Caterpillar 793D Mining Truck

Name Venue Date

Overview Caterpillar 793D Mining Truck

Safety Reminders

Emergency Contacts
Fire
Building: <Phone #> Municipal: <Phone #>

Emergency Information
Alarm Description
Evacuate Take cover All clear

Medical
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Unique Hazards
Room Floor/Building

First Responders
Room <Identify> Building <Location and name>

Emergency Procedures
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Overview

History Product Development Manufacturing & Distribution Specifications Features & Benefits Safety Health & Environment Equipping Your Truck Productivity Serviceability Product Support

Mining Truck Evolution

Caterpillars mining truck experience dates back over 40 years and includes the worlds largest truck
Cat Model 770 772 773 775 777 785 789 793 797 Year Introuced 2004 1971 1970 1992 1975 1984 1986 1991 1998

Over 50,000 construction and mining trucks (769-797) delivered since 1963 Over 18,000 large mining trucks (777-797) delivered since 1984 Update Yearly

Field Population

Truck Model 777 785 789 793 797

Total Units 10000+ 2900+ 2200+ 2700+ 350+

Fleet Hours 350 million 108 million 91 million 100 million 6.6 million

Highest Hour Unit

(As of December 2008)

150,000 139,700 116,703 106,891 69,755

Large Mining Truck Worldwide Fleet

Over 18,900 Shipments* (as of Feb. 31st 2009)

38%
North America

28% 20%
Latin America Asia Pacific, Indonesia & Australia

14%
Europe, Africa & Middle East

*Shipments leaving factory

(Percentages reflect 777,785, 789, 793,797, distribution)

Update Bi-Yearly

793 Worldwide Deliveries

Over 2,700 Shipments* (as of Dec. 2008)

36%
North America

28% 32%
Latin America Asia Pacific, Indonesia & Australia

4%
Europe, Africa & Middle East

*Shipments leaving factory

(Percentages reflect 793B, 793C and 793D distribution)

Update Bi-Yearly

100 -150 ton Product Strategy Cont.

777 D / F

HD785-7

HD985-5**

EH1700-3

TR100

DP905

7757

7514 - Electric

BH85-1 BH90

BH100

TR100

SRT95*

SF31904

Short Tons Metric Tons

80 72

85 77

90 82

95 86

100 90

105 95

110 100

115 104

120 109

125 113

130 118

135 122

140 127

145 132

150 136

155 141

160 145

* Pre Production ** Japan Only *** India Only

150 400 ton Product Strategy

785C / D

789

793D / F

795F-AC

797B / F

EH3000

EH3500-AC

EH4500-2

EH5000

HD 1500 -7

730E

830E - AC

860E

930E-4

960E

930E-4SE

MT300

MT3300A

MT3600 MT3700AC

MT4400AC

MT5500

MT6300A

Unit Rig
T252 T262 TI274 T282

7513

7530

7560

SF31904

SF32601

Short Tons Metric Tons

110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 3200 330 340 350 360 370 380 390 400 410 420 100 109 1188 127 136 145 154 163 172 181 191 200 209 218 2277 236 245 254 263 272 281 290 299 308 318 327 336 345 354 363 372 381 3

793 History

The 793 has continuously evolved to remain the leader in its class Cat 793 1991 - 1992 Over 50 sold B-Series 1992 - 1996 Over 500 sold C-Series 1996 - 2005 Over 1,300 sold D-Series Introduced 4Q 2005 Five arrangements for specific applications

D-Series Application Arrangements

The 793D is offered in five machine arrangements to match the application conditions found in your mine Standard Arrangement Balanced all-around performance Extended Life Wheel Groups For long uphill hauls

Extra Top Speed For long flat hauls

Extra Retarding For long downhill loaded hauls High Altitude Arrangement For operations above 2590 m (8,500 ft)

793D Standard Arrangement

Exceptional all-around performance Three factors combine to produce up to 9% more power at the wheels than the 793C: 5% more engine horsepower than 793C Common rail hydraulic system provides improved power train efficiency compared to 793C Hydraulically driven demand fan reduces parasitic load by operating only when needed Power at the wheels is a primary driver of cost per ton since it reduces cycle time

793D Extended Life Wheel Group Arrangement - Rear

For long uphill hauls Differences from Standard Arrangement Larger wheel bearings Wider wheel bearing spacing 29% increase in braking surface Larger spindle Spline-on brake group Benefits Longer brake life Extended life to overhaul Lower cost per ton

Extended Life (Rear)

Brakes Bearings

Standard (Rear)

793D Extended Life Wheel Group Arrangement - Front

Extended Life (Front) For long uphill hauls Differences from Standard Arrangement Larger wheel bearings Larger spindle, wider wheel bearing spacing Standard (Front) Larger brakes, 94 cm (37 in) vs 86 cm (34 in) Repositioned duo-cone seal Bottom mount steering arm fits either side Benefits Longer brake life and duo-cone seal life Extended life to overhaul Lower cost per ton Strut bolts (inner pattern)

Bottom mount steering arm

Spindle bolts (outer pattern)

