Download - Capacitacion de Camion Minero 793F CAT
Caterpillar ® 793F Off Highway TruckNPI – Operator Training Materials
Name
Venue
Date
Safety Reminders
Emergency Contacts
Fire•Building: <Phone #>•Municipal: <Phone #>
Medical•Building: <Phone #>•Municipal: <Phone #>
First Responders•Room <Identify>•Building <Location and name>
Emergency Information
Alarm Description• Evacuate• Take cover• All clear
Unique Hazards•Room•Floor/Building
Emergency Procedures•Equipment locations•Evacuation routes
History
Mining Truck Evolution
• Over 50,000 construction and mining trucks (769-797) delivered since 1963
• Over 18,000 large mining trucks (777-797) delivered since 1980
Caterpillar’s mining truck experience dates back over 40 years and includes the world’s largest truck
Field Population
Large Mining Truck Worldwide Fleet
Over 18,900 Shipments* (as of Feb. 31st 2009)
38%North America
20%Latin America
28%Asia Pacific, Indonesia &
Australia
14%Europe, Africa &
Middle East
*Shipments leaving factory (Percentages reflect 777,785, 789, 793,797, distribution)
793 Worldwide Deliveries
Over 2,700 Shipments* (as of Dec. 2008)
36%North
America
32%Latin
America
28%Asia
Pacific, Indonesia & Australia
4%Europe, Africa & Middle East
*Shipments leaving factory (Percentages reflect 793B, 793C and 793D distribution)
Future Mining Truck Market Segmentation100mt – 390mt
793 Fleet History
• Cat® 793– 1991 - 1992– Over 50 sold
• B-Series– 1992 - 1996– Over 500 sold
• C-Series – 1996 - 2005– Over 1,050 sold
• D-Series– 2005 - Today– Over 1,300 sold
• F-Series
More than 3,000 units sold since 1991
The 793 has continuously evolved to remain the leader in its class
F Series Development
• Enhanced Safety• Increasing performance
– Lower cost per ton– Lower maintenance costs– Increases operator efficiency– Streamlined operator station
• C175– Tier 2 compliant– Common rail fuel system– ATAAC
• Improved Serviceability– Ground level service– New engine designed for serviceability
The F-Series has evolved to offer increasing safety performance and service
Specifications
793D and 793F Specifications
793D 793F
Engine 3516B C175-16
Gross HP (1801 kW) 2,415 hp (1976 kW) 2,650 hp
GMOWGross Machine
Operating Weight
(383 739 kg) 846,000 lb (386 007 kg) 851,000 lb
(390 089 kg) 860,000 lb
Top Speed Loaded
(54.2 km/h) 33.7 mph (std.)
(59.9 km/h) 37.2 mph (opt.) (60 km/h) 37.3 mph (std.)
Payload (218 tonnes) 240 ton (226.8 tonnes) 250 ton
793F Dimensions
Competitive Comparison
F Series Design for maximum production
Exceptional Performance
Performance advantage and fuel economy • Highest payload for class at rated GMW• Fastest speed on grade for more cycles
per hour• Highest industry grade performance • No thermal limitations for time on grade• Four corner braking • Responsive traction control to maximize
performance in poor underfoot conditions • No fuel burn when retarding• Smooth ride allows faster cycles
Operator Differences between 793D and 793F
• Walk around inspection points• Cab – Your new office (Ergonomics)• Cat Comfort Seat• Brake systems• Speed on grade• Technology
Exceptional Performance– Grade Speed
• Highest grade speed means less time on grade – more production per hour
• Detail study established optimum horse power to deliver best speed on grade for fuel / power train cost
• High torque for pulling through poor underfoot or the ability to achieve a 28% maximum grade loaded
793F delivers fastest industry speed on grade
7.5% Faster speed on grade on a typical 16 min cycle can delivers +180,000 tons / year
11.5% Effective
793F 8.5 mph (+7.5%)AC 7.9 mph
Exceptional Performance – Brakes and Retarding
• Wet oil-cooled brakes combine service, secondary, park brake, and retarding functions
• Superior controllability with four corners braking / retarding
• Park brake holds loaded truck on up to a 15% grade
• Zero fuel burn during retarding• Traction controls improves tire life and keeps
truck moving through poor underfoot• Exceeds ISO 3450 braking requirements even
at 120% of rated payload• Braking system designed for repeated hard
stops
Oil-cooled multiple disc brakes, on all four wheels, provide enhanced control and exceptional braking and retarding performance; even in extreme road conditions
Regardless of paper specs many mines with both
Cat and AC drive trucks set faster loaded and
empty retarding speeds limits for the more controllable Cats
793F Brakes and Retarding
1. Parking/secondary piston
2. Service/retarding piston
3. Friction discs
4. Steel plates
5. Actuating springs
Oil-cooled multiple disc brakes on all four wheels deliver no fuel burn during retarding
• Purpose built integrated system• Multiple discs are continuously cooled by
oil and heat is exchanged to atmosphere by radiator through water-to-oil cooler
• Non-fade oil cooled design offers reliable performance and long life
• Four wheel balanced (60/40 rear to front split) braking improves handling and machine control
• Spring applied secondary parking brake systems enhance safety
• Sealed system prevents contamination• Brake wear measurements completed
quickly
1
2
3
45
Integrated Braking Control
Integrated Automatic Retarding Control and Traction Control System for one electronically controlled braking system
Traction Control System:• Improved traction in poor underfoot
conditions• Less slippage means less tire wear
Automatic Retarding Control (ARC):• Increases production due to faster
downhill speeds • Excellent controllability and reduced
operator effort • Less operator fatigue• Adjustable speed to match road and
traffic conditions • Engine overspeed protection
