785CMining Truck

Cat 3512B Electronic Unit Injection EngineGross power at 1750 rpm 1082 kW 1450 hpFlywheel power at 1750 rpm 1005 kW 1348 hp

Body capacity (SAE 2:1) 78 m3 102 yd3

Max. operating weight 249 480 kg 550,000 lbPayload weight

Standard configuration 118-136 metric tons 130-150 tons

2785C Mining TruckEngineered for performance, designed for comfort, built to last.

Top performance.The 785C is designed for highproduction and low cost-per-tonhauling in mining and constructionapplications.

Reliable, durable operation.Rugged construction and easymaintenance guarantee extended life with low operating costs.

Mechanical Power TrainStarting with the high torque rise,Caterpillar 3512B, Electronic UnitInjection (EUI) diesel engine, through theelectronic, six-speed power shifttransmission, the mechanical power trainis designed and built by Caterpillar,assuring the highest standards forquality, performance, efficiency andreduced operating costs.pg. 4-5

Oil-cooled Disc BrakesCaterpillar four-wheel forced oil-cooled, multiple disc brakes arecontinuously cooled for exceptional,non-fade braking and retarding. TheIntegrated Braking Control (IBC)system integrates the AutomaticRetarder Control (ARC) on all wheelsand Traction Control System (TCS) ondrive wheels only into one system toenhance truck performance andproductivity and improve operatorconfidence. pg. 8

Engine Power Train IntegrationThe Caterpillar intelligent power traincombines engine, transmission andbrake information over the CAT DataLink to optimize overall truckperformance. The CAT Data Linkallows the engine and transmission toelectronically exchange information sothe components work together as asystem for increased component lifeand improved operator comfort. TheElectronic Technician (ET) softwareprogram can access stored diagnosticdata to significantly reduce downtimeand improve troubleshooting. pg. 6-7

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4StructuresCaterpillar truck frames are built toresist the most severe twisting, highimpact applications. Mild steel providesflexibility, durability and resistance toimpact loads even in cold climates. Theframe incorporates 21 castings and twoforgings in high stress areas forincreased strength and extended life.pg. 10

Operators StationThe 785C operators station has beensignificantly improved over previousmodels by ergonomically designing fortotal machine control in a comfortableand productive environment. Allcontrols, levers, switches and gaugesare positioned to maximize productivityand minimize operator fatigue.Electronic hoist control provides ease ofoperation. The integral ROPS structureprovides superior operator protection. pg. 12

Vital Information Management System(VIMS)VIMS monitors vital machine systemsand functions. It helps coach theoperator in the operation of the machineand alerts him to out of specificationconditions. Down time is reduced byallowing service personnel to accessmachine data for faster, more accuratediagnosis. VIMS provides informationto enhance equipment management,increase productivity and reduce cost-per-ton. pg. 13-14

4 New feature3

4EngineThe field proven 3512B EUI engine delivers the power, and reliability necessary to perform in the worlds most demanding mining and heavy construction applications.

The Caterpillar Electronic Unit Injector(EUI) diesel engine is a four-strokedesign that uses long, effective powerstrokes for more complete fuelcombustion and optimum efficiency.The 3512B is designed with highdisplacement and a low operating rpmrating for extended hours of servicebetween scheduled overhauls andreduced operating costs.

The 23 percent torque rise provideshigh lugging force during accelerationand less down shifting on grade or inrough underfooting for faster cycletimes. Torque rise effectively matchesthe transmission shift points tomaximize efficiency and yield higherperformance.

The 3512B EUI engine providesunmatched combustion efficiency:

n Electronic Unit Injector (EUI) is aproven high-pressure, direct injectionfuel system. New components of thefuel system provide 22 percent higherinjection pressures than the previousgeneration of 3500 engines. Thehigher pressures provide improvedresponse times and more efficient fuelburn with lower emissions and lesssmoke.

n Electronic Control Module (ECM)utilizes advanced engine managementsoftware to monitor, control andprotect the engine utilizing self-diagnosing electronic sensors. Themodule controls a wide spectrum ofengine functions, providing infinitelyvariable injection timing to maintainpeak performance.

n Two-piece articulated pistons utilizea deep bowl, low crevice volumedesign that enhances combustionefficiency, improves fuel efficiencyand lowers emissions.

n Separate circuit aftercooler allowsthe aftercooler coolant to operate atlower temperatures than jacket waterfor a denser air charge in thecombustion chamber.

Results:

n 3512B EUI has improved fuelefficiency by three percent; NOxlevels are reduced by 20 percent andtransient smoke levels are down by asmuch as 15 percent. No derating up to3048 m (10,000 ft).

Proven reliability, durability andenhanced serviceability:

n 500 hour service interval for engineoil, oil and fuel filter changes,increasing mechanical availabilityand production.

n Additional electronic protection ofthe engine during cold starts, highaltitude operations, air filter pluggingand high exhaust temperatureconditions.

n Quick diagnosis of engine conditionsenable effective maintenance andrepairs utilizing the ElectronicTechnician (ET) service tool.

3 Large, differential and double-reduction final drives provide torquemultiplication of 22.75:1 to furtherreduce stress on the drive train.

The hydraulic steering system providesprecise, controllable steering:n The steering system is a separate

circuit from the other hydrauliccircuits to prevent crosscontamination and provide easierserviceability.

n Supplemental steering is provided byaccumulators for emergency use.Designed to provide at least three 90degree turns after engine failure.

Cat center mounted rims and cast rearwheels are mounted using studs andnuts to minimize maintenance andprovide outstanding durability.

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The CAT mechanical power train isdesigned for optimum componentmatch. A wide application range isavailable in each gear. A 35 percentstep between each gear allows thetransmission to utilize the full torquerange of the 3512B engine, resulting infewer shifts for extended power trainlife.n Overall power train efficiency of

between 82 and 85 percent ismaintained up to 15 percent effectivegrade.

n Electric drive power train trucksproduce their peak efficiency of 76 to79 percent at approximately five toseven percent effective grade.

n Higher power train efficiencyprovides faster truck speeds with lessfuel consumption.

