Overview

Caterpillar® 793D Mining Truck

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793 History

• Cat 793– 1991 - 1992

– Over 50 sold

• B-Series– 1992 - 1996

– Over 500 sold

• C-Series – 1996 - 2005

– Over 1,050 sold

• D-Series– Introduced 2005

– Five arrangements for specific applications

The 793 has continuously evolved to remain the leader in its class

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D-Series Application Arrangements

Standard Arrangement – Balanced all-around performance

Extended Life Wheel Groups – For long uphill hauls

Extra Top Speed – For long flat hauls

Extra Retarding – For long downhill loaded hauls

High Altitude Arrangement – For operations above 2590 m (8,500 ft)

The 793D is offered in five machine arrangements to match the application conditions found in your mine

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793D Standard Arrangement

• Exceptional all-around performance

• Three factors combine to produce up to 9% more power at the wheels than the 793C:

– 5% more engine horsepower than 793C

– Common rail hydraulic system provides improved power train efficiency compared to 793C

– Hydraulically driven demand 84” fan reduces parasitic load by operating only when needed

• Continuous Axle Filtration

• New extended life brake friction disc material

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793D Extended Life Wheel Group Arrangement - Rear

• For long uphill hauls

Differences from Standard Arrangement

• Larger wheel bearings

• Wider wheel bearing spacing

• 29% increase in braking surface

• Larger spindle

• Spline-on brake group

Benefits

• Longer brake life

• Extended life to overhaul

• Lower cost per ton

Standard (Rear)

Extended Life (Rear)Brakes Bearings

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793D Extended Life Wheel Group Arrangement - Front

• For long uphill hauls

Differences from Standard Arrangement

• Larger wheel bearings

• Larger spindle, wider wheel bearing spacing

• Larger brakes, 94 cm (37 in) vs 86 cm (34 in)

• Repositioned duo-cone seal

• Bottom mount steering arm fits either side

Benefits

• Longer brake life and duo-cone seal life

• Extended life to overhaul

• Lower cost per ton

Spindle bolts(outer pattern)Strut bolts

(inner pattern)

Bottom mountsteering arm

Extended Life (Front)

Standard (Front)

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Extra Retarding Arrangement

• For long downhill loaded hauls

Differences from Standard Arrangement

• Higher flow brake cooling

• Higher capacity cooling system

• Includes Extended Life Wheel Groups

Benefits

• 35% increase in downhill speed over the standard 793D

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793 Worldwide Deliveries

Over 1,600 Shipments (as of June 2005)

36%

34% 28%

2%

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793D Component Sources

Mapleton, Illinois• Engine block & head castings

Caterpillar designs and manufactures all major components of the 793D

Pontiac, Illinois• Fuel systems

Lafayette, Indiana• Engine

East Peoria, Illinois• Transmission• Gear sets

Joliet, Illinois• Cab• Hydraulics

Decatur, Illinois• Design & Engineering • Frame• Final assembly

Peoria, Illinois• Electronics

Truck Bodies• Mexico• Australia• Africa

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Completely Caterpillar

• Complete design control over entire truck

• Single-point accountability

• Enables Cat to optimize the truck as a whole rather than by individual component

• Ensures compliance with the high quality standards expected

793D Technical Team Decatur, Illinois

Design and manufacturing control ensures that the 793D operates as a complete and balanced unit

Specifications

Caterpillar® 793D Mining Truck

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793D Dimensions Shown with standard, dual-slope body

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793D Specifications (Metric)793D

Standard793D Extra Life Wheel Groups

793D Extra Top Speed

793D Extra Retarding

793D High Altitude

793C2

Maximum GMW (kg) 383 739 383 739 383 739 383 739 383 739 383 739

Chassis weight1 (kg) 116 772 118 757 118 747 118 714 119 371 118 220

Engine model 3516B HD 3516B HD 3516B HD 3516B HD 3516B 3516B HD

Displacement (L) 78 78 78 78 69 78

Gross power (kW) 1801 1801 1801 1801 1715 1715

Flywheel power (kW) 1743 1743 1743 1743 - 1615

Rated speed (rpm) 1,750 1,750 1,750 1,750 1,750 1,750

Engine derates above altitude3 (m) 2750 2750 2750 2750 3658 2743

Transmission speeds 6 Forward – 1 Reverse

Top speed (km/h) 54.3 54.3 59.9 54.3 54.3 54.3

1 Approximate clean chassis with full fuel, hoist, body mounting group and tires. Excludes body weight. Dependent on optional attachments. 2 Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with 3516B short stroke engine.3 Approximate altitude only. Changes with barometric pressure variations. Derate above this altitude is 1% per 1kPa- Data not available

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793D Specifications (Metric)

Brake discs per side - front 10 13 13 13 13 10

Brake area - front (m2) 8.98 13.47 13.47 13.47 13.47 8.98

Brake discs per side - rear 15 15 15 15 15 15

Brake area - rear (m2) 13.46 15.54 15.54 15.54 15.54 13.46

Brake disc outside diameter (mm)