793D Extra Top Speed Arrangement

For the long flat haul Differences from Standard Arrangement New transfer gear with lower gear ratio Hydraulic rear axle cooler Includes Extended Life Wheel Groups Benefits Top speed of 60 km/h (37 mph) 10% higher top speed than the other 793D arrangements

New transfer gear

Hydraulic rear axle cooler

Extra Retarding Arrangement

For long downhill loaded hauls Differences from Standard Arrangement Higher flow brake cooling Higher capacity cooling system Includes Extended Life Wheel Groups Benefits 35% increase in downhill speed over the standard 793D

High Altitude Arrangement

For operations above 2590 m (8,500 ft) Differences from Standard Arrangement 69 L (4,760 in 3 ) 3516B vs 78 L (4,211 in 3 ) 3516B HD used in other 793D arrangements Includes Extra Retarding arrangement Benefits Rated at 1715 kW (2,300 hp) to 3600 m (12,000 ft)

Product Development, Manufacturing & Distribution Caterpillar 793D Mining Truck

6 Sigma & CPS

A methodology that improves product quality, processes throughout the company, and customer satisfaction
6 Sigma CPI Enhances processes to enhance product quality Maintains quality during production and when product is in the field Keeps all accountable to deliver a superior product at all levels Caterpillar Production System (CPS) 6 Sigma based method for relentless improvement Focuses on 3 processes:

Core Governing Enabling

Design & Engineering

The 793D was developed by the truck engineering group in Decatur, Illinois using the latest design technologies and methodologies
New Product Introduction (NPI) process Concurrent Product and Process Design (CPPD) 6 Sigma methodology improves processes and product quality Collaborates with Cat design and manufacturing resources worldwide Designed at the same facility where its assembled

Research & Testing

Innovation begins at the Caterpillar Technical Center in Mossville, Illinois

Largest and most sophisticated research and development facility in the industry State-of-the-art laboratories, testing facilities, and simulators Interacts with design teams at each product facility

and hits the ground at the Tucson Proving Grounds

Complete machine cooling evaluations On-machine structural evaluations Complete machine noise evaluations Brake, steering, visibility & government standards Performance & machine productivity comparisons Machine endurance & reliability evaluations

Manufacturing & Assembly

From machine shop to assembly line, the 793D and its components are produced using the latest machining technology and highly skilled workforce
Close tolerance machining centers Automated material handling systems Extensive welder training Nondestructive weld testing Highly trained, experienced assemblers

Manufacturing Quality Assurance

Quality control practices have long been built into the Caterpillar manufacturing process, from machining to assembly
Engineered using computer-generated stress modeling Steel castings used in high stress locations Rollover fixtures ensure all welding is done horizontally, not overhead Ultrasonic weld inspection of all frames Caterpillar build cell quality certification Precise coordinate measuring Contamination control, for the entire process Laser hardened wheel spindles

Distribution & Support

When Cat products reach the field, they are supported by an advanced network of parts distribution facilities, dealer service centers, and technical training facilities
Caterpillars Global Distribution network maintains over 20 parts centers worldwide Dealer branch facilities, service trucks, trained technicians, and operator training programs provide customers with full-scale customer support Cat Product Support Center offers global training for dealer service technicians Global Minings Field Assembly Group commissions 793 trucks worldwide

793D Component Sources

Caterpillar designs and manufactures all major components of the 793D

Bodies also manufactured in Australia & South Africa

Completely Caterpillar

Design and manufacturing control ensures that the 793D operates as a complete and balanced unit
Complete design control over entire truck Single-point accountability Enables Cat to optimize the truck as a whole rather than by individual component Ensures compliance with the high quality standards expected

May 2004 Decatur Plant

Specifications Caterpillar 793D Mining Truck

793D Dimensions

Shown with MSD II body Dimensions are with dual slope body

7680 mm 25.2 ft

12 862 mm 42.2 ft

13 113 mm 43.0 ft Body Raised 1294 mm 4.2 ft

5610 mm 18.4 ft

5584 mm 18.3 ft

5871 mm 19.3 ft Empty

7680 mm 25.2 ft 6940 mm 22.8 ft 6500 mm 21.3 ft

1005 mm 3.3 ft 5905 mm 19.4 ft 12 862 mm 42.2 ft 3772 mm 12.4 ft

1364 mm 4.5 ft

6494 mm 21.3 ft

1128 mm 3.7 ft

4963 mm 16.3 ft 7605 mm 24.9 ft

793D Specifications (Metric)

793D Extra 793D Life Wheel Standard Groups Maximum GMW (kg) Chassis weight1 (kg) Engine model Displacement (L) Gross power (kW) Flywheel power (kW) Rated speed (rpm) Engine derates above altitude3 (m) Transmission speeds Top speed (km/h)

793D Extra Top Speed

793D 793D Extra Extra Retarding Retarding

793C 2

119 597

121 539

383 739 121 632 121 583

122 196

3516B HD 78 1801 1743 1,750 2591 6 Forward 1 Reverse 59.9

118 284 3516B 3516 B HD 69 78 1715 1615 3658 54.2 2743

54.2

Approximate clean chassis with full fuel, hoist, body mounting group and tires. Excludes body weight. Dependent on optional attachments. Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with the 69 liter 3516B. 3 Approximate altitude only. Changes with barometric pressure variations. Derate above this altitude is 1% per 1kPa - Data not available