Transmission/Chassis Control (TCC)module communicates over the CATData Link with the engine ECM tomanage engine speed during shifts forincreased clutch life and operatorcomfort. When the transmission is insixth gear, the engine is allowed to runout to 2000 rpm, so the truck canachieve speeds up to 55 km/h (34 mph).The shifts points are set at the factoryfor optimal performance, efficiency andcomponent life.n TCC monitors and records key

operating conditions and parametersfor later downloading and diagnostictroubleshooting by service personnel.

1 Lock-up Torque Converter combinesthe maximum rimpull and cushionedshifting of torque converter drivewith the efficiency and performanceof direct drive. The lock-up clutchengages at approximately 8 km/h (5mph). During shifts the lock-upclutch quickly releases and re-engages to reduce power train torqueloads. This action provides forsmoother shifting, extendedcomponent life, and increasedoperator comfort.n Rimpull at stall is 752.5 kN

(169,313 lb) 32 percentgradeability at maximum operatingweight.

2 Six speed, planetary power shifttransmission is designed for thehigher horsepower of the 3512Bengine. The design makes thetransmission more robust, with an extended life between overhauls.

n The transmission utilizes adedicated oil tank and circuit forcooler, cleaner oil and extendedcomponent life.

Mechanical Power TrainCompletely designed and manufactured by Caterpillar to assure maximum efficiency, high quality, extended service life and low operating costs.

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6Engine/Power Train IntegrationCombining the electronic engine control with the Caterpillar electronically programmabletransmission control allows these critical power train components to work more intelligently.

The CAT Data Link electronicallyconnects the engine and transmissioncontrols to optimize overall power trainperformance, reliability and componentlife for reduced power train operatingcosts. To lower operating cost-per-tonthe system incorporates:n Controlled throttle shifting. Engine

rpm is regulated during a shift toreduce driveline torque stress forsmoother shifts, extended componentlife and improved operator comfort.

n Directional shift managementregulates engine speed duringdirectional shifts to prevent damagecaused by high speed directionalchanges. This prevents shifts intoreverse when forward ground speedsare in excess of 4.8 km/h (3 mph).This protects the transmission fromhigh shock loads created by abusivedirectional shifts.

n Neutral coast inhibitor prevents thetransmission from shifting to neutralat speeds above 6.5 km/h (4 mph).This protects the transmission againstoperating with insufficientlubrication.

n Body-up shift inhibitor prevents thetransmission from shifting above apre-programmed gear without thebody fully lowered.

n Reverse neutralized with body-up. If the hoist lever is activated and thetransmission is in reverse, thetransmission will automatically shiftto neutral.

n Engine overspeed protection. Thetransmission control senses possibleoverspeed conditions and up shiftsone gear. If overspeed conditionsoccur in top gear, the lock-up clutchis disengaged.

n Programmable top gear. Thetransmission top gear may beelectronically set using ET. Thisfeature helps operators maintainspeed limits. Reprogramming of thetop gear can only be accomplishedwith the ET service tool.

n Anti-hunt function. The transmissionwill not allow an upshift ordownshift for approximately 2.3seconds after a shift has occurred.This prevents gear hunting whenoperating near a shift point andminimizes transmission shifts toincrease component life.

n Downshift inhibitor. Thetransmission will not allow a downshift to occur until engine speedreaches the downshift point,preventing an engine overspeedcondition.

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VIMS

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VIMS MainModule

7n Electronic Technician (ET) allowsfor easy access to service diagnosticdata through the use of a singleservice tool.

n ET accesses data stored in the engineand transmission controls via theCAT Data Link. Information ontransmission shift data, engine speed,fuel consumption and other data canbe retrieved by ET.

Integrated Braking Control (IBC)combines braking controlenhancements into one system forefficiency and simplification. IBCsystems, Automatic Retarder Control(ARC), and Traction Control System(TCS) both utilize the standard oilcooled disc brakes in their operation.

1 Gauge Cluster Module

2 Message Center Module

3 Integrated Braking Control (IBC)

4 Transmission/Chassis Control (TCC)

5 Brakes

6 Wheel Sensor

7 Transmission

8 CAT Data Link

9 Engine Control Module (ECM)

10 Sensors

11 Electronic Unit Injector (EUI)

Improved diagnostics/serviceability.The electronic engine and transmissioncontrols provide enhanced diagnosticcapability. The ability to store bothactive and intermittent indicators willsimplify problem diagnosis and totalrepair time, resulting in improvedmechanical availability and loweroperating cost.

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ET

8Oil-cooled Disc BrakesReliable braking gives operators the confidence to concentrate on truck operation andmaximize productivity.

Caterpillar four-wheel forced oil-cooled, multiple disc brakes arecontinuously cooled for exceptional,non-fade braking and retarding. TheIntegrated Braking Control (IBC)combines control of ARC and TCS,utilizing standard oil-cooled brakes toenhance truck performance and increaseproductivity.

Oil-cooled disc brakes are designedwith large discs and plates for reliable,adjustment-free operation, providingsuperior performance and service life incomparison to shoe-type and dry discbrake systems.

An oil film prevents direct contactbetween the discs. The film absorbs thebraking forces by shearing the oilmolecules. The heat generated istransferred to the oil and carried awayto oil coolers, extending brake life.

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

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Caterpillars patented, two-pistondesign combines the service, secondary,parking brake and retarding functions inthe same robust system. n The primary piston is hydraulically

actuated and provides both serviceand retarding functions.

n The secondary piston is spring-applied and is held in the disengagedposition by hydraulic pressure.

n The brake system is designed so that,in the event hydraulic systempressure drops below a specifiedlevel, the spring-applied secondarypiston automatically applies thebrakes. These brakes are designed tohold a fully loaded truck on a 15percent grade.

