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COM

Quarrying & Aggregate

Industry
A systematic approach to lower
your cost per ton

©2008 Caterpillar, All Rights Reserved. CAT, CATERPILLAR, their respective logos,“Caterpillar Yellow” and the POWER EDGE trade
dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
HECA3917
CONTENTS
04 THE RIGHT FLEET
05 Q&A OPERATIONS Value chaiN
06 STRIPPING, SITE PREPARATION AND RESTORATION
10 RIPPING
14 LOADING
18 HAULING
22 ROAD MAINTENANCE
24 RE-HANDLING AND LOADING
26 SAND AND GRAVEL
28 BLOCK HANDLING
30 WORK TOOLS
32 GROUND ENGAGING TOOLS and Cat Certified used
33 360° SOLUTIONS AND PAT SCALE TRUCK
34 Solutions for a more sustainable world

THE CATERPILLAR QUARRY SYSTEM 03

THE RIGHT FLEET Q&A Operations value chain
STRIPPING, SITE
ROAD RE-HANDLING
PREPARATION AND RIPPING LOADING HAULING CRUSHING
MAINTENANCE AND LOADING
RESTORATION

HYDRAULIC HYDRAULIC MEDIUM WHEEL QUARRY WATER WAGON ARTICULATED

EXCAVATORS (HEX) EXCAVATORS (HEX) LOADER (MWL) TRUCK (QT) ARTICULATED TRUCK DUMP TRUCK (ADT)

“Working alone, our Cat machines are impressive. TRACK-TYPE TRACK-TYPE LARGE WHEEL
LOADER (LWL)
ARTICULATED
DUMP TRUCK (ADT)
WATER WAGON
QUARRY TRUCK
MEDIUM WHEEL
TRACTORS (TTT) TRACTORS (TTT) LOADER (MWL)

Working together as a synchronised team, they’re unbeatable.”

WHEEL TRACTOR HYDRAULIC LARGE WHEEL MOTOR GRADERS (MG) HYDRAULIC

SCRAPERS (WTS) EXCAVATORS (HEX) LOADER (LWL) EXCAVATORS (HEX)

A systematic approach to lower your
cost per ton
Selecting the right machines for your quarry is
a vital decision. It will depend on many factors
including the type of rock, characteristics
of your site, and the precise quarrying
application. Your choice will directly affect
productivity, cost per ton and the profitability
of your whole operation.
For more than 80 years, Caterpillar has
been working with quarry operations
around the world. During this time, we have
developed an in-depth understanding of
the quarrying operation and of the machine
operator needs. This knowledge is used to
continuously improve the performance of
our product range. We believe that we offer
the most complete quarry machine and work
tool line-up available on the market today.
you build the best fleet for your particular
operation, from face to finish. FRONT SHOVELS (FS)
MOTOR GRADERS (MG)
By acquiring the right Cat machines for the
job and keeping both planned and unplanned
downtime to an absolute minimum, you can
reduce owning and operating costs – leading TRACK TYPE
LOADER (TTL)
to a lower cost per ton.
These are some of the key questions
Caterpillar can answer when you’re
planning a quarry operation:
• What types of machines do I need?
• How can I ensure maximum availability?
• How can I manage fuel costs?
• What operator training do I need?
• How can I reduce my cost per ton?
• What other support will I need?
• What kind of work tools do I need?

LOWER COST PER TON

With this expertise – combined with the
most complete quarrying and aggregates
product line-up in the market – we can help

COST AND VALUE COST AND VALUE COST AND VALUE COST AND VALUE COST AND VALUE
5% 13% 23% 34% 25%

04 THE CATERPILLAR QUARRY SYSTEM THE CATERPILLAR QUARRY SYSTEM 05

STRIPPING,
SITE PREPARATION
and RESTORATION
“Caterpillar’s mission is to help you prepare your site, manage it safely and profitably,
and then restore it for future generations.”
COMPLETE SOLUTIONS
Preparing your site professionally is
key to running a successful operation.
This includes clearing the land, erecting
buffer zones and berms, managing topsoil
and subsoil for use in restoration, and
constructing roads for safe and efficient
movement through the site.
Caterpillar takes a global view of your
operations and after carefully studying the
approved plans, we can recommend the right
hydraulic excavators, tractors, trucks, work
tools and motor graders for stripping and
preparing the site.
06 THE CATERPILLAR QUARRY SYSTEM
PROTECTING THE QUARRY ENVIRONMENT
A quarry has a limited life and the manner in
which it is stripped and restored at the end
of its lifecycle is vital to the environment.
Whether it is returned to nature – as a lake,
farmland or reserve – or to mankind (as
an amusement park or sports centre, for
example), final restoration is an engineering
and logistical challenge for the quarry owner.
Caterpillar is committed to sustainable
development and has developed a range
of machines to get the job done safely
and efficiently - even in the softest, most
difficult terrain.
YOUR ADVANTAGES WITH CATERPILLAR
FUEL EFFICIENCY TO HELP CONTROL COSTS
New generation Caterpillar off-road
machines are powered by ACERT™
Technology. These electronically
controlled engines are EU Stage IIIA
compliant and deliver higher performance
and reliability.
SYNCHRONISED EQUIPMENT
SPEEDS UP CYCLE TIMES
Cat® machines are even more productive
when they work together as integrated
systems. For example, the body of our
articulated trucks has a capacity and
geometry designed for fast loading and
high payloads when working with Cat
hydraulic excavators.
FASTER, MORE ACCURATE GRADING
Caterpillar’s AccuGrade™ technology
provides GPS or laser-based in-cab
grade control. The system speeds
up the grading process and provides
greater accuracy.
THE CATERPILLAR QUARRY SYSTEM 07
STRIPPING, SITE PREPARATION AND RESTORATION

