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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

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Today’s Agenda

• Strong market presence

• Historical trend to mechanical drive

– Product support = Availabili ty = Tons Moved

– Productivity

– Payload control

• Key features & benefits deliver:

– Health, Safety & Environment

– Lower Cost Per Ton / Availability

– Tires

• Serviceability – Customer’s Perception

• Competitive Update

• How we are doing?

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49,0003.9 million200+797

105,40070 million1900+793

105,50067 million1800+789

127,00071 million2300+785

Highest

Hour Unit(As of June 2006)

Fleet HoursTotal Units

Large Mining Truck Shipments

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785 Worldwide Fleet

Over 2,300 Shipments (as of June 2006)

35%North America

12%Latin America

35% Asia Pacific,

Indonesia &

Australia

18%Europe, Africa &

Middle East

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789 Worldwide Fleet

Over 1,800 Shipments (as of June 2006)

34%North America

17%Latin America

36% Asia Pacific,

Indonesia &

Australia

13%Europe, Africa &

Middle East

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785C Applications 2004 - 2005

Payload

150 T / 135 MT

Other Mining

6%

Coal

31%

Copper

7%

Iron Ore

14%

Gold

16%Contractor Coal

22%

Nickel

4%

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Payload200 T / 180 MT

789C Applications 2004 - 2005

Contractor Coal

39%

Other Mining

7%

Gold

6%

Iron Ore

13%

Copper 4%

Coal

31%

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World Truck Power Train Trends

(Shipments 120 tons – 400 tons) WHY?

1970

95%

Electric

5% Mechanical

Non-Cat 1980

20052000

19941990

56% Electric

44% Mechanical

785 & 789

37% Electric 63%

Mechanical

785, 789, 793

42% Electric

58% Mechanical

785 - 797

37% Electric 63%Mechanical

785 - 797

100% Electric

Market Introduction

785 1984

789 1986

793 1991797 1998

Note: Belaz numbers not available

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Reduction in Cost Per Ton

5% Factor 0% 1% 2% 3% 4% 5% 6% 7%

Operator Efficiency

Mechanical AvailabilityCycle Times

Payload

Utilization

Maintenance and Repair

Fuel Consumption

Machine CapitalMachine Life

Operator Wages

Tires

Lubricants

A 5% Change in Each o f the L is ted Facto rs Cause the Fo llowing % Reduct ion in Cost Per Tonne

The Top 5 Factors relate to Productivity… Not Cost

Cost per Ton: Sensitivity

PayloadCycle Times

Operator Efficiency

Utilization

Mechanical Availability

Cost

Ton

Fuel

Maintenance & Repair

Machine Capital

Operator Wages

Tires and Undercarriage

Lubricants

Residual Value

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Productivity

Caterpi llar 785C & 789C Mining Truck

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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 Buil t Integrated System

• Heavy-duty final dr ives withstand extreme loads

and forces, can be remanufactured

• One-piece cast wheels enhance durability

• Differentials designed for long li fe, lower cost-

per-ton operation

• Rear axle lube system cools and cleans

continuously

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G r o s s P o w e r T ra in E f f ic ie n c y

3 0 %

3 5 %

4 0 %

4 5 %

5 0 %

5 5 %

6 0 %

6 5 %

7 0 %

7 5 %

8 0 %

8 5 %

9 0 %

9 5 %

1 0 0 %

0 % 5 % 1 0 % 1 5 % 2 0 % 2 5 % 3 0 %

E f fe c t iv e G r a d e

G r o s s P

o w e r T r a i n E f f i c

i e n c y

7 9 3 D 7 9 7 B

A C D r iv e D C D r iv e

72.281.5DC

7983 AC

85.488793D

86.788797B

12%Peak

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

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Gross Power Train Efficiency

30%

35%

40%

45%

50%

55%

60%

65%

70%

75%

80%

85%

90%

95%

100%

0 10 20 30 40 50

Ground Speed-mph

G r o s s P o w

e r T r a i n E f f i c i e n c y

793D 797B AC Dr ive DC Dr ive

72.281.5DC

7983 AC

85.488793D

86.788797B

12%Peak

Mechanical drive systems are the most effic ient over a broad operating range

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Why do we have a payload policy?