No fuel is used during retarding. Theengine provides additional retarding byrunning against compression ondownhill hauls. During retardingapplications the engine ECM does notinject fuel into the cylinders forexceptional fuel economy.

Four corner retarding with 60/40percent split (rear/front) in brakingeffort provides superior control inslippery conditions. Control at all fourcorners increases operator confidencewhen compared to only rear wheeldynamic retarding systems.

9Integrated Braking Control (IBC)Electronically combines Automatic Retarding Control (ARC) and the Traction ControlSystem (TCS) into one, integrated control system.

1 Service Brake Sensor

2 Engine Sensor

3 ARC

4 ARC Switch

5 Brakes

6 Service Brakes

7 Axle Speed Sensor

8 TCS

ARC Production Advantages2500

2000

1500

1000

500

10Time (Seconds)

20 30 40 50 60

With Automatic Retarder Control(average speed, 1950 rpm)

With Manual Retarder Control(average speed, 1730 rpm)

Engi

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peed

(rpm

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700

The Automatic Retarder Control (ARC)is an integral part of the intelligentpower train. It electronically controlsretarding on grade to maintain optimumengine rpm and oil cooling. Settings areadjustable from 1850-1950 rpm inincrements of 10 rpm. While ARCmodulates the brakes, the operator mayalso apply additional braking forceusing either the manual retarder or thebrake pedal. When the operator appliesthe throttle, ARC is deactivated. Anauto resume feature reactivates thecontrol without additional operatorinput.

ARC results in:

n Increased production with fasterdownhill speeds. By maintainingconsistently higher engine speeds,overall truck speed will be higherthan a manually controlled truck.

n Excellent controllability and reducedoperator effort. Automatic brakemodulation provides a smoother ride,better control in slippery conditionsand allows the operator to focus moreon driving.

n Faster troubleshooting and diagnosiswith self-diagnostic capability andthe ability to communicate with ETthrough the CAT Data Link.

n Reduced operator fatigue resultingfrom ease of operation.

n Engine overspeed protection. ARCwill automatically activate whenengine speed exceeds factory presetlevels, regardless of other operatorinputs, including when the system isturned off, to help ensure thatengine overspeed conditions do notoccur.

ARC production advantages (versusmanual retarder control) are illustratedin the chart below.n ARC can increase vehicle speed by

as much as 15 percent over manualretarder control.

n The system allows trucks to operateat maximum speeds with aconsistently high engine speed.

n Truck handling is significantlyenhanced through improved retardingmodulation.

Traction Control System (TCS) improvestraction and truck performance in poorunderfoot conditions by electronicallymonitoring and controlling rear wheelslippage.n Axle sensors monitor wheel speed. If

slippage exceeds a set limit, the oilcooled disc brakes engage to slow thespinning wheel. Torque is thenautomatically transferred to the wheelwith better traction.

n Utilizes normal differential action toprovide superior maneuvering in poorunderfoot conditions. Should thesensors fail, normal differential actionis still available to maintain controland steering.

n Operators feel more confident withthe anti-slip benefits provided by theTCS.

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ARC TCS

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The 785C frame uses a box-sectiondesign and deep penetrating,continuous wrap around welds to resistdamage from twisting loads withoutadding extra weight. Frame repairs canbe made without preheating in ambienttemperatures above 16 C (60 F)avoiding metallurgy destruction.n Caterpillar truck frames use mild

steel providing flexibility, durabilityand resistance to impact loads evenin cold climates.

n The frame incorporates two forgingsand 21 castings in high stress areasproviding increased strength overfabricated structures.

StructuresThe backbone of the Cat truck.

1 Castings have large radii and areused in areas of high stressconcentration to dissipate the stressesthat can cause fatigue and cracking.n Castings allow welds to be

relocated to areas of lower stress,enhancing frame life.

2 Rollover Protection Structure (ROPS)is integral to the cab and integral tothe frame. The cab is resilientlymounted to the frame to reducevibration and noise levels.

The suspension system is designed todissipate haul road and loadingimpacts:n Four, independent variable rebound

suspension cylinders absorb shocksbefore forces get to the mainframe.This extends frame life and providesthe operator a more comfortable ride.

n Rear cylinders allow axle oscillationand absorb the bending and twistingstresses caused by uneven and roughhaul roads rather than transmit themto the main frame.

n Front cylinders are mounted to theframe and serve as steering kingpins.This provides for a tight turningradius, good maneuverability andreduced truck maintenance. Frontspindles and wheels are rigidlymounted to the cylinder rod ends,eliminating caster and camberadjustments.

n Front wheel caster and camber areset at the factory, no longer requiringfield adjustments.

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Truck Body SystemsCaterpillar builds a variety of rugged, durable bodies to perform in the toughest miningapplications.

1 Standard dual-slope body designprovides excellent load retention, alow center of gravity and cleandumping characteristics.n Reinforced, rolled steel top rail

increases body strength andprotects the body from damagecaused by the loading tool orfalling material.

n Eight degree V reduces shockloading and centers the load.

n 7.5 degree forward body slope and16 degree ducktail slope helpsretain loads on steep grades.

n Box-beams in floor, sidewalls, toprail, corner and cab canopy areasprovide added impact resistance.

2 Flat floor body design providessmooth metered dumping and higherdump clearances.n Flat floor design improves wear

characteristics of body tail.n 12 degree forward body floor

slope.n 400 Brinell steel.

Custom truck body options are availableto match individual job siteapplications. These products arespecifically designed to match materialhauled and provide extended servicelife. Your Caterpillar Dealer, throughCustom Products, can provide a bodysystem that will help you obtain thelowest cost-per-ton hauling solution.n Lightweight bodies to maximize

payloads in lighter, less abrasivematerial.

n Bodies to allow easy unloading ofsticky materials with high contactadherence qualities.

n Bodies that provide a larger targetarea for the loading tool.

n Miscellaneous products availableinclude: ducktail extensions, sideboards, tumblebars, rock boxes androck shedders.