ARTICULATED TRUCKS AND HYDRAULIC EXCAVATORS MATCHING GUIDE

Hydraulic EXCAVATORS 336DL 345DL 365CL 385CL

ARTICULATED
1.1-2.3 2.2-3.6 2.6-5.0 2.0-6.0
TRUCKS
Bucket size m3
Payload t* Capacity m3** 2.2 3.2 4.6 5.5

725 23.6 14.3 6-7 5 3

730 28.1 16.9 8 5-6 4 3

730 Ejector 28.1 16.9 8 5-6 4 3

735 32.7 19.7 6-7 4-5 3-4

740 38 22.9 5 4

740 Ejector 39.5 23.1 5 4

Note: Pass match has been calcuated by using a fill factor of 100%, a material density of 1,600kg/m3 and by selecting the ME (Mass Excavation) boom with medium stick
*Target Payload **Heaped 2:1

CAT EQUIPMENT FOR STRIPPING, SITE PREPARATION AND RESTORATION

HYDRAULIC EXCAVATORS TRACK-TYPE TRACTORS AND LOADERS MOTOR GRADERS

• Rugged and reliable, with high stability
• Fast cycle speeds for lower cost/ton
• Extra comfort and safety for your operators
• Full range of Cat Work Tools
• for each application
ARTICULATED TRUCKS
• Heavy-duty powerful workhorses
• ACERT™ Engines for lower fuel • • • •
• consumption
• High-performance with outstanding • •
• traction and flotation
• Industry-unique ejector body enables you
• to spread and dump on the go, without •
• raising the body
• The all-round Q&A machine for
• tough conditions
• Differential steering for productivity
• Panoramic visibility for increased
• on-site safety
• Unmatched power and durability for • •
• pushing heavy loads
• Full range of blades and rippers from Cat
• matching the application
• World-leading cab and controls for • • •
• operator productivity
• Advanced electronics and hydraulics
• AccuGrade™ blade control for faster,
• more precise grading
• Best return on investment
WHEEL TRACTOR-SCRAPERS
• Fast cycle times with quick loading
• High travel speed, loads and dumps
• on the run
• Moves easy-flowing material at
• low cost/metre
• Rugged construction and easy • • • • •
• maintenance for long life

08 THE CATERPILLAR QUARRY SYSTEM THE CATERPILLAR QUARRY SYSTEM 09

 RIPPING
“In the right conditions, ripping as an alternative to blasting
can considerably reduce the cost per ton of rock produced.”
COST ADVANTAGES
In addition to the safety and environmental
issues associated with the use of explosives –
ground vibration, neighbourhood damage, fly
rock, noise and dust – a rip and load operation
can often be an economical solution.
Depending on the rock structure and
accessibility of the work face, the higher
hydraulic power of modern machines
combined with more effective ripping tools
can deliver a lower cost per unit moved.
Rippers are particularly effective on rock with
a high degree of stratification, weakness
planes, weathering and brittleness.
MORE SELECTIVE EXTRACTION
Rather than repeatedly drilling and blasting,
within restricted time periods and with costly
security measures, ripping rock can be easier
and faster. In aggregate quarries it means
more selective rock extraction, resulting in
better quality product for the crusher, with
lower crushing and processing costs.
RIPPER MATCHING GUIDE
TR40 320D
TR45 323D
RIPPERS
TR55 345D
TR70 365C
10 THE CATERPILLAR QUARRY SYSTEM
Caterpillar offers two ripping solutions: track-
type tractors with a rear-mounted ripper for
open spaces; and hydraulic excavators with
Cat dedicated quick coupler with matching
bucket, ripper and hammer.
hydraulic EXCAVATORS
321D 323D
324D 328D
385C
YOUR ADVANTAGES WITH CATERPILLAR
EFFICIENCY OF RIPPERS
MATCHED TO MACHINES
All Cat Work Tools are performance-
matched to Cat machines, providing
the best possible performance for any
particular application.
FAST AND EASY TOOL CHANGE
Caterpillar’s unique Quick Coupler makes it
easy to release one work tool and connect
to another, eliminating machine idling time
between jobs.
For rip and load operations, a Cat hydraulic
excavator operator can change a ripper
attachment to a bucket in 30 seconds,
without leaving the cabin.
324D M322D M325D
329D 336D
THE CATERPILLAR QUARRY SYSTEM 11
 CAT EQUIPMENT FOR RIPPING
RIPPING
TRACK TYPE TRACTORS
• Durable construction for the
• toughest conditions
• Superior manoeuvrability
• Unbeatable traction and stability
• Spacious, comfortable cabin keeps • •
• operator fresh
• Full range of blades and rippers from •
• Cat matching the application

