Caterpillar 785C & 789C Mining Trucks Coal Standard

Name Steve Plott, Sarah Loomis & Joe Patterson

Venue Big Iron University St. Charles, IL
Date July 26, 2006

Todays Agenda
Strong market presence
Historical trend to mechanical drive
Product support = Availability = Tons Moved
Productivity
Payload control

Key features & benefits deliver:

Health, Safety & Environment
Lower Cost Per Ton / Availability
Tires

Serviceability Customers Perception

Competitive Update
How we are doing?

Mining Truck Evolution

Caterpillars mining truck experience dates back over 40 years and
includes the worlds largest truck
Mining Truck Evolution
Cat Model

Year of
Introduction

769

1963

773

1970

777

1975

785

1984

789

1986

793

1991

797

1998

Over 43,000 construction and mining

trucks (769-797) delivered since 1963
Over 6,200 large mining trucks (785-797)
delivered since 1984
3

Large Mining Truck Shipments

Total Units

Fleet Hours

Highest
Hour Unit
(As of June 2006)

785

2300+

71 million

127,000

789

1800+

67 million

105,500

793

1900+

70 million

105,400

797

200+

3.9 million

49,000

785 Worldwide Fleet

Over 2,300 Shipments (as of June 2006)

35%
North America

35%
12%
Latin America

Asia Pacific,
Indonesia &
Australia

18%
Europe, Africa &
Middle East

789 Worldwide Fleet

Over 1,800 Shipments (as of June 2006)

34%
North America

36%
17%
Latin America

Asia Pacific,
Indonesia &
Australia

13%
Europe, Africa &
Middle East

785C Applications 2004 - 2005

Other Mining
Nickel 6%
4%
Iron Ore
14%

Coal
31%

Copper
7%

Payload
150 T / 135 MT

Gold
16%

Contractor Coal
22%

789C Applications 2004 - 2005

Other Mining
7%
Iron Ore
13%

Coal
31%

Copper
4%
Gold
6%

Payload
200 T / 180 MT
Contractor Coal
39%
8

World Truck Power Train Trends

WHY?

(Shipments 120 tons 400 tons)

95%
Electric

100% Electric

1970

5% Mechanical
Non-Cat

56% Electric

1980
37% Electric

44% Mechanical
785 & 789

1990

1994

42% Electric

37% Electric
58% Mechanical
785 - 797

2000
9

Note: Belaz numbers not available

63%
Mechanical
785, 789, 793

Market Introduction
785 1984
789 1986
793 1991
797 1998

63%
Mechanical
785 - 797

2005

Machine Capital
Maintenance & Repair
Tires and Undercarriage
Fuel
Lubricants
Residual Value
Operator Wages

Cost per Ton: Sensitivity

Operator Efficiency
Cycle Times

Cost

Payload

Ton

Mechanical Availability
Utilization

A 5% Change in Each of the Listed Factors Cause the Following % Reduction in Cost Per Tonne

Reduction in Cost Per Ton

5% Factor

0%

1%

2%

3%

4%

5%

Operator Efficiency
Mechanical Availability
Cycle Times
Payload
Utilization
Maintenance and Repair
Fuel Consumption
Machine Capital
Machine Life
Operator Wages
Tires
Lubricants

10

The Top 5 Factors relate to Productivity Not Cost

6%

7%

Productivity
Caterpillar 785C & 789C Mining Truck

All Cat Mechanical Power Train

Cat is only manufacturer with fully integrated

drive train

Centralized design control allows Cat to

optimize performance & life

Higher power train efficiency delivers more

power to ground, burns less fuel, reduces
cost per ton

Wide application range

Automotive feel is easier to control

Cat design has fewer thermal limitations on

steep grades

No on-site high voltage power required

Control system manages engine speed

during shifts to increase clutch life and
improve operator comfort

Purpose Built Integrated System

12

Heavy-duty final drives withstand extreme loads

and forces, can be remanufactured
One-piece cast wheels enhance durability
Differentials designed for long life, lower costper-ton operation
Rear axle lube system cools and cleans
continuously