Liner options are available to helpextend the body systems life. A variety of steel grades provideoptions to absorb impacts whileresisting abrasion. Numerous optionscan be configured to save weight andextend the life: n A variety of steel grades: 260, 400

and 500 Brinell hardness as well asoverlay coatings.

n Wear plates in high wear areas.n Attachment options, huck bolting and

welding.

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The operating station on the 785C isergonomically designed for excellentmachine control in a comfortable,productive, and safe environment.

Exceptional all-around visibilityreduces strain and fatigue allowingconfident maneuvering and increasedproductivity.

Integral, sound-suppressedROPS/FOPS Cab is standard. The cab isresiliently mounted to the mainframeand isolates the operator from soundand vibration. (Sound levels are lessthan 80 dB(A) in the operatorcompartment as per SAE J1166 workcycle rating.)1 Ergonomically designed, air

suspension seat is fully adjustablefor operator comfort.n Retractable 75 mm (3") wide seat

belt provides positive,comfortable restraint.

n Integral adjustable armrest.

2 Electric hoist control is mountednext to the operators seat for easeof operation. This is a low effortcontrol to minimize operator input.

3 Secondary brake pedal is locatedon the floor to provide easyoperator control.

4 VIMS displays and operator keypad for precise machine statusinformation.

5 Tilt and telescoping steering wheelimproves operator access andcomfort.

6 Transmission console has beenredesigned with backlit gearindicators and ergonomic shiftknob.

7 Large storage compartment islocated under the trainer seat.

8 Trainer seat has wide hip andshoulder room. A back rest and seatbelt are standard. An optional airsuspended seat is available.

9 Powered operator window isstandard. Sliding trainer seatwindow is standard.

10 Operator controls for turn signal,high beam, intermittent windshieldwiper, windshield washer and hornhave been redesigned for operatorefficiency and comfort.

11 Standard heater and air conditionerhave a more efficient design,permitting increased flow,modulation, and serviceability.These systems provide fresh,pressurized, temperature-controlledair circulation.

Radio ready cab prewired with powerconverter, speakers, wiring harness,and antenna. Provision for add-oncommunication systems.

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Operators StationControl ease and comfort maximizes productivity.

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VIMS is an integrated Caterpillar-designed system that monitors machineperformance to provide criticalinformation on a real-time basis. VIMSmonitors many of the machinessystems through a single simple systemthat allows quick exchange ofinformation for smooth, efficientoperations. This helps keep the 785Cperforming at top production levels.

Gauge cluster in the cab maintains aconstant display of several, machinefunctions:n Engine coolant temperature.n Brake oil temperature.n Air system pressure.n Fuel level.

Speedometer/Tachometer/GearIndicator.

VIMS keypad allows the operator orservice technician to access through themessage center, gauge values (real-time) and stored information. Thekeypad can also be used by servicepersonnel to access diagnosticinformation.

Message center displays operatorrequested information and utilizes a three-category warning system to alertthe operator to an abnormal machinecondition.

The three-category alert systemprovides advisory information on anexception basis to the operator via themessage center on abnormal machineconditions. The information isdisplayed when conditions in amonitored system fall outside aprescribed setting for ordinaryoperations.

n Category I activates the alertindicator lamp when a systemcondition has been identified. (Noaction is required at this time.)Usually all that is required is toinform service personnel on thealerted condition as soon aspossible.

n Category II, a warning lamp(located above the gauge cluster)flashes in addition to the Category Ialert indicator lamp in the displaypanel. Instructions are displayed onhow machine operation should bemodified or which service shouldbe performed.

n Category III, the highest alert,sounds an audio action alert inaddition to the Category II alarms.The action lamp and alert remainon until the system readings returnto normal or the machine is shutdown.

Vital Information Management System (VIMS)Provides operators, service technicians and managers with vital machine and productiondata.

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VIMS simplifies trouble shooting,reduces down time and lowers operatingcosts by allowing minor problems to becorrected before they cause extensivedamage. Many sensors are incorporatedinto machine systems to monitorconditions.

Production management, a featurecomponent of VIMS, enhances truckand loading tool effectiveness forimproved fleet productivity and reducedoperation and maintenance cost.n Utilizes Cat-developed technology to

sense strut pressure to determinepayload weight accurately.

n Maximizes truck production whileavoiding future costs and downtimerelated to overloading.

n External lights on both sides of thetruck signal loading tool operatorwhen to cease loading.

n Stores 2400 cycles for a record ofpayload weight, cycle segment times,cycle segment distances and actualclock time and date of each cycle.

n Data can be accessed through themessage center, transmitted viaoptional radio or downloaded fordetailed analysis.

n Accurate to within 5 percent of theactual weight over a normal operatingshift.

Vital Information Management System (VIMS)Enhances truck and loader effectiveness for improved fleet productivity and reducedoperating and maintenance costs.

Well-managed mining operations focuson maximizing production and reducingcosts, which should result in lower cost-per-ton. When used properly, VIMS canbe used to increase productivity andreduce costs.

Payload Weight Distribution

Perc

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Payload Weight (Tons)

212

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1 Recommended Payload Ranges

Inefficient Payload Ranges

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Loads using the Payload Measurement System

Loads with no Payload Measurement System4

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The VIMS off-board software program(VIMS-PC) allows service personnel todownload a complete record ofproduction information, machine dataevents and system diagnostics to alaptop computer.

The VIMS-PC program uses thisinformation to generate usable reportsfor better machine management. Theinformation can also be used toestablish a baseline for machineperformance in specific applications,and to:n Improve the effectiveness of

scheduled maintenance programs.n Maximize component lives.n Improve machine availability.n Lower cost-per-ton.

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Parts availability. Most Cat parts areimmediately available off the shelf. CatDealers rely on our worldwidecomputer network to find parts instantlyand minimize your machine downtime.

Flexible financing. Your dealer canarrange attractive financing on theentire line of Cat equipment.

