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789D
Mining Truck
Engine (options) Weights – Approximate
Engine Model Cat
Gross Power – SAE J1995 1566 kW 2,100 hp Operating Specications
Rated Net Power – ISO 9249 1468 kW 1,969 hp Nominal Payload Capacity 181 tonnes 200 tons
Engine Model Cat
Gross Power – SAE J1995 1417 kW 1,900 hp
Net Power – SAE J1349 1320 kW 1,771 hp
®
3516C EUI Gross Machine Operating Weight (GMW) 324 319 kg 715,000 lb
®
3516B EUI
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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 andlong life.
Contents
Power Train – Engine .........................................3
Power Train – Transmission ..............................4
Engine/Power Train Integration ........................5
Structures.............................................................6
Operator’s Station ...............................................7
Cat Brake System................................................8
Truck Body Systems ...........................................9
Monitoring System............................................10
Safety ..................................................................11
Sustainability .....................................................12
Serviceability .....................................................13
Customer Support .............................................14
Speci cations ....................................................15
Standard Equipment .........................................23
Optional Equipment...........................................24
The Cat® 789D continues the tradition of Caterpillar’s proven
789Truck with high productivity and lowest in class cost per ton.
The 789D features the following:
• Safety and Sustainability. Safety is top priority.
• Engine options to meet regulatory requirements or application
speci c needs.
• Production capability with nominal payload capacity of
181metric tons (200 short tons).
• Performance with the 1976 kW (2,100 hp) engine delivers fast
speed on grade.
• Access and Egress with a diagonal stairway for primary machine
access and 600 mm (24 in) walkways. Another option is the
powered ground level access.
• Serviceability to enable safer and more ef cient maintenance.
• Larger tire options have been designed into the 789D to provide
a broader choice for tires. Applicable hauling conditions will
benet from increased tire life or signicant reduction in tire costs.
• Application specic capabilities for extreme ambient conditions,
high altitude applications, and extra quiet machine to reduce
spectator sound levels.
• A variety of Cat Truck Bodies are available including Mine Speci c
Design (MSD II), X, Combination, Gateless Coal and Dual
Slope bodies.
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Power Train – Engine
The Cat® 3500 series engines are built for power, reliability and efciency
forsuperior 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 ef 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 efciency and fast cycle times.
Enhanced Life
High displacement, low rpm rating, and conservative
horsepower ratings mean more time on the haul roads
andless 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 ef 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 ef 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.
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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 ef 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,
theproven 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,
efciency and clutch life.
2) Lock-Up Torque Converter
Combines maximum rimpull and cushioned shifting of
torque converter drive with the efciency and performance
of direct drive. Engages at approximately 7.2 km/h (4.5mph),
delivering more power to the wheels.
3) Final Drives
Cat 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 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
toprovide a broader choice for tires. Applicable hauling
conditions will benet from increased tire life or signi 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
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durability. Optional quick change rims also available.
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ET
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
andcomponent 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
tosimplify problem diagnosis and increase machine availability.
Integrated Braking Control (IBC)
Integrates Hydraulic Automatic Retarder Control and Traction Control into one system for optimum performance
andef 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.
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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.
Theraised and pinned body allows excellent access to
thetransmission.
Steel Structures
Mild steel used throughout frame provides exibility, durability,
and resistance to impact loads, even in cold climates.
Additionally, mild steel facilitates easy eld repair.
Castings
Castings have large radii with internal reinforcing ribs
todissipate stress in areas of high stress concentration.
Castingsmove welds to lower stress areas for greater
framelife.
Integral Four-Post ROPS Cab
Resiliently mounted to the main frame to reduce vibration
and sound, the integral ROPS is designed as an extension
ofthe truck frame. The ROPS/FOPS structure provides
“vesided protection” for the operator.
Suspension System
Designed to dissipate haul road and loading impacts
forlonger frame life and a more comfortable ride.
Cylinders
Four independent self-contained, oil pneumatic, variablerebound 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
andlow 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.
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Operator’s Station
Ergonomically designed for operator comfort, superior control,
andhighproductivity.
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
ofthe air tank lower on the chassis.
Ergonomic Layout
The 789D operator station is ergonomically designed for totalmachine control in a comfortable, productive and
safeenvironment. All controls, levers, switches and gauges arepositioned to maximize productivity and minimize
operatorfatigue.
