Off-Highway Trucks 789D SETTING THE BAR IN ITS SIZE CLASS

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789D
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789D

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Overview

What will it take to boost your bottom line? A truck with a tradition of proven performance in a wide variety of applications? A truck with the lowest cost per ton in its size class, for an overall reduction in your operating costs? The reliability and reduced costs that come with long life — from the engine and powertrain to the components, brakes and frame? With the Cat® 789D, you get all of this — and more. The 789D offers the lowest cost per ton in its size class and high reliability — reducing overall costs and delivering a better bottom line to the most important mine in the world: yours.

10-15% COST PER TON ADVANTAGE OVER THE COMPETITION

The 789D delivers a faster speed on grade than competitive trucks in certain applications, reducing cycle times and lowering overall costs.

WORKS FOR MINES OF EVERY SIZE AND TYPE

Engine Options:
Extreme Ambient
High Altitude
Extra Quiet

MOST POPULAR TRUCK IN ITS SIZE CLASS

The 789 is a tried and true performer that has been delivering results on mine sites around the world for decades. Developed specifically for high production mining applications, the 789D simply does its job, no matter the application or conditions.

Features At A Glance

Performance

PROVEN IN THE FIELD

Most popular 191-tonne (210-ton) truck in the mining industry
— 80% of the industry
— Delivering results for decades
— Easy to operate and maintain

FAST SPEEDS

The 789D delivers a faster speed on grade than competitive trucks, reducing cycle times and lowering overall costs. The 3500 series engines are 16-cylinder, four-stroke designs that use long, effective power strokes for more complete fuel combustion and optimum efficiency.
— The 23% net torque rise provides unequaled lugging force during acceleration, on steep grades and in rough underfoot conditions. Torque rise effectively matches transmission shift points for maximum efficiency and fast cycle times.
— And expanded tire options allow mines to take advantage of higher speeds, particularly in flat long-haul high-speed applications.

SUPERIOR CONTROLLABILITY

Like all Cat mechanical-drive trucks, the 789D features four-corner oil-cooled brakes and Automatic Retarding Control to improve handling and machine control so operators can work quickly and confidently.

Power to the ground

The Cat mechanical drive power train and power shift transmission provides unmatched operating efficiency and control on steep grades, in poor underfoot conditions, and on haul roads with high rolling resistance.

Integration

BUMPER-TO-BUMPER CATERPILLAR

The individual components, software, systems and engine that go inside a Cat truck have different purposes, but they have one very important thing in common: They are all manufactured by Caterpillar and supported by the Cat dealer network.

This integration ensures that the entire truck — from body to bumper, engine to electronics — can be fully optimized to deliver the lowest cost per ton.

YOUR PARTNER FOR THE COMPLETE EQUIPMENT LIFECYCLE

No one knows more about how to get the most from a piece of Cat equipment than your local Cat dealer. This one-of-a-kind, on-the-ground support network delivers expert service, integrated solutions, after-sales support, fast and efficient parts fulfilment, world-class rebuild and remanufacturing capabilities, and more.

Cat dealers operate as nearly 200 local businesses — each one fully embedded in and committed to the geographic area it serves. That means you work with people you know, who know your business, and who respond on your timeframe.

Sustainability

MINING — FOR A — BETTER WORLD

Governments and regulatory agencies mandate that you establish and follow environmentally sound policies and practices as you meet the demand for mined materials. We're focused on doing our part to make sure our trucks help you meet those regulations.

REDUCING EMISSIONS

We've designed the 789D with a number of enhancements that lessen its impact on the environment. Features like oil renewal systems, continuous rear axle filtration, extended life filters and longer maintenance intervals decrease the amount of waste contributed to the environment.

We also continue to research alternative energy sources such as biofuels (B20) and a liquefied natural gas-supplied Dynamic Gas Blending solutions to find new ways to reduce emissions. In addition, we preserve raw materials, conserve energy and reduce emissions through the Cat Reman program, which returns end-of-life components to like-new condition.