Machine management service. CatDealers help manage your equipmentinvestments with:n Vehicle systems analysis to match the

right machine to your job conditions.n Effective preventive maintenance

programs.n Diagnostic programs like Scheduled

Oil Sampling Analysis and TechnicalAnalysis.

n Exchange components for quickrepairs.

n Remanufactured products or rebuiltcomponents for maximumavailability and lower costs.

n Information to make the most cost-effective repair option decisions.

n Training for operators and mechanics.

Literature support. Operation andmaintenance manuals are easy to usehelping you get the full value of yourequipment investment.

Remanufactured components areeconomically available for manyCaterpillar components.

Ground-level access providesconvenient servicing to tanks, filtersand compartment drains, as well asengine shutdown capability. VIMS hasa ground-level access port for easierdownloading of information.

Caterpillar Electronic Technician (ET)accesses machine data easily. It quicklyruns tests, makes calibrations andretrieves system data to help find andcorrect problems before they becomecostly failures.

The maintenance platform providesaccess to engine, air filters, steeringhydraulic tank and batterycompartment.

Automatic lubrication system providesgrease to necessary components on aregular basis to reduce maintenance andimprove machine availability.

Fast fill service center (Wiggins)features high speed fuel and oilexchange.

Scheduled Oil Sampling (SOS) valvesspeed sampling and analysis reliability.

Oil Renewal System (ORS) is an optionavailable which extends oil changeintervals and reduces waste oil handlingby continuously burning oil from thesump through normal engine operation.Make-up oil must be added tocompensate for oil burned.

Individual, interchangeable enginecylinder heads can be removed easilyfor visual inspection of internal parts.

In-frame access allows maintenanceand minor repairs without majorcomponent removal. It also facilitatesmajor component removal andreplacement, if necessary.

Quick coupler pressure taps are locatedin most hydraulic systems providingclear, quick pressure checks anddiagnostics.

Radial seal air filters are easy tochange, reducing time required for airfilter maintenance.

Sealed electrical connectors lockoutdust and moisture. Wires are colorcoded for easy diagnosis and repair.Wiring harnesses are braided and have a protective sheath to prevent damage.

Total Customer Support and ServiceabilityCaterpillar machines are designed to spend less time down for maintenance, allowing more time on the job.

16 785C Mining Truck specifications

TransmissionCaterpillar six-speed, electronicallycontrolled, automatic power shifttransmission.

Maximum travel speeds (33.00-R51 tires)

1900 rpm km/h mphForward 1 12.1 7.5

2 16.3 10.23 22.2 13.84 29.9 18.65 40.6 25.26 54.8 34.0

Reverse 11.0 6.8Featuresn six speeds forward and one reversen reverse and first gear are both torque

converter driven with lock-up in firstthrough sixth gears

n single-lever shift control providesautomatic shifting in all gears up tothe one selected by the control lever

n each shift is individually modulatedfor maximum smoothness

n separate hydraulic circuit with coolern controlled throttle shift and directional

shift management maximize shiftsmoothness and minimize shiftdriveline stress

n electric control has built-indiagnostics and facility code memory,event memory and programmablefeatures

BrakesMeets the SAE J1473 OCT90, ISO 3450-1985 standards up to 249 480 kg(550,000 lb) maximum operating weight.

Featuresn service

- forced-oil-cooled- air-over-oil actuated- front and rear disc brakes- sealed from dirt and water- individually serviceable as units

n retarding system- hand operated friction lever provides

modulated engagement of servicebrakes for retarding

- Automatic Retarder Control standard

n secondary braking- spring-engaged, hydraulically

released- use disc brakes in service system

n parking brakes- spring-engaged, hydraulically

released- use disc brakes in service system- toggle switch activated

n traction system- minimize wheel slip by transferring

torque to wheel with traction- Traction Control System (TCS)

standard

EngineFour-stroke cycle, 3512B twin turbocharged and aftercooled diesel engine.

*Power rating conditionsn based on standard conditions of

25 C (77 F) and 99 kPa (29.32 in Hg) dry barometer

n used 35 API gravity fuel having anLHV of 42,780 kJ/kg (18,390 Btu/lb)when used at 30 C (86 F) [ref. a fueldensity of 838.9 g/L (7.001 lb/U.S. gal)]

n net power advertised is the poweravailable at the flywheel when theengine is equipped with fan, aircleaner, muffler and alternator

n no derating required up to 3048 m(10,000 ft) altitude

n automatic derate is included in theelectronic controls

Featuresn full electronic controln high pressure Electronic Unit

Injectionn two hard faced intake and two exhaust

valves per cylinder with valve rotatorsand hard, alloy-steel seats

n self-aligning roller followers on camshaft

n two-piece pistons have steel crowns,thermally isolated aluminum skirts,three rings each and are cooled bydual oil spray

n steel backed, copper-bondedcrankshaft bearings

n hardened crankshaft journalsn dry-type air cleaners with primary and

secondary elements and precleaner n 24-volt electric system with 105-amp

alternator and two 93-amp-hour, low-maintenance, high-output, 12-voltbatteries

n vane type air starter, quick connect forsupplemental air supply which isstandard

Net power kW hpCaterpillar 1005 1348ISO 9249 1005 1348SAE J1349 1005 1348EEC 80/1269 1005 1348

DimensionsBore 170 mm 6.7 inStroke 190 mm 7.5 inDisplacement 51.8 liters 3,158 in3

Ratings at 1750 rpm* kW hpGross power 1082 1450Net power 1005 1348

The following ratings apply at 1750 rpmwhen tested under the specified standardconditions for the specified standard:

Final DrivesPlanetary, full-floating

Ratios:Differential 2.10:1Planetary, double reduction 10.83:1Total reduction 22.75:1

Braking surface 150 962 cm2 (23,405 in2)

17785C Mining Truck specifications

FrameFull box-section with torque tubecrossmember.