G ro s s P o w e r T ra in E ffic ie n c y
Peak

12%

797B

88

86.7

95%

793D

88

85.4

90%

AC

83

79

85%

DC

81.5

72.2

Gross Power Train Efficiency

100%

80%
75%
70%
65%
60%
55%
50%
45%

793D

797B

A C D r iv e

D C D r iv e

40%
35%
30%
0%

5%

10%

15%

20%

25%

E ffe c tiv e G r a d e

14

Mechanical drive systems are the most efficient over a broad operating range

30%

Gross Power Train Efficiency

Gross Power Train Efficiency

100%
95%
90%
85%
80%
75%
70%
65%
60%
55%
50%
45%
40%
35%
30%
0

10

793D
AC Drive

797B
DC Drive

20

30

40

Peak

12%

797B

88

86.7

793D

88

85.4

AC

83

79

DC

81.5

72.2

50

Ground Speed-mph

15

Mechanical drive systems are the most efficient over a broad operating range

Why do we have a payload policy?

Clear consistent global message for Cat C-Series trucks and newer

RISK Management
MARC
Availability Guarantee

SAFETY
No loads should ever exceed the trucks steering and braking certification.
Exceeding the steering and braking certification would make the truck unsafe to
operate.

Provide optimum Cost per Ton

16

Caterpillar Integrated Design

Body and Payload

Power Train

Chassis

Wheel and Tires

Terrain

Suspension
17

Caterpillar Bodies

18

CAT 793D MSDII Option Example (No Liners)

19

Body Liner Placement

20

793D Target Payload Example

793D Gross Machine Weight (GMW):

846,000 lb

383,739 kg

793D Base Chassis Weight1:

266,587 lb

120,901 kg

Caterpillar MSDII 176m Body:

59,084 lb

26,800 kg

Caterpillar Custom Liner Package:

20,283 lb

9,200 kg

Target Payload:

250 Tons

227 Tonnes

Base chassis weight must include 100% fuel, debris, and attachments

21

22

23

Caterpillar 10/10/20 Payload Policy

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

80

90 %
85

90

95

100

105

% of Target Payload
24

SAFETY

Durability

Productivity

Number of Loads

No loads should be above 120% of the target payload

10%
110

115

120

Steering & Brake Certifications

Designed / tested / certified to meet

ISO 3450
SAE J1473
Health, safety and reclamation code standards for mines in British Columbia
SAE ROPS structure recommended practice

785C GMW 550,000 lbs. ( 249,480 kg) tested to 617,200 lbs. (280,000 kg)

789C GMW 700,000 lbs. ( 317,515 kg) tested to 785,500 lbs. (356,300 kg)

The test weights above allow compliance with normal payload distributions about the
target payload as reflected in Cat 10/10/20 payload policy
25

Why optimize payload?

Maintain safety certification

Haul at lowest cost per ton

Approximate 1:1 ratio in reducing cost per ton

Achieve optimum component lives

Reduce downtime

Minimize spillage

Impacts component life, fuel consumption, TIRE life,

cycle times, and availability

26

Competitive Update
Caterpillar 785C & 789C Mining Truck

Payload Capacity - 110 to 400 Ton Trucks

785C

EH3000

789C

EH3500

Unit Rig

MT3300

MT3300AC

MT3600B

797B

EH4500-2

730E

HD 1500

MT3000

793D

MT3700B

MT3700AC

T252

EH5000

830E

930E-3

830E - AC

930E-3SE

MT4400

MT4400AC

T262

960E

MT5500B

MT5900AC

T282B

100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 3200 330 340 350 360 370 380 390 400 410 420

Short Tons

28

The Competition

150 Tons
785C
HD1600
EH3000
MT3300

Cat
Komatsu
Hitachi
Terex

200 Tons
789C
730E
EH3500
MT3700
T262

Liebherr

This is the current size class distinction according to AEM

29

Terex MT3300 AC vs. 785C

Claim 25,000 hrs + major component life & 50,000 hrs chassis
Claim 10,000 hrs or less for 785C major components
Speed uphill and downhill vs. 785C?
Fuel consumption vs. 785C?
Repair cost vs. 785C?
Mechanical reliability / availability vs. 785C?
Independent wheel motor control?

30

785C & 789C Average Component Lives

Typically Cat LOHT are used on more severe hauls than
competitive trucks
Average component lives:
Engine -

16,000 hrs

Transmission -

12,000 hrs

Wheel Stations -

12,000 hrs

Differential -

12,000 hrs

Service brakes -

12,000 hrs +

Suspension cylinders -

15,000 hrs

Hoist cylinders -

15,000 hrs

Steering cylinders -

15,000 hrs

Competitors claims of 25,000 hrs or more Real?

