User manual CATERPILLAR 789D BROCHURE

[. . . ] · A variety of Cat Truck Bodies are available including Mine Specific Design (MSD II), X, Combination, Gateless Coal and Dual Slope bodies. Contents Power Train ­ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Power Train ­ Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine/Power Train Integration. . . . . . . . . . . . . . . . . . . . . . . . 5 Structures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operator's Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cat Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Truck Body Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Monitoring System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2 Power Train ­ Engine Engine Both the Cat® 3516B and 3516C EUI Quad turbocharged diesel engines deliver high power and reliability in the world's most demanding mining applications. The Cat ® 3500 series engines are built for power, reliability and efficiency for superior performance in the toughest applications. Design The 3500 series engines are 16-cylinder, four-stroke designs that uses long, effective power strokes for more complete fuel combustion and optimum efficiency. EPA Compliant Where applicable, the 3516C engine is compliant with U. S. Environmental Protection Agency emissions requirements. High Torque Rise The 23% net torque rise provides unequalled lugging force during acceleration, on steep grades and in rough underfoot conditions. Torque rise effectively matches transmission shift points for maximum efficiency and fast cycle times. Enhanced Life High displacement, low rpm rating, and conservative horsepower ratings mean more time on the haul roads and less time in the shop. 3516B Separate Circuit Aftercooler Allows the aftercooler circuit to operate cooler than jacket water temperature for a denser air charge and greater combustion efficiency. 3516C Air to Air Aftercooler (ATAAC) The 1566 kW (2, 100 hp) engine option uses an Air To Air Aftercooler to achieve an even greater reduction in air intake temperatures. This results in improved fuel efficiencies and desired emissions levels. Electronic Control Module (ECM) Utilizes advanced engine management software to monitor, control, and protect the engine utilizing self-diagnosing electronic sensors. Air Conditioner Compressor System The air conditioner compressor and lines have been moved to provide easier service, less connection points and compliance to EU standards. [. . . ] The kicked up floor design eliminates the tailgate and gives the volume required to meet target payload. 4) Combination Body ­ This is a multi-purpose, high volume body for light density, well fragmented material. Based off of the dual slope design for customers who need a flexible body to haul light ore (such as coal) and light, well fragmented overburden. 5) Dual Slope Body ­ The original standard body, the Dual Slope body, provides excellent load retention, maintains a low center of gravity with optimum load distribution, reduces shock loading and is available in lined and unlined configurations. The Dual Slope body is intended for tough applications including greenfield sites and contracting mines. Custom Body Options A variety of options including tail extensions, sideboards, tumble bars, rock boxes and rock shedders are available to maintain rated payload, reduce spillage and improve hauling efficiencies. 9 Monitoring System VIMS PC ET Vital machine health and payload data keeps the 789D performing at peak production levels. VIMSTM Monitoring System Intelligent Caterpillar designed machine monitoring system provides critical machine health and payload data in realtime to keep the 789D performing at top production levels. This system is translated and available in most of the major international languages. VIMS 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. Payload Management Max Payload Speed Manager is a feature that aids in managing the Cat 10/10/20 Overload Policy. Based on target payload weight and overload settings, the VIMS system logs and warns the operator when the truck reaches overload after 2nd gear reweigh. The truck will be limited to 2nd 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. Payload Weight Distribution Percentage of Total Loads Road Analysis Control (RAC) Optional system monitors haul road conditions by measuring frame rack, pitch, and