Quiet Cab
Integral, sound-suppressed ROPS/FOPS cab is resiliently mounted to the mainframe to isolate the operator from sound
andvibration 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
tomaneuver with condence 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.
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Cat® Brake System
Reliable braking with superior control gives the operator the condence
tofocus 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
samerobust system for optimum braking ef 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.
1) Parking/Secondary Piston 2) Service/Retarding Piston
3) Friction Discs 4) Steel Plates 5) Actuating Springs
6) Cooling Oil In 7) Cooling Oil Out
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
bothservice and retarding functions. The secondary piston
isspring-applied and held in the disengaged position by
hydraulic pressure. If hydraulic system pressure drops below
a specied 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 control 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
oraccelerator controls.
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Truck Body Systems
Cat designed and built for rugged performance and reliability
inthetoughest mining applications.
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 specic body options that yield a payload ranging from 177 to 188 metric tons (195 to 207 tons).
TheCaterpillar 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 congured with a variety of liner options to meet site speci c requirements
of a mine. Like the Dual Slope – the X body is designed for durability across a range of harsh applications.
2) Mine Specic Body (MSD II) – For mature mines with good operational and maintenance practices, the lighter weight
MSDII(Mine Specic Design) body is available in several sizes. It is a customer/site specic body that is designed to
maximize performance. The MSD II is designed to maximize payload, provide good durability and can be con gured
withavariety ofliner options to meet the specic 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 oor design eliminates the tailgate and gives the volume required
tomeettarget 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 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
centerof gravity with optimum load distribution, reduces shock loading and is available in lined and unlined con gurations.
The Dual Slope body is intended for tough applications including greeneld 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 ef ciencies.
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Monitoring System
Vital machine health and payload data keeps the 789D performing
atpeakproduction levels.
VIMS
PC
VIMS
ET
Payload Weight Distribution
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 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.
Percentage of Total Loads
Payload Weight (Tons)
Recommended Payload Range With Production Management
Inefcient Payload Ranges Without Production Management
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 ef 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 eet management and
productivity.
Machine Management
Service technicians or mine personnel can download data
and generate reports for better machine management.
Datacan be used to improve effectiveness of scheduled
maintenance programs, maximize component life,
improvemachine availability, and lower operating costs.
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Safety
Cat mining machines and systems are designed
with safety as their rst priority.
Product Safety
Caterpillar has been and continues to be proactive in developing mining machines that meet or exceed safety standards.
Safetyis 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 con 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 conrm the detected object.
Thecameras 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 suf cient capacity
toperform.
Standard Safety Features
Slip resistant surfaces, retractable, seat/shoulder belts with three-point operator restraint, wide-angle mirrors, body raised
indicator, body retaining cable, guard rails, reverse neutralizer when dumping, low interior sound level, secondary steering
system, ground level access shutoff switches.
SAFETY.CAT.COM™
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Sustainability
A variety of features improve sustainability in areas of decreasing waste,
extending component life and lowering emissions levels.
Sustainability Features
The 789D Mining Truck offers oil renewal systems, extended life ltersand extended maintenance intervals which aid in
decreasing the amount of waste contributed toourenvironment.
Oil Renewal System
Optional oil renewal system extends engine oil change intervals from 500 hours to 4,000 hours or more to increase machine
availability and reduce costs.
Engines with Advanced Technology
Engines with advanced technology contribute less emissions to the environment while maintaining fuel ef ciency.
Fuel Efciency
The engine provides additional retarding by running against compression on downhill hauls. During retarding applications the
engine ECM does not inject fuel into the cylinders for exceptional fuel economy.
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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 simplies 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, lters, drains, and
engine shutdown. Ground-level VIMS data port permits
easier downloading of information.
Autolube
Automatic lubrication system reduces maintenance time
byautomatically lubricating necessary components on
aregularbasis.
Fast Fill Service Center
Optional fast ll service center features high speedfuel
andoil exchange.
Scheduled Oil Sampling
S•O•SSM sampling valves speed sampling and analysis
reliability.
Pressure Test Points
Disconnect valves are conveniently located throughout
thehydraulic 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.
