Overview

Caterpillar 793D Mining Truck

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

D-Series Application Arrangements

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

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)

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

793D Extended Life Wheel Group Arrangement - Rear

For long uphill hauls

Extended Life (Rear)

Brakes

Bearings

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)

793D Extended Life Wheel Group Arrangement - Front

Extended Life (Front)

For long uphill hauls

Differences from Standard Arrangement
Larger wheel bearings
Larger spindle, wider wheel bearing spacing

Standard (Front)

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

Repositioned duo-cone seal
Bottom mount steering arm fits either side

Bottom mount
steering arm

Benefits
Longer brake life and duo-cone seal life
Extended life to overhaul
Lower cost per ton

Strut bolts
(inner pattern)

Spindle bolts
(outer pattern)

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

793 Worldwide Deliveries

Over 1,600 Shipments (as of June 2005)

2%

36%

34%

28%

793D Component Sources

Caterpillar designs and manufactures all major components of the 793D
Joliet, Illinois
Cab
Hydraulics

Pontiac, Illinois
Fuel systems

Peoria, Illinois
Electronics

Lafayette, Indiana
Engine

East Peoria, Illinois

Transmission
Gear sets
Mapleton, Illinois
Engine block & head castings
Decatur, Illinois
Design & Engineering
Frame
Final assembly

Truck Bodies
Mexico
Australia
Africa

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

10

Specifications
Caterpillar 793D Mining Truck

793D Dimensions

12

Shown with standard, dual-slope body

793D Specifications (Metric)

793D

793D Extra Life

793D

793D

793D

Standard

Wheel Groups

Extra Top Speed

Extra Retarding

High Altitude

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

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

54.3

54.3

Engine model

6 Forward 1 Reverse

Transmission speeds
Top speed (km/h)
1

54.3

54.3

59.9

54.3

Approximate clean chassis with full fuel, hoist, body mounting group and tires. Excludes body weight. Dependent on optional attachments.
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
2

13

793C2

793D Specifications (Metric)

793D

793D Extra Life

793D

793D

793D

Standard

Wheel Groups

Extra Top Speed

Extra Retarding

High Altitude

Fuel tank capacity (L)

4354

4354

4354

4354

4354

4467

Optional fuel tank (L)

4922

4922

4922

4922

4922

10

13

13

13

13

10

8.98

13.47

13.47

13.47

13.47

8.98

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

Brake discs per side - front

Brake area - front (m2)
Brake discs per side - rear

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

14

793C1

793D Specifications (English)

793D

793D Extra Life

793D

793D

793D

Standard

Wheel Groups

Extra Top Speed

Extra Retarding

High Altitude

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

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

33.7

33.7

Engine model

6 Forward 1 Reverse

Transmission speeds
Top speed (mph)
1

33.7

33.7

37.2

33.7

Approximate clean chassis with full fuel, hoist, body mounting group and tires. Excludes body weight. Dependent on optional attachments.
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
2

15

793C2

793D Specifications (English)

793D

793D Extra Life

793D

793D

793D

Standard

Wheel Groups

Extra Top Speed

Extra Retarding

High Altitude

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

10

13

13

13

13

10

13,921

20,874

20,874

20,874

20,874

13,912

15

15

15

15

15

15

20,847

24,084

24,084

24,084

24,084

20,869

34.5

37.0

37.0

37.0

37.0

34.5

34,781

44,958

44,958

44,958

44,958

34,781

Brake discs per side - front

Brake area - front (in2)
Brake discs per side - rear
Brake area - rear (in2)
Brake disc outside diameter
(in)
Total brake area (in2)
1

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

16

793C1

Features & Benefits

Caterpillar 793D Mining Truck

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

18

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

19

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

20

Torque Converter
The torque converter has been designed for higher horsepower

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

21

Rear Axle
The rear axle filtration system has been completely redesigned

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

22

Benefits of Continuous Filtration

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

Bearings with kidney looping and

4,000-hour oil changes showed
little wear after 18,000 hours

Bearings with oil changes at 1,200-hour

intervals, but without kidney looping,
showed pitting at 13,000 hours

Images magnified 50x

23

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

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

24

Automatic Retarder Control (ARC)

