Caterpillar® 793D Mining Truck

NameVenue

Date

OverviewCaterpillar® 793D Mining Truck

Safety Reminders

Emergency Contacts

Fire•Building: <Phone #>•Municipal: <Phone #>

Medical•Building: <Phone #>•Municipal: <Phone #>

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

Emergency Information

Alarm Description• Evacuate• Take cover• All clear

Unique Hazards•Room•Floor/Building

Emergency Procedures•Equipment locations•Evacuation routes

Overview

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

Mining Truck Evolution

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

Caterpillar’s mining truck experience dates back over 40 years and includes the world’s largest truck

Cat ModelYear

Introuced

770 2004772 1971773 1970775 1992777 1975785 1984789 1986793 1991797 1998

Update Yearly

Field Population

Truck Model

Total Units

Fleet Hours

Highest Hour Unit(As of December 2008)

777 10000+ 350 million 150,000785 2900+ 108 million 139,700789 2200+ 91 million 116,703793 2700+ 100 million 106,891797 350+ 6.6 million 69,755

Large Mining Truck Worldwide Fleet

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

38%North

America

20%Latin

America

28%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

32%Latin

America

28%Asia

Pacific, Indonesia & Australia

4%Europe, Africa & Middle East

*Shipments leaving factory (Percentages reflect 793B, 793C and 793D distribution)

Update Bi-Yearly

Short TonsMetric Tons

777 D / F

DP905

TR100

HD785-7

EH1700-3

HD985-5**

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

7757 7514 - Electric

72 77 82 86 100 109 127 132 136 141 14590 104 11895 113 122

80 85 90 95 110 120 140 145 150 155 160100 115 130105 125 135

BH85-1 BH90 BH100

TR100

SRT95*

SF31904

100 -150 ton Product Strategy Cont.

Short TonsMetric Tons

795F-AC785C / D

100 109 1188 127 154 172 209 218 2277 236 245 254 2722633

281 290 299 308 318 327136 163 191145 181 200 354336 345 372363 381

110 120 130 140 170 190 230 240 250 260 270 280 300290 310 3200 330 340 350 360150 180 210160 200 220 390370 380 410400 420

T252

Unit Rig

MT300 MT3600 MT5500

T262 T282

789 793D / F 797B / F

HD 1500 -7 730E 930E-4830E - AC

930E-4SE

EH3000 EH3500-AC EH4500-2 EH5000

MT6300AMT4400ACMT3700ACMT3300A

TI274

960E860E

7513 7530 7560

SF32601SF31904

150 – 400 ton Product Strategy

793 History

• 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

The 793 has continuously evolved to remain the leader in its class

D-Series Application Arrangements

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)

The 793D is offered in five machine arrangements to match the application conditions found in your mine

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 Standard (Rear)

Extended Life (Rear) Brakes Bearings

793D Extended Life Wheel Group Arrangement - Front

• For long uphill hauls

Differences from Standard Arrangement• Larger wheel bearings • Larger spindle, wider wheel

bearing spacing• 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 Spindle bolts

(outer pattern) Strut bolts(inner pattern)

Bottom mountsteering arm

Extended Life (Front)

Standard (Front)

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 & DistributionCaterpillar® 793D Mining Truck

6 Sigma & CPS

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

A methodology that improves product quality, processes throughout the company, and customer satisfaction

Design & Engineering

• 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

it’s assembled

The 793D was developed by the truck engineering group in Decatur, Illinois using the latest design technologies and methodologies

Research & Testing

• 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

Innovation begins at the Caterpillar Technical Center in Mossville, Illinois

… 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

• Close tolerance machining centers• Automated material handling systems• Extensive welder training• Nondestructive weld testing• Highly trained, experienced

assemblers

From machine shop to assembly line, the 793D and its components are produced using the latest machining technology and highly skilled workforce

Manufacturing Quality Assurance

• 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

Quality control practices have long been built into the Caterpillar manufacturing process, from machining to assembly

Distribution & Support

• Caterpillar’s 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 Mining’s Field Assembly Group commissions 793 trucks worldwide

When Cat products reach the field, they are supported by an advanced network of parts distribution facilities, dealer service centers, and technical training facilities