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Customer Support
Cat dealers have what it takes to keep mining haul trucks productive.
Commitment Makes the Difference
Cat dealers offer a wide range of solutions, services and products that help you lower costs, enhance productivity and manage
your operation more efciently. Support goes far beyond parts and service. From the time you select a piece of Cat equipment
until the day you rebuild, trade or sell it, the support you get from your Cat dealer makes the difference that counts.
Dealer Capability
Cat dealers will provide the level of support you need, on a global scale. Dealer expert technicians have the knowledge,
experience, training and tooling necessary to handle your repair and maintenance needs, when and where you need them.
Product Support
Cat dealers believe superior products deserve superior support. When Cat products reach the eld, they are supported by a
worldwide network of parts distribution facilities, dealer service centers, and technical training facilities to keep your equipment
up and running. Cat customers rely on prompt, dependable parts availability and expertise through our global dealer network,
ready to meet your needs 24/7.
Technology Products
Cat dealers offer a range of advanced technology products such as VIMS monitoring system and MineStar® information
management system. These products include radio data communications, machine monitoring and diagnostics, eet management,
and haul road maintenance software – all designed to improve eet efciency, increase productivity, and lower costs.
www.cat.com
For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at www.cat.com.
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Engine Weights – Approximate Final Drives
789D Mining Truck Specications
Engine Model 3516C – HD
Gross Power 1566 kW 2,100 hp
Rated Net Power 1468 kW 1,969 hp
(ISO 9249)
Bore 170 mm 6.7 in
Stroke 210 mm 8.3 in
Displacement 78.1 L 4,766 in
Optional Engine
Engine Model 3516B EUI
Gross Power 1417 kW 1,900 hp
Rated Net Power 1335 kW 1,791 hp
(ISO 9249)
Bore 170 mm 6.7 in
Stroke 190 mm 7.5 in
Displacement 69 L 4,211 in
• Power ratings apply at 1,750 rpm when
tested under the specic conditions for
thespeci ed standard.
• Ratings based on SAE J1995 standard air
conditions of 25° C (77° F) and 99 kPa
(29.32 Hg) barometer. Power based on fuel
having API gravity of 35 at 16° C (60° F) and
an LHV of 42 780 kJ/kg (18,390 BTU/lb)
when engine used at 30° C (86° F).
• 3516B engine, (STANDARD) no derate
required up to 2300 m (7,500 ft) altitude.
• 3516C engine, (EPA/ARB Flexibility)
no engine derate required up to 2743 m
(9,000ft).
• 3516C engine, (STANDARD) no engine
derate required up to 3658 m (12,000 ft).
• Where applicable, the 3516C engine,
(EPA/ARB Flexibility) arrangement
is compliant with U.S. Environmental
Protection Agency regulations.
Gross Machine 324 319 kg 715,000 lb
Operating Weight
(GMW)
Body Weight Range 23 920 kg- 52,850lb-
45 547 kg 100,414 lb
Empty Operating 98 694 kg 217,580 lb
Chassis Weight
3
(EOCW)
• Body weight varies depending on how body
is equipped.
• Estimated weight of debris is not included
in operating chassis weights.
• Chassis weight includes standard rims
and tires, all operating uid levels full,
100% fuel in standard tank and standard
mandatory attachments.
Operating Speci cations
3
Nominal Payload 181 tonnes 200 tons
Capacity
Standard MSD Body 130 m
3
(SAE 2:1)
Standard X Body 123 m
(SAE2:1)
Standard Dual Slope 108 m
3
3
Body (SAE 2:1)
Standard Combi 153 m
3
Body (SAE 2:1)
Standard Gateless 191 m
3
Coal Body (SAE 2:1)
• Refer to the Cat Mining Truck 10-10-20
payload policy for maximum gross machine
weight limitations.
Transmission
Forward 1 12.6 km/h 7.8 mph
Forward 2 17.1 km/h 10.6 mph
Forward 3 23.1 km/h 14.4 mph
Forward 4 31.2 km/h 19.4 mph
Forward 5 42.3 km/h 26.3 mph
Forward 6 57.2 km/h 35.5 mph
Reverse 11.8 km/h 7.3 mph
• Maximum travel speeds with standard
37.00-R57 tires.
