Caterpillar ® 793F Off Highway TruckNPI – Operator Training Materials

Name

Venue

Date

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

History

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 1980

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

Field Population

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)

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)

Future Mining Truck Market Segmentation100mt – 390mt

793 Fleet History

• Cat® 793– 1991 - 1992– Over 50 sold

• B-Series– 1992 - 1996– Over 500 sold

• C-Series – 1996 - 2005– Over 1,050 sold

• D-Series– 2005 - Today– Over 1,300 sold

• F-Series

More than 3,000 units sold since 1991

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

F Series Development

• Enhanced Safety• Increasing performance

– Lower cost per ton– Lower maintenance costs– Increases operator efficiency– Streamlined operator station

• C175– Tier 2 compliant– Common rail fuel system– ATAAC

• Improved Serviceability– Ground level service– New engine designed for serviceability

The F-Series has evolved to offer increasing safety performance and service

Specifications

793D and 793F Specifications

793D 793F

Engine 3516B C175-16

Gross HP (1801 kW) 2,415 hp (1976 kW) 2,650 hp

GMOWGross Machine

Operating Weight

(383 739 kg) 846,000 lb (386 007 kg) 851,000 lb

(390 089 kg) 860,000 lb

Top Speed Loaded

(54.2 km/h) 33.7 mph (std.)

(59.9 km/h) 37.2 mph (opt.) (60 km/h) 37.3 mph (std.)

Payload (218 tonnes) 240 ton (226.8 tonnes) 250 ton

793F Dimensions

Competitive Comparison

F Series Design for maximum production

Exceptional Performance

Performance advantage and fuel economy • Highest payload for class at rated GMW• Fastest speed on grade for more cycles

per hour• Highest industry grade performance • No thermal limitations for time on grade• Four corner braking • Responsive traction control to maximize

performance in poor underfoot conditions • No fuel burn when retarding• Smooth ride allows faster cycles

Operator Differences between 793D and 793F

• Walk around inspection points• Cab – Your new office (Ergonomics)• Cat Comfort Seat• Brake systems• Speed on grade• Technology

Exceptional Performance– Grade Speed

• Highest grade speed means less time on grade – more production per hour

• Detail study established optimum horse power to deliver best speed on grade for fuel / power train cost

• High torque for pulling through poor underfoot or the ability to achieve a 28% maximum grade loaded

793F delivers fastest industry speed on grade

7.5% Faster speed on grade on a typical 16 min cycle can delivers +180,000 tons / year

11.5% Effective

793F 8.5 mph (+7.5%)AC 7.9 mph

Exceptional Performance – Brakes and Retarding

• Wet oil-cooled brakes combine service, secondary, park brake, and retarding functions

• Superior controllability with four corners braking / retarding

• Park brake holds loaded truck on up to a 15% grade

• Zero fuel burn during retarding• Traction controls improves tire life and keeps

truck moving through poor underfoot• Exceeds ISO 3450 braking requirements even

at 120% of rated payload• Braking system designed for repeated hard

stops

Oil-cooled multiple disc brakes, on all four wheels, provide enhanced control and exceptional braking and retarding performance; even in extreme road conditions

Regardless of paper specs many mines with both

Cat and AC drive trucks set faster loaded and

empty retarding speeds limits for the more controllable Cats

793F Brakes and Retarding

1. Parking/secondary piston

2. Service/retarding piston

3. Friction discs

4. Steel plates

5. Actuating springs

Oil-cooled multiple disc brakes on all four wheels deliver no fuel burn during retarding

• Purpose built integrated system• Multiple discs are continuously cooled by

oil and heat is exchanged to atmosphere by radiator through water-to-oil cooler

• Non-fade oil cooled design offers reliable performance and long life

• Four wheel balanced (60/40 rear to front split) braking improves handling and machine control

• Spring applied secondary parking brake systems enhance safety

• Sealed system prevents contamination• Brake wear measurements completed

quickly

1

2

3

45

Integrated Braking Control

Integrated Automatic Retarding Control and Traction Control System for one electronically controlled braking system

Traction Control System:• Improved traction in poor underfoot

conditions• Less slippage means less tire wear

Automatic Retarding Control (ARC):• Increases production due to faster

downhill speeds • Excellent controllability and reduced

operator effort • Less operator fatigue• Adjustable speed to match road and

traffic conditions • Engine overspeed protection

Engages mechanical brakes on slipping wheel for quick and responsive traction control for

superior performance compared to traction motor modulation

Exceptional Performance - Retarding

• Balanced four corner control• Automatic Retarder Control for

easy operation• Adjustable speed auto retarder

allows speed to be set to traffic or conditions

• No fuel consumption during retarding reduces costs

• Maximum speed not limited by electric drive system overspeed protection

Four corner oil-cooled brakes and Automatic Retarder Control enable fast and confident downhill hauls

No fuel burn on loaded downhill haul could save $86,000 / year

Exceptional Performance - 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

• Payload sensors integrated into suspension cylinders

• All cylinders feature Advanced Surface Technology (AST) coating instead of chrome

