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Syncrude 797 Overview

September 2006

David Faber
Mining Manager – Canada
Caterpillar Global Mining
Agenda:

1. Introductions
2. 797B Center Casting Update
3. 797F Overview
4. 315 Yd Oil Sands Body

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Worldwide Fleet:
(As of June 2006)

1%
54%

35% 10%

Largest Opportunities Today:


•Oil Sands
•South America Copper
•Australian Coal
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Worldwide Population:

Other

1 - Michelin
1 - Total
North America
2 - Proving Ground
5 – Finning Canada
45 – Syncrude+++++
29 – Suncor+++
23 – Albian+++
7 – Peabody+ Asia-Australia
4 - Foundation Coal+
12 – Freeport+
115 Total
9 – BMA++
South America
45 – Escondida+++++ 4 – Anglo+
6 – Collahausi+ 25 Total
12 – Pelambres++
63 - Total 204 units delivered
+=Number of repeat purchases (period ending June-2006)
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797F: The First of a New Generation
Features, Specifications and Performance
Overview

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Safety Focus: Operator
• Safe Operator and Service Access
– Optional Powered Stairway Access
eliminating Rubber Ladder
– Widened Stairway to 600mm
– Catwalk Around Cab Widened to 600mm
– Toe boards Added to Handrails WAVS- Work Area Viewing
System
• Visibility and Accident Attenuation
Measures
– Heated Mirrors as Optional Attachment
– HID Lights Available
– WAVS Camera System Providing
Unmatched Visibility

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Safety Focus: Service
Ground Level Access

• Working at Heights
– Grouped Service Points
– C175-20 Service Points Accessible
– from Ground Level
– Battery Location Moved to Front
– Bumper from RH Platform
• Safe Serviceability
– For Low Altitude Applications, All Turbos Located to Front of
Engine, Segregating Hot and Cold Areas of the Engine
– Flat Haul Retarding Package Offers Reduced Service Points
– Ground Level Transmission (Machine) Lockout
– Ground Level Starter and transmission Lockout

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797F Frame
Caterpillar frames are designed to deliver long service life in rugged mining applications

• Engineered using computer-


generated stress modeling
• Steel castings used in high
stress locations
• Rollover fixtures ensure all
welding is done horizontally,
not overhead
• All critical welds and
castings are ultrasonically
tested
• Increased ROPS Capacity

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Engine Technical Specifications:
• C175-20 Single Block ACERT Engine
• Improved Serviceability over 3524
• Improved Fuel Efficiency over 3524
• Maintenance and Repair Cost Reduction
• C175-20 Service Points Accessible from Ground
Level

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Why the C175…
3500
– From 80 hp/cyl to over 220 hp/cyl since 1979
– Little remaining room for power growth or emissions
improvement
New Platform: C175
– Emissions flexibility & capability
– Improved Reliability and Durability
– Immediate growth and future capability
– Improved Cost Per Ton

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C175-16 & 3516BHD
Model C175-16 3516BHD

Truck Model 793F 793D

Displacement 84.8 L 78.4 L

Engine Weight (lb) 20,906 20,252

Bore x Stroke 175 x 220 170 x 215

Altitude Capability 8,500 ft 9,000 ft

Power Output (hp) 2650 2415

C175 3516BHD

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ACERTTM Technology
ACERTTM Technology for Large Mining Trucks
Cross Flow Heads
Four Valves/Cylinder

Multiple
Injection Series Turbos
Combustion (On Highway)

Superior
N0x / BSFC Reduce N0x, PM Valve Control
Tradeoff Recover Energy
(On Highway) )

Reduce HC, PM
Integrate
System

ACERT is a synergy
Controls
of complementary,
Oxidation Catalyst core technologies
(On highway)

330,000 engines
and counting…..