874.5 939.8 939.8 939.8 939.8 874.5

Total brake area (m2) 22.44 29.01 29.01 29.01 29.01 22.44

Fuel tank capacity (L) 4354 4354 4354 4354 4354 4467

Optional fuel tank (L) 4922 4922 4922 4922 4922 -

793D Standard

793D Extra Life Wheel Groups

793D Extra Top Speed

793D Extra Retarding

793D High Altitude

793C1

1 Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with 3516B short stroke engine.- Data not available

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793D Specifications (English)

Maximum GMW (lb) 846,000 846,000 846,000 846,000 846,000 846,000

Chassis weight1 (lb) 257,438 261,816 261,793 261,720 263,168 260,630

Engine model 3516B HD 3516B HD 3516B HD 3516B HD 3516B 3516B HD

Displacement (in3) 4,760 4,760 4,760 4,760 4,211 4,760

Gross power (hp) 2,415 2,415 2,415 2,415 2,300 2,300

Flywheel power (hp) 2,337 2,337 2,337 2,337 - 2,166

Rated speed (rpm) 1,750 1,750 1,750 1,750 1,750 1,750

Engine derates above altitude3 (ft) 9,000 9,000 9,000 9,000 12,000 9,000

Transmission speeds 6 Forward – 1 Reverse

Top speed (mph) 33.7 33.7 37.2 33.7 33.7 33.7

1 Approximate clean chassis with full fuel, hoist, body mounting group and tires. Excludes body weight. Dependent on optional attachments. 2 Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with 3516B short stroke engine.3 Approximate altitude only. Changes with barometric pressure variations. Derate above this altitude is 1% per 1kPa- Data not available

793D Standard

793D Extra Life Wheel Groups

793D Extra Top Speed

793D Extra Retarding

793D High Altitude

793C2

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793D Specifications (English)

Brake discs per side - front 10 13 13 13 13 10

Brake area - front (in2) 13,921 20,874 20,874 20,874 20,874 13,912

Brake discs per side - rear 15 15 15 15 15 15

Brake area - rear (in2) 20,847 24,084 24,084 24,084 24,084 20,869

Brake disc outside diameter (in)

34.5 37.0 37.0 37.0 37.0 34.5

Total brake area (in2) 34,781 44,958 44,958 44,958 44,958 34,781

Fuel tank capacity (gal) 1,150 1,150 1,150 1,150 1,150 1,180

Optional fuel tank (gal) 1,300 1,300 1,300 1,300 1,300 -

793D Standard

793D Extra Life Wheel Groups

793D Extra Top Speed

793D Extra Retarding

793D High Altitude

793C1

1 Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with 3516B short stroke engine.- Data not available

Features & Benefits

Caterpillar 793D Mining Truck

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793D Improvements by System

The 793D is the premier machine in its class, designed and built by Caterpillar using components and systems that have evolved through years of rugged mining applications

• Engine

• Cooling System

• Torque Converter

• Rear Axle

• Brakes

• Automatic Retarder Control (ARC)

• Hydraulic

• Operator Environment

• Sheet Metal

• Safety Enhancements

• Serviceability Improvements

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Engine System

• 3516B HD engine @ 2,415 gross horsepower

• 5% horsepower increase over the 793C (2,300 HP)

• Meets US EPA Tier I requirements

• New air induction system has fewer joints (16 vs 22), reducing the opportunity for dust ingestion

• 793D Engine Enhancements:– Drilled piston rod provide and maintain better lubrication and

improve reliability

– New floating core aftercooler reduces thermal stress

– New turbo with titanium compressor wheel is more robust

– Enhanced diagnostics with Electronic Technician

– New camshaft follower provides greater reliability

– New head gasket material ensures the bolted joints remains

solid and oil leaks are prevented

A proven performer for over 20 years, the 3500 series engine now has over 80,000 units worldwide working in a variety of applications

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New Generation Modular Radiator

Hydraulically driven, variable speed fan is matched to a new generation modular radiator with serpentine fins to improve cooling over the 793C system

• Improved heat rejection

• Greater cooling density

• Modular core design for ease of service

• Hydraulic fan (84 in.) operates on demand to reduce parasitic loads

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Torque Converter

• Additional clutch plate and disc maintains power train capability for both higher horsepower and higher top speed

• New oil level switch serves as an emergency warning is oil is suddenly lost

The torque converter has been designed for higher horsepower

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Rear Axle

• The rear axle filtration system used on the 793D is hydraulically driven, which provides a continuous flow of oil through the filter

• The 793C utilized a ground driven system, therefore when the truck is stationary, the oil is not being filtered

• Constant filtration provides cleaner oil and increased component life

• Part of new “common rail” hydraulic system

• 793D field follow SOS samples show excellent cleanliness levels

The rear axle filtration system has been completely redesigned

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Benefits of Continuous Filtration