170 yd
161 yd
141 yd
200 yd
250 yd
Differential Ratio 2.35:1
Planetary Ratio 10.83:1
Total Reduction 25.46:1
Ratio
• Double-reduction, planetary, with full
oating axles.
Suspension
Effective Cylinder
Stroke – Front
Effective Cylinder
Stroke – Rear
Rear Axle Oscillation ± 5.6°
105 mm 4.0 in
93 mm 3.5 in
Brakes
Brake Surface 81 693 cm2 12,662 in
–Front
Brake Surface 116 283 cm
–Rear
3
Standards SAE J1473 OCT90
3
• Gross Machine Operating Weight
3
3
is 324 319 kg (715,000 lb).
Body Hoists
Pump Flow – 731 L/min 193 gal/
3
HighIdle min
Relief Valve Setting 17 238 kPa 2,500 psi
– Raise
Body Raise Time – 18.9 Seconds
High Idle
High Idle Body 17.3 Seconds
Lower Time – Float
High Idle Body 15.6 Seconds
Lower Time – Power
ISO 3450:1996
2
18,024 in
2
2
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789D Mining Truck Specications
Weight Distributions – Service Re ll Capacities Sound
Approximate
Front Axle – Empty 46%
Rear Axle – Empty 54%
Front Axle – Loaded 33%
Rear Axle – Loaded 67%
Tires
Standard Tires 37.00-R57
Optional Tires 40.00-R57 and
42/90R57
• Productive capabilities of the 789D truck
are such that, under certain job conditions,
TKPH (TMPH) capabilities of standard
or optional tires could be exceeded and,
therefore, limit production.
• Caterpillar recommends the customer
evaluate all job conditions and consult the
tire manufacturer for proper tire selection.
Fuel Tank (standard) 2082 L 550 gal Sound Standards
Fuel Tank (optional) 3785 L 1,000 gal
Cooling System 725 L 192 gal
Crankcase 291 L 77 gal
Differential and 583 L 154 gal
Final Drives
Steering System 189 L 50 gal
Brake/Hoist System 909 L 241 gal
Transmission Tank 76 L 20 gal
ROPS
ROPS Standards
• ROPS (Rollover Protective Structure)
for cab offered by Caterpillar meets
ISO3471:2008 ROPS criteria.
• FOPS (Falling Objects Protective Structure)
meets ISO 3449:2005 Level II FOPS criteria.
• The operator sound pressure levels
are measured according to work cycle
procedures specied in ISO 6394:2008
andISO 6396:2008.
• The exterior sound power level for
the standard machine is tested using
ISO6393:2008 and ISO 6395:2008
procedures.
• Hearing protection may be needed when
operating with an open operator station
and cab (when not properly maintained or
doors/windows open) for extended periods
or in a noisy environment.
Steering
Steering Standards SAE J1511 OCT90
• Gross Machine Operating Weight
is 324 319 kg (715,000 lb).
ISO 5010:1992
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Dimensions
All dimensions are approximate. Dimensions are with standard dual slope body 344-7340 and 37.00R57 tires.
1
Height to Top of ROPS – Empty
1
Overall Body Length
2
Inside Body Length
3
Overall Length
4
Wheelbase
5
Rear Axle to Tail
6
Loaded Ground Clearance
7
Dump Clearance
8
Loading Height – Empty
9
Inside Body Depth – Maximum
10
Overall Height – Body Raised
11
Centerline Front Tire Width
12
Engine Guard Clearance – Loaded
13
Overall Canopy Width
14
Outside Body Width
15
Inside Body Width
16
Front Canopy Height – Empty
17
Rear Axle Clearance – Loaded
18
Centerline Rear Dual Tire Width
19
Overall Tire Width
20
2
10
3
7
5
4
6
11
9
8
17
13
12
14
15
16
18
19
20
Dual Slope
5510 mm
12 723 mm
8293 mm
12 697 mm
5700 mm
3604 mm
1036 mm
1535 mm
5595 mm
2684 mm
13 198 mm
5374 mm
1057 mm
7645 mm
6995 mm
6500 mm
6496 mm
1071 mm
4622 mm
6926 mm
18'1"
41'9"
27'3"
41'8"
18'8"
11'10"
3'5"
5'0"
18'4"
8'10"
43'4"
17'8"
3'6"
25'1"
22'11"
21'4"
21'4"
3'6"
15'2"
22'9"
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789D Mining Truck Specications
Retarding Performance
To determine retarding performance: Add lengths of all downhill segments and, using this total, refer to proper retarding chart. Read from
gross weight down to the percent effective grade. Effective grade equals actual % grade minus 1% for each 10 kg/t (20 lb/ton) of rolling
resistance. From this weight-effective grade point, read horizontally to the curve with the highest obtainable gear, then down to maximum
descent speed brakes can properly handle without exceeding cooling capacity. The following charts are based on these conditions: 32° C
(90° F) ambient temperature, at sea level, with 37R57 tires.