793D Component Sources

Caterpillar designs and manufactures all major components of the 793D

Bodies also manufactured in Australia & South Africa

Completely Caterpillar

• 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

Design and manufacturing control ensures that the 793D operates as a complete and balanced unit

May 2004 – Decatur Plant

SpecificationsCaterpillar® 793D Mining Truck

12 862 mm42.2 ft

5584 mm18.3 ft

5905 mm19.4 ft

12 862 mm42.2 ft

1005 mm3.3 ft

3772 mm12.4 ft

13 113 mm43.0 ft

Body Raised

5871 mm19.3 ftEmpty

1364 mm4.5 ft

7680 mm25.2 ft

5610 mm18.4 ft

1294 mm4.2 ft

7680 mm25.2 ft

6940 mm22.8 ft

6500 mm21.3 ft

6494 mm21.3 ft

1128 mm3.7 ft 4963 mm

16.3 ft

7605 mm24.9 ft

793D Dimensions

Shown with MSD II body Dimensions are with dual slope body

793D Specifications (Metric)

1 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 Standard

793D Extra Life Wheel

Groups

793D Extra Top

Speed

793D Extra

Retarding

793D Extra

Retarding793C2

Maximum GMW (kg)Chassis weight1 (kg) 119 597 121 539 121 632 121 583 122 196 118 284

Engine model 3516 B3516B

HDDisplacement (L) 69 78Gross power (kW)Flywheel power (kW) 1615Rated speed (rpm)Engine derates above altitude3 (m) 3658 2743Transmission speedsTop speed (km/h) 59.954.2 54.2

17431,750

25916 Forward – 1 Reverse

383 739

3516B HD78

1801 1715

793D Specifications (Metric)

(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 Standard

793D Extra Life Wheel

Groups

793D Extra Top Speed

793D Extra Retarding

793D Extra Retarding

793C2

Fuel tank capacity (L) 4467Optional fuel tank (L) -Brake discs per side - front

10 10

Brake area - front (m2) 8.98 8.98

Brake discs per side - rear

Brake area - rear (m2) 13.46 13.46

Brake disc outside diameter (mm) 876.3 876.3

Total brake area (m2) 22.44 22.44

15

15.54

939.829.01

43534921

13

13.47

793D Specifications (English)

1 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 Standard

793D Extra Life Wheel

Groups

793D Extra Top

Speed

793D Extra Retarding

793D Extra Retarding 793C2

Maximum GMW (lbs)Chassis weight1 (lbs) 263,666 267,947 268,153 268,045 269,396 260,771Engine model 3516 B 3516B HD

Displacement (in3) 4,211 4,760Gross power (hp)Flywheel power (hp) 2,166Rated speed (rpm)

Engine derates above altitude3 (ft) 12,000 9,000Transmission speedsTop speed (mph) 37.233.7 33.7

2,3371,750

8,5006 Forward – 1 Reverse

846 000

3516B HD

4,7602,415 2,300

793D Specifications (English)

(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 Standard

793D Extra Life Wheel

Groups

793D Extra Top

Speed

793D Extra

Retarding

793D Extra

Retarding793C2

Fuel tank capacity (gal) 1,180Optional fuel tank (gal) -Brake discs per side - front 10 10Brake area - front (in2) 13,912 13,912Brake discs per side - rearBrake area - rear (in2) 20,869 20,869Brake disc outside diameter (in) 34.5 34.5Total brake area (in2) 34,781 34,781

1524,084

3744,958

1,1501,300

1320,874

Features & BenefitsCaterpillar® 793D Mining Truck

793D Features & Benefits

• Frame & Structures• Suspension• Hydraulic System• Power Train• Cooling System• Brakes & Retarding• Operator Station• System Integration• Bodies & Liners • Tires & Rims

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

793D Frame

• 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

Caterpillar frames are designed to deliver long service life in rugged mining applications

Structures

Fabrications

Castings

Integral 4-post ROPS

Integrated Steering & Suspension

• Four-corner independent, nitrogen- over-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

Cat designed for excellent maneuverability, safe operation, lower operating costs, and a comfortable ride

Front Axle Steering Components

• 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

The 793D front suspension is a field proven design with dual tie-rods for optimum steering geometry to help extend tire life