31

Komatsu 730E DC/AC vs. 789C

DC drive is old technology with limited future
AC drive in this size class is still under development
Traction (independent wheel motor control) in poor underfoot conditions?
Power train efficiency lower
Challenge of multiple suppliers engine, alternator, wheel motors, chassis
Claim lower operating cost and easier PMs
GMW and empty weight vs. spec sheet?

730E Spec Sheet Eastern Coal Job Study

789C
789C With MSD
Gross Machine Weight
715,000 lbs
788,529 lbs
700,000 lbs
700,000 lbs
Empty Machine Weight
305,052 lbs
380,275 lbs
303,025 lbs
282,000 lbs
Target Payload for listed GMW
204.9 tons
167.4 tons
198.5 tons
209 tons

32

Euclid EH3500 vs. 789C

X3500 Prototype

Maximum Payload: 186t / 205 Tons

AC Drive with current EH3500
33

GE - Loading Policy
..any operation in the
extended range may result
in reduction or termination of
warranty provisions,
increases in operating costs
and/or more frequent
overhauls

Operation in the exceeded

range will result in increased
component wear and potential
failure .. not recommended ..
Likely to void all GE warranties
and guarantees including but not
limited to cost caps, availability
guarantees and all product
warranties.

extended

normal
exceeded
..mean must not
exceed rated
payload +2%
70

80
34

90

100
Payload

110

120

130

GE - Loading Policy

70

80

90

100
Payload

35

110

120

130

GE - Loading Policy

70

80
36

90

100
Payload

110

120

130

GE - Loading Policy

70

80
37

90

100
Payload

110

120

130

Features & Benefits HSE & Cost Efficiency

Caterpillar 785C & 789C Mining Truck

785C & 789C Features & Benefits

The 785C & 789C are the premier machines in their classes, designed and built by Caterpillar
using components and systems that have evolved through years of rugged mining applications
Cost per Ton
Availability

Safety & Operator Station

Powertrain

Systems Integration
Frame
Body

Front Axle & Steering

Retarding & Traction Control

Tires
39

Selling the 785C/789C Features and Benefits

1) Safety and Operator Station
2) Powertrain-Engine
3) Powertrain-Non-Engine
4) Frame
5) Body
6) Steering and Breaking

Top 3 Most Important F & B

F & B with Most Customer Resistance
How to overcome Customer Resistance
40

Standard Safety Features

The 785C & 789C offers the latest safety features for the protection of the operator and
mine employees
Standard Features
4-post ROPS
Oil-cooled brakes on 4 corners for
fade-resistant operation
Ground level secondary engine
shutdown and machine lockouts for
added safety and security
Three-point operator restraint
Lighted driver-side ladder and service
deck
10/10/20 Payload Policy applies

41

New Optional Safety Features

The 785C & 789C will offer the latest safety features for the protection of the
operator and mine employees
Custom Heated Mirrors

New Safety Enhancements

600 mm (24 in) wide diagonal stairway field kits for 785B/C & 789B/C in 4Q06
Closed-circuit television factory ready and
model specific kits 4Q06

Should heated mirrors be a custom option

for 785C & 789C?
(Currently optional on 793D)

42

New Optional Safety Features

The 785C & 789C offer optional features to enhance safety in specific operating
environments
New Safety Enhancements
High intensity discharge (HID) lighting in
high beams and back-up lights improves
night time visibility
Extended life carbon paper disc brakes provide longer
service life and increased heat resistance
than standard brakes

43

Operator Station
The 785C & 789C operator workstation is designed for maximum operator comfort, control,
convenience, and safety
Ergonomically designed
Excellent machine control
Exceptional all-around visibility
Resiliently-mounted, sound suppressed cab

4
8

- Sound levels less than 80 dB (A)

Air suspension seat - fully adjustable

Operator comfort = Higher Productivity!

10
5
7

1.

Air suspension seat

6. Storage Compartment

2.

Hoist lever (left side of seat)

7. Trainer seat

3.

Secondary brake pedal

8. Electric window

4.

Monitoring system

9. Operator controls

5.

