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Caterpillar OFF HIGHWAY TRUCKS 789D - catalog of spare parts

 

Caterpillar’s exclusive ownership of the design provides advantages by creating a single traction device that provides the best integration of high performance, availability and payload combined with low running costs and long service life. The Cat® 789D continues the tradition of the proven Caterpillar 789 Truck with high performance and the lowest cost per ton in its class.

Choose OFF HIGHWAY TRUCKS 789D section:

8X8654 8X8654 Caterpillar View
6Y7652 CUP Caterpillar View
6Y3484 BEARING Caterpillar View
8S9076 CUP Caterpillar View
8S9075 CONE Caterpillar View
5P6408 5P6408 Caterpillar View
5P4540 CUP Caterpillar View
5P4539 CONE Caterpillar View
5P4343 RACE Caterpillar View
7W1713 CORE ASSY. OIL COOLER TRANSMIS Caterpillar View
7W0050 COVER A Caterpillar View
6Y7651 6Y7651 Caterpillar View
8T2275 8T2275 Caterpillar View
8X6729 8X6729 Caterpillar View
6V3205 BEARING Caterpillar View
6V0460 CUP Caterpillar View
6V0459 CONE Caterpillar View
8T0231 BEARING Caterpillar View
7T1662 GEAR Caterpillar View
3T1064 3T1064 Caterpillar View
3T0992 HUB Caterpillar View
7S8576 BEARING A Caterpillar View
1P1367 PLUNGER Caterpillar View

ENGINE

Both Cat® 3516B and 3516C EUI Quad turbo-charged diesel engines provide high power and reliability in the most demanding mining jobs in the world.

DESIGN

The 3500 series engines are 16-cylinder four-stroke engines that utilize efficient long strokes for more complete combustion and optimum efficiency.

EPA COMPLIANT

Where applicable, the 3516C engine complies with the US EPA emissions requirements.

HIGH MOMENT

A 23% increase in torque provides unsurpassed thrust during acceleration, on steep inclines and in difficult conditions under your feet. Torque boost effectively corresponds to shift points for maximum efficiency and short cycle times.

EXTENDED LIFE

High displacement, low rev rating and conservative horsepower power mean more time on the roads and less time in the store.

3516B SUBSEQUENT COOLING CIRCUIT

Allows the aftercooler circuit to work below the temperature of the water in the jacket for a denser air load and greater combustion efficiency.

3516C AIR TO AIR AFCROOLER (ATAAC)

In the engine power of 1566 kW (2100 hp) air cooler is used to further reduce the intake air temperature. This results in improved fuel efficiency and desirable emission levels.

ELECTRONIC CONTROL MODULE (ECM)

It uses advanced engine management software to monitor, control and protect the engine using self-diagnosing electronic sensors.

AIR CONDITIONING COMPRESSOR SYSTEM

The compressor and air conditioner lines were relocated to provide easier maintenance, fewer connection points and compliance with EU standards. The automatic tension function makes the removal and adjustment of the belts no longer required.

MECHANICAL ELECTRICAL TRANSMISSION

Cat mechanical powertrain and power shift transmissions provide unparalleled performance and control on steep grades, under bad conditions, and on roads with high rolling resistance.

1) TRANSMISSION

The Cat six-speed planetary gearbox is equipped with a 3516 diesel engine with direct injection, providing constant power over a wide range of operating speeds.

ROBAST DESIGN

Designed for higher power 3516 engines, the proven transmission with a planetary gearbox is designed for a long service life between major overhauls.

CHASSIS TRANSMISSION CONTROL (TCC)

TCC uses engine speed data electronically to perform switching at given points for optimum performance, efficiency and clutch life.

2) BLOCKING THE MOMENT OF THE CONVERTER

It combines maximum thrust and smooth switching of the drive of the torque converter with the efficiency and efficiency of the direct drive. Turns on at a speed of about 7.2 km / h (4.5 miles per hour), providing more power to the wheels.

3) FINAL DRIVES

Cat final drives work like a planetary gearbox with a shift under load to provide maximum power on the ground. Dual-gear final drives that withstand high torque and impact loads provide high torque gains to further reduce the load on the transmission.