Hydraulic Power Management

• 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

Common rail hydraulics improve system efficiency by better sharing and controlling power needs for hydraulically-driven functions

Hydraulic pump

Common Rail Hydraulics

Optional Rear Axle

Common Rail Valve

Brake Cooling Pumps

Common Rail Pump

Fan/Common Rail Cooler

Common Rail and Fan Tank

Return Filter

Fan Pump

Brake Cooling Drive Motor

Solid Connection

MainEngineFan

Steering Cylinders

SteeringControl

Rear AxleLubricator Motor

Cooler Fan

3516B High Displacement EUI Engine

• 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

A proven performer for over 20 years, the 3500 series engine now has over 80,000 units worldwide working in a variety of applications

High Displacement Engine

Metric English

Ratings @ 1,750rpm Gross Power 1801 kW 2,415 hp Net Power 1743 kW 2,337 hpDimensions Bore 170 mm 6.7 in Stroke 215 mm 8.5 in Displacement 78 L 4,760 in3

3516B EUI Engine for High Altitude

• 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

A proven performer for over 20 years, the 3500 series engine now has over 80,000 units worldwide working in a variety of applications

High Altitude Arrangement Engine

Metric English

Ratings @ 1,750rpm Gross Power 1715 kW 2,300 hp Net Power 1615 kW 2,166 hpDimensions Bore 170 mm 6.7 in Stroke 190 mm 8.5 in Displacement 69 L 4,211 in3

Engine Comparisons

793C793C

(Tier 1)793D

(Tier 1)793D

High Altitude

Engine 3516B 3516B HD 3516B HD 3516B

Gross Power 1715 kW2,300 hp

1715 kW 2,300 hp

1801 kW 2,415 hp

1715 kW 2,300 hp

Displacement 69 L

4,211 in3

78 L

4,760 in3

78 L

4,760 in3

69 L

4,211 in3

BSFC g/kW-hr (lb/hp-hr)

211 (0.347)

201 (0.330)

206 (0.339)

221 (0.363)

BMEP 1704 kPa 247 psi

1508 kPa 219 psi

1583 kPa 230 psi

1704 kPa 247 psi

12

3

4

56

79

10

11

8

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

Brake Mean Effective Pressure (BMEP)

• BMEP measures how hard anengine is working

• Lower BMEP = longer life• Cat engines’ low BMEP

improves availability, extends service life and reduces overall costs

Cat engines have low BMEP, which means the 3500 works easier and lasts longer

0

500

1000

1500

2000

2500

793C

HD

793D

793B

793C

DDC16V40

00

QSK60

DDC16V40

00

QSK60

1715

kW

1715

kW

1801

kW

1611

kW

1864

kW

1864

kW

2051

kW

2013

kWE

ng

ine

BM

EP

(kP

a)

Oil supply from crankcase

Oil sent to tank via fuel return line

Oil metered via electronic controls

Oil Renewal System (ORS)

• 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

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

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

Superior Engine Oil Quality with ORS

Oil Degradation vs Time

Oil

Deg

rad

atio

n

Hours

0 1000 2000 3000 4000 5000

Non-ORS

ORS

Mechanical Power Train

Lock-up Torque Converter

Six-speed planetary power shift transmission

Differential and double reduction final drive

Transmission has internal changes to accommodate increased horsepower & top speed

Dual transmission output speed sensors

New two-piece transmissionharness for redundant

speed sensors

Oil level switch

Adapter to provide spacefor additional disc & platein lock-up clutch

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

New input transfer case to accommodate increased top speed gears

Rear axle filtrationis now continuous(no longer ground driven)

Transmission input speed sensor

Lock-up Torque Converter

• 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)

Combines the advantages of direct drive and converter drive to achieve high component reliability and maximum output performance

Controlled Throttle Shift

• 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

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

Controlled Throttle Shift (CTS)

Tra

nsm

issi

on

Ou

tpu

t T

orq

ue

C

lutc

h P

ow

er

Time

Precise Transmission Control

• 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

Electronically controlled individual clutch modulation reduces driveline torque stress for smoother shifts, extended component life and improved operator comfort

Pre

ssu

re

Time (in fractions of a second)