EMISSIONS OPTIONS

The 789D comes with two engine options: the Cat 3516B and 3516C EUI. Both of these quad turbocharged diesel engines deliver high power and reliability in the world's most demanding mining applications. The engines are 16-cylinder, four-stroke designs that use long, effective power strokes for more complete fuel combustion and optimum efficiency.

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.

Fuel Efficiency

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.

BUILT TO BE REBUILT

Cat trucks are designed to last over 100,000 hours, and many are going well beyond that. The frame, powertrain, engine and components are built to be rebuilt — using new, remanufactured or rebuilt parts and components — so you can take advantage of multiple lives of like-new performance at a fraction-of-new price.

Operating Cost

OPTIMIZED PAYLOAD

Contradicting a common belief that bigger is better, the 789D has a weight advantage over larger trucks so you can haul more with every load.
—The 789D also delivers a 10-15% cost per ton advantage over competitive trucks, depending on application.

A TRUCK YOU CAN DEPEND ON

The 789D has been a dependable performer on mine sites for decades, delivering high availability, reliability and reduced costs that come with long life — from the engine and powertrain to the components, brakes and frame.
— Component life is further enhanced thanks to the standard rear-axle continuous filtration feature, which operates when the engine is running.
— Cleaner oil helps promote longer lubrication that leads to longer life.

Technology Solutions

Cat® MineStar™ Solutions

Whether you want to address a single challenge or make step changes in the overall safety, efficiency and productivity of your surface operation, Cat® MineStar™ has a solution for you. MineStar is the mining industry's most comprehensive and thoroughly integrated suite of technology offerings.

FLEET

Cat Fleet helps you identify opportunities to improve truck efficiency in ways that reduce costs, boost productivity and add real value to your bottom line.
— Eliminate Queuing
— Optimize Shift Changes
— Reduce Fuel Stops

COMMAND FOR HAULING

This autonomous hauling solution helps improve productivity, efficiency and profitability while reducing overall costs.

What if your trucks could respond to calls to the shovel, move into position, haul to dump points and even report for maintenance — all without an operator on board? That's what Cat Command for hauling enables.

But this autonomous Cat MineStar solution is more than just an operator-free system. It takes advantage of the most sophisticated technologies available to deliver a next-generation haulage solution — one that boosts safety, productivity and availability on busy mine sites, especially those in difficult or remote locations. With autonomous hauling, the future is here — and we're there to help you bring it to your operation.

DETECT

With the MineStar Detect proximity detection system, you can equip your 789D with cameras to give your operators a better view of what's happening around their equipment — or combine cameras and radar into a true object detection system that automatically alerts operators to hazards.

You can even add satellite capabilities to provide proximity warnings and avoidance zones, seat-belt monitoring that encourages operators to buckle up, and in-cab systems that intervene when they detect fatigue or distraction.

Road Analysis Control (RAC)

Optional system monitors haul road conditions by measuring frame rack and pitch to improve haul road maintenance, cycle times, tire life and fuel efficiency.

Truck Body Systems

GET THE RIGHT BODY FOR THE JOB

When it comes to truck bodies, one size does not fit all. And when it comes to your Cat truck, Cat bodies are the best choice. We follow a dynamic approach to engineering — treating the body as part of a system rather than a static structure. Cat bodies are designed to be an integral part of the entire vehicle system, ensuring you achieve maximum chassis life.
— They're sized to meet payload requirements without compromise to vehicle balance, braking or control.
— From the design to the materials, manufacturing to shipping, the entire process meets Cat standards of quality and control.
— The Caterpillar exclusive 10/10/20 payload guidelines help achieve a balance of excellent payload with safe operation.

HIGH PERFORMANCE BODY

A new lightweight design that provides durability along with a higher payload.

