794 AC Large Mining Truck

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 The Broadest Range of Large Mining Trucks
Cat® LARGE MINING TRUCKS

Ton 150 200 250 320 360 400

Metric Ton 136 181 227 290 326 363

785D 789D 793F 794 AC 795F AC 797F

785G* 793D

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*Tier 4 Markets only
 Cat® 794 AC

• True 320 ton payload

• Over 120,000+ hours of operation, highest truck ~29,000 hours
• Fleet average 90% physical availability
• Leveraging over 4 million hours validation on 795 power train
• Positive feedback on performance, reliability and serviceability

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Cat Proprietary Electric Drive System Integration

Generator: Engine: Power inverter:

Capitalize on Cat’s leadership in Utilize Cat’s leadership and EMD experience and sourcing
electric power generation Experience in engines

Caterpillar
developed/
owned &
integrated
systems and Motors:
Controls and Hardware:
Cat designed and developed controls Cat design and specifications

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 Cat 794 AC

• Cat powertrain

• 100 % Cat part

numbers at
production

• Decatur
assembly

• Global Cat
dealer support

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 Introducing The 794 AC Overview

Safety
• Door sensor warning for park brake application
• Radial retard grid improves right hand view
• Wide Access & Egress
• Stored energy dissipation at shut down

Serviceability
• Ground level points
• Engine walkways
• Rear inverter cabinet access
• Simple dual bearing alternator mounting
• Brushless AC grid blower motor and alternator
• Individually serviceable wheel motors and final drives
Bumper to bumper product support
Performance through Cat dealers worldwide
• 320 Ton (291 tonnes)
• 2750, 3100 & 3500 HP to optimize performance
Reliability & Operating Cost
• State of the art High voltage IGBT for max AC efficiency
• Cat C175-16 engine
• Proven industry leading speed on grade
• Industry leading retarding capacity
• Cat AC Drive System
• Four corner wet disc brakes with blended mechanical
service brakes and dynamics – Operator confidence

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 794 AC Achievements – Better Bottom Line

Payload: 7% higher field payload than competition.

Lower empty weight and higher rated GMW

Speed on grade: 8% faster than competition

High consistent physical availability:

Equal or better than competition

Safety: four corner wet disc brakes along

with list of customer accepted features

Equal or Lower Fuel: Mines report equal or

lower fuel consumption vs competition

Serviceability: Ease of service with minimal labor

time and interventions. Fully integrated, all Cat drive
system. Industry matching component life.
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 794 AC Field Results

Total Seven Machines Operating (Hours from July 2017)

Total Hours: 150,000
Highest Hour: 29,400

Rio Tinto 4 Trucks

Total Availability: 90%

ASARCO Ray 1 Truck

Total Availability: 92%

Cerrejon 2 Trucks
Total availability: 93%

Toquepala 4 Trucks
Total availability: 94%

Grupo GAN 7 Trucks

Total availability: New
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 794 AC Field Results: High Productivity

794 AC vs. COMPETITOR

• High availability
Payload + 7%

• Bigger Payloads Speed on Grade (2700 hp)

Speed on Grade (3500 hp)
+20%
+ 8%

• Faster speed on grade

• Lower fuel
consumption reported

• 10% longer tire life

reported

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 794 AC Drivetrain Field Results : High confidence with TCO
Leveraging Highest 795 Component Hours commonality

Inverter
Engine Over 48,000hrs
Over 25,000hr

Retarding grid
Over 40,000hrs

Traction Alternator
Over 38,000hrs
Final Drives
Over 32,000hrs

Wheel motors
Over 40,000hrs

Note: highest hour machines are in Coal for

10 / Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING data Caterpillar LMT group has available.
794 AC Safety Features/ Walk around
MEGA Cab
Radial Retard
Rear Inverter Platform Engine start and Featuring:
Grid provides
with tie offs propel lockouts - Pressurized Mega Cab
excellent
- Cat comfort seat
visibility
- Sound suppression
Flat Deck, Toe - Integrated park and direction controls
Kicks - Warning for exiting without park set
- Automatic Retarder Control
- Anti-rollback Traction Control

600 mm wide
ladders

No Park brake
disc checks
inside axle box
LED
Headlights

Machine
Lockout at
ground
level

Engine and Generator Ground level Wet Disk brakes w/

Ground level filters
Service Platforms service center integrated park
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 Serviceability

Service Access
• Open engine access
• Engine service platforms
• Generator & inverter platforms
• Central hydraulic test station
• Cat VIMS system
• Ground level filters and service

Component layout
• Minimized hydraulics
• Hydraulic lines on one side
• Electric wiring on other side

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 Caterpillar AC Drive Train – Overview
Fully integrated - bumper to bumper
Power electronics
EMD cabinet, Cat controls, Mitsubishi Electric IGBT Retarding grids with AC fan motor
phase modules Radial Design
Advantage – High efficiency, state of Advantage - Efficiency, weight, sound,
art, fully integrated truck systems less maintenance and better visibility

High voltage traction alternator

Engine mounted dual bearing
Drivetrain cooling Advantage – Efficiency, serviceability &
lower weight
Hydraulically Driven
Advantage - Efficiency,
flexibility

Front and Rear Wet Disc Wheel motors

Brakes Advantage - cooled front Mounted in Rear Axle
Advantage – Serviceability
and rear mechanical braking for
stopping performance
High speed final drives
Ring Gear Drive
Advantage – Durability
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 Proprietary Cat AC Drive Inverter

• 4500V Rated – Lower weight, longer life

• Pressurized and filtered to reduces PM

• Evaporative cooled modular IGBT proven

in EMD locomotives

• Cat ECMs with fiber optics

• Large contactors with tungsten alloy tips

turn off at zero voltage to ensure long life

• Modular Components

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 Cat AC Drive Dynamic Retarding