bias to improve haul road maintenance, cycle times, tire life, and fuel efficiency. VIMS-PC Payload Weight (Tons) Recommended Payload Range Inefficient Payload Ranges With Production Management Without Production Management VIMS-PC, the off-board reporting software program, allows service personnel to download a complete record of machine health and productivity data to a laptop computer for diagnosis and analysis. Easy-to-use software enables service technicians and mine management to generate health and payload reports for more effective machine management. VIMS Supervisor Optional software allows mine management to easily manage and interpret VIMS data for optimum fleet management and productivity. 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. 10 Safety Product Safety Cat mining machines and systems are designed with safety as their first priority. Caterpillar has been and continues to be proactive in developing mining machines that meet or exceed safety standards. Safety is an integral part of all machine and system designs. Mining Technologies Cat® MineStarTM System encompasses a comprehensive suite of mining technologies grouped within a number of configurable capability sets, including Fleet, Terrain, Detect, Health, and Command. Object Detection is part of the Detect capability set and provides customers with a scalable system to aid in the awareness of machines and other objects in the near vicinity of working equipment. Object Detection systems are factory installed as standard equipment on 789D mining trucks. The fully integrated Object Detection system, RADAR AND CAMERA, provides both audible and visual indications of detected objects using radars which surround the machine, along with cameras on each side to allow the operator to confirm the detected object. The cameras supplement the radar alerts and are selectable by touch screen menus through an intuitive interface. Overload Policy Adherence to the Caterpillar 10/10/20 Overload Policy assures that steering and braking systems have sufficient capacity to perform. Standard Safety Features Slip resistant surfaces, retractable, seat/shoulder belts with three-point operator restraint, wide-angle mirrors, body raised indicator, body retaining cable, guard rails, reverse neutralizer when dumping, low interior sound level, secondary steering system, ground level access shutoff switches. SAFETY. CAT. COMTM 11 Sustainability Sustainability Features A variety of features improve sustainability in areas of decreasing waste, extending component life and lowering emissions levels. The 789D Mining Truck offers oil renewal systems, extended life filters and extended maintenance intervals which aid in decreasing the amount of waste contributed to our environment. Oil Renewal System Optional oil renewal system extends engine oil change intervals from 500 hours to 4, 000 hours or more to increase machine availability and reduce costs. Engines with Advanced Technology Engines with advanced technology contribute less emissions to the environment while maintaining fuel efficiency. Fuel Efficiency The engine provides additional retarding by running against compression on downhill hauls. During retarding applications the engine ECM does not inject fuel into the cylinders for exceptional fuel economy. 12 Serviceability Tie Off Points Less time spent on maintenance means more time on the haul roads. Enhances working environment during service of recommended maintenance areas. Servicing Ease Easy access to daily service points simplifies servicing and reduces time spent on regular maintenance procedures. Enhanced serviceability and 500-hour service intervals are designed to increase machine availability and productivity. Maintenance Platform Provides access to engine, steering hydraulic tank, and battery compartment. In-Frame Access Permits easy access to major components for easy servicing and removal. Ground-Level Access Allows convenient servicing to tanks, filters, drains, and engine shutdown. Ground-level VIMS data port permits easier downloading of information. Autolube Automatic lubrication system reduces maintenance time by automatically lubricating necessary components on a regular basis. Fast Fill Service Center Optional fast fill service center features high speed fuel and oil exchange. Scheduled Oil Sampling S·O·SSM sampling valves speed sampling and analysis reliability. Pressure Test Points Disconnect valves are conveniently located throughout the hydraulic systems for easy pressure testing. Sealed Electrical Connectors Electrical connectors are sealed to lock out dust and moisture. Wires are color coded for easy diagnosis and repair. Cylinder Heads Individual cylinder heads are interchangeable for easy removal and visual inspection of internal parts. On-Board Diagnostic Systems The VIMS system continuously monitors all critical machine functions and components to help locate faults quickly for faster repair. 