793D Specifications (Metric)

793D Standard Fuel tank capacity (L) Optional fuel tank (L) Brake discs per side front Brake area - front (m2) Brake discs per side rear Brake area - rear (m2) Brake disc outside diameter (mm) Total brake area (m2)

793D Extra Life Wheel Groups

793D Extra Top Speed 4353 4921

793D Extra Retarding

793D Extra Retarding

793C 2 4467 10 8.98

10 8.98

13 13.47 15

13.46 876.3 22.44

15.54 939.8 29.01

13.46 876.3 22.44

(1)

Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with 3516B short stroke engine. (-) Data not available

793D Specifications (English)

793D Standard Maximum GMW (lbs) Chassis weight1 (lbs) Engine model Displacement (in ) Gross power (hp) Flywheel power (hp) Rated speed (rpm) Engine derates above altitude (ft) Transmission speeds Top speed (mph)
3 3

793D Extra Life Wheel Groups

793D Extra Top Speed

793D Extra Retarding

793D Extra Retarding

793C

263,666

846 000 267,947 268,153 268,045 3516B HD 4,760 2,415 2,337 1,750 8,500 6 Forward 1 Reverse 37.2

269,396 3516 B 4,211

260,771 3516B HD 4,760 2,300 2,166

12,000 33.7

9,000

33.7

Approximate clean chassis with full fuel, hoist, body mounting group and tires. Excludes body weight. Dependent on optional attachments. 2 Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with the 69 liter 3516B. 3 Approximate altitude only. Changes with barometric pressure variations. Derate above this altitude is 1% per 1kPa - Data not available

793D Specifications (English)

793D Standard

793D Extra Life Wheel Groups

793D Extra Top Speed

793D Extra Retarding

793D Extra Retarding

793C2

Fuel tank capacity (gal) Optional fuel tank (gal) Brake discs per side - front Brake area - front (in 2) Brake discs per side - rear Brake area - rear (in 2) Brake disc outside diameter (in) Total brake area (in 2)
(1)

1,150 1,300 10 13,912 20,869 34.5 34,781 13 20,874 15 24,084 37 44,958

1,180 10 13,912 20,869 34.5 34,781

Tier I compliant ATY prefix (low altitude arrangement). Prior to 2000 the 793C was fitted with 3516B short stroke engine. (-) Data not available

Features & Benefits Caterpillar 793D Mining Truck

793D Features & Benefits

The 793D is the premier machine in its class, designed and built by Caterpillar using components and systems that have evolved through years of rugged mining applications Frame & Structures Suspension Hydraulic System Power Train Cooling System Brakes & Retarding Operator Station System Integration Bodies & Liners Tires & Rims

793D Frame

Caterpillar frames are designed to deliver long service life in rugged mining applications Engineered using computer-generated stress modeling Forgings and castings used in high stress locations Rollover fixtures ensure all welding is done horizontally, not overhead All critical welds are ultrasonically tested High strength low alloy (mild) steel is highly durable, easy to weld

Structures

Fabrications Castings

Integral 4-post ROPS

Integrated Steering & Suspension

Cat designed for excellent maneuverability, safe operation, lower operating costs, and a comfortable ride Four-corner independent, nitrogenover-oil cylinders offer superior performance and ease of service Front & rear struts have built-in rebound control to improve ride Front cylinders act as axle mounting group Turning radius designed to minimize tire wear

Front Axle Steering Components

The 793D front suspension is a field proven design with dual tie-rods for optimum steering geometry to help extend tire life Separate steering hydraulic system prevents cross contamination Secondary steering meets ISO 5010 up to 120% of target payload Twin double-acting cylinders Steering arm pin retention plate provides redundant pin retention Front suspension cylinders serve as kingpins Serviceable bracket assembly on steering box casting saves time at rebuild Two tie-rods allow optimum steering geometry

Hydraulic Power Management

Common rail hydraulics improve system efficiency by better sharing and controlling power needs for hydraulically-driven functions Delivers up to 4% additional power to the ground rather than to functions that are not needed at the time Provides priority to supply functions required for safe operation Very controllable; provides flexible power management

Hydraulic pump

Common Rail Hydraulics

Steering Cylinders

Main Engine Fan

Fan/Common Rail Cooler Return Filter

Steering Control

Fan Pump

Common Rail Pump Common Rail Valve Optional Rear Axle Cooler Fan Common Rail and Fan Tank

Rear Axle Lubricator Motor

Brake Cooling Pumps

Brake Cooling Drive Motor

Solid Connection

3516B High Displacement EUI Engine

A proven performer for over 20 years, the 3500 series engine now has over 80,000 units worldwide working in a variety of applications 25 mm (1 in) longer stroke than 69 L engine 2,415 gross horsepower from 78 L (4,760 in 3 ) Electronic Unit Injection (EUI) Turbocharged and aftercooled No waste gate 5% horsepower increase over the 793C Enhanced diagnostics with Electronic Technician (Cat ET) Electronic monitoring of key functions and logging critical indicators Me ets US EPA Tier I