Engages mechanical brakes on slipping wheel for quick and responsive traction control for
superior performance compared to traction motor modulation
Exceptional Performance - Retarding
• Balanced four corner control• Automatic Retarder Control for
easy operation• Adjustable speed auto retarder
allows speed to be set to traffic or conditions
• No fuel consumption during retarding reduces costs
• Maximum speed not limited by electric drive system overspeed protection
Four corner oil-cooled brakes and Automatic Retarder Control enable fast and confident downhill hauls
No fuel burn on loaded downhill haul could save $86,000 / year
Exceptional Performance - Steering & Suspension
• Four-corner independent, nitrogen- over-oil cylinders offer superior performance and ease of service
• Front & rear struts have built-in rebound control to improve ride
• Front cylinders act as axle mounting group
• Turning radius designed to minimize tire wear
• Payload sensors integrated into suspension cylinders
• All cylinders feature Advanced Surface Technology (AST) coating instead of chrome
• AST eliminates environmental hazards, improve wear and corrosion resistance (compared to chrome)
Designed for excellent maneuverability, safe operation, low maintenance cost, lower operating costs, and a comfortable ride
Low Operating Cost – Repair
• All Cat efficient mechanical power train delivers more power to the ground for greater productivity and lower operating costs
• Caterpillar C175 delivers more power for higher production than the 3500 while providing improved fuel efficiency at equal $ per hour repairs
• Proven mechanical power train delivers best cost per ton and allows R&I of separate components as needed
All Caterpillar design and manufactured components delivers: an integrated power train and controls system for optimum performance and cost
C175-16 is built for power, reliability, efficiency and low operating costs
Low Operating Costs –C175-16
• Gross output of 1,976 kW (2,650 hp) from 85 L (5,187 in3)
• Advanced technology for US EPA Tier 2 compliance
• More power with more life to overhaul than 3500s
• 3% more fuel efficient than the 3516B-HD delivers more production with equal or lower tons / gallon
• Better engine serviceability for faster repairs
• Four turbos reduce repair costs and leave engine accessible for repairs
• Ground level service points for easier service
• Field tested and validated in Mining & Electric Power (120,000 hours)
C175-16 Reliability
C175-16 Development
• Designed from experience of 3500, 3600 and MaK engines
• Labs development hours since 2004
• C175 in concept truck 2005
• Over 45,000 hours in mines on C175s running in modified 793Ds since 2006
• 30,000 hours in 793F pilots and 65,000 hours on C175-20s by mid 2009
• Hours accumulated on electric power generation and petroleum production engines
• Tear down and inspection of engine at 9,500 engine confirmed wear expectations
C175-16 engine extensively tested and validated before entering full-time production
2005 – C175 going into a 793D at Cat’s Proving Grounds
Low Operating Cost – Power Train
All Caterpillar powertrain delivers more power to the ground for greater productivity and lower operating costs
• Superior mechanical power density delivers high efficiency at the lowest system weight / cost
• Lock-up torque converter for efficient direct drive haulage
• Power transmitted through system using high speed / low torque
• Six speed planetary transmission optimizes power train efficiency
• Torque reduction is throughout power train and not all at final drives
• Proven Caterpillar double planetary reduction final drives only need to take a 16:1 reduction
Low Operating Cost - Transmission
• Six-speed planetary transmission matches engine power to a wide range of operating speeds
• Leverages Caterpillar’s core competency and proprietary technologies for manufacturing proven power shift clutches and planetary gear sets
• Electronic Clutch Pressure Control (ECPC) modulates clutch engagement individually and allows for exceptionally smooth shifting and ease of operation
• Valves on top of transmission improve serviceability
• Externally mounted pressure taps allow for quicker and cleaner diagnostics and service
Large diameter planetary clutch packs provide smooth shifting and limit clutch energy input for extended component life
Low Operating Cost - Rear Wheel Group
• Final drive works as a system with the transmission for only a 16:1 reduction
• Caterpillar system runs at about half the gear speeds of competitive AC drive final drives
• Lower speed system is more efficient
• Slower speeds and loads allow for balanced gear and bearing sizing to deliver longer life
• Lower operating temperatures for better component life
• Leverages Caterpillar’s core competency and proprietary technologies for manufacturing proven planetary gear sets
Caterpillar final drives work as a system with the transmission for maximum power to the ground at the lowest cost
Double planetaryFinal Drive
Oil Disc Brakes
Rear Wheel Station
Low Operating Costs - Continuous Axle Filtration
RAX Filtration w/ cooler
10% longer life saves $25,000
Continuous Rear Axle Filtration provides superior filtration for longer component life of differential and final drives
• Standard feature • Cleaner components equal 10
to 20% longer component life• Continuously circulates axle
lubricant through 6 micron filter to maintain ISO 18/15 cleanliness
• Reduces kidney loop maintenance times
NOTE: The rear axle cooler is optional.