HYDRAULIC EXCAVATORS
• Excellent stability, visibility
• and swing speed
• Powerful, reliable hydraulics for ripping
• and hammering
• Fuel efficient operation with
• ACERT™ Technology
• Performance-matched with Cat rippers,
• hammers and buckets

WORK TOOLS
• Caterpillar has a wide range of work • •
• tools, each one precisely matched to
• Cat machines
• Selection of Cat hammers, ideal for
reducing oversized rocks
• Cat ripper has a reinforced, one-piece •
• shank for extra durability
• Cat service and support ensures • • •
• maximum tool availability

12 THE CATERPILLAR QUARRY SYSTEM THE CATERPILLAR QUARRY SYSTEM 13

LOADING YOUR ADVANTAGES WITH CATERPILLAR

HIGHER PRODUCTIVITY WITH

“In a chain process like quarry ripping, loading and hauling,
you can’t afford even one weak link.”
CAREFUL COORDINATION LOWERS COST PER TON
Crusher capacity dictates the choice of all
other machines in the process. The loader
must be matched to the truck, with the right
bucket size to optimise loading cycles. But
the number of trucks used will depend on
the volume needed to keep the crusher fully
loaded as well as the distance from the
working face to the hopper.
Caterpillar has a world class range of wheel
loaders, hydraulic excavators, front shovel
machines, work tools and quarry trucks,
designed to work productively together.
Whether you are end-loading or drive-by
loading on the bench, or open-pit loading,
we can advise you on optimal loading
procedures and ideal cycle times, based on
loading productivity studies.
SYNCHRONISED MACHINES
Caterpillar® machines are designed
to work together right through the
chain. A coordinated fleet of hydraulic
excavators, wheel loaders and front
shovels can maximise uptime and
production rates, leading directly to a
lower cost per ton.
OPTIMAL LOADING PRODUCTIVITY
Caterpillar conducts job studies to
measure loading cycle productivity and
recommends improvements based on
the results.

LOADING MATCHING GUIDE

Wheel Loaders 938H 950H 962H 966H 972H 980H 988H 990H 992K 993K Hydraulic 336DL 345DL 365CL 385CL
Excavators
Articulated
Payload t* Capacity m3 2.3 - 3.0 2.7 - 4.0 2.9 -4.3 3.5 - 4.8 3.8 - 5.5 4.2 - 6.1 6.3 - 7.0 8.4 - 9.2 10.7 - 12.2 12.2 -14.5 1.1 - 2.3 2.2 - 3.6 2.6 - 5.0 2.0 - 6.0
Trucks
Bucket size m3
2.8 3.3 3.8 4.5 4.8 5.7 6.9 9.2 12.3 14.5 2.2 3.2 4.6 5.5

725 23.6 14.3 5-6 4-5 3-4 3-4 3 2-3 6-7 5 3

730 28.1 16.9 6-7 5-6 4-5 4 3-4 3-4 8 5-6 4 3

730 Ejector 28.1 16.9 6 - 7*** 5-6 4-5 4 3-4 3-4 8 5-6 4 3

735 32.7 19.7 7 - 8*** 6-7 5-6 4-5 4 3-4 6-7 4-5 3-4

740 38 24 6-7 5-6 4-5 4-5 5 4

740 Ejector 39.5 23.1 6 5-6 4-5 4-5 5 4

Quarry
trucks
770 36.3 25.1 4 - 5*** 3 5 4

772 45 31.1 5*** 3-4 6 5

773F 54.4 35.1 4-5 3-4 7-8 6

775F 63.5 41.9 5-6 4-5 3-4 7-8

777F 90.9 60.2 6 - 7*** 5 4

785D 140 78 6***

Note: Pass match has been calcuated by using a fill factor of 100%,a material density of 1,600kg/m3 and by selecting the ME (Mass Excavation) boom with medium stick *
Target Payload **Heaped 2:1 ***With high lift option
14 THE CATERPILLAR QUARRY SYSTEM THE CATERPILLAR QUARRY SYSTEM 15
 CAT EQUIPMENT FOR LOADING
LOADING
LARGE/MEDIUM WHEEL LOADERS
• Mobility and versatility for multi-face • •
• loading
• Longer cycle times (typically 35 secs)
• due to travel distance involved, but with •
• larger bucket fill
• Robust, durable machines designed for •
• tough conditions
• Maximum power and efficiency
• from hydraulics

