785C, 785D & 789C Mining Trucks

785C GMW 550,000 lbs. ( 249,480 kg)

130 -150 ton (118 – 136 metric tons)
785D GMW 550,000 lbs. ( 249,480 kg)
130 -150 ton (118 – 136 metric tons)

789C GMW 700,000 lbs. ( 317,515 kg)

170 -195 ton (154 – 177 metric tons)

2 CATERPILLAR: CONFIDENTIAL GREEN

 Experienced Mining Trucks

• Strong Worldwide presence – Reliable Reputation

• Mechanical drive
– Product support = Availability = Tons Moved
– Productivity
– Payload control
• Key features & benefits deliver
– Health, Safety & Environment
– Lower Cost Per Ton / Availability
– Tires
• Serviceability
– Dealer Support

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 All Cat Mechanical Power Train

• Cat is only manufacturer with fully

integrated drive train
• Centralized design control allows Cat to
optimize performance & life
• Higher power train efficiency delivers
more power to ground, burns less fuel,
reduces cost per ton • Heavy-duty final drives withstand
• Wide application range extreme loads and forces, can be
• Automotive feel is easier to control remanufactured
• One-piece cast wheels enhance
• Cat design has fewer thermal
durability
limitations on steep grades
• No on-site high voltage power required • Differentials designed for long life, lower
cost- per-ton operation
• Control system manages engine speed
during shifts to increase clutch life and • Rear axle lube system cools and cleans
improve operator comfort continuously

• Purpose Built Integrated System

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CATERPILLAR: CONFIDENTIAL GREEN
 Features & Benefits
Premier machines in their classes, designed and built by Caterpillar using components and
systems that have evolved through years of rugged mining applications

Cost per Ton

Availability

• Safety & Operator Station

• Powertrain
• Systems Integration
• Frame
• Body
• Front Axle & Steering
• Retarding & Traction Control
• Tires

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 Standard Safety Features

Standard Features
• 4-post ROPS
• Oil-cooled brakes on 4 corners for
fade-resistant operation
• Ground level secondary engine
shutdown and machine lockouts for
added safety and security
• Three-point operator restraint
• Lighted driver-side ladder and
service deck
• 10/10/20 Payload Policy applies

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 New Optional Safety Features

New Safety Enhancements

• 600 mm (24 in) wide diagonal stairway – standard
785D.
– custom field kits for 785B/C & 789B/C
• Closed-circuit television factory ready and model
specific kits
• High intensity discharge (HID) lighting in
high beams and back-up lights improves
night time visibility
• Extended life carbon paper disc brakes provide
longer service life and increased heat resistance
than standard brakes
– Standard 785D
– Optional 785C, 789C

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 Operator Station

• Ergonomically designed
• Excellent machine control
• Exceptional all-around visibility
• Resiliently-mounted, sound suppressed cab
- Sound levels less than 80 dB (A)
4
• Air suspension seat - fully adjustable 8
10
• Operator comfort = Higher Productivity! 9

5
3
1
7
6
1. Air suspension seat 6. Storage Compartment
2. Hoist lever (left side of seat) 7. Trainer seat
3. Secondary brake pedal 8. Electric window
4. Monitoring system 9. Operator controls
5. Transmission control 10. Heating/air conditioning
6. Storage compartment
2

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 Caterpillar Engines

A proven performer for over 25 years, the 3500 series engine now has over 105,000
units working worldwide in a variety of applications

• Electronic Control Module

– Reduces smoke
– Reduces emissions.
– Improves fuel efficiency
– Optimizes performance and life
– Communicates with transmission
and retarder
– Provides information for diagnostics and management decisions.
– Diagnoses own health and status
– Controls Oil Renewal System
• Cat engines operate at lower BMEP than competition -- improving
availability, extending life, reducing costs
• Purpose Built Integrated System

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Lock-up Torque Converter
Combines the advantages of direct drive and converter drive to achieve high component
reliability and maximum output performance
Lock-up clutch
• Increased power train
efficiency Torque
converter output
• High reliability from proven
design components Input

• 28% stall torque

• Broad converter performance
band
• Lock-up clutch engages at 6.4
Flow of power
km/h (4.0 mph)
Flow of oil

Torque converter drive mode

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 Six-Speed Planetary Transmission
Large diameter clutch packs are controlled to provide smooth shifting and to limit
clutch energy input for extended component life
• Torque converter lock-up in first
gear
• Downshift inhibitor prevents
engine overspeed
• Clutch packs mounted outside of
gear sets
for ease of service
• Directional shift management
automatically reduces engine
throttle before shifting

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 Controlled Throttle Shift

Reduces driveline torque stress for smoother shifts, extended component life,
and improved operator comfort
Controlled Throttle Shift (CTS)

Transmission Output Torque

• Regulates engine rpm during Shift without CTS
shifts
• Reduces torque spikes and
extends Shift with CTS
transmission life
• Smoother ride and less spillage
• Lowers operator fatigue
• Possible only through electronic
Clutch Power
integration of components Shift without CTS

Shift with CTS

Time

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 Rear Wheel Group
Heavy duty components and ease of service combine to deliver long life and reduced
downtime in the most rugged conditions