Low Operating Costs – Separate R&I Components
• Radiator• Engine• Torque Converter• Transmission• Pump drive• Differential• Axle• Brakes• Final Drives
Modular power train components allow for efficient remove and install plus allows for individual servicing to reduce unneeded repairs
Caterpillar’s individually serviceable wheel station components
Oil Disc Brakes
Final Drive sections
Spindle
Low Operating Costs - Prognostics
• On Board– Advisor display– Alert system– Payload indicator– Storage of data such as Events,
Trends, histograms, cumulative, snapshot and dataloggers
– Optional road analysis control to monitor haul road conditions
• Off Board– Ethernet and web connectivity– Near real time browser interface*– Trigger snapshots and data downloads
• Diagnosis and Analysis– VIMS PC off board diagnostic and
analysis software
VIMS improves effectiveness of scheduled maintenance, maximizes component life, improves availability, and lowers costs
* Requires use of a separate mine radio or cellular broadband system
• VIMS 3G monitoring system provides critical machine health and payload data in real-time
VIMS ™ System & Powertrain Integration
Low Operating Cost - Extended Tire Life
• Gross weight distribution is ideally 33% 67% front-to-rear axle
• Traction Control System reduces tire
slippage and wear • Integrated VIMS System Speed
Manager reduces heat separation failures by monitoring tonne kilometers per hour (ton miles per hour)
• Steering geometry and turning radius are designed to minimize tire scrub
The Cat 793F is designed specifically to extend tire life and reduce costs
Low Operating Cost - Tires & Rims
• Truck designed for 860,000lbs (390,000kg) GMW rating on extended life wheel stations
• Standard wheel stations rated at 851,000lbs (386,000kg) GMW
• 50/80R57 options allows for high TMPH (TKPH) ratings
• Different tire ratings from different tire manufacturers - work with your preferred tire supplier for correct tire and rim size per your application
• Tire GMW and speed limitations negotiated between site and the tire manufacturer
More Hours Per Year – Maintenance
• Grouped ground level maintenance and check points
• 1000 hour hydraulic filters• Oil level sight gauges• Front wheel sight glass• Batteries in bumper• Ecology drains • Final drives two piece covers• Electronic Clutch Pressure Controls
(ECPC) diagnostics• Service platforms on the engine and
transmission• AST coating can deliver 2 x life over
chrome• Optional electric start removes air system• Optional break wear indicators• Optional Fast fill service center
Ground level service points and extended hydraulic filter change intervals mean more time hauling and less time in maintenance
Over 793D possible +1% Availability for an additional 54,000 tons per year
1000 Hr Hydraulic filters save $66,000 in PM costs over machine life
Operator Comfort and Efficiency
• Integral 4 post ROPS exceeds ISO FOPS / ROPS standards
• Quiet at 76 dB(A) or less sound• Low operator vibration• Ergonomically designed
generation 3 Cat Comfort air suspension seat
• Electric hoist control• Secondary brake pedal• Integrated Parking Brake and gear
selector• VIMS™ Advisor displays • Tilt and telescoping steering wheel• Centralized controls• Large storage compartments• Full sized Trainer seat (option)• Powered operator window
The integral, sound-suppressed ROPS/FOPS cab gives the operator a comfortable and safe working environment
Visibility has increased to give the operator enhanced awareness of their surroundings and those around them.
Operator Comfort and Efficiency - Cab Visibility
Cat 793F visibility
• All new cab design • Increased internal size by 10% window surface by 40% and
visibility by 15% over the 793D• Open right hand platform for improved visibility• HID light option • WAVS factory camera option
Cat 793D visibility
Equipping Your Truck
793F Standard Equipment
Operator Environment• Air conditioner• 12 V DC Power Supply• Coat hook• Diagnostic connection port• Dome courtesy light• Gauges/Indicators:
– Transmission fluid temp
– Brake oil temp– Engine coolant temp– Fuel level– Torque converter
temp– Hour meter– Speedometer– Tachometer– Transmission gear
indicator– VIMS message
center w/ advisor
• Hoist, body control (electric)• ROPS cab-insulated/sound
suppressed• Seat, air suspension• Seat, passenger – air
suspension • Seat belt, 75 mm (3 in) wide
retractable• Steering wheel, tilt, padded,
telescopic• Storage compartment• Tinted glass• Window, electric powered,
operator• Windshield wiper, intermittent
control, washerPower Train• C175-16 Tier 2 Diesel Engine• Turbocharging (4) / Aftercooled• Air cleaner w/precleaner (4)• Automatic starter protection• Ground level engine shutdown• Ether starting aid (automatic)• Elevated low idle control• Crankcase protection• Multi-point oil pressure sensing
• Braking system:– Integrated park brake and
directional selector– Brake release motor
(towing)– Oil-cooled, multi-disc (front
& rear) (service, retarding, parking, secondary)
– Automatic Retarder Control
– Engine overspeed protection
– Extended life brake disc material
• Transmission:– 6-speed, auto power shift
w/ECPC– Body-up reverse
neutralizer– Body-up shift inhibitor– Controlled throttle shifting– Directional shift