• AST eliminates environmental hazards, improve wear and corrosion resistance (compared to chrome)

Designed for excellent maneuverability, safe operation, low maintenance cost, lower operating costs, and a comfortable ride

Low Operating Cost – Repair

• All Cat efficient mechanical power train delivers more power to the ground for greater productivity and lower operating costs

• Caterpillar C175 delivers more power for higher production than the 3500 while providing improved fuel efficiency at equal $ per hour repairs

• Proven mechanical power train delivers best cost per ton and allows R&I of separate components as needed

All Caterpillar design and manufactured components delivers: an integrated power train and controls system for optimum performance and cost

C175-16 is built for power, reliability, efficiency and low operating costs

Low Operating Costs –C175-16

• Gross output of 1,976 kW (2,650 hp) from 85 L (5,187 in3)

• Advanced technology for US EPA Tier 2 compliance

• More power with more life to overhaul than 3500s

• 3% more fuel efficient than the 3516B-HD delivers more production with equal or lower tons / gallon

• Better engine serviceability for faster repairs

• Four turbos reduce repair costs and leave engine accessible for repairs

• Ground level service points for easier service

• Field tested and validated in Mining & Electric Power (120,000 hours)

C175-16 Reliability

C175-16 Development

• Designed from experience of 3500, 3600 and MaK engines

• Labs development hours since 2004

• C175 in concept truck 2005

• Over 45,000 hours in mines on C175s running in modified 793Ds since 2006

• 30,000 hours in 793F pilots and 65,000 hours on C175-20s by mid 2009

• Hours accumulated on electric power generation and petroleum production engines

• Tear down and inspection of engine at 9,500 engine confirmed wear expectations

C175-16 engine extensively tested and validated before entering full-time production

2005 – C175 going into a 793D at Cat’s Proving Grounds

Low Operating Cost – Power Train

All Caterpillar powertrain delivers more power to the ground for greater productivity and lower operating costs

• Superior mechanical power density delivers high efficiency at the lowest system weight / cost

• Lock-up torque converter for efficient direct drive haulage

• Power transmitted through system using high speed / low torque

• Six speed planetary transmission optimizes power train efficiency

• Torque reduction is throughout power train and not all at final drives

• Proven Caterpillar double planetary reduction final drives only need to take a 16:1 reduction

Low Operating Cost - Transmission

• Six-speed planetary transmission matches engine power to a wide range of operating speeds

• Leverages Caterpillar’s core competency and proprietary technologies for manufacturing proven power shift clutches and planetary gear sets

• Electronic Clutch Pressure Control (ECPC) modulates clutch engagement individually and allows for exceptionally smooth shifting and ease of operation

• Valves on top of transmission improve serviceability

• Externally mounted pressure taps allow for quicker and cleaner diagnostics and service

Large diameter planetary clutch packs provide smooth shifting and limit clutch energy input for extended component life

Low Operating Cost - Rear Wheel Group

• Final drive works as a system with the transmission for only a 16:1 reduction

• Caterpillar system runs at about half the gear speeds of competitive AC drive final drives

• Lower speed system is more efficient

• Slower speeds and loads allow for balanced gear and bearing sizing to deliver longer life

• Lower operating temperatures for better component life

• Leverages Caterpillar’s core competency and proprietary technologies for manufacturing proven planetary gear sets

Caterpillar final drives work as a system with the transmission for maximum power to the ground at the lowest cost

Double planetaryFinal Drive

Oil Disc Brakes

Rear Wheel Station

Low Operating Costs - Continuous Axle Filtration

RAX Filtration w/ cooler

10% longer life saves $25,000

Continuous Rear Axle Filtration provides superior filtration for longer component life of differential and final drives

• Standard feature • Cleaner components equal 10

to 20% longer component life• Continuously circulates axle

lubricant through 6 micron filter to maintain ISO 18/15 cleanliness

• Reduces kidney loop maintenance times

NOTE: The rear axle cooler is optional.

Low Operating Costs – Separate R&I Components

• Radiator• Engine• Torque Converter• Transmission• Pump drive• Differential• Axle• Brakes• Final Drives

Modular power train components allow for efficient remove and install plus allows for individual servicing to reduce unneeded repairs

Caterpillar’s individually serviceable wheel station components

Oil Disc Brakes

Final Drive sections

Spindle

Low Operating Costs - Prognostics

• On Board– Advisor display– Alert system– Payload indicator– Storage of data such as Events,

Trends, histograms, cumulative, snapshot and dataloggers

– Optional road analysis control to monitor haul road conditions

• Off Board– Ethernet and web connectivity– Near real time browser interface*– Trigger snapshots and data downloads

• Diagnosis and Analysis– VIMS PC off board diagnostic and

analysis software

VIMS improves effectiveness of scheduled maintenance, maximizes component life, improves availability, and lowers costs

* Requires use of a separate mine radio or cellular broadband system

• VIMS 3G monitoring system provides critical machine health and payload data in real-time