STEERING SYSTEM

The hydraulic steering system is designed for exceptional smoothness and precise control. A separate chain prevents cross-contamination over a long service life.

ADDITIONAL STEERING

The optional steering system uses pressure accumulators and allows up to three turns at 90 degrees in the event of engine failure.

TIRES

Wider tire options were developed in the 789D to provide a wider selection of tires. Applicable conditions of carriage will benefit from an increase in tire life or a significant reduction in the cost of tires.

WHEELS AND RIMS

Cat center-mounted cast wheels and rims are mounted with studs and nuts, minimizing maintenance and extending service life. Optional quick-change discs are also available.

CAT DATA LINK

Electronically integrates computer-aided computer systems to optimize the overall performance of power transmission, improve the reliability and service life of components, and reduce operating costs.

ELECTRONIC TECHNICIAN (CAT ET)

The Cat ET service tool provides service technicians with easy access to stored diagnostic data via Cat Data Link, which simplifies problem diagnosis and improves machine availability.

INTEGRATED BRAKE MANAGEMENT (IBC)

Combines hydraulic automatic retarder and anti-slip system into one system for optimal performance and efficiency.

REVERSE BODY NEUTRALIZER

Automatically shifts the gearbox to neutral when the lift lever is activated when the gearbox is shifted in the opposite direction.

DRIVED ENGINE MOTION

Regulates engine speed during shifting to reduce power train load and clutch wear, controlling engine speed, locking torque converter and engaging gearbox clutch for smoother shifts and longer component life.

BOX DESIGN

Frame 789D has a box-section design that includes two forgings and 21 castings in high-stress areas with deep penetrating and continuous welds to resist damage from torsional loads without adding additional weight.

PERFORMANCE

The frame design with an open box section provides easy access to the power transmission components, reducing the total time for disassembly and assembly and reducing the total repair costs. Raised and secured housing provides excellent access to the transmission.

STEEL CONSTRUCTIONS

Mild steel used in the frame provides flexibility, durability and resistance to shock loads even in cold climates. In addition, mild steel facilitates field repair.

CASTING

Castings have large radii with internal stiffeners to dissipate stress in areas with high stress concentrations. Castings move welds in areas of lower stress to increase the service life of the frame.

INTEGRAL FOUR-ROSE CABLE

Elastic installation on the main frame to reduce vibration and noise, the built-in ROPS design is a continuation of the truck frame. The ROPS / FOPS structure provides “five-sided protection” for the operator.

SUSPENSION SYSTEM

Designed to eliminate bumps on the road and loading, which extends the service life of the frame and provides a more comfortable ride.

CYLINDERS

Four independent, self-contained, recoil-adjustable, oil-pneumatic suspended cylinders are designed to absorb shocks in the most demanding conditions.

DURABLE DESIGN

Sturdy cylinders use a large-diameter, low-pressure nitrogen / oil design for long life and minimal maintenance.

  • Front. Front cylinders with preset rollers and curved wheels are mounted on the frame and serve as steering stops for a small turning radius, excellent maneuverability and low operating costs.

  • Rear. Rear cylinders allow axle vibrations and absorb bending and torsional stresses caused by uneven, uneven roads, rather than transferring them to the main frame.

OPERATOR ENVIRONMENT

By packing popular attachments into devices, customers can now select one cab that is equipped with the required features. Available offers include a standard cabin, a deluxe cabin or a deluxe cabin for cold weather. 1) Air suspension seat and three-point operator limiter 2) Parking brake release valve 3) Simulator seat 4) Storage compartment 5) Operator window 6) Auxiliary brake pedal 7) Transmission console 8) Controls 9) Adjustable steering wheel / column (Tilt and telescoping) 10) Heating / Air conditioning 11) Monitoring system 12) Object detection monitor 13) Upper controls 14) Ready for radio communication

IMPROVED OPERATOR VIEW

Through the use of a fully integrated object detection system, RADAR and CAMERA, the operator can receive both sound and visual readings of the detected objects. In addition, an improved view of the right hand of the operator by moving the air cylinder down to the chassis.