HYDRAULIC EXCAVATORS
• Ideal for ‘sit and swing’ operations in •
• tight areas and for loading from above
• Powerful, reliable engine and hydraulics
• Outstanding operator comfort and • • •
• visibility
• Shortest loading cycle times
• (dump/swing/dig/swing of around 22 secs)

FRONT SHOVELS
• Excellent for high and tight benches
• Powerful breakout forces
• Heavy-duty frame and undercarriage • •
• specially designed for tough quarry and •
• aggregates applications
• High bucket fill and fast cycle times

16 THE CATERPILLAR QUARRY SYSTEM THE CATERPILLAR QUARRY SYSTEM 17

 HAULING
“We currently have Cat machines on jobsites with more than 65,000 hours.”

A CATERPILLAR LEGACY FOR SHORTER DISTANCES

A productive quarry operation is a coordinated
chain of procedures, each working at peak
performance. By setting up an efficient hauling
system, you can ensure high production rates
and lower your cost per ton.
When the distance from the face to the
crusher does not exceed 100 metres, the Cat
large wheel loader is the machine of choice,
loading and carrying the material directly into
the crusher at a low cost per ton.

The choice of machine for hauling loaded

material from the face to the crusher depends
on the jobsite conditions, distance to be
travelled and the volume to be moved, which
in turn is dependent on the crusher capacity.

Quarry trucks form the backbone of this

operation, with articulated trucks for difficult
conditions or poor haul roads.

Many quarry operators have discovered

that Caterpillar quarry trucks are the most
productive in the industry. For larger projects
and long-term use, their productivity, durability
and load impact resistance make them an
unbeatable investment.

YOUR ADVANTAGES WITH CATERPILLAR

PRODUCTIVE WORKSPACE
With short cycles on rough ground, quarry
hauling is extremely demanding on machine
operators. Comfortable Cat cabins with
easy-to-use controls help to keep them
fresh and focused on the job.
TRUCK BODIES AND LINERS FOR SPECIFIC
MATERIALS
We can help you choose the right quarry
truck body and liner for your operation. Dual-
slope and flat-floor bodies are both available
with any of six liner systems, to suit different
impact levels.
AXLE OIL COOLER
The axle oil cooler circulates oil from the
differentials through the cooler, filter and
brakes, helping to extend component life
and increase machine uptime.

18 THE CATERPILLAR QUARRY SYSTEM THE CATERPILLAR QUARRY SYSTEM 19

 CAT EQUIPMENT FOR HAULING
HAULING
LARGE WHEEL LOADERS
• The 3.88 m Lift arrangement keeps the
• load closer to the machine, improving
• ride quality for load and carry application
• The lock up clutch allows machine to
• run in direct drive at higher travel • • •
• speeds and greater fuel efficiency
• Wide range of Cat buckets and ground
• engaging tools to match your application
• Ride control for smoother travel
Cat’s Ride Control system improves
wheel loader ride stability, load
retention and operator comfort, allowing
faster travel and shorter cycle times
over rough terrain.

QUARRY TRUCKS
• Superior construction techniques and •
• materials for long-life durability in all •
• conditions
• Wide range of application-specific body
systems (floors and liners) on F-Series,
for increased resistance to impact
and wear
• Automatic Retarder Control is standard,
• with the option of compression brakes,
• for downhill haul roads
• Built-in information systems help you •
• optimise operations

ARTICULATED TRUCKS
• The 700 family feature highly productive
• and comfortable workspace
• Outstanding off-road suspension • • •
• systems and traction control for
•steep grade
• Renowned durability keeps ownership
• costs low
• Excellent visibility with curved one-• •
• piece windshield over sloping hood
• Only recommended for rough underfoot
conditions