Transmission control

10. Heating/air conditioning

6.

Storage compartment

44

Cab Visibility

Electric truck visibility

45

Cat 793D visibility

Cat Comfort Seat

The Caterpillar Comfort Seat with three-point operator restraint is the most durable
and supportive seat available for Cat Mining Trucks

Three-point restraint

High-back seat supports head and neck

Ride zone indicator adjusts seat suspension
to 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

ADJUSTMENT TRAINING!!
Ride zone indicator

46

Cat Comfort Seat Initiatives

Positive rake
Neutral rake
Negative rake

Lack of cushion tilt adjustment range

New seat testing 4Q06 with 3-position rake

Suspension bounce (rough roads or heavy

operators)
Special Instruction REHS2761 for install of a
second (passive) shock
Shock non conformance issue

3 point seat belt cinching down on

shoulder/neck
95% of complaints are solved with proper seat
set up by operator
PEVD5717 DVD training video for operators
on how to set up seat

47

Caterpillar Engines
A proven performer for over 25 years, the 3500 series engine now has over 105,000
units working worldwide in a variety of applications

Electronic Control Module

Reduces smoke
Reduces emissions.
Improves fuel efficiency
Optimizes performance and life
Communicates with transmission
and retarder
Provides information for diagnostics and management decisions.
Diagnoses own health and status
Controls Oil Renewal System

Cat engines operate at lower BMEP than competition -- improving

availability, extending life, reducing costs

Purpose Built Integrated System

48

Lock-up Torque Converter

Combines the advantages of direct drive and converter drive to achieve high component
reliability and maximum output performance
Lock-up clutch
Torque
converter output

Increased power train efficiency

High reliability from proven design components

Input

28% stall torque

Broad converter performance band
Lock-up clutch engages at 6.4 km/h (4.0 mph)
Flow of power
Flow of oil

Torque converter drive mode

49

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

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

50

Controlled Throttle Shift

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

Regulates engine rpm during shifts

Reduces torque spikes and extends
transmission life
Smoother ride and less spillage

Transmission Output Torque

Controlled Throttle Shift (CTS)

Shift without CTS

Shift with CTS

Possible only through electronic

integration of components

Clutch Power

Lowers operator fatigue

Shift without CTS

Shift with CTS

Time

51

Rear Wheel Group

Heavy duty components and ease of service combine to deliver long life and reduced
downtime in the most rugged conditions
Laser-hardened spindle in the wheel bearing
journal area
Integrated wheel and hub reduces removal
and installation time
Rotated and flushed with oil at factory, then filled
with filtered oil before shipping
Duo-Cone seals are air and oil checked after
assembly as part of quality control

52

Ecology Drains
Easily accessible drain plugs are installed in components to provide an environmentally
safe and effective method to drain fluids

Ecology drains are standard equipment and

located throughout the 785C & 789C
Engine (1)
Radiator (2)
Transmission
Torque converter
Hydraulic tank
Fuel tank
Alongside the fuel tank is the optional Wiggins
service center that has quick fill and drains for
the truck fluids

53

Oil Renewal System (ORS)

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

Oil supply from crankcase

Improves average engine oil quality

Lessens environmental impact
Decreases service downtime
Exclusive integrated Caterpillar controls

Oil sent to tank via fuel return line

Oil metered via electronic controls

54

Superior Engine Oil Quality with ORS

Because ORS constantly burns old oil which is replaced by 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

Oil Degradation

Non-ORS

ORS

1000

2000

3000
Hours

55

4000

5000

Caterpillar Integrated Systems

Purpose-built, integrated systems

All components built for mining - no

adapted automotive components

All major control modules communicate

over Cat Data Link

Centralized design control over entire

system allows Cat to optimize
performance and life

Engine, Transmission, Brakes

Electronic Technician

Vital Information Management System

Other Production Management Systems

True Weight Production Management
System
Max Payload and Speed Manager
RAC

MineStar

56

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

57

Caterpillar Truck Body Options

Standard Dual Slope Body

Standard Flat Floor Body

58

MSD II Body

Gateless Coal Body

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
59

Front Axle Steering Components

The 785C & 789C front suspension is 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

60

Brakes and Retarding

Oil-cooled multiple disc brakes on all four wheels provide exceptional braking and retarding
Integrated systems deliver optimum
performance