ERGONOMIC PLAN

Operator Station 789D is ergonomically designed to fully control the machine in a comfortable, productive and safe environment. All controls, levers, switches and sensors are positioned to maximize productivity and minimize operator fatigue.

Quiet cabin

The built-in noise protected ROPS / FOPS cab is elastically mounted on the base unit to isolate the operator from noise and vibration for a quiet, safe and comfortable ride.

ZOOM VIEW

Designed to provide excellent all-round visibility and clear lines of sight on the road. A large field of view allows the operator to maneuver confidently for high performance.

RADIO READY

The operator station comes with power ports, speakers, antenna, and electrical connections to simplify radio installation. Check with your dealer about the full range of available Cat radio options, including satellite radio.

INTEGRATED BRAKE SYSTEM

The Cat oil-cooled brake system provides reliable performance and control in the most extreme road conditions. The integrated system combines service, secondary, parking brakes and braking functions in one reliable system for optimal braking performance.

FOUR ANGULAR ABSENCE

A four-turn delay with a 60/40 percent split (rear / front) when braking provides excellent control in slippery conditions. A balanced braking torque at the front and rear ensures exceptional braking performance and minimizes wheel lock, especially during deceleration.

OIL COOLED BY SEVERAL DISC BRAKES

Cat four-wheel multidisk service brakes with forced oil cooling are continuously cooled with water-oil heat exchangers for exceptional braking performance and deceleration without fading.

ADVANCED LIFE DISC BRAKES

Friction material with an increased service life has double the service life compared to standard brakes and is twice as resistant to glazing for a more stable braking power with less noise

PISTONS

Cat`s two-component piston design combines service, auxiliary, parking brake and deceleration functions in one system. The primary piston hydraulically activates both service and delay functions. The secondary piston is spring-loaded and held in the disengaged position by hydraulic pressure. If the pressure in the hydraulic system drops below a specified level, the spring-loaded secondary piston automatically activates the brakes.

HAND BRAKE

A water-cooled, spring-loaded parking brake is applied to all four wheels, providing excellent parking capacity on all inclines up to 15 percent.

HYDRAULIC AUTOMATIC DELAY CONTROL (HARC)

The electronically controlled hydraulically activated automatic retarder control system controls the deceleration on a slope to maintain optimum engine speed and oil cooling. Additional braking can be applied using a manual retarder or brake pedal. HARC is deactivated when the operator applies a brake or accelerator control.

KUZOVSKY BODIES

Compliance with the truck body and its application is an important part of achieving the best performance of your 789D. Caterpillar offers a variety of body styles for specific applications that provide payloads ranging from 177 to 188 metric tons (from 195 to 207 tons). Caterpillar 10/10/20`s exclusive load recommendations help to achieve an optimal balance of payload and safe operation.

BODY OPTIONS

1) Cat body "X". Case X is a heavy-duty body with various lining options to meet the specific requirements of the mine. Like Dual Slope, the X case is designed for durability in the toughest conditions. 2) Housing for mines (MSD II) - For mature mines with good operational and maintenance practices, MSD II (mine-specific design) with a lighter weight is available in several sizes. This is a client / site specific authority designed to maximize productivity. MSD II is designed to maximize payload, ensure good durability and can be configured with various liner options to meet mine specific requirements. 3) Frameless coal hull - This specialized large volume hull, available in several sizes, is designed for use in specialized coal transport with minimal impact. A raised floor design eliminates the tailgate and gives the volume needed to achieve the target payload. 4) The combined case is a multipurpose large-volume case for light density, well-fragmented material. Based on a double slope design for customers requiring a flexible body for transporting light ore (eg coal) and light, well-fragmented overburden. 5) The dual body - the original standard body, dual body, provides excellent load retention, maintains a low center of gravity with an optimal load distribution, reduces the impact load and is available in veneered and not veneered configurations. The body of the Dual Slope is designed for harsh environments, including new sites and mines.

CUSTOMS BODY OPTIONS

Various options are available, including tail extensions, sidewalls, rolls, rock boxes and snow plows to maintain nominal payloads, reduce leakage and improve transportation efficiency.