management– Neutral coast inhibitor– Neutral start switch– Programmable top gear
793F Other Standard Equipment
Electrical• Alarm, backup• Brushless Alternator 150 ampere• Batteries (2), 12V, 93 amp-hour• Converters, 12V electrical• Electrical system, 24V, 10, 20 & 25 amp• Directional signals (front & rear LED)• Front stair access/Service deck• Stop/taillights (LED)• Engine compartment light• Headlights w/ lo-hi beam selector• Backup and hazard lights• VIMS Blue Light (LED)General• Traction Control System• Auto lubrication system• Aux "buddy" dumping quick connect• Aux steering quick connect (towing)• Driveline operator safety guard• Fast fill fuel system• Fuel filter w/ water separator
• Ground level VIMS System data port• Ground level battery disconnect• Hi-speed crankcase oil change • Reservoirs (4):
– Brake– Hoist– Steering/Engine Hyd. Fan – Torque Converter/transmission
• Rock ejectors• Supplemental steering (automatic)• Tie down eyes• Vandalism protection locks
VIMS System
• Includes VIMS System Payload Monitor w/MAX Payload& Speed Manager
• Recommended using download cable 127-9797and PC based software JERD 2175
• Supplemental software "VIMS System Supervisor" YERA 1403Order separately (Computer not provided)
Antifreeze
• Extended Life Coolant to -35C (-30F)
793F Optional Equipment
• WAVS Camera System• Fire extinguisher• Brake wear gauge• Fuel heater• Cold weather starting• Wiggins service center• Rims
– Standard– Quick Change
• Truck Body Arrangements• High intensity discharge (HID) lighting for
high beam retrofits• Electric start• Extra retarding• Extended life wheel stations• SL-V grease injectors• Heated mirrors/seats• *Object Detection System• Engine timer shut down• Throttle lock• Cabin pre-cleaner air filter• Rear axle cooler
Machine Design Details
Engine Specifications
C175-16 Engine
Starting Options
Electric Start:
• Eliminates air system
Air Start:• Ground level access
to air tank drain• Consolidated air
system• Less time to service
air dryer system
Cooling System
• ATAAC vs. D-Series JWAC– Reduces internal combustion temperature
and emissions– Achieves Tier 2 *– Mid-Support Liner allows for better cooling
of cylinders
• On demand variable speed hydraulic cooling fan
– Reduces parasitic loss
• Mesabi Radiator (Standard) – Designed to withstand harsh conditions
and operating environments– Individual folded cores for serviceability
and maintenance– Seals allow tube to be replaced
individually
The 793F Cooling System new features will provide long life, higher durability, easier serviceability and reduce downtime
Seal
Tube
Hydraulic Cooling Fan
* Tier 2 – US and Canada only EPA exhaust emissions regulations
793F Upper Powertrain
TransmissionECPC ControlsInternal improvements for increased HPOutput Spline Lube & hardness Improvements
37 MPH Standard
Larger DriveshaftSight Gauge
CoversTorque Converter& Lock-Up Clutch (LUC)Higher Durability Output BearingIncreased LUC PressureAAA Blade to Maintain Rimpull
Continuous Rear Axle Filtration – Ground Level Access
New Service Platform
C175-16 Engine
Multi-link Suspension
Lower stress Housing
External Pressure Tap Block
Front Mounted Screens
793F Frame & Rear Axle
Frame updates include larger castings for new Multi-Link 4-Bar Rear Suspension
Multi-Link 4-Bar rear suspension allows more room for greater serviceability
Lower stress rear axle housing
Torque tube redesign
Tail casting modifications
New machined cab mounting points for better fit up and less vibration
Main Frame
Fabrications
Castings
Integral 4-post ROPS
• Mild steel provides flexibility, durability, and resistance to impact loads
• Does not require special weld procedures or stress relieving with shot penning or heating
• Box-section design with continuous welds
• Castings used in high stress areas
• Ultrasonically tested welds
Caterpillar frames are designed to deliver long service life in rugged mining applications
• Lighter than traditional A-Frame design.
• Transfers and supports loads to the frame more efficiently than the A-Frame design.
4 Bar Link Suspension
793F Hydraulics & Cooling
All hydraulic brakes
Simplified cooling system – one less water pump and oil cooler
Secondary reduction final drive with segmented bearing
AST (Advanced Surface Technology) on Struts & Hoist Cylinders, 2x Life on Recoating
• No Risk to Environment • Resurfacing Method• Thermal Spray • Gases combined with fine metal powder and sprayed three times the
speed of sound onto rod surface. Ground to like new polish.• Extends life 3 times longer• Better Wear Resistance• Reduces Repair time• Increases quality with life• Reduced Seal Leakage
AST- Advanced Surface Technology
Increasing availability, reliability, and durability AST lowers operating costs on the machine
• Advance Service Technology provides improved wear resistance and repair time
• Available on front/rear struts and hoist cylinders
• Replaces chroming
AST Cylinders
793F Power Train
C175-16 Engine @ 2650 GHP a 10% increase over 793D 3516B HD.
AAA T/C blade to maintain the same stall rimpull of 28% as 793D.
Higher durability output bearing on T/C.Larger drive shaft
New transmission with ECPC (Electronic Clutch Pressure Control) resulting in smoother shifting and better serviceability
Service Platform for better access from engine to rear housing.