NOTE: Select the proper gear to maintain engine rpm at the highest possible level, without overspeeding the engine. If cooling oil
overheats, reduce ground speed to allow transmission to shift to the next lower speed range.
GROSS WEIGHT
0 100 200 300 400 500 600 700 800 lb x 1000
0 50 100 150 200 250 300 350 400
L
E
1
2
3
4
5
30%
6
25%
20%
15%
10%
5%
kg x 1000
EFFECTIVE GRADE
(Grade minus Rolling Resistance)
18
0 10 20 30 40 50 60 70
0 5 10
15 20 25 30 35 40 mph
km/h
SPEED
Continuous Grade Length*
*at sea level
Page 19
Retarding Performance
GROSS WEIGHT
0 100 200 300 400 500 600 700 800 lb x 1000
0 50 100 150 200 250 300 350 400 kg x 1000
L
E
30%
25%
20%
0
0
*at sea level
0 0 100
1
2
3
10
5 10
20 30 40 50
Grade Distance – 450 m (1,475 ft)*
200
300 400 500 600
50
100
4
5
15 20 25 30 35
6
SPEED
GROSS WEIGHT
700
150 200 250
E
30%
300
L
15%
10%
5%
60
350
25%
40
800
20%
70 km/h
mph
lb x 1000
400 kg x 1000
EFFECTIVE GRADE
(Grade minus Rolling Resistance)
0
0
*at sea level
1
2
3
10
5 10
20 30 40 50
Grade Distance – 600 m (1,975 ft)*
4
5
15 20 25 30 35
6
SPEED
15%
10%
EFFECTIVE GRADE
5%
60
70 km/h
40
mph
(Grade minus Rolling Resistance)
19
Page 20
Retarding Performance
789D Mining Truck Specications
GROSS WEIGHT
0 100 200 300 400 500 600 700 800 lb x 1000
0 50 100 150 200 250 300 350 400 kg x 1000
L
E
1
30%
25%
20%
15%
2
3
4
5
0
0
10
5 10
20 30 40 50
15 20 25 30 35
6
10%
EFFECTIVE GRADE
5%
60
70 km/h
40
mph
(Grade minus Rolling Resistance)
SPEED
Grade Distance – 900 m (2,950 ft)*
*at sea level
GROSS WEIGHT
0 100 200 300 400 500 600 700 800 lb x 1000
0 50 100 150 200 250 300 350 400 kg x 1000
L
E
1
30%
25%
20%
15%
20
0
0
*at sea level
2
3
10
5 10
20 30 40 50
Grade Distance – 1500 m (4,900 ft)*
4
15 20 25 30 35
5
6
SPEED
10%
EFFECTIVE GRADE
5%
60
70 km/h
40
mph
(Grade minus Rolling Resistance)
Page 21
Gradeability/Speed/Rimpull
To determine gradeability performance: Read from gross weight down to the percent of total resistance. Total resistance equals actual
percent grade plus 1% for each 10 kg/t (20 lb/ton) of rolling resistance. From this weight-resistance point, read horizontally to the
curve with the highest obtainable gear, then down to maximum speed. Usable rimpull will depend upon traction available and weight
on drive wheels.