• Continuous retarding power

of 4086 KW (5480 HP)
• AC electric motor – less
maintenance than DC
• Thermal grid protection
model
• Quieter and less weight than
box grids
• Better visibility than box grids

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 Caterpillar AC Drive Train - Traction Alternator/Generator

• Close coupled dual bearing brushless

alternator
- No Shimming!
- Increased Serviceability (can be removed
without removing the engine)
• Temperature sensors on bearings
monitored - reliability
• Provision to add grease to bearings
– increased life
• Easy access to diodes
– serviceability

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 Caterpillar AC Drive Train – Final Drive/Traction Motors

• Serviceability
• Traction motors, brakes and final
drives separate for ease of service
• Continuous rear axle lube and
filtration system for longer life
• Improved component life and lower
operating costs
• Final drives leverage proven
Caterpillar core competency on
gear design and manufacturing
• Double reduction ring gear output
finals balance system and deliver
longer life
• Optimized for high ground torque
applications Ring gear output
35:1 red. ratio

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 Cat Four Corner Wet Disc Brakes

• Four corner blended service braking for Dual Function

control Brake Pedal

• Brake temperature monitored for

component life

• Spring applied secondary parking brake

• Non-fade multiple discs oil cooled

• Dual Function Brake Pedal

• Brake wear measurements simple

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 Cat AC Drive Performance Features

• Steering Assist and Traction

Control – improved machine
controllability and tire life
• Anti-Rollback and Reverse Shift
Inhibit – helps ensure movement
in the desired direction
• Automatic Retarding Control –
Makes retarding easier, more
efficient and helps ensure truck
remains in the dynamic retarding
envelop

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 Cab Layout & Design –Comfort, Safety and Performance

• Large spacious cab with ample storage

• 2 full-size reclining Cat suspension seats

• Wide field of view for greater visibility

• Integrated park with direction control

• Warning for exiting cab without setting

park brake

• Cat automatic retarder control

• Cat VIMS and payload monitor

• Integrated ROPS and FOPS

• Low sound level (75 dBa)

• Reduced operator vibration

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794 AC Frame and Structures

Independent Front Axle

• Wheel alignment does not
Straight Frame Rail Design
change under load
• Same frame design concept that has
• Interchangeable front
been used since 1990. Over 18M hours
suspension cylinders
• Deep cross section reduces bending
• Isolates frame from road
induced stress

The Rear axle mounts to the frame with a nosecone joint.

• Same design as legacy Unit Rig MT6300
• Utilizes spherical bearing and hardened pin
• Bearing surface is replaceable

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 High Efficiency Dump Body Overview

• Perimeter beam and curved floor, front,

and canopy strengthens body

• Strength of base plates allow minimal

wear package & lower weight

• Bolsterless design

• Runners transfer weight to truck frame

• Patented Joint Isolation

Load bearing on high strength base plate
• Body options to meet life needs (shown with exaggerated flex)
– Long life rock body with liners
– Low weight for payload over life Low stress at weld
Support Spring plate Joint Isolation

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 794 AC Advantages

DELIVERING A BETTER BOTTOM LINE

• Safety

• Performance

• Cat Components & Vertical

Integration

• Industry Leading Best

Operating Cost

• Ease of service

• Operator comfort with Mega Cab

• Reliability and Dealer Support

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 794 AC Large Mining Truck

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Thank You!

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 Field Study Payload

Two scale studies show:

• Empty weight on target 329.5
• Rated payload 319.1 tons Tons
• Average payload 329.5 tons

Target Payload
9/19/13 - 9/20/13 Average Empty Rated Payload Payload
Empty kg (lbs) GMW kg (lbs) Target kg (lbs) Target Tonnes (tons)
MT5300D AC Average 232 103 (511,700) 521 631 (1,150,000) 289 528 (638,300) 289.5 (319.1)
930ESE
WeightsAverage 245 393 (541,000) 505 755 (1,115,000) 260 362 (574,000) 260.4 (287.0)
9/19/13 - 9/20/13 Average Empty Rated Average Loaded Average
Empty kg (lbs) GMW kg (lbs) GMW kg (lbs) Payload tonnes (tons)
MT5300D AC Average 232 103 (511,700) 521 631 (1,150,000) 531 063 (1,170,794) 298.9 (329.5)
930ESE Average 245 393 (541,000) 505 755 (1,115,000) 540 834 (1,192,348) 296.6 (327)

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 Cat AC Advantages Over Competitive AC
• Sealed & Pressurized Cabinets
– No cleaning, less maintenance
– Increased component life

• State of the art High voltage IGBTs

– Maximum AC drive system efficiency
– Fewer power cables to motors
– Lighter systems

• AC Grid Blower Motor

– Longer life
– Less Maintenance

• Variable Hydraulic blower fan

– Optimized cooling even at idle for increased
component performance and life

• Dual bearing brushless alternator

– Longer life
– Less maintenance
– No shimming!

• Thermal sensors on alternator and motor

bearings / motor windings
– Better prognostics
– Longer life and lower cost
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 794 AC – Front Suspension and Beam Axle

• Wheel alignment does not change

under load
• Constant tire contact patch
• Longer front tire life
• Suspension unit does not carry
steering and braking loads
• Steering geometry allows for a
smaller stroke front suspensions
• Provides excellent serviceability to
suspension cylinders
• Interchangeable front suspension
cylinders
• No need to remove front tires
• Isolates frame from road induced
stress for longer life and better
ride
• Better cornering/turning stability
• Shorter Turning Radius – 16.2 m

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