Fully enclosed drive shaft
Larger PTO drive shaft
Lock-up Torque Converter
• Updated to accommodate 2650 hp
• Increased power train efficiency
• High reliability from proven design components
• 28% stall torque
• Broad converter performance band
• Lock-up clutch engages at 7.3 km/h (5.1 mph)
Combines the advantages of direct drive and converter drive to achieve high component reliability and maximum output performance
Advanced Controlled Throttle Shift
• Regulates engine rpm during shifts
• Reduces torque spikes and extends transmission life
• Smoother ride and less spillage
• Lowers operator fatigue
• Possible only through electronic integration of components
Reduces driveline torque stress for smoother shifts, extended component life and improved operator comfort
Controlled Throttle Shift (CTS)
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Time
Shift without CTS
Shift with CTS
Shift with CTS
Shift without CTS
793F Extended Life Wheel Group Arrangement
Differences from Standard Arrangement• Larger wheel bearings • Wider wheel bearing spacing• Larger brakes, 94 cm (37 in) vs 86 cm (34
in) • 29% increase in braking surface• Larger spindle
Benefits• Higher rated Gross Machine Weight
(851,000lbs to 860,000 lbs)• Longer brake life• Extended life to overhaul• Lower cost per ton• 50/80R57 Tire option for higher TMPH
Rear Wheel Group
• Laser-hardened spindle
• One-piece cast wheel
• Large bearings
• Continuous rear axle filtration
• Oil cleanliness to ISO 16/13
Heavy duty components and continuous filtration contribute to proven durability in the most rugged conditions
Front Axle Steering Components
• Separate steering hydraulic system prevents cross contamination
• Steering system 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
The 793F front suspension is a field proven design with dual tie- rods for optimum steering geometry to help extend tire life
Extra Retarding Arrangement
Differences from Standard Arrangement
• Higher flow brake cooling• Higher capacity cooling system• Includes Extended Life Wheel Groups• Larger thermostat• Larger dia. cooling lines• One additional brake cooler • One additional water pump • Copper ATAAC
Benefits• 35% increase in downhill speed over
the standard 793D• Higher flow capacity• Higher heat rejection• Increased coolant flow• Faster cooling
Offering enhanced braking for long downhill loaded hauls
Tires
Caterpillar Truck Bodies
793 MSDII Body Size Options
793 MSDII Body is available in 3 sizes to meet a variety of material density ranges:
• 209 yd 3 (160 m 3 )– 2750-3000 lbs/lcy material
• 230 yd 3 (176 m 3 )– 2500-2750 lbs/lcy material
• 250 yd 3 (191 m 3 ) – 2300 – 2500 lbs/lcy material
793 X Body Size Options
793 X Body is available in 3 sizes to meet a variety of material density ranges:
• 195 yd 3 (150 m 3 )– 3000+ lbs/lcy
• 204 yd 3 (155 m 3 )– 2800-3000 lbs/lcy
• 210 yd 3 (160 m 3 )– 2650-2800 lbs/lcy
Caterpillar Body Liner Options - Types
Smooth Plate for cohesive materials
Rock Box for dry andnon-cohesive materials
Zipper Grid forsemi-cohesive materials
Mechanically Attached Wear Plate System
(MAWPS) semi-cohesive to non-
cohesive materials
Productivity
90 %
No loads should be above 120% of the target payload
90% of loads should fall into this rangeNo more than 10% of loads should exceed 110% of the target payload
10/10/20 Overload Policy
• No more than 10% of loads above 110%
• No loads above 120%
• The average payload shall not exceed the target
MineStar™ System – Integrated Mine Information
Radio Network
Rep
ort
ing
KPIs/Graphing
BusinessIntelligence
Reports
Assignment Health
Production Monitoring
MachineTracking
MaterialTracking
Machine Guidance
MineStar…
GPS Infrastructure: Satellites, Repeaters, Base Station
Administration ManagementProductionEngineering
and Geology
SafetyMaintenanceProcessing
Data Flow
Note: MineStar systems availability for specific markets depends on applicable radio licenses.
Road Analysis Control (RAC)
• Existing suspension cylinder pressure sensors measure pitch & bias of truck, and frame rack (twist)
• System identifies haul road problem areas to avoid and correct
• Transmits real time data and GPS locations to haul road maintenance via radio, if equipped
• Improved haul roads help optimize truck component life, fuel consumption, and safety
RAC monitors and logs haul road severity to increase truck life and reduce cost/ton
VIMS™ System Speed Manager
• VIMS System MAX Speed Manager
• VIMS System TKPH (TMPH) Speed Manager
• VIMS System MAX Payload Speed Manager
Fully integrated with VIMS System, Speed Manager consists of three features that help optimize truck safety and performance, lower costs, and extend service life
New Features
New Features
• Standard– 600 mm (23.6 in) wide access from ground to cab– Improved secondary egress ladder – Top deck, hood, platform and walkway is all one level – Ground level access service points– Ground level access to filters– Three-way lock-out/tag-out box at ground level– Engine bay designed without any hydraulic routings
above the turbos.– Spring assist struts on hood providing less effort to
open.
• Standard (cont…)- Fully enclosed driveshaft- Reduced operator sound and vibration- Toe kicks - Dual body retaining cables
• Optional- Optional WAVS (Work Area Vision System)- Object Detection System
New Features (Cont.)
New Features (Cont.)
• Engine– C175 – 16 ACERT Engine EPA Tier II compliant.
• Provides 10% more power.• Common rail fuel system.
• Power Train– Increased speed on grade and a higher top speed– Extended life wheel station attachment for long, uphill
hauls, improving wheel groups where bearing life has been a limiting factor (Optional)
– Extra retarding attachment for downhill loaded applications, providing an extra gear of retarding capability for 35 percent more speed downhill (Optional)
– Electronic Clutch Pressure Control (ECPC)
New Features (Cont.)
• Improved main frame– More robust design– 4-Bar Link Suspension replaces A-Frame Design, which allows
more room for greater serviceability – Battery Box integrated into front bumper design for better
serviceability
• Hydraulic Brakes– All hydraulic brake system vs. the air over hydraulics system– Extended Life Brakes (XLP) are standard in all configurations
• Serviceability– All Service Points accessible from ground level
New Features (Cont.)