GROSS WEIGHT*
lb x
1000
200
180
160
140
120
100
RIMPULL
80
60
40
20
0 100 200 300 400 500 600 700 800 900 lb x 1000
N x
1000
0 50 100 150 200 250 300 350 400 kg x 1000
800
700
600
1C
30%
LE
25%
20%
15%
500
400
300
200
100
1D
2D
3D
4D
5D
10%
5%
6D
(Grade Plus Rolling)
TOTAL RESISTANCE
0
0
0 10 20 30 40 50 60
km/h
0 5 10 15 20 25 30 35 40 mph
SPEED
*at sea level
21
Page 22
789D Mining Truck Specications
Weight/Payload Calculation
(Example)
kg lb kg lb kg lb
1
Chassis
Tires (6) 37.0-R57 18 370 40,500 18 370 40,500 18 370 40,500
Standard Rims (6) 29-57 10 425 22,980 10 425 22,980 10 425 22,980
Estimated Empty Chassis Weight
2
Type of Truck Body
Body Weight 23 970 52,845 30 132 66,430 26 610 58,665
Fully Lined Body (Optional and Recommended) 6150 13,560 7350 16,200 9707 21,400
Estimated Operating Machine Weight
3% Debris Allowance
Potential Target Payload
3
4
2
1
Includes: common arrangement, 100% fuel (2082 L/550 gal), fluids and standard mandatory attachments.
2
Weights will vary dependent on configuration and may include ±2% variation due to standard material tolerances.
3
Calculations include 3% debris allowance. However, actual debris allowance should be considered based upon known site conditions.
4
It is recommended to work with your Global Mining representative to calculate target payload per specific site.
69 900 154,100 69 900 154,100 69 900 154,100
98 695 217,580 98 695 217,580 98 695 217,580
MSD Body X Body Dual Slope Body
128 815 283,985 136 177 300,210 135 012 297,645
3864 8,520 4085 9,006 4050 8,929
Tonnes Tons Tonnes Tons Tonnes Tons
192 211 184 203 185
204
22
Page 23
Standard equipment may vary. Consult your Cat dealer for details.
789D Standard Equipment
POWER TRAIN
Diesel engine/turbocharged/aftercooled:
– Ground level engine shutdown
– Ether starting aid (automatic)
– Aftercooler (separate circuit or air to air)
– Elevated low idle control
– Automatic starter protection
– Multi-point all pressure sensing
Braking system:
– Brake release motor (towing)
– Oil-cooled, multi-disc (front and rear)
(service retarding, parking, secondary)
– Automatic Retarder Control
– Engine overspeed protection
– Extended life brake disc material
Transmission:
– 6-speed, automatic powershift with
electronic control (TCC)
– Controlled throttle shifting
– Individual clutch modulation
– Body-up shift inhibitor
– Directional shift management
– Downshift/reverse shift inhibitor
– Oil level sensor
– Neutral start switch/coast inhibitor
– Body-up reverse neutralizer
– Programmable top gear
– Lock-up torque converter
– Rear axle continuous lubrication/
ltration
ELECTRICAL
Alarm, backup
Alternator, 105 amp
Batteries, 12V (2), 93 amp-hour
Converter, 12V electrical
Electrical system, 24V, 15 amp
Lighting system:
– Backup and hazard lights
– Auxiliary work lights (2) rear,
(1) RH side, (1) LH side
– Directional signals (front and rear LED)
– Engine compartment lights
– External payload lights
– Headlights with lo-hi beam selector
– Ladder light and service deck lights
– Left-hand ladder/service deck
– Stop/tail lights (LED)
– VIMS, blue light (LED)
OPERATOR ENVIRONMENT
STANDARD CAB
– Operator seat
– Non-suspension trainer seat
– Flip down front visor
– Standard side of cab access
DELUXE CAB
– Heated and ventilated operator seat
– Suspension trainer seat
– Retractable front visor
– Rear of cab access and standard side
ofcab access
– Vacuum, cab clean-out
– Operator Footrest
DELUXE COLD WEATHER CAB
– Heated and ventilated operator seat
– Suspension trainer seat
– Retractable front visor
– Rear of cab access and standard side
ofcab access
– Vacuum, cab clean-out
– Operator Footrest
– Deluxe Diffuser
Air conditioner
Auxiliary power connection/cigarette lighter
Diagnostic connection port
Dome courtesy light
Entertainment Radio Ready:
– 5 amp converter