20 THE CATERPILLAR QUARRY SYSTEM THE CATERPILLAR QUARRY SYSTEM 21

ROAD
MAINTENANCE
“The lifeline of your production chain.”
The construction and maintenance of a
safe, productive haul road is crucial to site
productivity. A poor haul road will immediately
impact on site mobility with a negative effect
on machine wear, fuel efficiency and your cost
per ton. The haul road is the lifeline of your
activity; it’s always worth taking care of it.
Caterpillar’s M-Series motor graders are
the ideal machines for fast shaping and
maintenance of haul roads. This machine will
help keep down your fleet’s fuel consumption
and tyre wear, and improve the comfort and
safety of your truck operators.
Once you’ve got your haul road built there’s yet
another thing you cannot afford to overlook.
Dust. Small particles though they are, dust
thrown up by continuous haulage on dirt roads
can reduce visibility and mobility, in addition
to causing health concerns for workers. Here’s
where the water trucks step in. Equipped with
a sophisticated system of water distribution,
they efficiently reduce dust on haul roads and
adjacent areas.
22 THE CATERPILLAR QUARRY SYSTEM
Caterpillar works closely with water
technology companies and can offer you the
right high performance water trucks depending
on the type and length of your haul roads as
well as climate factors like dryness and wind.
Typically the water trucks are of the same type
as the main hauling system as they are then
perfectly matched to the underfoot conditions.
WHAT IS A GOOD HAUL ROAD?
• Constant grades (8% to 10%)
• 3 trucks width, smooth surface
• No blind spots
• Elevated curves, safety berms
• Good drainage and dust control
CAT EQUIPMENT FOR ROAD MAINTENANCE
M-SERIES MOTOR GRADER
• Intuitive joystick controls and superior • Improved serviceability keeps operating • •
• visibility ensure that even less-experienced • costs in check
• operators can maintain haul roads • Extremely durable machine
• Compatible with a wide range of
• work tools
THE CATERPILLAR QUARRY SYSTEM 23
RE-HANDLING YOUR ADVANTAGES WITH CATERPILLAR

AUTO-DIG FOR MORE CONSISTENT

and LOADING
OPERATION ROAD TRUCKS and WHEEL LOADERS MATCHING GUIDE

This function automates the bucket

movement during the loading cycle, Wheel 938H 950H 962H 966H 972H 980H 988H
helping to reduce operator fatigue and loaders
raise productivity by providing more 2.3 - 3.0 2.7 - 4.0 2.9 - 4.3 3.5 - 4.8 3.8 - 5.5 4.2 - 6.1 6.3 - 7.7
consistent operations throughout the day. Road trucks Bucket size m3
“Secondary handling, stockpiling and loading on-highway Capacity t 2.8 3.3 3.8 4.5 4.8 5.7 6.9
trucks requires mobility and speed, as well as lifting force. RIDE CONTROL FOR SMOOTHER TRAVEL
3-4 3 3 2-3 2
Semitrailer 22 - 28
This is where Caterpillar wheel loaders come into their own.” Cat’s Ride Control system improves wheel
4 3-4 3-4 3 2-3
loader ride stability, load retention and
operator comfort, allowing faster travel 4 axle 20 4-5 4 3-4 3 2-3 2-3 1-2
HIGHER PRODUCTIVITY LOWERS COST and shorter cycle times over rough terrain.
3-axle 17 3-4 3 2-3 2-3 2-3 1-2 1-2
OF OWNERSHIP
Caterpillar H Series wheel loaders are an The operator is key to wheel loader HIGHER PRODUCTIVITY WITH UNIPLUS BUCKET 2-axle 11 2-3 2 1-2 1-2 1-2 1 1
excellent choice when it comes to moving productivity, making comfort and ease of Designed for stockpiling, the Cat Uniplus
loose materials quickly. They prove their worth operation essential. The Cat H Series offers bucket as a flat-floor design with large
again and again, with short cycle times, deep a world-class cab with easy-access ladder, opening and a load centre close to the
pile penetration, excellent controllability, high unbeatable space and comfort, low sound machine, for greater and safer productivity.
lift forces and excellent fuel efficiency. levels and good body vibration protection. ARTICULATED TRUCKS and WHEEL LOADER MATCHING GUIDE

With its load-sensing hydraulic system and Revolutionary electronics provide low-effort
automated loading process, the Cat H Series operation with easy joystick and lever control. Wheel 938H 950H 962H 966H 972H 980H 988H
loaders
wheel loader provides higher productivity and
more consistent operation throughout the day, 2.3-3.0 2.7-4.0 2.9-4.3 3.5-4.8 3.8-5.5 4.2-6.1 6.3-7.7
Articulated Bucket size m3
no matter how long the operator works. Trucks Payload t* Capacity m3** 2.8 3.3 3.8 4.5 4.8 5.7 6.9

725 23.6 14.3 5-6 4-5 3-4 3-4 3 2-3 2-3

730 28.1 16.9 6-7 5-6 4-5 4 3-4 3-4 2-3

730 Ejector 28.1 16.9 6-7*** 5-6 4-5 4 3-4 3-4 2-3

735 32.7 19.7 7-8*** 6-7 5-6 4-5 4 3-4 3-4

740 38 24 6-7 5-6 4-5 4-5 3-4

740 Ejector 39.5 23.1 6 5-6 4-5 4-5 3-4

*Target Payload **Heaped 2:1 ***With high lift option

CAT EQUIPMENT FOR RE-HANDLING
AND LOADING
WHEEL LOADERS
• Faster cycle times with Auto-dig, return to
• dig functions and shift-on-the-go
• Great stability with Ride Control and
• optimised weight distribution
• Excellent controllability with command
• control steering, electro-hydraulic controls,
• full lifting capacity and fine modulation of •
• lift and tilt movements
• Excellent visibility with large window • • •
• over sloped hood, high-intensity discharge •
• lights and an optional rear view camera
ARTICULATED TRUCKS
• The 700 family feature highly productive •
• and comfortable workspace
• Outstanding off-road suspension systems •
• and traction control
• Renowned durability keeps ownership • •
• costs low
• Excellent visibility with curved one-piece •
• windshield over sloping hood

24 THE CATERPILLAR QUARRY SYSTEM THE CATERPILLAR QUARRY SYSTEM 25

 SAND
and GRAVEL

“Caterpillar’s wide range of machines and specifications offers

sand and quarry producers specific cost-efficient solutions.”