VIMS ™ MONITORING SYSTEM

Caterpillar`s intelligent machine monitoring system provides real-time, machine-specific data and payloads in real-time, allowing the 789D to operate at the highest level of production. This system is translated and available in most major international languages.

PRODUCTION MANAGEMENT

Production management improves the efficiency of trucks and loading tools, improves fleet performance and helps extend the life of truck frames, tires, rims and powertrain components, while reducing operating and maintenance costs.

DOWNLOAD MANAGEMENT

Max Payload Speed ā€‹ā€‹Manager is a feature that helps manage Cat 10/10/20 policies. Based on a given payload weight and overload settings, VIMS records and alerts the operator when the truck reaches an overload after 2nd gear. The truck will be limited to 2nd gear at 1750 rpm, and the automatic setting of the retarder speed drops to 1750 rpm until the load is relieved. Payload management allows the manager to increase the efficiency and productivity of the cargo / loading tool, preventing overloads that may damage component life and affect operator safety.

MANAGEMENT OF ROAD ANALYSIS (RAC)

An optional system monitors road conditions on the road, measuring frame racks, inclination and incline to improve road maintenance, cycle time, tire life and fuel efficiency.

SIMS-PC

VIMS-PC, an external reporting software, allows service personnel to download a complete log of machine status and performance data into a laptop computer for diagnosis and analysis. Easy-to-use software allows service and mine managers to create health and payload reports for more efficient machine management.

VIMS SUPERVISOR

Additional software allows mine managers to easily manage and interpret VIMS data for optimal fleet management and performance.

MACHINE MANAGEMENT

Technicians or mine personnel can upload data and create reports for better machine control. The data can be used to increase the effectiveness of routine maintenance programs, increase component life, increase equipment availability and reduce operating costs.

PRODUCT SAFETY

Caterpillar has been and continues to actively develop mining machines that meet or exceed safety standards. Safety is an integral part of all machine and system designs.

MINING TECHNOLOGIES

Cat® MineStar ™ includes a full set of mining technologies, grouped into several customizable feature sets, including Fleet, Terrain, Detect, Health and Command. Object detection is part of a set of detection capabilities and provides customers with a scalable system that helps recognize machines and other objects in close proximity to work equipment. Object detection systems are installed at the factory as standard equipment for 789D mining dump trucks. The fully integrated object detection system RADAR AND CAMERA provides an audible and visual indication of the detected objects using radars that surround the car, as well as cameras on each side, to allow the operator to confirm the detected object. Cameras complement radar warnings and are selected using the touch menu via an intuitive interface.

OVERLOAD POLICY

Compliance with the Caterpillar 10/10/20 overload policy ensures that the steering and braking systems have adequate performance.

STANDARD SAFETY FUNCTIONS

Slip-resistant surfaces, retractable, safety-belt / shoulder belts with three-point operator restriction, wide-angle mirrors, raised body indicator, cable restraint, fencing, neutralizer reverse when reset, low noise level in the cabin, additional steering system, ground level access switches

FEATURES OF SUSTAINABLE DEVELOPMENT

The 789D Mining Truck offers oil change systems, extended life filters and extended maintenance intervals that help reduce the amount of waste introduced into our environment.

OIL UPDATE SYSTEM

An optional oil change system extends engine oil change intervals from 500 hours to 4000 hours or more to increase machine availability and reduce costs.

ENGINES WITH MODERN TECHNOLOGY

Advanced technology engines reduce emissions to the environment while maintaining fuel efficiency.

FUEL EFFICIENCY

The engine provides additional deceleration, working against compression on slopes. When braking, the ECM engine does not inject fuel into the cylinders for exceptional fuel economy.

TIE THE DOTS

Improves the working environment during maintenance of recommended service areas.

EASE OF MAINTENANCE

Easy access to daily service points simplifies maintenance and reduces time spent on regular maintenance procedures. Enhanced serviceability and 500-hour service intervals are designed to increase machine availability and productivity.

SERVICE PLATFORM

Provides access to the engine, steering cylinder and battery compartment.

ACCESS FRAMEWORK

Provides easy access to key components for easy maintenance and removal.