• Starting System– Air start (Standard)– Electrical start (Optional)
• Cab and Operator Environment– Increased ROPS capacity– 15% improved visibility – New cab mounts reducing vibration and noise levels– New cab/controls
• Adjustable retarding control• Transmission and Hoist controls
• Monitoring System– VIMS 3G with Advisor monitoring system
Machine Inspections
Right Side Inspection
Inspect the following:- Tires/rims
- Front wheel oil sight gauge
- Steering system components
- Suspension cylinder
- Air tank
- Filters
- Transmission/Torque converter
- Hydraulic tank sight gauges
- Hoist cylinder
- Frame and body
Front wheel oil level - check
• Check the front wheel oil level using the sight gauges and maintain the oil level to the bottom of filler plug.
Air tank
Air tank drain
Hydraulic Tank
2) Hoist and brake cooling reservoir
3) Steering/Hyd. Fan reservoir
1) Brake actuation reservoir
4) Two Brake cooling pumps
Hydraulic Tank
Brake/Hoist Fill
Brake sight gauge
Hoist sight gauge
Steering/Fan Fill
Steering/Engine Hydraulic Fan sight gauges
Brake and Hoist sight gauges
(2) Brake reservoir sight gauge(1) Hoist reservoir sight gauge
Steering and Engine hydraulic fan reservoir sight gauges
Steering and Eng. hyd. fan reservoir sight gauge
1
2Engine “running” check
Engine “stopped” check
Rear Inspection
Inspect the following:- Lights
- Suspension cylinders
- Leaks
- Oil level sight gauge
- Grease fittings and lines
- Rock ejectors
- Tire tread
- Body pins
- Body cables
Differential and Final Drive Oil Check
Differential and Final Drive Oil Sight Gauge
Left Side Inspection
Inspect the following:- Handrails- Engine Oil level sight gauge- Auto Lube Reservoir- Tires/rims- Front wheel oil sight gauge- Steering system components- Suspension cylinder- Torque convertor/Trans. oil
level sight gauge - Fuel tank- Hoist cylinder- Frame and body
Engine Oil Level Sight Gauge location
Engine Oil Level Sight Gauge
If the engine is stopped and the oil is cold, maintain the oil level in the upper green range.
If the engine is running at low idle and the oil is at operating Tempture, maintain the oil level in the lower green range.
Engine Oil Level Sight Gauge
A
B
Auto Lubrication System
Auto Lube System (Electric Motor)
Front wheel oil level - check
• Check the front wheel oil level using the sight gauges and maintain the oil level to the bottom of filler plug.
Torque Converter/Trans. oil level check
1
2
Check oil level in Torque Converter sump with engine at an idle.
Oil at operating temp. (hot) in upper sight gauge (1)
Oil at ambient temp. (cold) in lower sight gauge (2)
Front Inspection
Inspect the following:• Ground level controls• Lights• Auto Lube Reservoir• Air filters• Radiator• Battery compartment• Fast Fill Service Center
(Optional)• Ladders and platforms• Engine compartment• Coolant level• Windows/Mirrors
793F Ground Level Energy Isolation Box (standard)
Engine Shutdown Switch (4)
Battery Charge Receptacle (mounted beside box, not pictured)
Machine/ Transmission Lockout (6) & Indicator Lamp
Engine/Starter Lockout (5) & Indicator Lamp
Battery Lockout (1)
VIMS Data Port
Engine Service Lights Switch (2)
Ladder Lamp Switch (3)
VIMS Event Light
*NOTE: This is a standard feature on the F series. Please continue to refer to site specific “lock out/tag out” policies.
Battery compartment
• Battery Box integrated into front bumper design for better serviceability
Fast fill service center (optional)
Hoist and Brake Oil Port (1)
Engine Oil Port (2)Torque Conv./Trans Oil Port (3) Level indicator for hoist/brake oil (cold) (5)
Level indicator for hoist/brake oil (hot) (6)
5 6
Level indicator for Torq. Conv./Trans. oil (cold) (4)Level indicator for Torq. Conv./Trans. oil (hot) (7)
47
Level indicator for
coolant (Full) (8)
Level indicator for Auto Lube Reservoir (Full) (14)
Power switch for Fast Fill
service center (15)
Steering system Oil Port (9)
Engine Coolant Port (10)
Diesel Fuel Port (11)
Level indicator for Engine oil
(Full engine on) (12)
Level indicator for Steering oil (Full engine off)
(13)
• 600 mm wide walkway to cab
• Improved secondary egress
• Powered folding stair attachment (optional)
Access and Egress
Top Deck Enhancements
Enhancements:- Top Deck is now
all one level.
- Toe kicks are standard now.
Radiator Coolant Level Check
Left side cab checks
Cab fresh air filterWindshield washer reservoir
Cab Features
Operator Comfort and Efficiency
Cat 793F Cat 793D
Operator Environment - Pedals
Foot rest
Accelerator
Service brake
Secondary brake
Steering Wheel and controls
Steering Wheel Control
Manual Retarder Control Lever
Multi Function Control Lever
Steering Wheel Tilt/Telescope Control Lever(Below Multi function control lever)
Cat Comfort Seat
The Caterpillar Comfort Seat with three-point operator restraint is the most durable and supportive seat available for Cat Mining Trucks
Three-point restraint • High-back seat supports head and neck
• Ride zone indicator adjusts seat suspension to operator’s 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
Note: Refer to “Operations and Maint. Manual” SEBU8406-00 for more detailed explanation of adjustments. *
* Additional resources listed below in speaker notes for seat and adjustments to ensure operator comfort.
