2
QSK60
CUMMINS
MTU/DDC
CUMMINS
Engine Weight kg
(lb)

Model
Manufacturer
Model
Manufacturer
20V4000
20V4000
CUMMINS
MTU/DDC
COOLING SYSTEM
Fan Diameter mm
(in)
102
2438
(96)
September 2006
MANUFACTURER
MODEL
HITACHI
EH5000
KOMATSU
930E-3
KOMATSU
930E-3SE
TEREX/
UNIT RIG
MT5500B
TEREX/
UNIT RIG
MT5900AC
CAT
797B
LIEBHERR
T282B
TRAVEL SPEEDS
Forward 1 km/h
(mph)
11.3
(7.0)
Forward 2 km/h
(mph)
15.2
(9.5)
Forward 3 km/h
(mph)
20.5
(12.7)
Forward 4 km/h
(mph)
27.7
(17.2)
Forward 5 km/h
(mph)
37.2
(23.1)
Forward 6 km/h
(mph)
50.3
(31.2)
Forward 7 km/h
(mph)
67.6
(42.0)
Reverse 1 km/h
(mph)
12.9
(8.0)

(mph)
66.9
(41.6)
64.5
(40.0)
64.5
(40.0)
65.0
(40.0)
65.0
(40.0)
REDUCTIONS
Differential
1.265
Final Drive
16.670
TIRES
Tires
53/80R63
53/80R63
53/80R63
55/80R63
55/80R63
59/80R63
55/80R63
55/80R63
58/80R63
56/80R63
Weight kg
(lb)
Optional Tires
BRAKES REAR
Discs per Side
Outside Diameter mm
(in)
Total Area cm2
(in2)
180 741
(28,015)
194 050
(30,078)
15
787
(31)
787
(31)
1067
(42)
711
(28)
194 050
(30,078)
198 387
(30,750)
BRAKES FRONT
Disc per Side
Outside Diameter mm
(in)
(in2)
18 548
(2,875)
194 050
(30,078)
10
1308
(52)
1308
(52)
1067
(42)
1194
(47)
194 050
(30,078)
132 258
(20,500)
Dry Disc OD mm
(in)
SUSPENSION SYSTEM
Front Strut Diameter mm
(in)
400
(16)
Rear Strut Diameter mm

(in)
381
(15)

(in)
239
(9)
239
(9)
184
(7)
184
(7)
165
(6.5)

(i )
328
(13)
328
(13)
305
(12)
305
(12)
318
(12 5)
September 2006
103
MANUFACTURER
HITACHI
EH5000
MODEL
KOMATSU
930E-3
KOMATSU
930E-3SE
TEREX/
UNIT RIG
MT5500B
TEREX/
UNIT RIG
MT5900AC
CAT
797B
LIEBHERR
T282B
STEERING SYSTEM
40
Number of Cylinders
30
(99)
25
(81)
25
(81)
32
(106)
32
(106)
39.9
(130.9)
33.6
(110)
30
(97)
30
(97)
40.5
(132.8)
36.6
(120.1)
25.0
28

(ft)
(ft)
39
HOIST SYSTEM
Body Raise secs
22
21
21
Body Float Down secs
24
24
24
23
23
12
12
18.1
18
Body Power Down secs
28
28
18.5
BODY
Body Type
N/A
Flat Floor
Flat Floor
Flat Floor
Flat Floor
MSD II
N/A
Capacity Struck m3
(yd3)
144
(188)
171
(224)
171
(224)
158
(207)
158
(207)
187
(245)
122
(160)

(yd3)
196
(257)
211
(276)
211
(276)
218
(285)
218
(285)
241
(315)
184
(240)
Data provided is for a representative body. Several mine specific design (MSD) bodies are available. All weights, capacities, and dimensions are dependent on the
machine configuration (body type, attachments, tires, and optional equipment selected).
REFILL CAPACITIES
Fuel Tank 1 L
(gal)
3785
(1,000)
4542
(1,200)
4542
(1,200)
Fuel Tank 2 L
(gal)
3028
(800)
3028
(800)
3785
(1,000)
4920
(1,300)
4920
(1,300)
6814
(1,800)
Cooling System L
(gal)
697
(184)
594
(157)
719
(190)
591
(156)
757
(200)
1194
(315)
456
(120)
Crankcase L
(gal)
242
(64)
280
(74)
341
(90)
250
(66)
390
(103)
417
(110)
240
(63)