Featuresn integral front bumpern front box beams for suspension

cylinder and ROPS supportn box-section rear crossmember for

body and ROPS support withattachment points for maintenanceplatform and rear engine hood hingesupport

n castings are used to provide additionalstrength in critical stress areas

n mild-steel plates [310 mPa (42,000psi) minimum yield strength] andcastings [241 mPa (35,000 psi)minimum yield strength] provide:- flexibility- durability- good resistance to impact loads

SuspensionIndependent, self-contained, oil-pneumatic suspension cylinder on eachwheel.

Featuresn variable rebound rate reduces impact

and smooths riden front suspension cylinders are bolted

to upper and lower frame members formaximum support

n rear sway bar attaches to frame anddifferential housing, minimizes lateralsway, improves machine handling andoperator comfort

Body HoistsTwin, two-stage hydraulic cylindersmounted outside the main frame, doubleacting in second stage.

Featuresn power raise in both stages and power

down in first stage downn pump capacity is 750 L/min

(198 gpm)n relief valve setting is 172 bar/17 238

kPa (2,500 psi)n body raise time (1750 engine rpm) is

15.18 sec.n body lower time

- power down at high idle 15.94 sec.- float 16.17 sec.

n electronic body controln automatic body-lower modulation to

reduce frame impact

SteeringSeparate hydraulic system.

Featuresn the steering hydraulic system is

separate from the main hydraulicsystem to prevent cross-contamination

n secondary steering is provided by abladder-type accumulator

n normal and secondary steeringsystems meet SAE J1511 OCT90 andISO 5010-1984 standards up tomaximum operating weight249 480 kg (550,000 lb)

n twin, double-acting cylindersn front suspension cylinders serve as

kingpinsn turning diameter on front wheel track

(standard tires) 27.5 m (90' 2")n machine clearance turning circle

30.2 m (99' 2")n steering angle (left or right) 36

Featuresn productive capabilities of the 785C

truck are such that, under certain jobconditions, Tkm/h/Ton-mph limits ofthe tires could be exceeded and,therefore, affect production

n Caterpillar recommends the userevaluate all job conditions and consultthe tire manufacturer to make propertire selection

ROPSIntegral ROPS cab is standard.

Featuresn ROPS (Rollover Protection Structure)

offered by Caterpillar for the machinemeets ROPS criteria SAE J1040APR88, SAE J231 JAN81, ISO 3471-1994, ISO 3449-1992 LEVEL II

n when properly installed andmaintained, the cab offered byCaterpillar when tested with doors andwindows closed as per work cycleprocedures specified in ANSI/SAEJ1166 MAY90, results in an operatorsound exposure Leq (equivalent soundlevel) of less than 80 dB(A)

n this operator weighted sound exposuremeets OSHA and MSHAoccupational noise exposure criteria

BodyStandard dual-slope main floor with Vbottom.

Featuresn high-tensile, heat-treated steel side

wall, front wall and floor plates with900 mPa/9000 bar (130,500 psi)minimum yield strength

n exhaust heating is optionaln V bottom centers load and

maintains low center of gravityn rear floor ducktail helps retain loads

and reduce spillagen body options to meet specific mine

application needs are availablethrough your Cat Dealer from CustomProducts

Effective cylinder stroke:Front 318 mm 12.5"Rear 165 mm 6.5"Rear axle oscillation 5.5 Canopy plate thickness:

Front (40%) 6 mm 0.25"Rear (60%) 10 mm 0.39"

TiresStandard: 33.00-R51 (E4)-1328 kg (-2,925 lb): 33.00-R51 (E3)

Exterior Sound Rating

n The machine in a standardconfiguration, when measured andoperated as per the prescribed modesin ANSI/SAE J88 JUN86, has a 15 msound pressure level of 89 dB(A) forthe mode that gives the highest level

18 785C Mining Truck specifications

Standard vehicle:(with body option 1) kg lbChassis with hoistand body mountinggroup with tires 74 466 164,166Option 1 (body, empty)

21 258 46,865Total empty weight 95 724 211,031Max. operating

weight 249 480 550,000Weight distribution (machine

with body option 1):Empty Loaded

Front Axle 47% 33%Rear Axle 53% 67%

DimensionsAll dimensions are approximate

Service Refill CapacitiesU.S.

L GallonsFuel tank 1893 500Cooling system 379 100Crankcase 204 54Differentials 436 115Front wheels, each 11.5 3Final drives, each 74 19.5Steering tank 90 24Steering system

(includes tank) 117 31Brakes, converter,

Hoist tank 337 89Brakes, converter,

Hoist system(includes tank) 641 169

Transmission Hydraulic tank 76 20

Transmission system(includes tank) 248 65.5

Weights(approximate)

NOTE: Standard dual-slope body shown.

19785C Mining Truck specifications

Gradeability/Speed/Rimpull

To determine gradeability performance:Read from gross weight down to thepercent of total resistance. Totalresistance equals actual percent gradeplus 1% for each 10 kg/t (20 lb/ton) ofrolling resistance. From this weight-resistance point, read horizontally to thecurve with the highest obtainable gear,then down to maximum speed. Usablerimpull will depend upon tractionavailable and weight on drive wheels.

mph

km/h

33.00-R51 TiresGross Weight

70 100 150 200 300 400 600 lb x 1000

90

70

5040

30

20

15

10

5

3

2

1

200

100

50

20

10

5

20 5 10 15 20 25 30 35 40 45 50

0 10 20 30 40 50 60 70 80

Speed

Rim

pull

Tota

l Res

ista

nce

(Gra

de p

lus

Rolli

ng)

5 15 25 35 45 55 65 75

20 30 40 50 70 100 150 200 300 kg x 1000

1st Gear

1st Gear

2nd Gear

3rd Gear

4th Gear

5th Gear

6th Gear

4%

6%

8%10%

15%

LE

20%25%

30%

2%

kg x1000

lb x1000

Torque Converter DriveDirect Drive

Typical Field Empty Weight136 080 kg (300,000 lb) Load

20 785C Mining Truck specifications

To determine retarding performance: Add lengths of alldownhill segments and, using this total, refer to properretarding chart. Read from gross weight down to the percenteffective grade. Effective grade equals actual % grade minus1% for each 10 kg/t (20 lb/ton) of rolling resistance. From thisweight-effective grade point, read horizontally to the curvewith the highest obtainable gear, then down to maximum

descent speed brakes can properly handle without exceedingcooling capacity. The following charts are based on theseconditions: 32 C (90 F) ambient temperature, at sea level,with 33.00R51 tires.NOTE: Select the proper gear to maintain engine rpm at thehighest possible level, without overspeeding the engine. Ifcooling oil overheats, reduce ground speed to allowtransmission to shift to the next lower speed range.