The HP body features robust top rail geometry with internal stiffeners and a high-visibility load placement indicator.
— Floating bolsters and spring plates improve overall durability by avoiding welds in high stress areas.
— In addition, the body requires only minimal liner coverage due to thicker and harder base plates.
— Curved front / side transitions minimize carryback.

MINE SPECIFIC BODY (MSD II)

For mature mines with good operational and maintenance practices, the lighter weight MSD II body is available in several sizes. It is a customer / site specific body that is designed to maximize performance.

GATELESS COAL BODY

This specialized high-volume body, available in several sizes, is targeted at dedicated coal haulage applications with minimal impact.

DUAL SLOPE BODY

The original standard body, the Dual Slope body provides excellent load retention, maintains a low center of gravity with optimum load distribution, reduces shock loading and is available in lined and unlined configurations.

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 efficiencies.

Serviceability

Tie Off Points

Enhances working environment during service of recommended maintenance areas.

Servicing Ease

Easy access to daily service points simplifies 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, filters, drains, and engine shutdown. Ground-level VIMS data port permits easier downloading of information.

Autolube

Automatic lubrication system reduces maintenance time by automatically lubricating necessary components on a regular basis.

Fast Fill Service Center

Optional fast fill service center features high speed fuel and oil exchange.

Scheduled Oil Sampling

S•O•S℠ sampling valves speed sampling and analysis reliability.

Pressure Test Points

Disconnect valves are conveniently located throughout the hydraulic 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.

Full Specifications Standard Equipment Optional Equipment

Product Specifications for 789D

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US
Metric

Engine

Engine Model	Cat® 3516C HD Cat® 3516C HD
Gross Power - SAE J1995	2100 HP 1566 kW
Rated Net Power - ISO 9249	1969 HP 1468 kW
Bore	6.7 in 170 mm
Stroke	8.3 in 210 mm
Displacement	4766 in³ 78.1 l
Net Power	1969 HP 1468 kW
Gross Power	2100 HP 1566 kW

Optional Engine

Engine Model	3516B EUI 3516B EUI
Gross Power	1900 HP 1417 kW
Rated Net Power - ISO 9249	1791 HP 1335 kW
Bore	6.7 in 170 mm
Stroke	7.5 in 190 mm
Displacement	4211 in³ 69 l

Weights - Approximate

Nominal Rated Payload	210 ton (US) 191 t
Rated Gross Machine Weight	715000 lb 324319 kg
Chassis Weight	218542 lb 99129 kg

Body - Dual Slope

Body Weight

60684 lb 27526 kg

Operating Specifications

Standard MSD Body (SAE 2:1)	170 yd³ 130 m³
Standard X Body (SAE 2:1)	161 yd³ 123 m³
Standard Dual Slope Body (SAE 2:1)	141 yd³ 108 m³
Standard Combi Body (SAE 2:1)	200 yd³ 153 m³
Standard Gateless Coal Body (SAE 2:1)	250 yd³ 191 m³

Transmission

Forward - 1	7.8 mile/h 12.6 km/h
Forward - 2	10.6 mile/h 17.1 km/h
Forward - 3	14.4 mile/h 23.1 km/h
Forward - 4	19.4 mile/h 31.2 km/h
Forward - 5	26.3 mile/h 42.3 km/h
Forward - 6	35.5 mile/h 57.2 km/h
Reverse	7.3 mile/h 11.8 km/h
Top Speed - Loaded	35.5 mile/h 57.2 km/h

Final Drives

Differential Ratio	2.35:1 2.35:1
Planetary Ratio	10.83:1 10.83:1
Total Reduction Ratio	25.46:1 25.46:1

Suspension

Effective Cylinder Stroke - Front	4 in 105 mm
Effective Cylinder Stroke - Rear	3.5 in 93 mm
Rear axle - Oscillation	±5.6° ±5.6°

Brakes

Brake Surface - Front	12662 in² 81693 cm²
Brake Surface - Rear	18024 in² 116283 cm²
Standards	SAE J1473 OCT90 ISO 3450:1996 SAE J1473 OCT90 ISO 3450:1996