VIMS ™ System & Powertrain Integration

Low Operating Cost - Extended Tire Life

• Gross weight distribution is ideally 33% 67% front-to-rear axle

• Traction Control System reduces tire

slippage and wear • Integrated VIMS System 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 793F is designed specifically to extend tire life and reduce costs

Low Operating Cost - Tires & Rims

• Truck designed for 860,000lbs (390,000kg) GMW rating on extended life wheel stations

• Standard wheel stations rated at 851,000lbs (386,000kg) GMW

• 50/80R57 options allows for high TMPH (TKPH) ratings

• Different tire ratings from different tire manufacturers - work with your preferred tire supplier for correct tire and rim size per your application

• Tire GMW and speed limitations negotiated between site and the tire manufacturer

More Hours Per Year – Maintenance

• Grouped ground level maintenance and check points

• 1000 hour hydraulic filters• Oil level sight gauges• Front wheel sight glass• Batteries in bumper• Ecology drains • Final drives two piece covers• Electronic Clutch Pressure Controls

(ECPC) diagnostics• Service platforms on the engine and

transmission• AST coating can deliver 2 x life over

chrome• Optional electric start removes air system• Optional break wear indicators• Optional Fast fill service center

Ground level service points and extended hydraulic filter change intervals mean more time hauling and less time in maintenance

Over 793D possible +1% Availability for an additional 54,000 tons per year

1000 Hr Hydraulic filters save $66,000 in PM costs over machine life

Operator Comfort and Efficiency

• Integral 4 post ROPS exceeds ISO FOPS / ROPS standards

• Quiet at 76 dB(A) or less sound• Low operator vibration• Ergonomically designed

generation 3 Cat Comfort air suspension seat

• Electric hoist control• Secondary brake pedal• Integrated Parking Brake and gear

selector• VIMS™ Advisor displays • Tilt and telescoping steering wheel• Centralized controls• Large storage compartments• Full sized Trainer seat (option)• Powered operator window

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

Visibility has increased to give the operator enhanced awareness of their surroundings and those around them.

Operator Comfort and Efficiency - Cab Visibility

Cat 793F visibility

• All new cab design • Increased internal size by 10% window surface by 40% and

visibility by 15% over the 793D• Open right hand platform for improved visibility• HID light option • WAVS factory camera option

Cat 793D visibility

Equipping Your Truck

793F Standard Equipment

Operator Environment• Air conditioner• 12 V DC Power Supply• Coat hook• Diagnostic connection port• Dome courtesy light• Gauges/Indicators:

– Transmission fluid temp

– Brake oil temp– Engine coolant temp– Fuel level– Torque converter

temp– Hour meter– Speedometer– Tachometer– Transmission gear

indicator– VIMS message

center w/ advisor

• Hoist, body control (electric)• ROPS cab-insulated/sound

suppressed• Seat, air suspension• Seat, passenger – air

suspension • Seat belt, 75 mm (3 in) wide

retractable• Steering wheel, tilt, padded,

telescopic• Storage compartment• Tinted glass• Window, electric powered,

operator• Windshield wiper, intermittent

control, washerPower Train• C175-16 Tier 2 Diesel Engine• Turbocharging (4) / Aftercooled• Air cleaner w/precleaner (4)• Automatic starter protection• Ground level engine shutdown• Ether starting aid (automatic)• Elevated low idle control• Crankcase protection• Multi-point oil pressure sensing

• Braking system:– Integrated park brake and

directional selector– Brake release motor

(towing)– Oil-cooled, multi-disc (front

& rear) (service, retarding, parking, secondary)

– Automatic Retarder Control

– Engine overspeed protection

– Extended life brake disc material

• Transmission:– 6-speed, auto power shift

w/ECPC– Body-up reverse

neutralizer– Body-up shift inhibitor– Controlled throttle shifting– Directional shift

management– Neutral coast inhibitor– Neutral start switch– Programmable top gear

793F Other Standard Equipment

Electrical• Alarm, backup• Brushless Alternator 150 ampere• Batteries (2), 12V, 93 amp-hour• Converters, 12V electrical• Electrical system, 24V, 10, 20 & 25 amp• Directional signals (front & rear LED)• Front stair access/Service deck• Stop/taillights (LED)• Engine compartment light• Headlights w/ lo-hi beam selector• Backup and hazard lights• VIMS Blue Light (LED)General• Traction Control System• Auto lubrication system• Aux "buddy" dumping quick connect• Aux steering quick connect (towing)• Driveline operator safety guard• Fast fill fuel system• Fuel filter w/ water separator

• Ground level VIMS System data port• Ground level battery disconnect• Hi-speed crankcase oil change • Reservoirs (4):

– Brake– Hoist– Steering/Engine Hyd. Fan – Torque Converter/transmission

• Rock ejectors• Supplemental steering (automatic)• Tie down eyes• Vandalism protection locks