13 Customer Support Commitment Makes the Difference Cat dealers have what it takes to keep mining haul trucks productive. Cat dealers offer a wide range of solutions, services and products that help you lower costs, enhance productivity and manage your operation more efficiently. [. . . ] If cooling oil overheats, reduce ground speed to allow transmission to shift to the next lower speed range. GROSS WEIGHT 0 0 100 50 200 100 300 150 400 200 500 250 600 300 30% 700 800 350 lb x 1000 400 kg x 1000 E L 25% 20% 15% 1 2 3 4 5 6 10% 5% 0 0 5 10 10 20 15 30 20 40 25 50 30 35 60 40 70 km/h mph SPEED Continuous Grade Length* *at sea level 18 EFFECTIVE GRADE (Grade minus Rolling Resistance) Retarding Performance GROSS WEIGHT 0 0 100 50 200 100 300 150 400 200 500 250 600 300 30% 700 800 350 lb x 1000 400 kg x 1000 E L 25% 20% 1 2 3 4 5 6 15% 10% 5% 0 0 5 10 10 20 15 30 20 40 25 50 30 35 60 40 70 km/h mph SPEED Grade Distance ­ 450 m (1, 475 ft)* *at sea level GROSS WEIGHT 0 0 100 50 200 100 300 150 400 200 500 250 600 300 30% 700 800 350 lb x 1000 400 kg x 1000 E L 25% 20% 15% 1 2 3 4 5 6 5% 10% 0 0 5 10 10 20 15 30 20 40 25 50 30 35 60 40 70 km/h mph SPEED Grade Distance ­ 600 m (1, 975 ft)* *at sea level EFFECTIVE GRADE (Grade minus Rolling Resistance) EFFECTIVE GRADE (Grade minus Rolling Resistance) 19 789D Mining Truck Specifications Retarding Performance GROSS WEIGHT 0 0 100 50 200 100 300 150 400 200 500 250 600 300 30% 700 800 350 lb x 1000 400 kg x 1000 E L 25% 20% 15% 1 2 3 4 5 6 5% 10% 0 0 5 10 10 20 15 30 20 40 25 50 30 35 60 40 70 km/h mph SPEED Grade Distance ­ 900 m (2, 950 ft)* *at sea level GROSS WEIGHT 0 0 100 50 200 100 300 150 400 200 500 250 600 300 30% 700 800 350 lb x 1000 400 kg x 1000 E L 25% 20% 15% 1 2 3 4 5 6 5% 10% 0 0 5 10 10 20 15 30 20 40 25 50 30 35 60 40 70 km/h mph SPEED Grade Distance ­ 1500 m (4, 900 ft)* *at sea level 20 EFFECTIVE GRADE (Grade minus Rolling Resistance) EFFECTIVE GRADE (Grade minus Rolling Resistance) Gradeability/Speed/Rimpull To determine gradeability performance: Read from gross weight down to the percent of total resistance. Total resistance equals actual percent grade plus 1% for each 10 kg/t (20 lb/ton) of rolling resistance. From this weight-resistance point, read horizontally to the curve with the highest obtainable gear, then down to maximum speed. Usable rimpull will depend upon traction available and weight on drive wheels. GROSS WEIGHT* lb x 1000 N x 1000 0 0 1C 100 50 200 100 300 150 400 200 500 250 600 300 700 800 350 900 lb x 1000 400 kg x 1000 200 180 160 140 120 500 100 400 80 300 60 40 20 0 200 100 0 800 700 600 E 30% L 25% 20% RIMPULL 1D 15% 2D 3D 4D 5D 6D 10% 5% 0 0 5 10 10 20 15 30 20 40 25 30 50 35 60 40 mph SPEED *at sea level TOTAL RESISTANCE (Grade Plus Rolling) km/h 21 789D Mining Truck Specifications Weight/Payload Calculation (Example) kg 69 900 18 370 10 425 98 695 lb 154, 100 40, 500 22, 980 217, 580 kg 69 900 18 370 10 425 98 695 30 132 7350 136 177 4085 Tonnes 184 lb 154, 100 40, 500 22, 980 217, 580 X Body 66, 430 16, 200 300, 210 9, 006 Tons 203 kg 69 900 18 370 10 425 98 695 lb 154, 100 40, 500 22, 980 217, 580 Chassis Tires (6) 37. 0-R57 Standard Rims (6) 29-57 Estimated Empty Chassis Weight2 Type of Truck Body Body Weight Fully Lined Body (Optional and Recommended) Estimated Operating Machine Weight2 3% Debris Allowance3 1 MSD Body 23 970 52, 845 6150 13, 560 128 815 283, 985 3864 8, 520 Tonnes 192 Tons 211 Dual Slope Body 26 610 58, 665 9707 21, 400 135 012 297, 645 4050 8, 929 Tonnes 185 Tons 204 Potential Target Payload 1 2 4 Includes: common arrangement, 100% fuel (2082 L/550 gal), fluids and standard mandatory attachments. Weights will vary dependent on configuration and may include ±2% variation due to standard material tolerances. 3 Calculations include 3% debris allowance. [. . . ]