SPECIAL NEEDS
Sand and gravel production has specific
characteristics. The aggregate comes from
shallow pits, sometimes under water, and
is dug out or dredged rather than ripped or
blasted. The material is looser and softer than
rock. Environmental regulations are strict,
requiring a progressive work and restore
approach.
For all these reasons, sand and gravel
producers require different equipment and
machine specifications from crushed rock
operators, including smaller, more flexible
load and carry machines and the choice of a
wider range of hydraulic excavators to suite
their particular extraction conditions.
Caterpillar offers long-reach excavators
– equipped with heavy duty bases,
counterweights and undercarriages – for
wet or wide bench extraction. Designed to
withstand extreme digging conditions, these
machines are equipped with reinforced
upper frames.
FUEL EFFICIENT SOLUTIONS
Cat mid-sized wheel loaders and articulated
trucks, with superior fuel efficiency and
safety features, offer sand and gravel
producers high productivity and low owning
and operating costs.

CAT EQUIPMENT FOR SAND AND GRAVEL

• Long-reach, heavy duty excavators for wide
• bench and wet excavation
• R eliable, durable mid-sized wheel loaders •
• with state-of-the-art electronics and • • •
• hydraulics for greater productivity in any •
• conditions
• Heavy-duty articulated trucks with • • • •
• outstanding traction and flotation
• C at’s wide range of buckets designed for
• sand and gravel applications