(gal)
(gal)
701
(185)
27
(7)
Steering Tank L
(gal)
61
(16)
947
(250)
Steering System L
(gal)
947
(250)
235
(62)
291
(77)
432
(114)
Brake/Hoist Hydraulic Tank L

(gal)
(gal)
104
4730
(1,250)
965
(255)
1325
(350)
1325
(350)
1033
(273)
1033
(273)
996
(263)
1211
(320)
1211
(320)
1842
(486)
TC/Trans Sump L
(gal)
190
(50)
TC/Trans System (Includes Sump) L

(gal)
629
(166)
570
(150)
1510
(400)
September 2006
Notes
September 2006
105
The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and
is intended exclusively for their information and training. It may contain unverified analysis and facts observed by various Caterpillar or dealer employees.
However, effort has been made to provide reliable results regarding any information comparing Caterpillar built and competitive machines. Effort has been
made to use the latest available spec sheet and other material in the full understanding that these are subject to change without notice. Any reproduction
of this release without the foregoing explanation is prohibited.
CAT, CATERPILLAR, their respective logos, Caterpillar Yellow and the POWER EDGE trade dress, as well as corporate and product identity used herein,
are trademarks of Caterpillar and may not be used without permission.
September 2006
www.cat.com
2006 Caterpillar
All Rights Reserved
Printed in the U.S.A.

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Caterpillar Product Information

Cat Mining Trucks

For Dealer Sales Personnel

Machine Positioning Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cat Mining Trucks 785C, 789C, 793D, 797B

Machine Positioning Strategy

Cat Mining Trucks 785C, 789C, 793D, 797B

Highest Hour Unit

Cat Mining Trucks 785C, 789C, 793D, 797B

Competitive Situation Caterpillar

Target Payload Capacity*

* Approved weights as of 2005.

Cat Mining Trucks 785C, 789C, 793D, 797B

Competitive Situation Komatsu

Cat Mining Trucks 785C, 789C, 793D, 797B

Competitive Situation Komatsu

Cat Mining Trucks 785C, 789C, 793D, 797B

Competitive Situation Komatsu

Cat Mining Trucks 785C, 789C, 793D, 797B

Competitive Situation Liebherr

Cat Mining Trucks 785C, 789C, 793D, 797B

Competitive Situation Terex/Unit Rig

Cat Mining Trucks 785C, 789C, 793D, 797B

Competitive Situation Hitachi

Cat Mining Trucks 785C, 789C, 793D, 797B

Competitive Situation Hitachi

Successes and Selling Points.

Cat Mining Trucks 785C, 789C, 793D, 797B

Other Competition: Truck Manufacturers

Cat Mining Trucks 785C, 789C, 793D, 797B

Other Competition: Components

General Electric (GE).

Cat Mining Trucks 785C, 789C, 793D, 797B

Caterpillar integral ROPS cab frame.

Caterpillar Truck Frames. Cat frames are built

Integral ROPS Cab. Frame is designed for an

Mild Steel Construction. The high strength low

Cat Mining Trucks 785C, 789C, 793D, 797B

Crack propagation rates are much higher,

Caterpillar Integral Four-Post ROPS Cab.

Integral Four-Post ROPS Cab. Resiliently mounted

The full scale fatigue testing conducted by

Increasing yield strength comes at the expense

Cat Mining Trucks 785C, 789C, 793D, 797B

Mild steel provides a balance of medium yield

Caterpillar Frame Design Versus Competition.

Critical welds are 100 percent ultrasonically

Castings are used in areas of high stress.

Cat Mining Trucks 785C, 789C, 793D, 797B

Euclid/Hitachi truck frame.

Euclid/Hitachi Frame Design.

Liebherr truck frame.

Liebherr Frame Design.

All fabricated. No castings used. More vulnerable

Fabrication and welding in high stress areas,

No consistent frame design among various

Nickel copper combination steel frame.

Material yield strength varies among models.

Minimal section high stress dump

Cat Mining Trucks 785C, 789C, 793D, 797B

789C HAA 797B HAA*

*Two Stage Turbo charging

Cat 3500B Engine Enhancements. The improvements