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

• RISK Management – MARC

– Availabi lity Guarantee

• SAFETY

No loads should ever exceed the truck’s steering and braking certification.

Exceeding the steering and braking certification would make the truck unsafe to

operate.

• Provide optimum Cost per Ton

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Caterpillar Integrated Design

Body and Payload

Power Train Chassis

Suspension

Wheel and Tires Terrain

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Caterpillar Bodies

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CAT 793D MSDII Option Example (No Liners)

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Body Liner Placement

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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 176m³ Body: 59,084 lb 26,800 kg

• Caterpillar Custom Liner Package: 20,283 lb 9,200 kg

• Target Payload: 250 Tons 227Tonnes

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

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% of Target Payload

80 85 90 95 100 105 110 115 120

N u m b e r o f L o a d s

90 % 10%

S A F E T

Y

P r o d u c t i v i t y

D u r a b i l i t y

Caterpillar 10/10/20 Payload Policy

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

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Steering & Brake Certifications

• Designed / tested / certi fied 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 distribut ions about the

target payload as reflected in Cat 10/10/20 payload policy

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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 availabili ty

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Payload Capacity - 110 to 400 Ton Trucks

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 410400100 420

Unit Rig

MT3000 MT3300 MT3600B MT3700B MT4400 MT5500B

T252 T262 T282B

785C 789C 793D 797B

Short Tons

HD 1500 730E 830E 930E-3

830E - AC 930E-3SE

960E

EH3000 EH3500 EH4500-2 EH5000

MT5900ACMT4400ACMT3700ACMT3300AC

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The Competition

150 Tons

785CHD1600

EH3000

MT3300

200 Tons

789C730E

EH3500

MT3700

T262

Cat

Komatsu

Hitachi

Terex

Liebherr

• This is the current size class distinction according to AEM

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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?

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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 cyl inders - 15,000 hrs

– Hoist cylinders - 15,000 hrs

– Steering cylinders - 15,000 hrs

Competitors c laims of 25,000 hrs or more – Real?

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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 MSDGross 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

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Euclid EH3500 vs. 789C

X3500 Prototype

Maximum Payload: 186t / 205 Tons

AC Drive with current EH3500

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GE - Loading Policy

70 80 90 100 110 120 130

Payload

“..any operation in the

extended range may result

in reduction or termination of

warranty provisions,

increases in operating costs

and/or more frequentoverhauls…”

normalextended

exceeded

“Operation in the exceeded

range will result in increased

component wear and potential

failure .. not recommended ..

Likely to void all GE warrantiesand guarantees including but not

limited to cost caps, availability

guarantees and all product

warranties.”

“..mean must not

exceed rated

payload +2%…”

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GE - Loading Policy

70 80 90 100 110 120 130

Payload

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GE - Loading Policy

70 80 90 100 110 120 130

Payload

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Features & Benefits – HSE & Cost Efficiency


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785C & 789C Features & Benefits

• Safety & Operator Station

• Powertrain

• Systems Integration

• Frame

• Body

• Front Axle & Steering

• Retarding & Traction Control

• Tires

The 785C & 789C are the premier machines in their c lasses, designed and bui lt by Caterpi llar

using components and systems that have evolved through years of rugged mining applications

Cost per Ton

Availability

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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

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New Optional Safety Features

The 785C & 789C wil l offer the latest safety features for the protection of the

operator and mine employees

New Safety Enhancements• 600 mm (24 in) wide diagonal stairway -

field ki ts for 785B/C & 789B/C in 4Q06

• Closed-circuit television factory ready and

model specif ic ki ts 4Q06

• Should heated mirrors be a custom option

for 785C & 789C?