Electronic Control Example ofdepressurization of one clutch and pressurization ofanother during atransmission shift

With Hydraulic Control

Six-Speed Planetary Transmission

• 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

Large diameter clutch packs are controlled to provide smooth shifting and to limit clutch energy input for extended component life

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

Bearings with kidney looping and 4,000-hour oil changes showed

little wear after 18,000 hours

Images magnified 50x

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

13,000 hours

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

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

1

6

2

3

5

7

4

Brakes and Retarding

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

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

Integrated Braking Control

Integrates the Hydraulic Automatic Retarding Control and the Traction Control System into one electronically controlled braking system

1

6

2

3

5

7

4

6

7 8

1. Service brake sensor

2. Engine sensor

3. HARC

4. HARC switch

5. Brakes

6. Service brakes

7. Axle speed sensor

8. TCS

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

Operator Station

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

The integral, sound-suppressed ROPS/FOPS cab gives the operator a comfortable and safe working environment

1 8

2

5

7

3

4

6

9 10 11

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

Ride zone indicator

Three-point restraint • High-back seat supports head

and neck• Ride zone indicator adjusts seat

suspension to operator’s 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

VIMS

1. Gauge Cluster2. Message Center and Keypad3. ADEM III Engine Control Module4. CAT Data Link5. Action Alarm6. Action Lamp7. Payload Lamps8. Payload Display (optional)9. Radio System (optional)10. Data Port (VIMS-PC)11. Service Lamp12. Diagnostic Connector (Cat ET)13. Integrated Brake Control (IBC) Module14. Transmission/Chassis Control (TCC)

Module15. Road Analysis Control (RAC) Module

(optional)

CatET

VIMS Speed Manager

• VIMS MAX Speed Manager • VIMS TKPH (TMPH) Speed Manager • VIMS MAX Payload 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

MineStar® – Integrated Mine Information System

Radio Network

Rep

ort

ing

KPIs/Graphing

BusinessIntelligence

Reports

Assignment Health Production Monitoring

MachineTracking

MaterialTracking

Machine Guidance

MineStar…

GPS Infrastructure: Satellites, Repeaters, Base Station

Administration/ ManagementProduction

Engineering and Geology

SafetyMaintenanceProcessing

Data Flow

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

7265 mm

6982 mm

Front to Rear Body Flare

• 1 ° 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

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

Exhaust Outlet

Body Exhaust Heat

Pivot Area and Hoist Brackets

• Factory pre-assembled and installed

• Internal and external gussets provide full support

• Solid piece pivot bracket

• Internal and external gussets optimize stress distribution

• Minimizes impact damage to floor

• Analyzed and tested for optimal floor rib coverage

Understructure Gussets & 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 3 (149 m 3 )

– 3000+ lbs/lcy• 204 yd 3 (156 m 3 )

– 2800-3000 lbs/lcy• 210 yd 3 (160 m 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

Exhaust Outlet

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

Body Exhaust Heat

Gussets and Ribs

Internal and external gussets optimize stress distribution

• Minimizes impact damage to floor

• Analyzed and tested for optimal floor rib coverage

Understructure

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

• Complete forward machine coverage• Canopy rock shedders• Rock ejectors

• Upper sidewall lifting eyes• Loading Target

Impact & wear protection that maximizes body life & performance

F A C L T

ragmentation

brasion

ohesion

oading

ool

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

FACLT & Body Liner Segmentation

L 1 L 1

L 1 L 2 L 2

L 3

L 3

L 4 L 4

L 5 L 5

L 6 L 6

L 7 L 7 L 8 L 8

L 9 L 9

L 10 L 10

L 11 L 11

L 12 L 12

L 13

L 14

L 15

L 15 L 15

Body Liners

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

Smooth Plate forcohesive materials

Rock Box for dry andnon-cohesive materials

Zipper Grid forsemi-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

29" rim 32" rim

Goodyear 40.00R57

Michelin 40.00R57

Bridgestone 40.00R57

Bridgestone 46/90R57

Michelin 44/80R57

793D Tire & Rim Options

Competitive

Caterpillar

Extended Tire Life

• 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

The Cat 793D is designed specifically to extend tire life and reduce costs

Sustainability

NameGlobal Mining Division

Month Year

Caterpillar® 793D Mining Truck

Sustainable Development at Caterpillar

• Our vision is a world in which all people’s 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

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

--Jim Owens, Caterpillar

Chairman and CEO .