26 THE CATERPILLAR QUARRY SYSTEM THE CATERPILLAR QUARRY SYSTEM 27


CAT BLOCK HANDLING WORK TOOLS
Quick Coupler system for easy
changeover and optimum lifting and
breakout forces.
Extreme Duty buckets. Rock bucket for
rock loading and overburden operations,
marble bucket for handling high-value
breakable marble and heavy duty block
handling bucket for loading large squared
blocks and boulders.
Fork providing good balance and the
ability to move and place blocks safely.
Breaker Tine for prying loose large stone
blocks
Clearing rake for clearing and
controlling loose objects
28 THE CATERPILLAR QUARRY SYSTEM
BLOCK
HANDLING
EXTREME DUTY CONDITIONS
Caterpillar block handling wheel loaders are
the weight lifters of the quarry industry. They
have the power to lift heavy loads and the
durability to handle extreme duty conditions.
The Cat block handling work tool system is
based around a quick coupler and a range of
rugged tools specifically designed for handling
and manipulating large stone blocks.
CAT BLOCK HANDLING WHEEL LOADERS
• Caterpillar durability is designed in - (not •
• added on) - around strong, solid structures
• that are built to last
• Powered by oversized tilt cylinders, with •
• extreme-service transmission for extra • •
• reliability
• Heavy-duty front structures and box-• • •
• section front linkage provide superior • •
• strength
• Efficient, well-balanced hydraulics and• •
• low-effort electronic controls in world-• •
• class cabin help operator achieve high • •
• productivity
• Dedicated Cat Block Handling Quick • • •
• coupler with full range of Cat Extreme Duty
• Work Tools
THE CATERPILLAR QUARRY SYSTEM 29
WORK TOOLS
TOTAL SYSTEM SOLUTIONS
Caterpillar Work Tools tailor Cat machines to the specific requirements of your operation. Specially designed to be fully compatible
with our machines, Cat Work Tools enhance the utility of your Cat quarry fleet, equipping it to complete all quarry tasks productively
and cost efficiently.
CAT QUICK COUPLERS
Caterpillar’s unique Quick Coupler enables
operators to release one work tool and
connect another, simply and in a matter of
seconds. The Cat Quick Coupler eliminates
machine idling time between jobs and makes
Cat hydraulic excavators and wheel loaders
more versatile, more efficient and easier to
operate. It is an industry standard with more
than 40,000 units sold.
CAT HAMMERS
Cat hammers provide heavy forces and a high
number of blows per minute, with a wide
oil flow acceptance. Each hammer has wear
plates with visual wear indicators, heavy duty
hosing and suspension system, and a simple
dust seal. Cat hammers are precisely matched
to the hydraulics of Cat excavators, increasing
productivity at the rock face and during the
secondary breaking of large blocks.
CAT BUCKETS
HYDRAULIC EXCAVATOR BUCKETS
Caterpillar offers a wide range of buckets for
hydraulic excavators, each one designed and
tested to bring the best out of your machine
in specific applications.
30 THE CATERPILLAR QUARRY SYSTEM
ROCK EXCAVATION R BUCKET
Rock excavation R buckets are excellent if
you’re digging and loading hard materials like
rocky soil, shot rock and limestone. They’re
more robust than extreme excavation buckets,
with thicker wear plates to extend bucket life,
sidebars pre-drilled for optional protectors
and a spade-edge for greater penetration.
An oversized version provides higher digging
performance and carrying capacity.
HEAVY-DUTY ROCK EXCAVATION HDR BUCKET
These buckets are made with quenched
and tempered steel (400 Brinell) for
extended bucket life. They are particularly
suited for aggressive digging and loading
in the industry’s toughest materials such
as granite and basalt. They come with an
extreme wear package, sidebar protectors
and edge-segments to deal with abrasive
conditions.
BOTTOM DUMP FRONT SHOVEL BUCKET
Developed specifically for high production
Quarry applications, the Front Shovel delivers
high bucket fill factors and fast cycle times
to maximize productivity. Designed and
built to meet the performance and reliability
expectations of Caterpillar customers,
these buckets deliver dependability. The
recommended bucket for Front Shovels is
a bottom dump bucket. It is designed for
strength, performance and long service life.
These buckets include Cat hydraulics, Cat
GET and wear parts.
UNIVERSAL PLUS BUCKETS FOR WHEEL LOADERS
The universal plus bucket has an optimized
profile that enhances the visibility, stability
and carrying capacity of your medium wheel
loaders. With a flat floor design, large bucket
opening and debris deflector equipped as
standard, you get better, safer productivity.
SERRATED EDGE BUCKETS FOR WHEEL LOADERS
Serrated edge buckets are designed for low
abrasion rock environment to give your wheel
loaders maximum penetration and carrying
capacity. The bucket edge is specially
designed with self-sharpening
chamfers, which will last for the life of the
cutting edge. The used edge can be easily
replaced and with no pin-on or bolt-on
material – such as tips – the chance of iron
falling into the crusher is greatly reduced.
HEAVY DUTY QUARRY BUCKET
FOR WHEEL LOADERS
The Heavy Duty Quarry bucket is tailored to
larger loaders working in high-impact and/
or high-abrasion quarry applications. These
buckets present a long floor for easier,
quicker loading and the large radius offers
minimal resistance as the material builds
up. Their wide opening ensures good load
retention after racking back and offers at the
same time the right fill factor.
ROCK BUCKETS FOR WHEEL LOADERS
These buckets are designed to work
principally in mining and quarry industries,
with either straight or spade edges. The
straight edge has higher breakout force and
increased dump clearance; the spade edge
offers better penetration.
RIPPERS loaders, these extreme duty Block Handling
RIPPERS FOR HYDRAULIC EXCAVATORS Work Tools are built for the demanding quarry
With excellent penetration from a rigid and block handling markets. The complete
and reinforced construction combined with system is based around a dedicated Quick
optimized tip radius, rippers for hydraulic Coupler and a series of rugged Work Tools
excavators extract weaker rock types, specifically for handling and manipulating
efficiently. When working with abrasive large stone blocks. These Work Tools have
material, protect your ripper with an optional been optimized for Caterpillar block handling
shank protector. wheel loaders and offer excellent rack back
FORKS and dump angles.
FORKS FOR WHEEL LOADERS
Few work tool lines can match the range and