High Displacement Engine

Metric Ratings @ 1,750rpm Gross Power Net Power Dimensions Bore Stroke Displacement

English

1801 kW 2,415 hp 1743 kW 2,337 hp 170 mm 215 mm 78 L 6.7 in 8.5 in 4,760 in3

3516B EUI Engine for High Altitude

A proven performer for over 20 years, the 3500 series engine now has over 80,000 units worldwide working in a variety of applications 25 mm (1 in) shorter stroke than 78 L engine 2,300 gross horsepower from 69 L (4,211 in 3 ) Electronic Unit Injection (EUI) Turbocharged and aftercooled Enhanced diagnostics with Electronic Technician (Cat ET) Electronic monitoring of key functions and logging critical indicators

High Altitude Arrangement Engine

Metric Ratings @ 1,750rpm Gross Power Net Power Dimensions Bore Stroke Displacement

English

1715 kW 1615 kW 170 mm 190 mm 69 L

2,300 hp 2,166 hp 6.7 in 8.5 in 4,211 in 3

Engine Comparisons

793C Engine Gross Power Displacement BSFC g/kW-hr (lb/hp-hr) BMEP 3516B 1715 kW 2,300 hp 69 L 4,211 in3 211 (0.347) 1704 kPa 247 psi

793C (Tier 1) 3516B HD 1715 kW 2,300 hp 78 L 4,760 in3 201 (0.330) 1508 kPa 219 psi

793D (Tier 1) 3516B HD 1801 kW 2,415 hp 78 L 4,760 in3 206 (0.339) 1583 kPa 230 psi

793D High Altitude 3516B 1715 kW 2,300 hp 69 L 4,211 in3 221 (0.363) 1704 kPa 247 psi

Power Train Integration

1. Gauge cluster module 2. Message center module 3. Integrated Braking Control 4. Transmission/Chassis Control 5. Brakes 6. Wheel sensor 7. Transmission 8. Cat data link 9. Engine Control Module 10. Sensors 11. Electronic Unit Injector

2 1 3 8 4

10 9 11 7 5

Brake Mean Effective Pressure (BMEP)

Cat engines have low BMEP, which means the 3500 works easier and lasts longer BMEP measures how hard an engine is working Lower BMEP = longer life Cat engines low BMEP improves availability, extends service life and reduces overall costs
2500 Engine BMEP (kPa) 2000 1500 1000 500 0

Oil Renewal System (ORS)

On 3500 engines, ORS meters used crankcase oil into the fuel system to be burned, replaced by new oil as the system is regularly topped off Eliminates regular oil changes and oil disposal costs Improves average engine oil quality Lessens environmental impact Decreases service downtime Exclusive integrated Caterpillar controls US EPA Tier I compliant Oil supply from crankcase

Oil sent to tank via fuel return line Oil metered via electronic controls

Superior Engine Oil Quality with ORS

Because ORS constantly replaces old oil with new, the quality level remains consistent and free of the quality degradation experienced in oil during a typical 500-hour life cycle

Oil Degradation vs Time

Non-ORS

Oil Degradation

ORS

1000

2000

3000 Hours

4000

5000

Mechanical Power Train

Torque converter & lock-up clutch (additional clutch disc & plate added)

Rear axle filtration is now continuous (no longer ground driven)

New two-piece transmission harness for redundant speed sensors New input transfer case to accommodate increased Differential and top speed gears double reduction final drive

Lock-up Torque Converter

Adapter to provide space for additional disc & plate in lock-up clutch Oil level switch Six-speed input speed sensor Transmissionplanetary power shift transmission Dual transmission output speed sensors Transmission has internal changes to accommodate increased horsepower & top speed

Lock-up Torque Converter

Combines the advantages of direct drive and converter drive to achieve high component reliability and maximum output performance Increased power train efficiency High reliability from proven design components 28% stall torque Broad converter performance band Lock-up clutch engages at 7.3 km/h (4.5 mph)

Controlled Throttle Shift

Reduces driveline torque stress for smoother shifts, extended component life and improved operator comfort
Transmission Output Torque

Regulates engine rpm during shifts Reduces torque spikes and extends transmission life Smoother ride and less spillage Lowers operator fatigue Possible only through electronic integration of components

Controlled Throttle Shift (CTS)

Clutch Power

Time

Precise Transmission Control

Electronically controlled individual clutch modulation reduces driveline torque stress for smoother shifts, extended component life and improved operator comfort Microprocessor controls hydraulics for smoother clutch transition during shifts Reduces torque spikes and extends transmission life Possible only through electronic integration of components Together with Controlled Throttle Shifting provides: - Smoother ride and less spillage - Lower operator fatigue
Example of depressurization of one clutch and pressurization of another during a transmission shift Pressure Electronic Control

With Hydraulic Control

Time (in fractions of a second)

Six-Speed Planetary Transmission

Large diameter clutch packs are controlled to provide smooth shifting and to limit clutch energy input for extended component life Torque converter lock-up in first gear Smart shifting eliminates gear hunting Downshift inhibitor prevents engine overspeed Clutch packs mounted outside of gear sets for ease of service Directional shift management automatically reduces engine throttle before shifting