Seat control adjustments
Back cushion angle lever
Fore/Aft adjustment
lever
Height adjustment
lever
Ride adjustment
lever
Seat cushion tilt
Ride indicator
NOTE: There are additional adjustments not shown in this photo, please see below and refer to OMM.
Hazard Flasher Switch
Headlight, Parking Lights, and Taillights Switch
Fog Light Switch
Engine Start Switch
Cigarette Lighter
12 volt receptacle
VIMS Advisor Screen
Access Light Switch
Heated Mirror Switch(If equipped)
Panel Light Switch
Air Conditioner Switch
Instrumentation Panel
Fan Speed Switch Temp. Variable Control
Instrument Cluster
New machine starting option will allow the elimination of an air system.
Electric Start System
ATC - Automatic Temp. Control
Heating and Air Conditioning System
Air Conditioner Switch – - Pushing the “top” of the switch “manually”
turns on the AC.
- If the switch is in the “middle” position the AC system is off.
- Pushing the “bottom” of the switch will turn on the Automatic Temperature Control.
Instrument Cluster
VIMS™ 3G with Advisor
Transmission Control
Automatic Retarder Control(ARC)
Automatic Retarder Adjustment
Left Power window switch
Hoist Control
Throttle backup and Throttle Lock Switch
WAVS Camera Switch (If Equipped)
Right Power Window Switch
Console Controls
Console Controls – Transmission Control Lever
Shift control release button
Decrement button
Increment button (on front of control handle)
Console Controls – Hoist Control Lever
Body Lower
Body “Float”
Body “Hold”
Body Raise
Console Switches
Automatic Retarder Control(ARC)
Automatic Retarder Adjustment
Left Power window switch
Throttle backup (Stand.) and Throttle Lock
Switch (Optional)
WAVS Camera Switch (If Equipped)
Right Power Window Switch
(If equipped)
Brake Release Switch
Idle Shutdown Timer Switch (If equipped) See speaker
notes.
Overhead console switches
Traction Control System Test switch
Display Front Camera Right-hand Camera Rear Camera
Optional system to enhance the operators vision
Rear view automatically displayed when machineis placed in reverse
WAVS Camera System
The system consists of:• An interactive touch screen display in
the cab
• Medium Range Radars front & rear (~ 20 metre range)
• Short Range Radar front, rear & sides(~ 7 metre range)
• Cameras on all 4 sides of the machine
Caterpillar Integrated Object Detection System TM
Alerts the operator during startup and initial machine movement of
objects within the machine’s immediate surroundings, particularly “blind spots.”
Cat Integrated Object Detection System Benefits
• Improves site safety by enhancing operator’s situational awareness
• Stand alone machine system - does not require any off-board infrastructure
• Easy to learn user interface
• Minimizes nuisance audible alarms
• Scalable solution allows user to start with camera system and later add radars
• Available January 2010 on Large Mining Trucks– 785, 789, 793 & 797– Additional models expected later 2010
• Can be ordered with new truck or retrofitted to existing– Listed as optional attachment on truck
price pages
• Marketing materials being completed and uploaded to Cat Electronic Sales Library
• Dealers start targeting customers for system now
Cat Integrated Object Detection System
VIMS™ 3G with Advisor
Preset Buttons
Digital display area
Scroll up/left button
Scroll down/right
button
Back button
Main “Home” menu button
OK button
Warning Levels
Category Message Display Action Lamp Action alarm
Level 1 Displayed on Advisor screen Solid Amber N/A
Level 2 Displayed on Advisor screen Flash Red N/A
Level 2S Displayed on Advisor screen Flash Red Continuous
Level 3 Displayed on Advisor screen Flash Red Pulse
Advisor “Home” Screen
Actual Gear Transmission control position Top drive Gear
Date/Time
“More options” indicator
Menu items
Status of ARC *
Advisor “Home” Menu Selections
Advisor “Operator” Menu Selections
Advisor “Operator” Menu Selection Map
Advisor “Monitor” Menu Selection
Advisor “Monitor” Menu Selection Parameters
Advisor “Payload” Menu Selection
Advisor “Payload” Menu Selection View
Advisor “Service” Menu Selection
Advisor “Service” Menu Selection Map
Advisor “Service - Diagnostics” Menu Map
Advisor “Diagnostics – Active Events” Menu
Active Events List
Advisor “Diagnostics – Logged Events” Menu
Logged Events List
Advisor “Diagnostics – Triggered Snapshot” Menu
Advisor “Diagnostics – Data-logger Start” Menu
Advisor “Diagnostics – Data-logger Stop” Menu
Advisor “Diagnostics – Data-logger Reset” Menu
Advisor “Service - Submenus” Menu
Advisor “Service - Calibration” Menu
Advisor “Settings” Menu
Advisor “Service Mode” Menu
793F Operation
1. When the engine is stopped, check level of steering oil is in proper range in upper sight gauge.
2. After engine is started, check level of steering oil is in the proper range in the lower sight gauge.
3. With engine running and engine start switch in “on” position, shut engine down with the ground level shut down switch (front bumper).
4. Return to cab and turn steering wheel to the left and to the right.
5. If steering wheel does not turn or there are problems turning the wheel, consult your local Cat dealer.
Secondary Steering Test
793F Operation
Brake System Tests
• Service• Secondary• Parking
793F Operation
Service and Secondary Brake System Test1. Fasten the seat belt before you test the brakes.2. Check the area around the machine. Make sure that the machine and area is clear of personnel and clear of obstacles.
