Caterpillar’s exclusive design ownership provides advantages by creating a total hauling unit that delivers the best integration of high production, availability, and payload in combination with low operating cost and long life.
Power Train – Engine
The Cat® 3500 series engines are built for power, reliability and effi ciency for superior performance in the toughest applications.
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.
Design
The 3500 series engines are 16-cylinder, four-stroke designs that uses long, effective power strokes for more complete fuel combustion and optimum effi ciency.
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 effi ciency 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 effi ciency.
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 effi ciencies 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. Auto tension functionality makes removing and adjusting belts no longer necessary.
Power Train – Transmission
Cat mechanical power train delivers more power to the ground for greater productivity and lower operating costs.
Mechanical Power Train
The Cat mechanical drive power train and power shift transmission provides unmatched operating effi ciency and control on steep grades, in poor underfoot conditions, and on haul roads with high rolling resistance.
1) Transmission
The Cat six-speed planetary power shift transmission is matched with the direct-injection 3516 diesel engine to deliver constant power over a wide range of operating speeds.
Robust Design
Designed for the higher horsepower of the 3516 engine, the proven planetary power shift transmission is built tough for long life between overhauls.
Transmission Chassis Control (TCC)
TCC uses electronically transferred engine rpm data to execute shifts at preset points for optimum performance, effi ciency and clutch life.
2) Lock-Up Torque Converter
Combines maximum rimpull and cushioned shifting of torque converter drive with the effi ciency and performance of direct drive. Engages at approximately 7.2 km/h (4.5 mph),
delivering more power to the wheels.
3) Final Drives
Cat fi nal drives work as a system with the planetary power shift transmission to deliver maximum power to the ground.
Built to withstand the forces of high torque and impact loads, double reduction fi nal drives provide high torque multiplication to further reduce drive train stress.
Steering System
Hydraulic steering control system is designed for exceptional smoothness and precise control. A separate circuit prevents cross contamination for long life.
Supplemental Steering
Supplemental steering system uses pressure accumulators and allows up to three 90 degree turns in case of engine failure.
Tires
Larger tire options have been designed into the 789D to provide a broader choice for tires. Applicable hauling conditions will benefi t from increased tire life or signifi cant reduction in tire costs.
Wheels and Rims
Cast rear wheels and Cat center-mount rims are mounted using studs and nuts to minimize maintenance and maximize durability. Optional quick change rims also available.
Engine/Power Train Integration
Electronically combines critical power train components to work more intelligently and to optimize overall truck performance.
Cat Data Link
Electronically integrates machine computer systems to optimize overall power train performance, increase reliability and component life, and reduce operating costs.
Electronic Technician (Cat ET)
Cat ET service tool provides service technicians with easy access to stored diagnostic data through the Cat Data Link to simplify problem diagnosis and increase machine availability.
Integrated Braking Control (IBC)
Integrates Hydraulic Automatic Retarder Control and Traction Control into one system for optimum performance and effi ciency.
Body-up Reverse Neutralizer
Automatically shifts the transmission to neutral if the hoist lever is activated while transmission is shifted in reverse.
Controlled Throttle Shifting
Regulates engine rpm during shifting to reduce power train stress and clutch wear by controlling engine speed, torque converter lock-up and transmission clutch engagement for smoother shifts and longer component life.
Structures
Rugged Cat structures are the backbone of the 789D mining truck’s durability.
Box-Section Design
The 789D frame uses a box-section design, incorporating two forgings and 21 castings in high stress areas with deep penetrating and continuous wrap-around welds to resist damage from twisting loads without adding extra weight.
Serviceability
The open box-section frame design allows easy access to power train components, reducing overall removal and installation time, and lowering overall repair costs.
The raised and pinned body allows excellent access to the transmission.
Steel Structures
Mild steel used throughout frame provides fl exibility, durability, and resistance to impact loads, even in cold climates.
Additionally, mild steel facilitates easy fi eld repair.
Castings
Castings have large radii with internal reinforcing ribs to dissipate stress in areas of high stress concentration.
Castings move welds to lower stress areas for greater frame life.
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 ROPS/FOPS structure provides “fi ve sided protection” for the operator.
Suspension System
Designed to dissipate haul road and loading impacts for longer frame life and a more comfortable ride.
Cylinders
Four independent self-contained, oil pneumatic, vari ablerebound suspension cylinders are designed to absorb shocks
in the most severe applications.
Durable Design
Rugged cylinders utilize large diameter bore and low pressure nitrogen/oil design for long life with minimal maintenance.
• Front. Front cylinders with preset caster and camber are mounted to the frame and serve as steering kingpins for a tight turning radius with excellent maneuverability and low maintenance.
• Rear. Rear cylinders allow axle oscillation and absorb bending and twisting stresses caused by rough, uneven haul roads rather than transmitting them to the main frame.
Operator’s Station
Ergonomically designed for operator comfort, superior control, and high productivity.
Operator Environment
Through the packaging of popular attachments into arrangements, customers can now select one cab that is equipped with desired features. Available offerings include a Standard Cab, Deluxe Cab or Deluxe Cold Weather Cab.