Rear Wheel Group

Laser-hardened spindle One-piece cast wheel Large bearings Continuous rear axle filtration Oil cleanliness to ISO 16/13

Benefits of Continuous Filtration

Caterpillar's success with kidney looping resulted in the continuous filtration system now found in the rear axle of the 793D

Bearings with kidney looping and 4,000-hour oil changes showed little wear after 18,000 hours

Bearings with oil changes at 1,200-hour intervals, but without kidney looping, showed pitting at 13,000 hours

Images magnified 50x

New Generation Modular Radiator

Hydraulically driven, variable speed fan is matched to a new generation modular radiator with serpentine fins to improve cooling over the 793C system Improved heat rejection Greater cooling density Modular core design for ease of service Hydraulic fan, 198 cm (78 in) or 213 cm (84 in), operates on demand to reduce parasitic loads

Brakes and Retarding

Oil-cooled multiple disc brakes on all four wheels provide exceptional braking and retarding Forced oil cooling for fade resistance Spring applied, hydraulic released secondary/parking brake for added safety Braking & retarding on all four wheels Redundant systems Sealed from contaminants Extended Life brake discs standard on all arrangements

7 1. 3

2.
4

3. 4. 5. 6. 7.

Parking/secondary piston Service/retarding piston Friction discs Steel plates Actuating springs Cooling oil in Cooling oil out

Integrated Braking Control

Integrates the Hydraulic Automatic Retarding Control and the Traction Control System into one electronically controlled braking system Hydraulic Automatic Retarding Control: Increases production due to faster downhill speeds Excellent controllability and reduced operator effort Less operator fatigue Engine overspeed protection New hydraulic engagement offers smoother, more responsive operation than 793C pneumatic design Traction Control System: Improved traction in poor underfoot conditions Less slippage means less tire wear

2 6 7 3 5 7 6 8

1. 2. 3. 4.

Service brake sensor Engine sensor HARC HARC switch

5. 6. 7. 8.

Brakes Service brakes Axle speed sensor TCS

Operator Station

The integral, sound-suppressed ROPS/FOPS cab gives the operator a comfortable and safe working environment 1. Ergonomically designed, air suspension seat 2. Electric hoist control 3. Secondary brake pedal 4. VIMS displays and operator keypad 5. Tilt and telescoping steering wheel 6. Transmission console 7. Large storage compartment 8. Trainer seat 9. Powered operator window 10. Operator controls 11. Standard heater and air conditioner

4 9 10 3 11 6

Cab Visibility

Electric truck visibility

Cat 793D visibility

Cat Comfort Seat

The new Cat Comfort Seat with three-point restraint offers operators added safety and comfort High-back seat supports head and neck Ride zone indicator adjusts seat suspension to operators weight Adjustable rake lower cushion Washable seat cover Dual retractor lap and shoulder belt system Adjustable shoulder belt has six vertical height settings for optimum fit

Three-point restraint

Ride zone indicator

VIMS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Gauge Cluster Message Center and Keypad ADEM III Engine Control Module CAT Data Link Action Alarm Action Lamp Payload Lamps Payload Display (optional) Radio System (optional) Data Port (VIMS-PC) Service Lamp Diagnostic Connector (Cat ET) Integrated Brake Control (IBC) Module Transmission/Chassis Control (TCC) Module Road Analysis Control (RAC) Module (optional)

Cat ET

VIMS Speed Manager

Fully integrated with VIMS, Speed Manager consists of three features that help optimize truck safety and performance, lower costs, and extend service life VIMS MAX Speed Manager VIMS TKPH (TMPH) Speed Manager VIMS MAX Payload Speed Manager

MineStar Integrated Mine Information System

GPS Infrastructure: Satellites, Repeaters, Base Station

Radio Network MineStar

KPIs/ Graphing

Assignment

Health

Production Monitoring

Machine Tracking

Material Tracking

Machine Guidance

Reporting

Data Flow
Engineering and Geology Production Administration/ Management

Business Intelligence

Reports

Processing

Maintenance

Safety

793 MSDII Body Size Options

793 MSDII Body is available in 3 sizes to meet a variety of material density ranges: 209 yd 3 (160 m 3 ) 2750-3000 lbs/lcy material 250 yd 3 (191 m 3 ) 2500-2750 lbs/lcy material 250 yd 3 (191 m 3 ) 2300 2500 lbs/lcy material

Front to Rear Body Flare

6982 mm

1 r flare front interior body width to rear interior body width Improved material flow / release Reduces wear on rear sidewalls (less material contact

Front to Rear Flare

7265 mm

Body Exhaust Heat

Highly cohesive applications Carry back reduction system Hot surface improves material flow Targets problem areas

Exhaust Outlet

Alternative Body Exhaust Heat Views

Pivot Area and Hoist Brackets

Factory pre-assembled and installed Internal and external gussets provide full support Solid piece pivot bracket