VIMS System

• Includes VIMS System Payload Monitor w/MAX Payload& Speed Manager

• Recommended using download cable 127-9797and PC based software JERD 2175

• Supplemental software "VIMS System Supervisor" YERA 1403Order separately (Computer not provided)

Antifreeze

• Extended Life Coolant to -35C (-30F)

793F Optional Equipment

• WAVS Camera System• Fire extinguisher• Brake wear gauge• Fuel heater• Cold weather starting• Wiggins service center• Rims

– Standard– Quick Change

• Truck Body Arrangements• High intensity discharge (HID) lighting for

high beam retrofits• Electric start• Extra retarding• Extended life wheel stations• SL-V grease injectors• Heated mirrors/seats• *Object Detection System• Engine timer shut down• Throttle lock• Cabin pre-cleaner air filter• Rear axle cooler

Machine Design Details

Engine Specifications

C175-16 Engine

Starting Options

Electric Start:

• Eliminates air system

Air Start:• Ground level access

to air tank drain• Consolidated air

system• Less time to service

air dryer system

Cooling System

• ATAAC vs. D-Series JWAC– Reduces internal combustion temperature

and emissions– Achieves Tier 2 *– Mid-Support Liner allows for better cooling

of cylinders

• On demand variable speed hydraulic cooling fan

– Reduces parasitic loss

• Mesabi Radiator (Standard) – Designed to withstand harsh conditions

and operating environments– Individual folded cores for serviceability

and maintenance– Seals allow tube to be replaced

individually

The 793F Cooling System new features will provide long life, higher durability, easier serviceability and reduce downtime

Seal

Tube

Hydraulic Cooling Fan

* Tier 2 – US and Canada only EPA exhaust emissions regulations

793F Upper Powertrain

TransmissionECPC ControlsInternal improvements for increased HPOutput Spline Lube & hardness Improvements

37 MPH Standard

Larger DriveshaftSight Gauge

CoversTorque Converter& Lock-Up Clutch (LUC)Higher Durability Output BearingIncreased LUC PressureAAA Blade to Maintain Rimpull

Continuous Rear Axle Filtration – Ground Level Access

New Service Platform

C175-16 Engine

Multi-link Suspension

Lower stress Housing

External Pressure Tap Block

Front Mounted Screens

793F Frame & Rear Axle

Frame updates include larger castings for new Multi-Link 4-Bar Rear Suspension

Multi-Link 4-Bar rear suspension allows more room for greater serviceability

Lower stress rear axle housing

Torque tube redesign

Tail casting modifications

New machined cab mounting points for better fit up and less vibration

Main Frame

Fabrications

Castings

Integral 4-post ROPS

• Mild steel provides flexibility, durability, and resistance to impact loads

• Does not require special weld procedures or stress relieving with shot penning or heating

• Box-section design with continuous welds

• Castings used in high stress areas

• Ultrasonically tested welds

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

• Lighter than traditional A-Frame design.

• Transfers and supports loads to the frame more efficiently than the A-Frame design.

4 Bar Link Suspension

793F Hydraulics & Cooling

All hydraulic brakes

Simplified cooling system – one less water pump and oil cooler

Secondary reduction final drive with segmented bearing

AST (Advanced Surface Technology) on Struts & Hoist Cylinders, 2x Life on Recoating

• No Risk to Environment • Resurfacing Method• Thermal Spray • Gases combined with fine metal powder and sprayed three times the

speed of sound onto rod surface. Ground to like new polish.• Extends life 3 times longer• Better Wear Resistance• Reduces Repair time• Increases quality with life• Reduced Seal Leakage

AST- Advanced Surface Technology

Increasing availability, reliability, and durability AST lowers operating costs on the machine

• Advance Service Technology provides improved wear resistance and repair time

• Available on front/rear struts and hoist cylinders

• Replaces chroming

AST Cylinders

793F Power Train

C175-16 Engine @ 2650 GHP a 10% increase over 793D 3516B HD.

AAA T/C blade to maintain the same stall rimpull of 28% as 793D.

Higher durability output bearing on T/C.Larger drive shaft

New transmission with ECPC (Electronic Clutch Pressure Control) resulting in smoother shifting and better serviceability

Service Platform for better access from engine to rear housing.

Fully enclosed drive shaft

Larger PTO drive shaft

Lock-up Torque Converter

• Updated to accommodate 2650 hp

• 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 (5.1 mph)

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

Advanced 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)

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Shift without CTS

Shift with CTS

Shift with CTS

Shift without CTS

793F Extended Life Wheel Group Arrangement

Differences from Standard Arrangement• Larger wheel bearings • Wider wheel bearing spacing• Larger brakes, 94 cm (37 in) vs 86 cm (34

in) • 29% increase in braking surface• Larger spindle

Benefits• Higher rated Gross Machine Weight

(851,000lbs to 860,000 lbs)• Longer brake life• Extended life to overhaul• Lower cost per ton• 50/80R57 Tire option for higher TMPH

Rear Wheel Group

• Laser-hardened spindle

• One-piece cast wheel

• Large bearings

• Continuous rear axle filtration

• Oil cleanliness to ISO 16/13

Heavy duty components and continuous filtration contribute to proven durability in the most rugged conditions