– (Currently optional on 793D)

Custom Heated Mirrors

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New Optional Safety Features

New Safety Enhancements

• High intensity discharge (HID) lighting inhigh beams and back-up l ights improves

night time visibility

• Extended life carbon paper disc brakes provide longer

service li fe and increased heat resistancethan standard brakes

The 785C & 789C offer optional features to enhance safety in specific operating

environments

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Operator Station

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

The 785C & 789C operator workstation is designed for maximum operator comfort, control,

convenience, and safety

1

8

5

10

4

3

6

7

9

2

•Ergonomically designed

•Excellent machine contro l

•Exceptional all-around visibility

•Resiliently-mounted, sound suppressed cab

- Sound levels less than 80 dB (A)

• Air suspension seat - fu lly adjustable

•Operator comfort = Higher Productivity!

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Cab Visibil ity

Electric truck visibility Cat 793D visibility

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Cat Comfort Seat

• 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 fi t

• ADJUSTMENT TRAINING!!

The Caterpil lar Comfort Seat with three-point operator restraint is the most durable

and supportive seat available for Cat Mining Trucks

Ride zone indicator

Three-point restraint

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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 heavyoperators)

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

Cat Comfort Seat Initiatives

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Caterpillar Engines

• Electronic Control Module

– Reduces smoke – Reduces emissions.

– Improves fuel efficiency

– Optimizes performance and l ife

– Communicates with transmissionand 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 -- improvingavailability, extending li fe, reducing costs

• Purpose Buil t Integrated System

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

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Lock-up clutch

Input

Torque

converter output

Flow of power

Flow of oil

Torque converter drive mode

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 6.4 km/h (4.0 mph)

Combines the advantages of direct drive and converter drive to achieve high component

reliability and maximum output performance

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Six-Speed Planetary Transmission

• Torque converter lock-up in first gear • Downshift inhibitor prevents engineoverspeed

• Clutch packs mounted outside of gear sets

for ease of service

• Directional shift management automaticallyreduces engine throttle before shifting

Large diameter clutch packs are controlled to provide smooth shifting and to limi t

clutch energy input for extended component life

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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 shi fts, extended component li fe,

and improved operator comfort

Controlled Throttle Shift (CTS)

T

r a n s m i s s i o n O u t p u t T o r q

u e

C l u t c h P o w e r

Time

Shift without CTS

Shift with CTS

Shift with CTS

Shift without CTS

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Rear Wheel Group

• 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

Heavy duty components and ease of service combine to deliver long li fe and reduced

downtime in the most rugged conditions

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Ecology Drains

• 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 fi ll and drains forthe truck fluids

Easily accessible drain plugs are installed in components to provide an environmentally

safe and effective method to drain fluids

2

1

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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 andoil disposal costs

• Improves average engine oil quality

• Lessens environmental impact

• Decreases service downtime

• Exclusive integrated Caterpillar controls

ORS meters used crankcase oil into the fuel system to be burned, replaced by new oil as

the system is regularly topped off

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Because ORS constantly burns old oil which is replaced by new, the quality level remains consistent

and free of the quality degradation experienced in oi l dur ing a typical 500-hour li fe cycle

Superior Engine Oil Quality with ORS

Oil Degradation vs Time

O i l D e g r a

d a t i o n

Hours

0 1000 2000 3000 4000 5000

Non-ORS

ORS

Caterpillar Integrated Systems

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Caterpillar Integrated Systems

• Purpose-built, integrated systems

– 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®

• 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

F

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Frame

• Engineered using computer-generated

stress modeling

• Forgings and castings used in highstress locations

• Rollover fixtures ensure all welding is done

horizontally, not overhead

• Al l cr itical welds are ultrasonically tested

• High strength low alloy (mild) steel is highly

durable, easy to weld

Caterpillar ® frames are designed to deliver long service li fe in rugged mining applications

Caterpillar Truck Body Options

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Caterpillar Truck Body Options

Standard Dual Slope Body

Standard Flat Floor Body

MSD II Body

Gateless Coal Body

B d Li

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Body Liners

Caterpil lar offers modular liner plate packages for addit ional impact and wear protection