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Cat Common Rail Fuel System
Advantages
Meets emissions
Lower fuel consumption

Better transient response

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C175 Technology Upgrades
• Robust Crankshaft & Block
• Drilled Connecting Rod
• Forged Steel Piston
• Mid-Support Liner
• Cross Flow Head
• Single Camshaft
• HP Common Fuel Rail
• Leverage ACERT
Technology
• Industry Leading
Performance

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C175-16 793F LAA

• 2650 Hp
• Tier II compliant
• 8,500 ft. altitude capability
• Single stage turbocharging
• Remote ATAAC 1st Prototype Truck @ TPG

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C175-20 797F
LAA

• 4000 Hp
• Tier II compliant
• 4,500ft. altitude capability
• Single stage turbocharging
• Remote ATAAC

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Product Line-Up - Machines C175 provides
significant power, life,
cost, weight and O&O
cost improvement

V12 V16 V20 V20


ACERT ACERT ACERT ACERT

C175
V12

C32 785 994 789 793 797

D11/777/992 New
Current
V8 V12 V16 V24
V16
3500B
D11/777/992 994 785 789 793 797

500 1,000 1,500 2,000 2,500 3,000 3,500 4,000


Mechanical Drive Machine - Hp

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C175 Engine

• 60 o Bank Angle

• Single Camshaft

• Piston Technology

• Long Stroke

• ATTAC

C175 3500B
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Lock-up Torque Converter
Combines the advantages of direct drive and converter drive to achieve high component
reliability and maximum output performance

• Higher capacity lock-up


Clutch to accommodate
the increased hp of
797F (3550 to 4000)
• Same Performance
Specifications as 797B
– 28% stall torque
– Lock-up clutch engages
at 7.3 km/h (4.5 mph)

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Seven-Speed Planetary Transmission
Large diameter clutch packs are controlled to provide smooth shifting and to limit
clutch energy input for extended component life

• Torque converter lock-up in first gear


• 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 a n ges
before shifting c a n t ch
ig n if i up of
• Latching Valves have been replaced No s y gro
ta r
by software to control gear selection o p lan e m is sion
t r ans
and application of brakes to control T
797F
machine ground speed (like ADT and
QCT)
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Rear Wheel Group & Differential
Heavy duty components and continuous filtration contribute to proven durability in
the most rugged conditions

• One-piece cast wheel changing


from ductile iron to cast steel
(improves salvage capability)
• Same durability features as 797B
– Laser-hardened spindle
– Large bearings
– Continuous rear axle filtration
– Oil cleanliness to ISO 16/13
• New differential design with larger
bearings and coarser pitch pinion
and bevel gear

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797F Brake / Retarding Options:
Downhill Haul
• Two Retarding Options:
– Downhill Haul Option Equivalent
Performance to Today’s Machine
– Flat Haul Option which Offers
Simpler and More Cost Effective
System
• Differences between the
Systems:
– Hydraulic Tank Flat Hauling
– Number of Brake Oil Coolers
– Hydraulic Pump Drive Stack
– Line Sizes
– Engine Fan Hyd. Drive
¾Improved Serviceability for Machines that don’t
need extreme retarding capacity
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VIMS Enhancements

• More memory
– Longer Snapshots
– Continuous Data-logger
• Standard Open Communication Interfaces
– Ethernet
– FTP
– GPS
• Site Specific User Configurable Features
– Adjustable Event trip limits
– Selectable Data Logger and Snapshot activation criteria
– Configurable Data Logger run lengths
– User defined trends

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Productivity Enhancements:
• Performance
– 13% Increase in Power from 797B (+450 HP)
• Maintains Rimpull @ Stall
– Maintains 1,375,000 GMW
– 360 tonne (400 Ton) Nominal Payload with MSD II Body
– 19% Increase in Speed on 12% Effective Grade: 12.88 kph (8 mph)
– Extended-Life 1000 Hour Filters (except engine oil and air filters)
• New Cab
– Next Generation VIMS & ECM controllers
• VIMS expandable to Gen III
– Increased Operator Visibility
– Improved Access/Egress
– Wider Walkways
– WAVS Camera System Option
• Electric Start Option

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Innovative new tire
Non-directional tread architecture for increased
pattern eliminates load capacity at lower
constraints related a pressure.
specific direction of Deep longitudinal
rotation. micro grooves
provide improved
lateral adherence.

Multiple lateral
micro grooves
increase
longitudinal
adherence when
driving and braking.

The continuously
variable shaped
grooves minimize
the risk of stone
retention.
Independent tread blocks
Extra deep tread depth dramatically improve wear
increases rubber volume for rate by better distributing the
longer tire life and lower longitudinal forces across
operating cost. the entire tread face.

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