Understructure Gussets & Rib Coverage

Internal and external gussets optimize stress distribution Minimizes impact damage to floor Analyzed and tested for optimal floor rib coverage

793 X Body Size Options

793 X Body is available in 3 sizes to meet a variety of material density ranges:

195 yd 204 yd 210 yd
3

(149 m 3 ) (156 m 3 ) (160 m 3 )

3000+ lbs/lcy
3

2800-3000 lbs/lcy
3

2650-2800 lbs/lcy

Sidewall to Floor Integration

Improved structural integrity thru Direct sidewall floor integration Direct sidewall rib floor rib termination Tapered sidewall ribs added flexibility & durability

Cross Section

Body Exhaust Heat

Exhaust Outlet
Highly cohesive applications Carry back reduction system Hot surface improves material flow Targets problem areas

Understructure
Gussets and Ribs Internal and external gussets optimize stress distribution Minimizes impact damage to floor Analyzed and tested for optimal floor rib coverage

Pivot Areas and hoist brackets Factory pre-assembled and installed Internal and external gussets provide full support Solid piece pivot bracket

Guards, Lifting Points, & Loading Target

Upper sidewall lifting eyes Loading Target

Complete forward machine coverage Canopy rock shedders Rock ejectors

Mine Specific Design (F.A.C.LT)

Impact & wear protection that maximizes body life & performance

F ragmentation A brasion C ohesion L oading T ool

FACLT & Body Liner Segmentation

L1 L2 L1

L1 L2

L4

L3

L4

L5 L8 L7

L3

L5 L8

L 11

L 13

L 11

L7

L9

L6

L6 L 12 L 14 L 12

L9

L 10 L 15 L 15 L 15

L 10

Body Liners

Caterpillar offers modular liner plate packages for additional impact and wear protection

Smooth Plate for cohesive materials

Zipper Grid for semi-cohesive materials

Rock Box for dry and non-cohesive materials Mechanically Attached Wear Plate System (MAWPS) for all mining conditions

793D Tires & Rims

Cat center mount rim offers reduced stress and longer life than offset flange designs Stud mounted rim stays torqued while wedge mounted design require constant attention 793D Tire & Rim Options
29" rim 32" rim

Competitive

Goodyear Michelin Bridgestone Bridgestone Michelin

40.00R57 40.00R57 40.00R57 46/90R57 44/80R57

3 3 3 3 3 3 3

Caterpillar

Extended Tire Life

The Cat 793D is designed specifically to extend tire life and reduce costs Gross weight distribution is ideally 33/67 front-to-rear axle Traction Control System reduces tire slippage and wear Integrated VIMS Speed Manager reduces heat separation failures by monitoring tonne kilometers per hour (ton miles per hour) Steering geometry and turning radius are designed to minimize tire scrub

Sustainability Caterpillar 793D Mining Truck

Name Global Mining Division Month Year

Sustainable Development at Caterpillar

Our vision is a world in which all peoples basic requirements for shelter, clean water, effective sanitation and reliable power are not only met but provided in a way that sustains our environment. Our mission is to enable economic growth through infrastructure and energy development and to provide solutions that protect people and preserve the planet. Our strategy is to provide work environments, products, services and solutions that make wise use of the world's natural resources and reduce harmful impacts on people and nature. This means we leverage assets including technology and innovation to:
Promote and protect individual safety Provide employment, education, and training Minimize the use of energy, materials, and water Maximize recycling (remanufacturing) Minimize harmful emissions (e.g. air, noise, etc), water discharges, waste and use of hazardous substances Optimize the use of renewable resources

Executive Summary

Our commitment to being a leader in sustainable development will keep us focused on what really mattersmaking the intelligent choices that will drive the growth of our business and help create a more sustainable world.

--Jim Owens, Caterpillar Chairman and CEO .

Caterpillar Goals
Sustainable Development & Strategic Areas of Improvement > Enterprise SD Goals

Customer Goals
SD SAI > Enterprise SD Customer Goals

Standard Safety Features

The 793D offers the latest safety features for the protection of the operator and mine employees Standard Features 4-post ROPS Oil-cooled brakes for fade-resistant operation Electrical lockouts at ground level for added safety and security New Standard Safety Enhancements Three-point operator restraint 600 mm (24 in) wide stairway and wider railed cab access area eases operator movement Toe boards eliminate objects from accidentally being kicked off the deck Closed-circuit television ready 10/10/20 Payload Policy applies

Optional Safety Features

The 793D offers optional features to enhance safety in specific operating environments Rear cab access platform & handrail provide enhanced access to cab service panel and rear window High intensity discharge lighting in high beams and back-up lights improves night time visibility Ground level transmission lockout Heated mirrors External payload display Throttle lock
Rear platform

Transmission lockout

Ecology Drains

Easily accessible drain plugs are installed in components to provide an environmentally safe and effective method to drain fluids Installed on Engine (#1) Transmission Torque converter Hydraulic tank Fuel tank Radiator (#2)