Smooth Plate for cohesive materials

Rock Box for dry and non-cohesive materials

Zipper Grid for semi-cohesive materials

Mechanically Attached Wear Plate System

(MAWPS) for all mining conditions

Front Axle Steering Components

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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 providesredundant 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 785C & 789C front suspension is field-proven design with dual tie-rods for

optimum steering geometry to help extend tire life

Brakes and Retarding

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1

6

2

3

5

7

4

Brakes and Retarding

• Integrated systems deliver optimumperformance

• 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 contro l,

minimizes wheel lock-up• Traction Contro l System improves

performance in poor underfoot

• Automated Retarder Control al lows faster,safer downhill travel

• Sealed system prevents contamination• Brake wear measurements completed quickly

• Purpose Built Integrated System

1. Parking/secondary piston

2. Service/retarding piston3. 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

Integrated Braking Control

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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. HARC4. HARC switch

5. Brakes

6. Service brakes

7. Axle speed sensor 8. TCS

Hydraulic Automatic Retarding Control :

• Increases production due to fasterdownhill speeds

• Excellent controllability; reducedoperator effort for less fatigue

• Engineoverspeedprotection

• Hydraulic engagement offers smoother,more responsive operation than previouspneumatic design

Traction Control System:

• Improved traction in poor underfoot conditions

• Less slippage means less tire wear

Benefit of Caterpillar Traction Control System

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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 AC Competitor

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Extended Tire Life

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Extended Tire Life

• Gross weight d istr ibution is ideally 33/67

front-to-rear axle

• Traction Control System attachment reduces

tire slippage and wear

• Steering geometry and turn ing radius are

designed to minimize tire scrub

The Cat 785C & 789C are designed specifically to extend t ire li fe and reduce costs

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T I R E = C O S T

T I R E S = P R O F I T

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Serviceability


VIMS™ System

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y

CatET

785C & 789C Reduces Cost Per Ton

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Safety

• Oil cooled brakes at 4 corners with 40/60

split,dead engine full stop capability,

ROPS/FOPS, 10/10/20 payload control policy

• Diagonal stairway, HID lighting, extended

wear brakes, and WAVS rear vis ion

camera

Production

• Fast cycle times – broad operating range

• 2 axle retarding

• Optimize payload with MSD Bodies

Mechanical Availability

• Improved reliability, higher uptime

• 3500 Series engine has lower BMEP thancompetition—improving availability, extendinglife, and reducing costs.

Utilization

• One safe source for support• Traction control allows continued operation

in poor underfoot conditions

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

785C & 789C Reduces Cost Per Ton

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Operator efficiency

• Operator station comfort and ergonomics

• Operator conf idence in braking and retardingoptimizes downhi ll speed

• Good visibility

Fuel cost per ton

• Engine fuel efficiency

• Highest power train effic iency

• Zero fuel consumption while retarding

Maintenance cost per hour

• Field-proven components throughout the

truck

• VIMS™ System capabili ty allows diagnostics

and prognostics to extend service life

of components

• Dealer and factory REMAN

Tire cost per hour

• Weight distribution and low Empty Machine

Weight

• VIMS™ TKPH/TMPH Speed Manager

• Traction Control System – limited slip

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Caterpillar 789 Mining Truck PINS

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Note: Belaz sales not available

789 Shipments / PINS History

6966

39

77

48

6259

47

53

65

0

50

100

150

200

250

300

350

1996 1997 1998 1999 2000 2001 2002 2003 2004 2005

0

10

20

30

40

50

60

70

80

90

CAT (Units) Industry (Units) PINS

In Conclusion

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•Strong market presence

•Viewed histor ical trend to mechanical drive

–Product support = Availabili ty = Tons Moved

–Productivity

–Payload control

•Reviewed features & benefits deliver:

–Health, Safety & Environment

–Lower Cost Per Ton / Availability

–Tires

•Discussed Serviceability – Customer’s Perception

•Discussed Competition

•Keep up the good work!

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QuestionsCaterpillar 785C Mining Truck

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