• Laser-hardened spindle in the

wheel bearing journal area
• Integrated wheel and hub
reduces removal
and installation time
• Rotated and flushed with oil at
factory, then filled with filtered oil
before shipping
• Duo-Cone ™ seals are air and
oil checked after assembly as
part of quality control

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 Ecology Drains
Easily accessible drain plugs are installed in components to provide an environmentally
safe and effective method to drain fluids

1
• Ecology drains are standard equipment
and located throughout the 785C &
789C
– Engine (1)
– Radiator (2)
– Transmission
– Torque converter
– Hydraulic tank
– Fuel tank 2
• Alongside the fuel tank is the optional
Wiggins service center that has quick
fill and drains for the truck fluids

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 Front Axle Steering Components
The 785C & 789C front suspension is field-proven design with dual tie-rods for
optimum steering geometry to help extend tire life

• Separate steering hydraulic system

prevents cross contamination
• Secondary steering meets ISO 5010 up
to 120% of target payload
• Twin double-acting cylinders
• Steering arm pin retention plate
provides redundant pin retention
• Front suspension cylinders serve
as kingpins
• Serviceable bracket assembly on
steering box casting saves time at
rebuild
• Two tie-rods allow optimum steering
geometry

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 Brakes and Retarding
Oil-cooled multiple disc brakes on all four wheels provide exceptional braking and retarding
• Integrated systems deliver optimum
performance 2
• Non-fade, oil cooled design offers
reliable performance, long life
• Spring-applied secondary and parking 1
systems
enhance safety
• Four-wheel braking improves control
• 40/60 brake torque split improves
control, minimizes wheel lock-up 1. Parking/secondary piston
7
• Traction Control System improves 2. Service/retarding piston
performance in poor underfoot 3
• Automated Retarder Control allows 3. Friction discs
faster, 4 4. Steel plates
safer downhill travel
• Sealed system prevents contamination
5. Actuating springs
• Brake wear measurements completed 5 6 6. Cooling oil in
quickly 7. Cooling oil out
• Purpose Built Integrated System

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 785 Specifications

785D (MSY) 785C (APX)

Target GMW – kg (lb) 249 480 (550,000) 249 480 (550,000)

Operating Machine Weight –kg (lb.) 111 618 (246,084) 111 008 (244,704)

Nominal Payload 136 tonnes (150 tons) 136 tonnes (150 tons)

3512B EUI
Engine model 3512C HD-EUI
Displacement – L (in3) 58,56 (3,573) 51,8 (3,158)

Gross power – kW (hp) 1082 (1,450) 1082 (1,450)

Engine derates above altitude – m (ft) 4267 (14,000) 3050 (10,000)

Top speed, loaded – km/h (mph) 56.0 (35.0) 56.0 (35.0)

Target fuel consumption, engine rebuild (gallons) 575,000 525,000

BSFC g/kw-hr 210.4 211.3

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 One engine –
both LAA &
HAA capability

785D FEATURES
3512C HD
(with CPI
improvements)

Tier II Certified

Maintained or
Continuous Slightly
rear axle improved Fuel
filtration Consumption

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 Canopy X Body
Coverage

Front Frame 785D FEATURES

Extended

Handrail bump
out at cab

Wide
Toe Guards
Stairway
(Standard)
Extended Life
Brake Disc

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Continuous Rear Axle Filtration

• Standard feature
• Continuously circulates axle
lubricant through 6 micron filter to
maintain ISO 18/15 cleanliness.
• Cleaner components equal 10 to
20% longer component life.
• Reduces kidney loop maintenance
times.

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 785D Value - Summary

• Component and parts commonality with the proven 3500

series HD engine

• Continuous Rear Axle Filtration

• Diagonal Front Access Stairway

• 3512C HD Tier II Engine

• New “X” series bodies w/extended canopy coverage

• Minimum new content change (maintenance department

proficiency, existing tooling utilization, mixed fleet transition)

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785C, 785D & 789C Reduces Cost Per Ton
Safety
• Oil cooled brakes at 4 corners with
40/60 split,dead engine full stop Utilization
capability, ROPS/FOPS, 10/10/20 • One safe source for
payload control policy support
• Diagonal stairway, HID lighting,
extended wear brakes, and WAVS • Traction control allows
rear vision camera continued operation in
poor underfoot conditions
Production
Owning cost
• Fast cycle times – broad operating
range • Long economic life
• 2 axle retarding • Higher resale value than
• Optimize payload with MSD Bodies competition. Even though
a customer may not resell
Mechanical Availability
their truck, the high resale
• Improved reliability, higher uptime is indicative of the
• 3500 Series engine has lower remaining value in older
BMEP than competition—improving Cat trucks
availability, extending life, and
reducing costs.

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 785C, 785D & 789C Reduces Cost Per Ton

Maintenance cost per hour Operator efficiency

• Field-proven components throughout • Operator station comfort and
the truck ergonomics
• VIMS™ System capability allows • Operator confidence in braking and
diagnostics and prognostics to extend retarding optimizes downhill speed
service life
of components • Good visibility

• Dealer and factory REMAN Fuel cost per ton

Tire cost per hour • Engine fuel efficiency

• Weight distribution and low Empty • Highest power train efficiency

Machine Weight • Zero fuel consumption while retarding
• VIMS™ TKPH/TMPH Speed Manager
• Traction Control System – limited slip

24 CATERPILLAR: CONFIDENTIAL GREEN