Equipping Your Truck Caterpillar 793D Mining Truck

793D Standard Equipment

Electrical Alarm, backup Alternator, 105 ampere Batteries, 12 V (2), 93 amp-hour Converter, 12 V electrical Electrical system, 24 V, 15 amp Directional signals (front & rear LED) Front stair access/Service deck Stop/taillights (LED) Engine compartment Operator Environment Air conditioner Ashtray/Cigarette lighter Coat hook Diagnostic connection port Dome courtesy light Entertainment Radio Ready Gauges/Indicators: - Air cleaner service indicator - Quad gauge panel: Air pressure Brake oil temperature Engine coolant temperature Fuel level - Electric engine control fault indicator - Electric hour meter/tachometer - Speedometer - Tachometer - Transmission gear indicator VIMS message center w/universal gauge VIMS keypad Heater/defroster (11,070 kCal/43,930 BTU) Horn Hoist, body control (electric) Storage compartment ROPS cab-insulated/sound suppressed Seat belt, 75 mm (3 in) wide retractable Steering wheel, tilt, padded, telescopic Tinted glass Window, electric powered, operator Windshield wiper, intermittent control, washer Power Train 3516B Diesel Engine Turbocharging (4) Aftercooled Air cleaner w/precleaner (4) Ground level engine shutdown Ether starting aid (automatic) Elevated low idle control Multi-point oil pressure sensing Automatic starter protection Braking system: - Brake release motor (towing) - Oil-cooled, multi-disc (front & rear) (service, retarding, parking, secondary) - Automatic Retarder Control - Engine overspeed protection Transmission : - 6-speed, automatic power shift w/TCC - Body-up shift inhibitor - Controlled throttle shifting - Directional shift management - Neutral coast inhibitor - Neutral start switch - Downshift/Reverse shift inhibitor - Individual clutch modulation - Body-up reverse neutralizer - Programmable top speed - Lock-up torque converter

793D Other Standard Equipment

Air line dryer Traction Control System Auto lubrication system (Lincoln) Aux "buddy" dumping quick connect Aux steering quick connect (towing) Driveline operator safety guard Fast fill fuel system (Wiggins) Ground level VIMS data port Ground level battery disconnect Hi-speed crankcase oil change (Wiggins) Reservoirs (3): - Brake - Hoist/Steering/Transmission - Converter Rock ejectors Stairway, 600 mm Supplemental steering (automatic) Tie down eyes Tow hooks (front)/Tow pin (rear) Vandalism protection locks Vital Information Management System (VIMS) Includes VIMS Payload Monitor w/MAX Payload & Speed Manager Recommended using download cable 127-9797 and PC based software JERD 2175 Supplemental software "VIMS Supervisor" YERA 1403. Order separately (Computer not provided) Antifreeze Extended Life Coolant to -35C (-30F)

793D Optional Equipment

Ground level transmission lockout Oil Renewal System (ORS) Road Analysis Control (RAC) External digital payload display High intensity discharge (HID) lights replace halogen high beams Heated mirrors Rear cab access platform & handrail Rim guard

Arrangements Extra Retarding Extra Top Speed Extended Life Wheel Groups High Altitude Bodies Dual slope Flat floor MSDII

Custom Products

Caterpillar and your dealer work together to offer you custom attachments and retrofits to meet the specific demands of your mine site Design and fabrication of specialized attachments to meet site-specific needs New technology retrofitted to older models Past custom products include: High altitude engine arrangements High intensity discharge (HID) lighting for high beam retrofits Field installed wider stairways Electric start

Road Analysis Control (RAC)

RAC monitors and logs haul road severity to increase truck life and reduce cost/ton Existing suspension cylinder pressure sensors measure pitch & bias of truck, and frame rack (twist) System identifies haul road problem areas to avoid and correct Transmits real time data and GPS locations to haul road maintenance via radio, if equipped Improved haul roads help optimize truck component life, fuel consumption, and safety

Productivity Caterpillar 793D Mining Truck

10/10/20 Overload Policy

No more than 10% of loads above 110% No loads above 120% The average payload shall not exceed the target

90% of loads should fall into this range No more than 10% of loads should exceed 110% of the target payload No loads should be above 120% of the target payload

90 %

793D Performance

Preliminary data projects faster uphill speeds and higher productivity than its predecessors 5% increase in gross horsepower New hydraulic power management system Optional extra retarding package should achieve one additional gear on downhill hauls (up to 35% speed increase)

Serviceability Caterpillar 793D Mining Truck

Right Side Inspection

1. Front and rear tires Check inflation; inspect inside of tire for damage or wear; remove large rocks from treads; check front wheel cover for bolts that are loose or missing 2. Right steering cylinder, tie rod, and front suspension cylinder 3. Power train Check for leaks at torque converter and transmission 4. Hydraulic tank, hoist and brake oil Check that filler cap is properly installed; check oil level sight gauge; look for leaks or damage 5. Automatic lubricant reservoir Check oil level in sight gauge; inspect tank for leaks 6. Right hoist cylinder Look for leaks, cracking, or marks on chrome 7. Frame and body Inspect for cracks or damage

5 7 6 1 4 3 2 1

Front Inspection

1. Ground level controls Make sure switch covers are down; inspect warning light and VIMS connection 2. Front operating lights Check for damage 3. Radiator Check for leaks; remove any debris 4. Engine Check for oil and coolant leaks; check oil sump dipstick using the appropriate side for 10 low idle or engine stopped; drain moisture and sediment from the air tanks 5. Ladders and platform Make sure that the ladders and hand rails are secure 2 6. Check the coolant levels in the coolant tanks 7. Remove debris that may obstruct the air filters 8. Check steering system hydraulic oil level sight gauge 9. Make sure that all of the windows are clean; make sure that the operator's vision is not impaired by dust, mud, or other foreign materials 10. Adjust the mirrors for proper vision.