ACCESS TO EARTH LEVEL

Provides convenient maintenance of tanks, filters, drains and engine shutdown. Ground VIMS data port makes it easier to download information.

AUTOLUBE

An automatic lubrication system reduces maintenance time by automatically lubricating the necessary components on a regular basis.

FAST FILL SERVICE CENTER

An optional quick refueling service center provides high-speed fuel and oil change.

OIL SELECTION SCHEDULE

S • O • SSM sampling valves provide fast sampling and reliable analysis.

PRESSURE TEST POINTS

Disconnect valves are conveniently located throughout the hydraulic system for easy crimping.

Sealed electrical connectors

Electrical connectors are sealed to protect against dust and moisture. The 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

VIMS constantly monitors all critical functions and components of the machine to help quickly detect faults and speed up repairs.

COMMITMENT MAKES DIFFERENCE

Cat dealers offer a wide range of solutions, services, and products to help you reduce costs, increase productivity, and manage your work more efficiently. Support goes far beyond parts and service. From the moment you choose Cat equipment to the day you rebuild, trade, or sell it, the support you get from your Cat dealer is important.

DEALERSHIP OPPORTUNITIES

Cat dealers provide you with the level of support you need globally. Specialist dealers have the knowledge, experience, training and tools needed to meet your repair and maintenance needs, when and where you need them.

PRODUCT SUPPORT

Cat dealers believe superior products deserve superior support. When Cat products enter the field, they are supported by a worldwide network of parts distribution centers, dealer service centers and technical training centers to keep your equipment in working condition. Cat customers rely on prompt, reliable availability of spare parts and experience in our global dealer network, ready to meet your needs 24/7.

TECHNOLOGICAL PRODUCTS

 

Cat dealers offer a range of advanced technology products, such as the VIMS monitoring system and the MineStar® information management system. These products include radio data transmission, machine monitoring and diagnostics, fleet management and vehicle maintenance software — all designed to increase fleet efficiency, increase productivity and reduce costs.

 

ENGINE

Engine Model

3516C - HD

Gross Power - SAE J1995

2100.0 HP

Bore

6.7 in

Stroke

8.3 in

Displacement

4766.0 in³

Net Power

1969.0 HP

Gross Power

2100.0 HP

Rated Net Power - ISO 9249

1969.0 HP

WEIGHTS - APPROXIMATE

Gross Machine Operating Weight (GMW)

715000.0 lb

Body Weight Range

23 920 kg-45 547 kg (52,850 lb-100,414 lb)

Empty Operating Chassis Weight (EOCW)

218542.0 lb

OPERATING SPECIFICATIONS

Nominal Payload Capacity

200.0 ton (US)

Standard Combi Body (SAE 2:1)

200.0 yd³

Standard Dual Slope Body (SAE 2:1)

141.0 yd³

Standard Gateless Coal Body (SAE 2:1)

250.0 yd³

Standard MSD Body (SAE 2:1)

170.0 yd³

Standard X Body (SAE 2:1)

161.0 yd³

FINAL DRIVES

Differential Ratio

2.35:1

Planetary Ratio

10.83:1

Total Reduction Ratio

25.46:1

TRANSMISSION

Forward - 1

7.8 mile/h

Forward - 2

10.6 mile/h

Forward - 3

14.4 mile/h

Forward - 4

19.4 mile/h

Forward - 5

26.3 mile/h

Forward - 6

35.5 mile/h

Reverse

7.3 mile/h

SUSPENSION

Effective Cylinder Stroke - Front

4.0 in

Effective Cylinder Stroke - Rear

3.5 in

Rear axle - Oscillation

±5.6°

BODY HOISTS

Pump Flow - High Idle

193.0 gal/min

Relief Valve Setting - Raise

2500.0 psi

Body Raise Time - High Idle

18.9 s

High Idle Body Lower Time - Float

17.3 s

High Idle Body Lower Time - Power

15.6 s

BRAKES

Brake Surface - Rear

18024.0 in²

Standards

SAE J1473 OCT90 ISO 3450:1996

Brake Surface - Front

12662.0 in²

WEIGHT DISTRIBUTIONS - APPROXIMATE

Front Axle - Empty

46.0 %

Front Axle - Loaded

33.0 %

Rear Axle - Empty

54.0 %

Rear Axle - Loaded

67.0 %

SERVICE REFILL CAPACITIES

Brake Hoist System

241.0 gal (US)