Bearings with kidney looping and4,000-hour oil changes showed

little wear after 18,000 hours

Images magnified 50x

Bearings with oil changes at 1,200-hour intervals, but without kidney looping,

showed pitting at 13,000 hours

Caterpillar's success with kidney looping resulted in the continuous filtration system now found in the rear axle of the 793D

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Brakes

• The new brake discs are made with a friction material that provides extended life and increased heat resistance

• New carbon paper friction material

• Extended Life Brake Discs offer:

– Improved material life (2X-4X)

– Better heat resistance

– Better wear rate

– Consistent braking power

– Less glazing

New extended life brake frictions discs are standard on the 793D

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Automatic Retarder Control (ARC)

• 793C actuates ARC via air

• 793D requires less air system demand, therefore uses a smaller compressor

• 793D requires fewer air system components

• Hydraulic actuated ARC provides:

– smoother engagement

– quicker response

The 793D is standard equipped with hydraulic actuated ARC

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Hydraulic System

• Provides more flexible power management

• Ability to turn functions on/off upon demand

• Reduces parasitic power losses by up to 4% under certain conditions

• A common pump to supply the following systems:

– Steering (Priority)

– Brake Cooling Motor

– RAX Filtration Motor

– Rear Axle Cooling Fan (if equipped)

The 793D has a new hydraulic power management strategy, designed to reduce parasitic losses

Hydraulic pump

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Hydraulic System

Optional Rear Axle

Common Rail Valve

Brake Cooling Pumps

Common Rail Pump

Fan/Common Rail Cooler

Common Rail and Fan Tank

Return Filter

Fan Pump

Brake Cooling Drive Motor

Solid Connection

MainEngineFan

Steering Cylinders

SteeringControl

Rear AxleLubricator Motor

Cooler Fan

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Operator Environment

• High-back seat supports head and neck

• Ride zone indicator adjusts seat suspension to operator’s weight

• Adjustable rake lower cushion

• Washable seat cover

• Dual retractor lap and shoulder belt system

• Adjustable shoulder belt has six verticalheight settings for optimum fit

The new Cat Comfort Seat with three-point restraint offers operators added safety and comfort

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Sheet Metal

• The new catwalk design includes triangular shaped gussets which extend from the bottom of the catwalks to the bottom of the cab

• The new catwalks were validated via finite element analysis and 793D field follow test iron

The 793D Cab Catwalk design has improved service life and is less susceptible to cracking

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Sheet Metal

• New design has a thicker, domed back plate and new mounting bracket geometry

• New design allows for improved serviceability of the glass

• Finite element analysis of new design indicates an 87% stress reduction (100 times life improvement) versus the previous design

• Heated mirrors available on the 793D

The 793D LH mirror design has improved service life and is less susceptible to cracking

793C

793D

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• The catwalk adjacent to the operator’s door has been extended to allow a larger area to stand when entering/exiting the cab.

• The chain guard, used on the 793C, has been replaced with a continuous side handrail shaped to provide a totally guarded environment.

Safety Enhancement

The new wider catwalk and continuous handrail, introduced with the 793D, offers added safety when moving in or out of the cab.

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• The 793C handrails do not have toe boards

• This is a standard feature on the 793D

• Toe boards provide protection from slipping and prevent any tools or loose items from falling from the platforms

Safety Enhancement

Introduced with the 793D, all handrails are equipped with toe boards for added safety.

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• The fender lights provide full width front lighting for added safety when approaching oncoming traffic at night.

• This is a standard feature on the 793D

• The 793C upper lights are located in the top of the radiator grille.

Safety Enhancement

Similar to the 797, the 793D has the upper front lights (high beam) located in the fenders versus the radiator.

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• The new 600 mm wide front stairway provides additional comfort and ease for operators and mechanics to access/egress the truck

• The 793C has a 400 mm wide stairway

• This is a standard feature on the 793D

Safety Enhancement

The 793D is standard equipped with a wide diagonal ladder.

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• The rear access platform provides easy access to the back of the cab

• Especially helpful when cleaning rear window or accessing rear cab compartment (ECM’s)

• Equipped with a handrail that folds down to provide clearance when the body is lowered

Safety Enhancement

The 793D offers an optional rear access platform.

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• The ground level transmission lockout system is designed to provide worry free machine troubleshooting with the engine running

• The lockout box is located on the front bumper just above the battery disconnect box

• When the system is turned on/locked, even if the transmission shift cane or park brake switch are bumped or moved, machine state will not change

Safety Enhancement

The 793D offers an optional ground level transmission lockout.

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• HID lights are offered as an attachment on the 793D

• More Intense Light – One 70 Watt HID lamp produces 5000 to 6000 lumen of light, the same light intensity as four 65 Watt halogen lamps.

• Longer Life – Excellent Vibration Resistance. HID lamp life is typically 4 to 8 times longer than halogen.

• Better Light Quality – More closely resembles daylight than halogens.

• More Efficient – Equivalent draw on the machine’s electrical system while producing four times more illumination.

Safety Enhancement

Turning night into day, High Intensity Discharge (HID) lighting offers greater light intensity, better light quality and longer life than halogen lights