1) Air Suspension Seat with Three-Point Operator Restraint 2) Parking Brake Reset Valve 3) Trainer Seat 4) Storage Compartment 5) Operator Window 6) Secondary Brake Pedal 7) Transmission Console 8) Operator Controls 9) Adjustable Steering Wheel/Column (Tilt and Telescoping) 10) Heating/Air Conditioning 11) Monitoring System 12) Object Detection Monitor 13) Upper controls 14) Radio Ready
Enhanced Operator Visibility
Through the use of the fully Integrated Object Detection System, RADAR AND CAMERA, the operator can receive both audible and visual indications of detected objects. In addition, the operators right hand view is improved due to relocation of the air tank lower on the chassis.
Ergonomic Layout
The 789D operator station is ergonomically designed for total machine control in a comfortable, productive and safe environment. All controls, levers, switches and gauges are positioned to maximize productivity and minimize operator fatigue.
Quiet Cab
Integral, sound-suppressed ROPS/FOPS cab is resiliently mounted to the mainframe to isolate the operator from sound and vibration for a quiet, secure and comfortable ride.
Viewing Area
Designed for excellent all-around visibility and clear sight lines to the haul road. The large viewing area enables the operator to maneuver with confi dence for high productivity.
Radio Ready
The operator’s station comes ready with power ports, speakers, antenna, and electrical connections to facilitate trouble-free radio installation. Consult your dealer for the complete line of available Cat radio options including satellite radio.
Cat® Brake System
Reliable braking with superior control gives the operator the confi dence to focus on productivity.
Integrated Braking System
The Cat oil-cooled braking system delivers reliable performance and control in the most extreme haul road conditions. The integrated system combines the service, secondary, parking brake and retarding functions in the same robust system for optimum braking effi ciency.
Four Corner Retarding
Four corner retarding with 60/40 percent split (rear/front) in braking effort provides superior control in slippery conditions. Balanced front to rear brake torque provides exceptional braking performance and minimizes wheel lock-up, especially during retarding.
Oil-Cooled Multiple Disc Brakes
Cat four-wheel, forced oil-cooled, multiple disc service brakes are continuously cooled by water-to-oil heat exchangers for exceptional, non-fade braking and retarding performance.
Extended Life Disc Brakes
Extended life friction material has double the wear life of standard brakes and is twice as resistant to glazing for more consistent braking power with less noise.
Pistons
The Cat two-piece piston design combines the service, secondary, parking brake, and retarding functions in the same system. The primary piston hydraulically actuates both service and retarding functions. The secondary piston is spring-applied and held in the disengaged position by hydraulic pressure. If hydraulic system pressure drops below a specifi ed level, the spring-applied secondary piston automatically applies the brakes.
Parking Brake
Oil-cooled, spring-applied, hydraulically released parking brake is applied to all four wheels for superior parking capability on all grades up to 15 percent.
Hydraulic Automatic Retarder Control (HARC)
Hydraulically activated automatic retarder contro l system electronically controls retarding on grade to maintain optimum engine rpm and oil cooling. 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.
Truck Body Systems
Cat Truck Bodies
Matching the truck body to the application is a critical part of achieving the best value from your 789D. Caterpillar offers a variety of application specifi c body options that yield a payload ranging from 177 to 188 metric tons (195 to 207 tons).
The Caterpillar exclusive 10/10/20 payload guidelines help achieve a balance of excellent payload with safe operation.
Body Options
1) Cat “X” Body – The X body is a heavy duty body confi gured with a variety of liner options to meet site specifi c requirements of a mine. Like the Dual Slope – the X body is designed for durability across a range of harsh applications.
2) Mine Specifi c Body (MSD II) – For mature mines with good operational and maintenance practices, the lighter weight MSD II (Mine Specifi c Design) body is available in several sizes. It is a customer/site specifi c body that is designed to maximize performance. The MSD II is designed to maximize payload, provide good durability and can be confi gured with a variety of liner options to meet the specifi c requirements of the mine.
3) Gateless Coal Body – This specialized high volume body, available in several sizes, is targeted at dedicated coal haulage applications with minimal impact. The kicked up fl oor 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 fl exible 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 confi gurations.
The Dual Slope body is intended for tough applications including greenfi eld 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 effi ciencies.
Monitoring System
Vital machine health and payload data keeps the 789D performing at peak production levels.
VIMS™ 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.
Production Management
Production Management enhances truck/loading tool effectiveness, improves fl eet 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.
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 effi ciency.
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 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 fl eet 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.
Safety
Cat mining machines and systems are designed with safety as their fi rst priority.
Product Safety
Caterpillar has been and continues to be proactive in developing mining machines that meet or exceed safety standards.
Safety is an integral part of all machine and system designs.
Mining Technologies
Cat® MineStar™ System encompasses a comprehensive suite of mining technologies grouped within a number of confi gurable 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 confi rm 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 suffi cient 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.
Serviceability
Less time spent on maintenance means more time on the haul roads.
Tie Off Points
Enhances working environment during service of recommended maintenance areas.
Servicing Ease
Easy access to daily service points simplifi es 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, fi lters, 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 fi ll 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.
Harnesses are braided for protection. 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.
See You Soon!!!
MARYGAR
0 comments:
Post a Comment