Front Axle Steering Components

• Separate steering hydraulic system prevents cross contamination

• Steering system 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 793F front suspension is a field proven design with dual tie- rods for optimum steering geometry to help extend tire life

Extra Retarding Arrangement

Differences from Standard Arrangement

• Higher flow brake cooling• Higher capacity cooling system• Includes Extended Life Wheel Groups• Larger thermostat• Larger dia. cooling lines• One additional brake cooler • One additional water pump • Copper ATAAC

Benefits• 35% increase in downhill speed over

the standard 793D• Higher flow capacity• Higher heat rejection• Increased coolant flow• Faster cooling

Offering enhanced braking for long downhill loaded hauls

Tires

Caterpillar Truck Bodies

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

• 230 yd 3 (176 m 3 )– 2500-2750 lbs/lcy material

• 250 yd 3 (191 m 3 ) – 2300 – 2500 lbs/lcy material

793 X Body Size Options

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

• 195 yd 3 (150 m 3 )– 3000+ lbs/lcy

• 204 yd 3 (155 m 3 )– 2800-3000 lbs/lcy

• 210 yd 3 (160 m 3 )– 2650-2800 lbs/lcy

Caterpillar Body Liner Options - Types

Smooth Plate for cohesive materials

Rock Box for dry andnon-cohesive materials

Zipper Grid forsemi-cohesive materials

Mechanically Attached Wear Plate System

(MAWPS) semi-cohesive to non-

cohesive materials

Productivity

90 %

No loads should be above 120% of the target payload

90% of loads should fall into this rangeNo more than 10% of loads should exceed 110% of the target payload

10/10/20 Overload Policy

• No more than 10% of loads above 110%

• No loads above 120%

• The average payload shall not exceed the target

MineStar™ System – Integrated Mine Information

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 ManagementProductionEngineering

and Geology

SafetyMaintenanceProcessing

Data Flow

Note: MineStar systems availability for specific markets depends on applicable radio licenses.

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

VIMS™ System Speed Manager

• VIMS System MAX Speed Manager

• VIMS System TKPH (TMPH) Speed Manager

• VIMS System MAX Payload Speed Manager

Fully integrated with VIMS System, Speed Manager consists of three features that help optimize truck safety and performance, lower costs, and extend service life

New Features

New Features

• Standard– 600 mm (23.6 in) wide access from ground to cab– Improved secondary egress ladder – Top deck, hood, platform and walkway is all one level – Ground level access service points– Ground level access to filters– Three-way lock-out/tag-out box at ground level– Engine bay designed without any hydraulic routings

above the turbos.– Spring assist struts on hood providing less effort to

open.

• Standard (cont…)- Fully enclosed driveshaft- Reduced operator sound and vibration- Toe kicks - Dual body retaining cables

• Optional- Optional WAVS (Work Area Vision System)- Object Detection System

New Features (Cont.)

New Features (Cont.)

• Engine– C175 – 16 ACERT Engine EPA Tier II compliant.

• Provides 10% more power.• Common rail fuel system.

• Power Train– Increased speed on grade and a higher top speed– Extended life wheel station attachment for long, uphill

hauls, improving wheel groups where bearing life has been a limiting factor (Optional)

– Extra retarding attachment for downhill loaded applications, providing an extra gear of retarding capability for 35 percent more speed downhill (Optional)

– Electronic Clutch Pressure Control (ECPC)

New Features (Cont.)

• Improved main frame– More robust design– 4-Bar Link Suspension replaces A-Frame Design, which allows

more room for greater serviceability – Battery Box integrated into front bumper design for better

serviceability

• Hydraulic Brakes– All hydraulic brake system vs. the air over hydraulics system– Extended Life Brakes (XLP) are standard in all configurations

• Serviceability– All Service Points accessible from ground level

New Features (Cont.)

• Starting System– Air start (Standard)– Electrical start (Optional)

• Cab and Operator Environment– Increased ROPS capacity– 15% improved visibility – New cab mounts reducing vibration and noise levels– New cab/controls

• Adjustable retarding control• Transmission and Hoist controls

• Monitoring System– VIMS 3G with Advisor monitoring system

Machine Inspections

Right Side Inspection

Inspect the following:- Tires/rims

- Front wheel oil sight gauge

- Steering system components

- Suspension cylinder

- Air tank

- Filters

- Transmission/Torque converter

- Hydraulic tank sight gauges

- Hoist cylinder

- Frame and body

Front wheel oil level - check

• Check the front wheel oil level using the sight gauges and maintain the oil level to the bottom of filler plug.