6 5

10

7 3 4 5 1 2 2

Left Side Inspection

1. Front and rear tires Check inflation; inspect inside of tire for damage or wear; remove large rocks from treads; check front wheel cover for bolts that are loose or missing 2. Left steering cylinder, tie rod, and front suspension cylinder 3. Power train Check oil level sight gauge in torque converter sump (see Note below); check for leaks at torque converter and transmission 4. Fuel tank Check that filler cap is properly installed; check fuel level sight gauge; look for leaks or damage 5. Left hoist cylinder Look for leaks, cracking, or marks on chrome 6. Frame and body Inspect for cracks or damage

6 2 3 4 1 1 5

Note: The torque converter sump oil level is checked with the body down and the engine off. There are two sight gauges. Use the lower gauge if the oil is cold. Use the upper gauge if the oil is at operating temperature.

Rear Inspection

1. 2. 3. 4.

Inspect lights for damage Check suspension cylinders Look for leaks around filter Check oil level sight gauge; check grease fittings
1 2 3 2

Product Support Caterpillar 793D Mining Truck

Dealer Support
We offer a dealer network and support system that is unparalleled by any competitor Cat dealers continue to support the customer through the entire life of the machine on every angle

Repair and Maintenance Process Engineering

Equipment Management Services

Parts and Component Support

Caterpillar Global Factory Support

23 parts distribution centers 13 training centers 107 manufacturing facilities

Caterpillar Global Dealer Network

267 locally owned businesses 1,665 dealer branch stores 93,000 employees supporting you $7.8 billion in assets 50+ years average tenure

More than our top 3 competitors combined

Parts & Service Support Worldwide

Cat dealers offer a wide range of parts and service plans that will maximize uptime and return on your investment
Preventive maintenance programs Diagnostic programs, such as Scheduled Oil Sampling and Technical Analysis Rebuild and Reman options Operator training Customer support agreements

Caterpillar Certified Rebuild (CCR)

The CCR program offers a like-new machine with a renewed warranty and serial number, all at a much lower cost than a comparable new machine
Inspection Disassembly Reconditioning Engineering updates Power train testing Reassembly Performance testing Repainting New serial number/warranty Customer evaluation

Off Highway Truck Reman Components

We offer the following Reman components from 777-797 to decrease down time, reduce cost, and increase quality.
Engines Engine Components Final Drives Torque Converter Transmission Electric Drive Components Drivetrain Components Wheel assemblies, Spindles, Carriers, Clutch Plates Hydraulics Piston Motors, Gear Pumps, Rods / Cylinders Electronic Components Starters, Alternators, ECUs Price 40 70% below new parts

More information at catreman.cat.com

Percentage Commonality in Parts Numbers

793D Reduces Cost per Ton

Safety Key safety features you are used to on Cat trucks (oil cooled brakes, ROPS/FOPS, 10/10/20) Plus new enhanced safety features contribute to further lowering your costs More rimpull, faster cycle times Optional +10% top speed Optional +35% downhill speed Optimized payload (with MSD bodies) Traction control allows continued operation in poor underfoot conditions Improved reliability, higher uptime 3516B HD engine has lower BMEP and no wastegate for improved durability and reliability Long economic life Higher resale value than competition. Even though a customer may not resell their truck, the high resale is indicative of the remaining value in older Cat trucks Maintenance Cost per hour Improvements throughout the truck (Engine, Torque Converter, Transmission, Differential, Wheel groups, brakes, frame, electrics and electronics) VIMS capability allows diagnostics and prognostics to extend service life of components Weight distribution and low Empty Machine Weight (EMW) Steering geometry VIMS TKPH (TMPH) Speed Manager Operator station comfort and ergonomics Operator confidence in braking and retarding optimizes downhill speed Mechanical power train efficiency HD engine Zero fuel consumption while retarding

Production

Tire Cost per hour

Utilization

Operator Efficiency

Mechanical Availability

Fuel Cost per Ton

Owning Cost

113

Questions Caterpillar 793D Mining Truck

Caterpillar 793D Mining Truck

Media Support

www.cat.com www.safety.cat.com www.catreman.cat.com www.catminer.cat.com Mining Truck Bodies Body Maintenance Ground Rules Product Development Video Specalog Show Spec Sheet VIMS WAVS Virtual Operator Training Mining Safety Brochure Minestar CPI RAC Marketing Bulletin

AEHQ5600-01 AEHQ5877 AEXC0681 TEKQ0647-03 TERV0101 AEXQ0370 AEHQ6017-01 AERV5715 TELQ4461 TEJB9452