Retarding Performance

0 10 20 30 40 50 60 70 80 90

0 5 10 15 20 25 30 35 40 45 50 55

0 100 200 300 lb x 1000400

mph

km/h

0 30 60 90 120 150 180 210 240 270 kg x 1000

1st Gear

500 600

5th Gear

6th Gear

2nd Gear

3rd Gear

5%

15%

10%

20%25%30%

4th Gear

SpeedContinuous Grade Length

Effe

ctiv

e G

rade

(Fav

orab

le)

Gross Weight

Typical Field Empty Weight136 080 kg (300,000 lb) Load

21785C Mining Truck specifications

0 10 20 30 40 50 60 70 80 90

0 5 10 15 20 25 30 35 40 45 50 55

0 100 200 300 lb x 1000400

mph

km/h

SpeedGrade Distance 450 m (1500 ft.)

Effe

ctiv

e G

rade

(Fav

orab

le)

0 30 60 90 120 150 180 210 240 270 kg x 1000

Gross Weight

1st Gear

500 600

6th Gear

2nd Gear

3rd Gear

5%

15%

10%

20%25%30%

4th Gear5th Gear

0 10 20 30 40 50 60 70 80 90

0 5 10 15 20 25 30 35 40 45 50 55

0 100 200 300 lb x 1000400

mph

km/h

SpeedGrade Distance 600 m (2000 ft.)

Effe

ctiv

e G

rade

(Fav

orab

le)

0 30 60 90 120 150 180 210 240 270 kg x 1000

Gross Weight

1st Gear

500 600

6th Gear

2nd Gear

3rd Gear

5%

15%

10%

20%25%30%

4th Gear5th Gear

0 10 20 30 40 50 60 70 80 90

0 5 10 15 20 25 30 35 40 45 50 55

0 100 200 300 lb x 1000400

mph

km/h

SpeedGrade Distance 900 m (3000 ft.)

Effe

ctiv

e G

rade

(Fav

orab

le)

0 30 60 90 120 150 180 210 240 270 kg x 1000

Gross Weight

1st Gear

500 600

6th Gear

2nd Gear

3rd Gear

5%

15%

10%

20%25%30%

4th Gear5th Gear

0 10 20 30 40 50 60 70 80 90

0 5 10 15 20 25 30 35 40 45 50 55

0 100 200 300 lb x 1000400

mph

km/h

SpeedGrade Distance 1500 m (5000 ft.)

Effe

ctiv

e G

rade

(Fav

orab

le)

0 30 60 90 120 150 180 210 240 270 kg x 1000

Gross Weight

1st Gear

500 600

6th Gear

2nd Gear

3rd Gear

5%

15%

10%

20%25%30%

4th Gear5th Gear

22 785C Mining Truck specifications

Standard EquipmentStandard equipment may vary. Consult your Caterpillar Dealer for specifics.

Air cleaner (2)Air conditionerAir line dryerAir starter, vane-typeAlarm, back-upAlternator (105-amp)Automatic Retarder ControlBatteries, 93-amp-hour, low-

maintenance, 12-volt (2)Body mounting groupBody prop cableBrake release motor for towingBrakes system:

Oil-cooled, multiple-disc, frontand rear

ParkingSecondary, emergency

Cab, ROPS:AshtrayCigarette lighterCoat hookDiagnostic connectorElectric window (operator only)Glass, tintedHeater/defroster: 11 070 kCal

(43,930 Btu)HornInsulated and sound suppressedLight, dome/courtesyMirrors, right and leftQuad-Gauge Panel:

Air pressureBrake oil temperatureCoolant temperatureFuel level

Seat, air suspensionSeat, passenger, with storage area

Seat belts, 75 mm (3") wideretractable

SpeedometerSteering, automatic supplementalSteering wheel, tilt, padded,

telescopicStorage compartmentSun visorTachometerTransmission gear indicatorVIMS Dataports (2)VIMS KeypadVIMS Message Center with

Universal GaugeWindshield wiper and washer

Crankcase protectionDriveline operator safety guardDumping, auxiliary quick connect for

buddy dumpingElectrical system, 24-volt to 12-voltEngine Caterpillar 3512B with

Electronic Injection and Multi PointOil Pressure Sensing

Fast-fill fuel system, WigginsGround level:

Battery disconnectEngine shutdownVIMS Dataport

Lighting system:Back up lights, halogenDirection signals and hazard warning

(rear halogen)Headlights, halogen, with dimmerLH Ladder light and service

deck lightsStop and tail lights (LED)Under-hood light

Oil change system, quick serviceReservoirs (separate):

Brake/converter/hoistSteeringTransmission

Rims, center mounted for33.00-R51 tires

Rock ejectorsStarting aid, ether, automaticSteering, auxiliary quick connect

for towingTie down eyesTow hooks, frontTow pin, rearTraction Control SystemTransmission, six-speed, automatic

power shift, electronic control anddownshift inhibitor, reverseneutralizer during dumping, andneutral start switch, reverse shiftinhibitor, controlled throttle shifting,directional shift management, neutralcoast inhibitor, body-up shiftinhibitor

Vandalism protection locksVital Information Management System

with Production Manager

23785C Mining Truck specifications

Optional EquipmentWith approximate changes in operating weights.Optional equipment may vary. Consult your Caterpillar Dealer for specifics.

kg lbBodies see chart belowBody extensions:

Tail (Option 1) 665 1,465Sideboards (Option 1 - increases

capacity to 91 m3 / 119 yd3) 798 1,760Body heat (exhaust) 36 80Body and tail extension liners (900 mPa/9000 Bar / 130,500 psi

minimum yield strength; 400 Brinell steel)Full-length liner (Option 1) 7633 16,828Tail extension liner (Option 1 - use with

full liners when tail extension used) 338 745Grid liner (Option 2 - covers rear

third of body only) 1145 2,525Fuel tank 2500 L (660 gal.) 209 460

kg lbHeater, fuel

recirculation type, non-electric 2 5Heater, engine coolant and oil

120-volt external power source 2 5Heater, engine coolant and oil

240-volt external power source 10 22Oil Renewal System 11 25Prelube system 24 53Rim, spare for 33.00 - 51 tire 889 1,960Shutter group, inside mounted 265 585Starting system,

Air (TDI Turbine) -5 -10Air (IR Turbine) -17 -37

Variable pitch fan, Flexxaire 273 600Variable speed fan, Rockford 182 400

Truck Body

CapacityStruck 57 m3 74 yd3 74 m3 96 yd3Heaped 2:1 (SAE) 78 m3 102 yd3 91 m3 119 yd3

Empty Loading Height 4978 mm 16' 4" 5555 mm 18' 10"Plate Thickness

Sidewall 12 mm .47" 12 mm .47"Front 14 mm .55" 14 mm .55"Bottom 20 mm .79" 20 mm .79"

Weight* 21 258 kg 46,864 lb 24 595 kg 54,175 lb

Specification and Standard Dual-Slope Flat FloorDimensions Option 1 Option 2

* - Standard dual-slope body has no sideboards, tail extension, or liners.* - Flat floor body has 20 sideboards included, no tail extension or liners.

400 Brinell steel is standard.Other options are available through Custom Products. Consult your Caterpillar Dealer for more information.

785C Mining Truck

AEHQ5320-01 (2-99)(Replaces AEHQ5060)

Featured machines may include additional equipment only for special applications.

See your authorized Caterpillar Dealer for available options.

Materials and specifications are subject to change without notice.

www.CAT.com 1998 Caterpillar

Printed in U.S.A.

785C Mining TruckIntroductionMechanical Power TrainEngine Power Train IntegrationOil-cooled Disc BrakesStructuresOperators StationVital Information Management System (VIMS)

EngineThe Caterpillar Electronic Unit Injector (EUI)The 23 percent torque riseThe 3512B EUI engine provides unmatched combustion efficiency:Electronic Unit Injector (EUI)Electronic Control Module (ECM)Two-piece articulated pistonsSeparate circuit aftercooler

Results:Proven reliability, durability and enhanced serviceability:

Mechanical Power TrainThe CAT mechanical power train is designed for optimum component matchTransmission/Chassis Control (TCC) moduleTCCLock-up Torque ConverterRimpull

Six speed, planetary power shift transmissionLarge, differential and double-reduction final drivesThe hydraulic steering systemCat center mounted rims and cast rear wheels

Engine/Power Train IntegrationThe CAT Data LinkControlled throttle shiftingDirectional shift managementNeutral coast inhibitorBody-up shift inhibitorReverse neutralized with body-upEngine overspeed protectionProgrammable top gearAnti-hunt functionDownshift inhibitor

Improved diagnostics/serviceability.Electronic Technician (ET)

Integrated Braking Control (IBC)

Oil-cooled Disc BrakesCaterpillar four-wheel forced oil-cooled, multiple disc brakesOil-cooled disc brakesAn oil filmCaterpillars patented, two-piston designThe primary pistonThe secondary piston

No fuel is usedFour corner retarding

Integrated Braking Control (IBC)The Automatic Retarder Control (ARC)ARC results in:Increased productionExcellent controllability and reduced operator effortFaster troubleshooting and diagnosisReduced operator fatigueEngine overspeed protection

ARC production advantagesTraction Control System (TCS)

StructuresThe 785C frame uses a box-section designCastings have large radiiRollover Protection Structure (ROPS)The suspension system

Truck Body SystemsStandard dual-slope body designReinforced, rolled steel top railBox-beams

Flat floor bodyCustom truck body optionsLiner options

Operators StationThe operating stationExceptional all-around visibilityIntegral, sound-suppressed ROPS/FOPS CabErgonomically designed, air suspension seatElectric hoist controlSecondary brake pedalVIMS displays and operator key padTilt and telescoping steering wheelTransmission consoleLarge storage compartmentTrainer seatPowered operator windowOperator controlsStandard heater and air conditionerRadio ready cab

Vital Information Management System (VIMS)VIMS is an integrated Caterpillar-designed systemGauge clusterSpeedometer/Tachometer/Gear Indicator.VIMS keypadMessage centerThe three-category alert systemCategory ICategory IICategory III

VIMS simplifies trouble shooting,Production managementThe VIMS off-board software program (VIMS-PC)Payload Weight Distribution

Total Customer Support and ServiceabilityParts availabilityFlexible financingMachine management serviceLiterature supportRemanufactured componentsGround-level accessCaterpillar Electronic Technician (ET)The maintenance platformAutomatic lubrication systemFast fill service center (Wiggins)Scheduled Oil Sampling (SOS)Oil Renewal System (ORS)Individual, interchangeable engine cylinder headsIn-frame accessQuick coupler pressure tapsRadial seal air filtersSealed electrical connectors

SpecificationsEngineTransmissionFinal DrivesBrakesFrameROPSSteeringSuspensionBodyBody HoistsTiresExterior Sound RatingDimensionsService Refill CapacitiesWeightsGradeability/Speed/RimpullRetarding PerformanceContinuous Grade LengthGrade Distance 450 m (1500 ft.)Grade Distance 600 m (2000 ft.)Grade Distance 900 m (3000 ft.)Grade Distance 1500 m (5000 ft.)

Standard EquipmentOptional EquipmentTruck Body