Air tank

Air tank drain

Hydraulic Tank

2) Hoist and brake cooling reservoir

3) Steering/Hyd. Fan reservoir

1) Brake actuation reservoir

4) Two Brake cooling pumps

Hydraulic Tank

Brake/Hoist Fill

Brake sight gauge

Hoist sight gauge

Steering/Fan Fill

Steering/Engine Hydraulic Fan sight gauges

Brake and Hoist sight gauges

(2) Brake reservoir sight gauge(1) Hoist reservoir sight gauge

Steering and Engine hydraulic fan reservoir sight gauges

Steering and Eng. hyd. fan reservoir sight gauge

1

2Engine “running” check

Engine “stopped” check

Rear Inspection

Inspect the following:- Lights

- Suspension cylinders

- Leaks

- Oil level sight gauge

- Grease fittings and lines

- Rock ejectors

- Tire tread

- Body pins

- Body cables

Differential and Final Drive Oil Check

Differential and Final Drive Oil Sight Gauge

Left Side Inspection

Inspect the following:- Handrails- Engine Oil level sight gauge- Auto Lube Reservoir- Tires/rims- Front wheel oil sight gauge- Steering system components- Suspension cylinder- Torque convertor/Trans. oil

level sight gauge - Fuel tank- Hoist cylinder- Frame and body

Engine Oil Level Sight Gauge location

Engine Oil Level Sight Gauge

If the engine is stopped and the oil is cold, maintain the oil level in the upper green range.

If the engine is running at low idle and the oil is at operating Tempture, maintain the oil level in the lower green range.

Engine Oil Level Sight Gauge

A

B

Auto Lubrication System

Auto Lube System (Electric Motor)

Front wheel oil level - check

• Check the front wheel oil level using the sight gauges and maintain the oil level to the bottom of filler plug.

Torque Converter/Trans. oil level check

1

2

Check oil level in Torque Converter sump with engine at an idle.

Oil at operating temp. (hot) in upper sight gauge (1)

Oil at ambient temp. (cold) in lower sight gauge (2)

Front Inspection

Inspect the following:• Ground level controls• Lights• Auto Lube Reservoir• Air filters• Radiator• Battery compartment• Fast Fill Service Center

(Optional)• Ladders and platforms• Engine compartment• Coolant level• Windows/Mirrors

793F Ground Level Energy Isolation Box (standard)

Engine Shutdown Switch (4)

Battery Charge Receptacle (mounted beside box, not pictured)

Machine/ Transmission Lockout (6) & Indicator Lamp

Engine/Starter Lockout (5) & Indicator Lamp

Battery Lockout (1)

VIMS Data Port

Engine Service Lights Switch (2)

Ladder Lamp Switch (3)

VIMS Event Light

*NOTE: This is a standard feature on the F series. Please continue to refer to site specific “lock out/tag out” policies.

Battery compartment

• Battery Box integrated into front bumper design for better serviceability

Fast fill service center (optional)

Hoist and Brake Oil Port (1)

Engine Oil Port (2)Torque Conv./Trans Oil Port (3) Level indicator for hoist/brake oil (cold) (5)

Level indicator for hoist/brake oil (hot) (6)

5 6

Level indicator for Torq. Conv./Trans. oil (cold) (4)Level indicator for Torq. Conv./Trans. oil (hot) (7)

47

Level indicator for

coolant (Full) (8)

Level indicator for Auto Lube Reservoir (Full) (14)

Power switch for Fast Fill

service center (15)

Steering system Oil Port (9)

Engine Coolant Port (10)

Diesel Fuel Port (11)

Level indicator for Engine oil

(Full engine on) (12)

Level indicator for Steering oil (Full engine off)

(13)

• 600 mm wide walkway to cab

• Improved secondary egress

• Powered folding stair attachment (optional)

Access and Egress

Top Deck Enhancements

Enhancements:- Top Deck is now

all one level.

- Toe kicks are standard now.

Radiator Coolant Level Check

Left side cab checks

Cab fresh air filterWindshield washer reservoir

Cab Features

Operator Comfort and Efficiency

Cat 793F Cat 793D

Operator Environment - Pedals

Foot rest

Accelerator

Service brake

Secondary brake

Steering Wheel and controls

Steering Wheel Control

Manual Retarder Control Lever

Multi Function Control Lever

Steering Wheel Tilt/Telescope Control Lever(Below Multi function control lever)

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 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

Note: Refer to “Operations and Maint. Manual” SEBU8406-00 for more detailed explanation of adjustments. *

* Additional resources listed below in speaker notes for seat and adjustments to ensure operator comfort.

Seat control adjustments

Back cushion angle lever

Fore/Aft adjustment

lever

Height adjustment

lever

Ride adjustment

lever

Seat cushion tilt

Ride indicator

NOTE: There are additional adjustments not shown in this photo, please see below and refer to OMM.

Hazard Flasher Switch

Headlight, Parking Lights, and Taillights Switch

Fog Light Switch

Engine Start Switch

Cigarette Lighter

12 volt receptacle

VIMS Advisor Screen

Access Light Switch

Heated Mirror Switch(If equipped)

Panel Light Switch

Air Conditioner Switch

Instrumentation Panel

Fan Speed Switch Temp. Variable Control

Instrument Cluster

New machine starting option will allow the elimination of an air system.