Body Hoists

Pump Flow - High Idle	193 gal/min 731 l/min
Relief Valve Setting - Raise	2500 psi 17238 kPa
Body Raise Time - High Idle	18.9 s 18.9 s
High Idle Body Lower Time - Float	17.3 s 17.3 s
High Idle Body Lower Time - Power	15.6 s 15.6 s

Weight Distributions - Approximate

Front Axle - Empty	46 % 46 %
Rear Axle - Empty	54 % 54 %
Front Axle - Loaded	33 % 33 %
Rear Axle - Loaded	67 % 67 %
Note	Weight distributions optimized with Cat body. Weight distributions optimized with Cat body.

Tires

Standard Tires	37.00-R57 37.00-R57
Optional Tires	40.00-R57 40.00-R57

Service Refill Capacities

Fuel Tank - Standard	550 gal (US) 2082 l
Fuel Tank - Optional	1000 gal (US) 3785 l
Cooling System	192 gal (US) 725 l
Crankcase	77 gal (US) 291 l
Differential - Final Drives	154 gal (US) 583 l
Steering System	50 gal (US) 189 l
Brake Hoist System	241 gal (US) 909 l
Transmission Tank	20 gal (US) 76 l

ROPS

ROPS Standards

Standards Standards

Sound

Sound Standards

Standards Standards

Steering

Steering Standards	SAE J1511 OCT90 ISO 5010:1992 SAE J1511 OCT90 ISO 5010:1992
Steering Angle	36.07 ° 36.07 °
Turning Diameter - Front Wheel	90.32 ft 27.53 m
Vehicle Clearance - Turn Circle	99.18 ft 30.23 m

789D Standard Equipment

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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/filtration

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 of cab 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 of cab 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 and washer

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 fill 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

789D Optional Equipment

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BODY

Dual slope body: Body, dual slope, 109 m3 (142 yd3)

Dual slope body attachments:
– Extensions, 457 mm (18"), side, DS, 123 m3 (161 yd3)
– Extension, wraparound tail, DS
– Liner, entire body, DS
– Liner, wraparound, DS, 450 BHN
– Rock deflector, rear tire, DS

X body: Body, X, 123 m3 (161 yd3)

X body attachments: Extensions, side, X, 185 mm (7"), 131 m3 (171 yd3); Extensions, side, X, 385 mm (15"), 138 m3 (181 yd3)

MSD II body: Body, MSD II, 130 m3 (170 yd3)

MSD II body attachments:
– Extensions, side, MSD II, 141 m3 (185 yd3)
– Extensions, side, MSD II, 153 m3 (200 yd3)

Combination body: Body, combi, 153 m3 (200 yd3)

Combination body attachments: Extensions, side, combi, 195 m3 (255 yd3)

Gateless coal body: Body, gateless coal, 191 m3 (250 yd3)

Gateless coal body attachments: Extensions, side, coal, 214 m3 (280 yd3); Extensions, side, coal, 237 m3 (310 yd3)

Body lighting group - rear:
– Directional signals (LED)
– Stop/tail lights (LED)

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)

See how 789D compares against frequently compared products.

US
Metric

Off-Highway Trucks 789D

789D

Nominal Rated Payload: 210 ton (US); 191 t
Engine Model: Cat® 3516C HD; Cat® 3516C HD
Gross Power - SAE J1995: 2100 HP; 1566 kW

Selected Model

Off-Highway Trucks 785D

785D

Nominal Rated Payload: 154 ton (US); 140 t
Engine Model: Cat® 3512C HD; Cat® 3512C HD
Gross Power - SAE J1995: 1450 HP; 1082 kW

Model Details

Off-Highway Trucks 793D

793D

Nominal Rated Payload: 256 ton (US); 232 t
Engine Model: Cat® 3516B HD; Cat® 3516B HD
Gross Power - SAE J1995: 2415 HP; 1801 kW

Model Details

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