Cooling System

192.0 gal (US)

Crankcase

77.0 gal (US)

Differential - Final Drives

154.0 gal (US)

Fuel Tank - Optional

1000.0 gal (US)

Fuel Tank - Standard

550.0 gal (US)

Steering System

50.0 gal (US)

Transmission Tank

20.0 gal (US)

TIRES

Optional Tires

40.00-R57

Standard Tires

37.00-R57

ROPS

ROPS Standards

Standards

SOUND

Sound Standards

Standards

STEERING

Steering Angle

36.07 °

Turning Diameter - Front Wheel

90.32 ft

Vehicle Clearance - Turn Circle

99.18 ft

Steering Standards

SAE J1511 OCT90 ISO 5010:1992

OPTIONAL ENGINE

 

Bore

6.7 in

Displacement

4211.0 in³

Engine Model

3516B EUI

Gross Power

1900.0 HP

Rated Net Power - ISO 9249

1791.0 HP

Stroke

7.5 in

Specifications

Engine

Gross Power 2100hp

Net Power 1969hp

Displacement 4766cu in

Bore 6.7in

Stroke 8.3in

Gross Power - SAE J1995 2100hp

Engine Model3516C - HD

Rated Net Power - ISO 9249 1969hp

Transmission

Reverse 7.3 mile/h

Forward – 17.8mph

Forward – 210.6mph

Forward – 314.4mph

Forward – 419.4mph

Forward – 526.3mph

Forward – 635.5mph

Steering

Steering Standards SAE J1511 OCT90 ISO 5010:1992

Steering Angle 36.1degrees

Turning Diameter -Front Wheel 90.4ft in

Vehicle Clearance - Turn Circle 99.2ft in

Tires

Standard Tires 37.00-R57

Optional Tires 40.00-R57

Brakes

Brake Surface – Front12662in2

Brake Surface – Rear18024in2

Standards SAE J1473 OCT90 ISO 3450:1996

Body Hoists

Pump Flow - High Idle 193 gal/min

Relief Valve Setting – Raise 2500 psi

Body Raise Time - High Idle 18.9 s

High Idle Body Lower Time – Float 17.3 s

High Idle Body Lower Time – Power 15.6 s

Final Drives

Planetary Ratio 10.83:1

Differential Ratio 2.35:1

Total Reduction Ratio25.46:1

Operating Specifications

Nominal Payload Capacity 400000lb

Standard MSD Body (SAE 2:1) 170yd3

Standard X Body (SAE 2:1) 161yd3

Standard Dual Slope Body (SAE 2:1) 141yd3

Standard Combi Body (SAE 2:1) 200yd3

Standard Gateless Coal Body (SAE 2:1) 250yd3

Service Refill Capacities

Cooling System 192gal

Differential - Final Drives 154gal

Crankcase 77gal

Brake Hoist System241gal

Fuel Tank – Standard550gal

Fuel Tank – Optional1000gal

Transmission Tank20gal

Steering System 50gal

Weight Distributions – Approximate

Front Axle – Empty46 %

Front Axle – Loaded33 %

Rear Axle – Empty54 %

Rear Axle – Loaded67 %

Weights - Approximate

Body Weight Range23 920 kg-45 547 kg (52,850 lb-100,414 lb)

Gross Machine Operating Weight (GMW) 715000lb

Empty Operating Chassis Weight (EOCW) 218542lb

ROPS

ROPS Standards Standards

Sound

Sound Standards Standards

Suspension

Rear axle – Oscillation

Effective Cylinder Stroke – Front 4in

Effective Cylinder Stroke – Rear 3.5in

Optional Engine

Engine Model 3516B EUI

Gross Power 1900hp

Rated Net Power - ISO 9249 1791hp

Bore 6.7in

Stroke 7.5in

 

Displacement 4211cu in