Electric Start System

ATC - Automatic Temp. Control

Heating and Air Conditioning System

Air Conditioner Switch – - Pushing the “top” of the switch “manually”

turns on the AC.

- If the switch is in the “middle” position the AC system is off.

- Pushing the “bottom” of the switch will turn on the Automatic Temperature Control.

Instrument Cluster

VIMS™ 3G with Advisor

Transmission Control

Automatic Retarder Control(ARC)

Automatic Retarder Adjustment

Left Power window switch

Hoist Control

Throttle backup and Throttle Lock Switch

WAVS Camera Switch (If Equipped)

Right Power Window Switch

Console Controls

Console Controls – Transmission Control Lever

Shift control release button

Decrement button

Increment button (on front of control handle)

Console Controls – Hoist Control Lever

Body Lower

Body “Float”

Body “Hold”

Body Raise

Console Switches

Automatic Retarder Control(ARC)

Automatic Retarder Adjustment

Left Power window switch

Throttle backup (Stand.) and Throttle Lock

Switch (Optional)

WAVS Camera Switch (If Equipped)

Right Power Window Switch

(If equipped)

Brake Release Switch

Idle Shutdown Timer Switch (If equipped) See speaker

notes.

Overhead console switches

Traction Control System Test switch

Display Front Camera Right-hand Camera Rear Camera

Optional system to enhance the operators vision

Rear view automatically displayed when machineis placed in reverse

WAVS Camera System

The system consists of:• An interactive touch screen display in

the cab

• Medium Range Radars front & rear (~ 20 metre range)

• Short Range Radar front, rear & sides(~ 7 metre range)

• Cameras on all 4 sides of the machine

Caterpillar Integrated Object Detection System TM

Alerts the operator during startup and initial machine movement of

objects within the machine’s immediate surroundings, particularly “blind spots.”

Cat Integrated Object Detection System Benefits

• Improves site safety by enhancing operator’s situational awareness

• Stand alone machine system - does not require any off-board infrastructure

• Easy to learn user interface

• Minimizes nuisance audible alarms

• Scalable solution allows user to start with camera system and later add radars

• Available January 2010 on Large Mining Trucks– 785, 789, 793 & 797– Additional models expected later 2010

• Can be ordered with new truck or retrofitted to existing– Listed as optional attachment on truck

price pages

• Marketing materials being completed and uploaded to Cat Electronic Sales Library

• Dealers start targeting customers for system now

Cat Integrated Object Detection System

VIMS™ 3G with Advisor

Preset Buttons

Digital display area

Scroll up/left button

Scroll down/right

button

Back button

Main “Home” menu button

OK button

Warning Levels

Category Message Display Action Lamp Action alarm

Level 1 Displayed on Advisor screen Solid Amber N/A

Level 2 Displayed on Advisor screen Flash Red N/A

Level 2S Displayed on Advisor screen Flash Red Continuous

Level 3 Displayed on Advisor screen Flash Red Pulse

Advisor “Home” Screen

Actual Gear Transmission control position Top drive Gear

Date/Time

“More options” indicator

Menu items

Status of ARC *

Advisor “Home” Menu Selections

Advisor “Operator” Menu Selections

Advisor “Operator” Menu Selection Map

Advisor “Monitor” Menu Selection

Advisor “Monitor” Menu Selection Parameters

Advisor “Payload” Menu Selection

Advisor “Payload” Menu Selection View

Advisor “Service” Menu Selection

Advisor “Service” Menu Selection Map

Advisor “Service - Diagnostics” Menu Map

Advisor “Diagnostics – Active Events” Menu

Active Events List

Advisor “Diagnostics – Logged Events” Menu

Logged Events List

Advisor “Diagnostics – Triggered Snapshot” Menu

Advisor “Diagnostics – Data-logger Start” Menu

Advisor “Diagnostics – Data-logger Stop” Menu

Advisor “Diagnostics – Data-logger Reset” Menu

Advisor “Service - Submenus” Menu

Advisor “Service - Calibration” Menu

Advisor “Settings” Menu

Advisor “Service Mode” Menu

793F Operation

1. When the engine is stopped, check level of steering oil is in proper range in upper sight gauge.

2. After engine is started, check level of steering oil is in the proper range in the lower sight gauge.

3. With engine running and engine start switch in “on” position, shut engine down with the ground level shut down switch (front bumper).

4. Return to cab and turn steering wheel to the left and to the right.

5. If steering wheel does not turn or there are problems turning the wheel, consult your local Cat dealer.

Secondary Steering Test

793F Operation

Brake System Tests

• Service• Secondary• Parking

793F Operation

Service and Secondary Brake System Test1. Fasten the seat belt before you test the brakes.2. Check the area around the machine. Make sure that the machine and area is clear of personnel and clear of obstacles.

3. Test the brakes on a dry, level surface.4. Start the engine.5. Depress respective brake control in order to apply the respective brake system.6. Move the transmission control to the “D” position.7. Gradually increase the engine speed to 1300 rpm. The machine should not move.8. Reduce the engine speed to an idle. Move the transmission control to the P position. Stop the engine.