Non-fade, oil cooled design offers reliable

performance, long life

Spring-applied secondary and parking systems

enhance safety
Four-wheel braking improves control
40/60 brake torque split improves control,
minimizes wheel lock-up
Traction Control System improves
performance in poor underfoot
Automated Retarder Control allows faster,
safer downhill travel
Sealed system prevents contamination
Brake wear measurements completed quickly
Purpose Built Integrated System

61

7
3
4

1.
2.
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

6
7

Excellent controllability; reduced

operator effort for less fatigue
Engine overspeed protection

7
5

Hydraulic engagement offers smoother,

more responsive operation than previous
pneumatic design
Traction Control System:

Improved traction in poor underfoot conditions

Less slippage means less tire wear

62

1.
2.
3.
4.

Service brake sensor

Engine sensor
HARC
HARC switch

5.
6.
7.
8.

Brakes
Service brakes
Axle speed sensor
TCS

Benefit of Caterpillar Traction Control System

Electronically monitors & controls rear wheel slippage
Automatic application of rear brake prevents torque loss
Enhanced performance in poor underfoot
Faster cycle times & less tire wear = lower cost per ton

Cat

63

AC Competitor

64

Extended Tire Life

The Cat 785C & 789C are designed specifically to extend tire life and reduce costs

Gross weight distribution is ideally 33/67

front-to-rear axle
Traction Control System attachment reduces
tire slippage and wear
Steering geometry and turning radius are
designed to minimize tire scrub

65

TIRE

TIRES =

66

COST

PROFIT

Tire Availability

Michelin, Bridgestone & Goodyear?

Belshina?

Cat Policy Letters on bias and

oversize

Other potential sources bias ply

and radial

Cat is helping with tire supply too!!

67

Serviceability
Caterpillar 785C & 789C Mining Truck

VIMS System

Cat
ET

69

785C & 789C Reduces Cost Per Ton

Safety
Oil cooled brakes at 4 corners with 40/60
split,dead engine full stop capability,
ROPS/FOPS, 10/10/20 payload control policy

Utilization

Diagonal stairway, HID lighting, extended

wear brakes, and WAVS rear vision
camera

Traction control allows continued operation

in poor underfoot conditions

One safe source for support

Production

Owning cost

Fast cycle times broad operating range

Long economic life

2 axle retarding

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

Optimize payload with MSD Bodies

Mechanical Availability
Improved reliability, higher uptime
3500 Series engine has lower BMEP than
competitionimproving availability, extending
life, and reducing costs.
70

785C & 789C Reduces Cost Per Ton

Maintenance cost per hour

Operator efficiency

Field-proven components throughout the

truck

Operator station comfort and ergonomics

VIMS System capability allows diagnostics

and prognostics to extend service life
of components

Operator confidence in braking and retarding

optimizes downhill speed
Good visibility

Dealer and factory REMAN

Fuel cost per ton

Tire cost per hour

Engine fuel efficiency

Weight distribution and low Empty Machine

Weight

Highest power train efficiency

VIMS TKPH/TMPH Speed Manager

Traction Control System limited slip

71

Zero fuel consumption while retarding

Caterpillar 785 Mining Truck PINS

785 Shipments / PINS History
100

400
350

85

90

89

80

83

80

300

65

90
79

75

80
70

63

250

60

200

50
40

150

30
100
20
50

10

0
1996

1997

1998

1999

CAT (Units)

Note: Belaz sales not available

72

2000

2001

2002

Industry (Units)

2003
PINS

2004

2005

Caterpillar 789 Mining Truck PINS

789 Shipments / PINS History
90

350
77

300

80
66

65
250

59

70

62
60

53
200

69

48

47

50
39
40

150

30
100
20
50

10

0
1996

1997

1998

1999

CAT (Units)
Note: Belaz sales not available

73

2000

2001

2002

Industry (Units)

2003

2004

PINS

2005

In Conclusion
Strong market presence
Viewed historical trend to mechanical drive
Product support = Availability = Tons Moved
Productivity
Payload control

Reviewed features & benefits deliver:

Health, Safety & Environment
Lower Cost Per Ton / Availability
Tires

Discussed Serviceability Customers Perception

Discussed Competition
Keep up the good work!

74

Questions
Caterpillar 785C Mining Truck