The 793D is standard equipped with hydraulic actuated 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

25

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

26

Hydraulic pump

Hydraulic System
Main
Engine
Fan

Steering Cylinders

Fan/Common Rail Cooler

Return Filter

Steering
Control

Fan Pump

Common Rail Pump

Common Rail Valve
Optional Rear Axle
Cooler Fan
Rear Axle
Lubricator Motor
Brake Cooling Pumps

Solid Connection
27

Brake Cooling
Drive Motor

Common Rail
and Fan Tank

Operator Environment
The new Cat Comfort Seat with three-point restraint offers operators added safety and
comfort
High-back seat supports head and neck
Ride zone indicator adjusts seat suspension to
operators weight
Adjustable rake lower cushion
Washable seat cover
Dual retractor lap and shoulder belt system
Adjustable shoulder belt has six vertical
height settings for optimum fit

28

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

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

29

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

793C
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

30

793D

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

31

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

32

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

33

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

34

Safety Enhancement
The 793D offers an optional rear access platform.
The rear access platform provides easy access to
the back of the cab
Especially helpful when cleaning rear window or
accessing rear cab compartment (ECMs)
Equipped with a handrail that folds down to
provide clearance when the body is lowered

35

Safety Enhancement
The 793D offers an optional ground level transmission lockout.
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

36

Safety Enhancement
Turning night into day, High Intensity Discharge (HID) lighting offers greater light intensity,
better light quality and longer life than halogen lights
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 machines
electrical system while producing four times more
illumination.
37

Productivity
Caterpillar 793D Mining Truck

Mittal Steel Study

Minorca Waste Haul - Plan
7,000

26

6,000

23

22
19
Scales

5,000

14
Dump

4,000

3,000

1
Load Ar ea

2,000
5,000

39

6,000

7,000

8,000

9,000

10,000

11,000

12,000

13,000

Overview of the study

Haul profile was 8698 ft one-way

793C (ATY 514) vs. 793D (FDB106)
Operators not using ARC correctly so return portion of
test was was considered equal for each truck

40

Overview of the study

Results of speed trap #1

7.2% faster for the 793D with .3% lower GMW

Results of speed trap #2

7.3% faster for the 793D with .4% lower GMW

Overall Result
The 793D average haul speed was found to be 12.1mph
compared to 11.3 mph - a 6.6% improvement.
41

Cripple Creek Ex. Retarding Study

42

Cripple Creek Study

43

Overview of the study

793C vs. 793D and Hitachi 4500s

Altitude was 10,200 ft
10% grade loaded downhill

44

Overview of the study

Overall Result
- 793D MA2 has one extra gear downhill v/s 793C with speed
advantage of 41+%
- 793D was the fastest truck both downhill and uphill with an
overall cycle time advantage of 12.3% over the 793C
- The availability from the beginning of the year for the 793C
was over 90% and for the 793D over 94%. The EH4500s were
from about 74% to 81%.
45

US Steel High Speed Arrangement Study May 2005

46

US Steel Study
Minntac Ore Haul - Plan
10,000

22
20
28

8,000

30
6,000
17
4,000

15

(30,000)

(25,000)

(20,000) 9
6

10

2,000

(15,000)

(10,000)

(5,000)

(2,000)

23
1
(4,000)

(6,000)

47

Overview of the study

793C standard vs. 793D high speed arrangement
EMW look to be in line with what is expected
Both trucks averaged 270-272 ton payloads - 11% overload
793D was 10% faster loaded and 6% faster empty (2-3 more
cycle/hour)
Overall productivity advantage for the 793D was 8%
(FPC analysis projected 7-8%)

48