NOTICE If the machine moved while testing the brakes, contact your Caterpillar dealer. Have the dealer inspect and, if necessary, repair the service brake before returning the

machine to operation.

793F Operation

Parking Brake System Test1. Fasten the seat belt before you test the brakes.2. Check the area around the machine. Make sure that the machine and area is clear of personnel and clear of obstacles.

3. Test the brakes on a dry, level surface.4. Start the engine.5. When the transmission control is in the P position, depress the “increment” button (front of control lever) and depress the “decrement” button (left side of the control lever) at the same time.

6. While both buttons are depressed, Move the transmission control to the D position.Note: The buttons can now be released and the parking brake will remain on.7. Gradually increase the engine speed to 1300 rpm. The machine should not move.8. Reduce the engine speed to an idle. Move the transmission control to the P position. Stop the engine.

NOTICE If the machine moved while testing the brakes, contact your Caterpillar dealer. Have the dealer inspect and, if necessary, repair the service brake before returning the

machine to operation.

Reference materials

• 793F OMM #SEBU8406-00• 793F Specalog #AEHQ6038• 793F Salesgram #TEKQ0751-01• 793F Marketing Bulletin #TEJB9479• 793F Product Bulletin #TEJB9163• Cat Comfort Seat Salesgram #TEKQ0239• “Cat Comfort Seat with three point operator restraint” video

#AEVN5717 (Avail. in Spanish and Portuguese)

• Integrated Object Detection System Salesgram #TEKQ0747-02• Integrated Object Detection System Specalog #AEHQ6054 (Avail. In

Spanish, Portuguese, Indonesia and French)

• F Series Supporting documents; https://catminer.cat.com/trucks• STMG media #1869

Questions

793F Highlights

Comfort Cab• Integrated 4 post

ROPS• Exceptional visibility• Integrated Parking

Brake and gear selector

• 76 dB(a)

Right Hand Deck• One level platform• Open view (no air or

steering tank)• Reinforced attachment

location• Light hoods with spring

assist and locks• Steel deck around cab

access

Tire Options• 40R57• 46/90• 50/80

Body• Mine and

application specific• Balance of weight /

durability

Access• 600 mm wide• Rear cab

access option

Lock Out Tag Out • Battery Disconnect• Engine start lockout• Transmission lockout

Bumper Service • Wiggins center• Auto lube• Batteries

Wheel Sight Gauge• Increased reliability• Reduced unscheduled

down-time

Two Piece Cover• Ease of service

Visibility• HID option• Heated mirror

option• WAVS option

Mesabi Radiator• Robust for mining• Individual

serviceable cores

793F Highlights

C175-16• Tier 2 Compliant• 2650 HP• 85 litters• More fuel efficient

than 3500• On demand fan

system

Clean and Open Engine• Only 4 turbos• Turbos above engine• Space for in chassis repairs• Reduced number of

external Tubes or Hoses

Power Shift Transmission• Six speed planetary

transmission optimizes power train efficiency

• Electronic Clutch Pressure Control for smooth shifting and ease of service

Wheel Station• Separate brake, spindle

and brake service• Double reduction

planetary final drive• Low reduction ratio allows

for robust design

Ground Level Service• 1000 hr hydraulic filters• Oil sight gauges• Filter placement and height• SOS port placement• Bottom load filters• Drain plugs

4 Link Suspension• No A-frame• Load direct into

frame• Open for service

Starting Options• Optional

electric start removes air system

• Cold weather system available

Ground Service• Sight gauge• Filters

Continuous rear axle filtration

793F Highlights

4 Corner Oil Brakes • 40 / 60 front rear split• Sealed cooled and filtered for

performance, production, and reliability

• Wet oil-cooled brakes combine service, secondary, park brake, and retarding functions

• Balanced 4 wheel retarding• Zero fuel burn during retarding

Frame• Castings• Box section • Mild steel• Ultrasound tests

ROPS Mounting• Cab mounting integrated

to machine frame• Exceeds ISO standards• Engineered with

customer additions in mind

• MARC mounts reduced sound and vibration

Brake Wear Indicators• Increase reliability• Reduces unscheduled

down time

Service• Modular

component design• On board

diagnostics• Extended

hydraulic systems filter life

• Competitive R&I times

ARC• Automatic

Retarder control • Adjustable

retarding speed

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

Safety - Features

• Hydraulic lines not routed above engine turbos

• Ground level secondary engine shutdown and machine lock-out with tag-outs

• 600mm wide walkways, ladders and catwalk

• Bottom loading filters• Filter drains• Brushless alternator• Fully enclosed driveshaft• Required moving part guards• Rear access ladder• Wide secondary egress ladder• Service platforms• Spring strut hoods and retention locks• Front deck is all one level• Ground level filters• Increased ROPS capacity• Increased operator visibility• Low operator sound and vibration• Toe kicks• Optional WAVS (Work Area Vision System)

Design features target to help reduce haulage injures