Executive Summary

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

Caterpillar Goals

SD SAI > Enterprise SD “Customer” Goals…

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 securityNew 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

Transmission lockout

Rear platform

• 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

Ecology Drains

• Installed on– Engine (#1)– Transmission– Torque converter– Hydraulic tank– Fuel tank– Radiator (#2)

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

2

Equipping Your TruckCaterpillar® 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

• 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

Caterpillar and your dealer work together to offer you custom attachments and retrofits to meet the specific demands of your mine site

Road Analysis Control (RAC)

• 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

RAC monitors and logs haul road severity to increase truck life and reduce cost/ton

ProductivityCaterpillar® 793D Mining Truck

10/10/20 Overload Policy

90 %

No loads should be above 120% of the target payload

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

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

target

793D Performance

• 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)

Preliminary data projects faster uphill speeds and higher productivity than its predecessors

ServiceabilityCaterpillar® 793D Mining Truck

1

6 2 7

1

5 3

4

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

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 “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

6. Check the coolant levels in the coolant tanks

7. Remove debris that may obstruct the air filters

8. Check steering system hydraulic oil levelsight 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.

1

6

2

9

58

4

10

2 7

5

37 2

10

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

1

6

2

1

5 3

4

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

2

1

3 4

1. Inspect lights for damage

2. Check suspension cylinders

3. Look for leaks around filter

4. Check oil level sight gauge; check grease fittings

2

Product SupportCaterpillar® 793D Mining Truck

Dealer Support

Parts and ComponentSupport

Equipment ManagementServices

Repair and MaintenanceProcess Engineering

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

Caterpillar Global Factory Support

• 23 parts distribution centers

• 13 training centers

• 107 manufacturing facilities

Caterpillar Global Dealer Network

267locally owned businesses

1,665dealer branch stores

93,000employees supporting you

$7.8 billionin assets

50+ yearsaverage tenure

More than our top 3 competitors combined

Parts & Service Support Worldwide

• Preventive maintenance programs• Diagnostic programs, such as

Scheduled Oil Sampling and Technical Analysis

• Rebuild and Reman options• Operator training• Customer support agreements

Cat dealers offer a wide range of parts and service plans that will maximize uptime and return on your investment

Caterpillar Certified Rebuild (CCR)

• Inspection• Disassembly• Reconditioning• Engineering updates• Power train testing• Reassembly• Performance testing• Repainting• New serial number/warranty• Customer evaluation

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

Off Highway Truck Reman Components

• 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, ECU’s• Price 40 – 70% below new parts

We offer the following Reman components from 777-797 to decrease down time, reduce cost, and increase quality.

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

Production

• More rimpull, faster cycle times

• Optional +10% top speed

• Optional +35% downhill speed

• Optimized payload (with MSD bodies)

Utilization

• Traction control allows continued operation in poor underfoot conditions

Mechanical Availability

• Improved reliability, higher uptime

• 3516B HD engine has lower BMEP and no wastegate for improved durability and reliability

Owning Cost

• 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

Tire Cost per hour

• Weight distribution and low Empty Machine Weight (EMW)

• Steering geometry

• VIMS TKPH (TMPH) Speed Manager

Operator Efficiency

• Operator station comfort and ergonomics

• Operator confidence in braking and retarding optimizes downhill speed

Fuel Cost per Ton

• Mechanical power train efficiency

• HD engine

• Zero fuel consumption while retarding

113

QuestionsCaterpillar® 793D Mining Truck

Caterpillar® 793D Mining Truck

Media Support

www.cat.comwww.safety.cat.comwww.catreman.cat.comwww.catminer.cat.com

Mining Truck BodiesBody MaintenanceGround RulesProduct Development Video

Specalog AEHQ5600-01 Show Spec Sheet AEHQ5877 VIMS AEXC0681WAVS TEKQ0647-03Virtual Operator Training TERV0101Mining Safety Brochure AEXQ0370Minestar AEHQ6017-01CPI AERV5715RAC TELQ4461Marketing Bulletin TEJB9452