3. Test the brakes on a dry, level surface.4. Start the engine.5. Depress respective brake control in order to apply the respective brake system.6. Move the transmission control to the “D” position.7. Gradually increase the engine speed to 1300 rpm. The machine should not move.8. Reduce the engine speed to an idle. Move the transmission control to the P position. Stop the engine.
NOTICE If the machine moved while testing the brakes, contact your Caterpillar dealer. Have the dealer inspect and, if necessary, repair the service brake before returning the
machine to operation.
793F Operation
Parking Brake System Test1. Fasten the seat belt before you test the brakes.2. Check the area around the machine. Make sure that the machine and area is clear of personnel and clear of obstacles.
3. Test the brakes on a dry, level surface.4. Start the engine.5. When the transmission control is in the P position, depress the “increment” button (front of control lever) and depress the “decrement” button (left side of the control lever) at the same time.
6. While both buttons are depressed, Move the transmission control to the D position.Note: The buttons can now be released and the parking brake will remain on.7. Gradually increase the engine speed to 1300 rpm. The machine should not move.8. Reduce the engine speed to an idle. Move the transmission control to the P position. Stop the engine.
NOTICE If the machine moved while testing the brakes, contact your Caterpillar dealer. Have the dealer inspect and, if necessary, repair the service brake before returning the
machine to operation.
Reference materials
• 793F OMM #SEBU8406-00• 793F Specalog #AEHQ6038• 793F Salesgram #TEKQ0751-01• 793F Marketing Bulletin #TEJB9479• 793F Product Bulletin #TEJB9163• Cat Comfort Seat Salesgram #TEKQ0239• “Cat Comfort Seat with three point operator restraint” video
#AEVN5717 (Avail. in Spanish and Portuguese)
• Integrated Object Detection System Salesgram #TEKQ0747-02• Integrated Object Detection System Specalog #AEHQ6054 (Avail. In
Spanish, Portuguese, Indonesia and French)
• F Series Supporting documents; https://catminer.cat.com/trucks• STMG media #1869
Questions
793F Highlights
Comfort Cab• Integrated 4 post
ROPS• Exceptional visibility• Integrated Parking
Brake and gear selector
• 76 dB(a)
Right Hand Deck• One level platform• Open view (no air or
steering tank)• Reinforced attachment
location• Light hoods with spring
assist and locks• Steel deck around cab
access
Tire Options• 40R57• 46/90• 50/80
Body• Mine and
application specific• Balance of weight /
durability
Access• 600 mm wide• Rear cab
access option
Lock Out Tag Out • Battery Disconnect• Engine start lockout• Transmission lockout
Bumper Service • Wiggins center• Auto lube• Batteries
Wheel Sight Gauge• Increased reliability• Reduced unscheduled
down-time
Two Piece Cover• Ease of service
Visibility• HID option• Heated mirror
option• WAVS option
Mesabi Radiator• Robust for mining• Individual
serviceable cores
793F Highlights
C175-16• Tier 2 Compliant• 2650 HP• 85 litters• More fuel efficient
than 3500• On demand fan
system
Clean and Open Engine• Only 4 turbos• Turbos above engine• Space for in chassis repairs• Reduced number of
external Tubes or Hoses
Power Shift Transmission• Six speed planetary
transmission optimizes power train efficiency
• Electronic Clutch Pressure Control for smooth shifting and ease of service
Wheel Station• Separate brake, spindle
and brake service• Double reduction
planetary final drive• Low reduction ratio allows
for robust design
Ground Level Service• 1000 hr hydraulic filters• Oil sight gauges• Filter placement and height• SOS port placement• Bottom load filters• Drain plugs
4 Link Suspension• No A-frame• Load direct into
frame• Open for service
Starting Options• Optional
electric start removes air system
• Cold weather system available
Ground Service• Sight gauge• Filters
Continuous rear axle filtration
793F Highlights
4 Corner Oil Brakes • 40 / 60 front rear split• Sealed cooled and filtered for
performance, production, and reliability
• Wet oil-cooled brakes combine service, secondary, park brake, and retarding functions
• Balanced 4 wheel retarding• Zero fuel burn during retarding
Frame• Castings• Box section • Mild steel• Ultrasound tests
ROPS Mounting• Cab mounting integrated
to machine frame• Exceeds ISO standards• Engineered with
customer additions in mind
• MARC mounts reduced sound and vibration
Brake Wear Indicators• Increase reliability• Reduces unscheduled
down time
Service• Modular
component design• On board
diagnostics• Extended
hydraulic systems filter life
• Competitive R&I times
ARC• Automatic
Retarder control • Adjustable
retarding speed
Large Mining Truck Worldwide Fleet
Over 18,900 Shipments* (as of Feb. 31st 2009)
38%North
America
20%Latin
America
28%Asia
Pacific, Indonesia & Australia
14%Europe, Africa & Middle East
*Shipments leaving factory (Percentages reflect 777,785, 789, 793,797, distribution)
Update Bi-Yearly
Safety - Features
• Hydraulic lines not routed above engine turbos
• Ground level secondary engine shutdown and machine lock-out with tag-outs
• 600mm wide walkways, ladders and catwalk
• Bottom loading filters• Filter drains• Brushless alternator• Fully enclosed driveshaft• Required moving part guards• Rear access ladder• Wide secondary egress ladder• Service platforms• Spring strut hoods and retention locks• Front deck is all one level• Ground level filters• Increased ROPS capacity• Increased operator visibility• Low operator sound and vibration• Toe kicks• Optional WAVS (Work Area Vision System)
Design features target to help reduce haulage injures