– Speakers
– Antenna wiring
Gauges/indicators:
– Air cleaner service indicator
– Quad gauge panel
• Air pressure
• Brake oil temperature
• Engine coolant temperature
• Fuel level
Electric hour meter
Electric engine control fault indicator
Engine idle shutdown
Mirrors, right and left
Speedometer
Tachometer
Transmission gear indicator
VIMS message center with universal gauge
VIMS keypad
Heater/defroster (11 070 kCal/43,930 BTU)
Horn
Hoist, body control (electric)
Integrated object detection system
ROPS cab, insulated/sound suppressed
Seatbelt, operator, 75 mm/3" wide
Seatbelt, trainer, two points
Stairway and walkway access, 600 mm (24 in)
Steering wheel, tilt, padded, telescopic
Window, operator, electric powered
Windshield wiper, intermittent control
andwasher
FLUIDS
Extended Life Coolant to –35° C (–30° F)
OTHER STANDARD EQUIPMENT
Air line dryer
Auto lubrication system
Auxiliary “buddy” dumping quick connect
Auxiliary steering quick connect (towing)
Body mounting group
Center mounted rims (6) (29×57)
(used for 37.00 R57 tires)
Driveline guard (fully enclosed)
Fast ll fuel system
Ground level VIMS data port
Ground level battery disconnect
Rock ejectors
Supplemental steering (automatic)
Tie off points
Tow hooks (front)
Tow pin (rear)
Traction Control System
Vital Information Management System
23
Page 24
789D Optional Equipment
Optional equipment may vary. Consult your Cat dealer for details.
BODY
Dual slope body:
3
– Body, dual slope, 109 m
(142 yd3)
Dual slope body attachments:
– Extensions, 457 mm (18"), side, DS,
3
(161yd3)
123m
– Extension, wraparound tail, DS
– Liner, entire body, DS
– Liner, wraparound, DS, 450 BHN
– Rock deector, rear tire, DS
X body:
3
– Body, X, 123 m
(161 yd3)
X body attachments:
– Extensions, side, X, 185 mm (7"),
3
(171 yd3)
131 m
– Extensions, side, X, 385 mm (15"),
3
(181 yd3)
138 m
MSD II body:
3
– Body, MSD II, 130 m
(170 yd3)
MSD II body attachments:
– Extensions, side, MSD II,
3
(185 yd3)
141 m
– Extensions, side, MSD II,
3
(200 yd3)
153 m
Combination body:
3
– Body, combi, 153 m
(200 yd3)
Combination body attachments:
– Extensions, side, combi, 195 m
Gateless coal body:
3
– Body, gateless coal, 191 m
(250 yd3)
Gateless coal body attachments:
3
– Extensions, side, coal, 214 m
– Extensions, side, coal, 237 m
(280 yd3)
3
(310 yd3)
Body lighting group – rear:
– Directional signals (LED)
– Stop/tail lights (LED)
3
(255 yd3)
ELECTRICAL
Lockout transmission, ground level
Auxiliary work lights
(1) RH side, (1) LH side
POWER TRAIN
Prelube, engine
Oil renewal system
FILTRATION CONFIGURATIONS
Rear axle, cooler
OTHER ATTACHMENTS
Information management:
Control, road analysis (RAC)
Cold weather:
– Brake oil, recirculating
– Cold weather start
Service center:
– Service, 3516B, standard volume
– Service, 3516B, large volume
– Service, 3516C, standard volume
– Service, 3516C, large volume
– Service, engine oil, standard
Miscellaneous:
– Fire extinguisher, portable
– Hub odometer, kilometers
– Wheel chocks
– Gauge, brake wear indicator
ANTIFREEZE
Coolant, –50° C (–58° F)
24
Page 25
Notes
25
Page 26
Notes
26
Page 27
27
Page 28
789D Mining Truck
For more complete information on Cat products, dealer services, and industry solutions,
visitus on the web at www.cat.com
© 2011 Caterpillar Inc.
All rights reserved
Materials and specications are subject to change without notice. Featured machines
inphotos may include additional equipment. See your Cat dealer for available options.
CAT, CATERPILLAR, SAFETY.CAT.COM, their respective logos, “Caterpillar Yellow”
andthe“Power Edge” trade dress, as well as corporate and product identity used herein,
aretrademarks of Caterpillar and may not be used without permission.
24
AEHQ6237-01 (08-2011)
Replaces AEHQ6237
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