utility of Cat Forks. Forks transform loaders
into high performance material handling
platforms capable of sorting, stacking and
working wherever product. The variety of Cat
Forks encompasses specialty models designed
for every conceivable task. And these forks are
designed specifically for Cat loaders; matched
precisely to their capabilities to help assure
maximum performance and reliability.
BLOCK HANDLING
WORK TOOLS FOR WHEEL LOADERS
Designed to increase the versatility and
productivity of Caterpillar block handling wheel
THE CATERPILLAR QUARRY SYSTEM 31
GROUND
ENGAGING TOOLS
Choosing the right Ground Engaging Tool (GET) will instantly optimize your machine’s
productivity while lowering your owning and operating costs.
CAT K SERIES TOOTH SYSTEM - A DIFFERENCE
®
IN PERFORMANCE
The K Series Tooth System represents a new
standard of performance, easy change-outs
and long-term sharpness resulting in more
productivity and minimum downtime. Its
redesigned tip shape helps it stay sharper
throughout its wear life. Vertical retention
makes tip change-outs quick and easy. All
this translates into better penetration and
less strain on the machine.
CAT Certified Used Equipment
a cost-effective alternative
Cat Certified Used are low hour used machines
sold with a minimum 6-month warranty. Each
machine is dealer inspected and serviced
to a strict ‘Cat Certified Used’ standard. The
inspection covers the entire machine - from
engine, hydraulics, tyres/tracks, transmission
32 THE CATERPILLAR QUARRY SYSTEM
CAT WEAR PRODUCTION PRODUCTS - TOTAL
®
WEAR PROTECTION
Mechanically Attached Wear Plate
System (“M.A.W.P.s”)
The solid and skeletal Mechanically Attached
Wear Plate System provides a hammerless
method for installation and removal of wear
plates. Solid MAWPs protect equipment,
such as the bucket base. The skeletal plates
are designed to trap material allowing
for material-on-material wear rather than
wearing the truck steel body liner.
New Wear Protection Products: Tough
Machines Need Tough Protection
Caterpillar machines are born tough and
are designed for years of use. New wear
protection parts like Chocky Bars, Wear
Buttons, Roll Bars and Wear Blocks protect
machines and buckets from wear, maximizing
wear-life and uptime.
and electrical systems to the finer points
in the operator’s station and general
appearance. Where necessary, machines
are serviced using original Cat parts, fluids
and filters. When sold, each machine is
100% work ready. Naturally, your Cat dealer
supports each machine after the sale.
360° SOLUTIONS
Thus, while it is important to have the
right machines for every job, it’s equally
important that your machines have the right
Ground Engaging Tools. This will ensure
that your machine stays up and running for
a long time and you can extract maximum
value from them.
PAT SCALE TRUCK
Whatever the size of your quarry operation,
Caterpillar wants you to be successful.
Our customer support services and renowned
global dealer network will ensure that you get
maximum productivity from your synchronised
Cat quarry fleet.
360° SOLUTIONS: TAILORED TO YOUR NEEDS
Today you need more than great machines.
That’s why we offer packages with financial
services, product support, warranties and
machines. As a result you get the specific
business solution you need.
• The right machine for your business.
Your Cat dealer will help you select the best
machine for your activities and applications.
• The most attractive finance package.
Cat Financial can offer you a range of
flexible, highly competitive financial
solutions to make it easier and faster
to obtain the Cat equipment you need.
• The most cost-effective Cat Customer
Support Agreement. The surest way to run
your machine at peak performance and
avoid the costs of unscheduled downtime.
• The most beneficial Cat Warranty,
for your total peace of mind. The warranty
coverage from your Cat dealer is backed by
the worldwide resources of Caterpillar.
ASK FOR A CATERPILLAR ANALYSIS
OF YOUR QUARRY
Caterpillar has Production Analysis Teams
to help you increase the efficiency of your
operation and reduce your cost per ton. It’s a
hands-on service: we come to your site with
our scale truck and analyse production –
working with data from your real applications,
machines and operators – to identify the cost
per ton out of the face.
The objective is to find the optimal production
organisation for your specific quarry, from
loading technique through to haul road
characteristics, to reduce your cost per ton.
THE CATERPILLAR QUARRY SYSTEM 33
Solutions for a
more sustainable
world
ENGINE EMISSIONS
We strive to constantly develop engines that
work with optimum efficiency while keeping
the environment clean. With Acert Technology
to lower emissions, engines also improve
maintenance costs through less engine wear
and less oil consumption.
BIODEGRADABLE HYDRAULIC OIL
Extended service and maintenance intervals
increase machine availability and reduce the
frequency of fluid handling. Available through
your dealer, Cat HEES biodegradable hydraulic
oil is fully decomposed by soil or water
microorganisms with little or no deposits.
34 THE CATERPILLAR QUARRY SYSTEM
CAT REMAN PARTS
Thanks to recycling, Cat machines have an
extended life cycle. We recycle used products
into “like new” Cat Reman products that offer
the same performance and quality as new
parts at a fraction of the new price.
OPERATOR TRAINING
Cat machines work best with trained and
efficient operators. Most Cat machines
working in Q&A are equipped with training
seats. Operators also have the possibility to
be trained on Cat simulators. Some dealers
also offer Eco Operator TrainingSM to improve
fuel efficiency.
FEATURES FOR A SAFER JOBSITE
We believe that jobsites should be safe and
comfortable to ensure maximum operator
efficiency and productivity. Cat machines come
equipped with features that contribute to such
a working environment.
VIBRATION
Operating controls mounted on the seat
reduce vibration impact for the operator
thus creating a more comfortable working
environment.
NOISE LEVELS
In an industry like Q&A, where loud operating
sounds are a given, we strive to maintain a
quieter working atmosphere where operator
and exterior sound levels meet all regulations.
CAB ACCESS
In order to avoid most common operator
injuries, Caterpillar has developed industry-
leading operator cab access. Thus ensuring
that maximum work efficiency.
WORK TOOLS
Work Tools offered by Caterpillar are
performance matched to the machines,
further increasing operating efficiency. Cat
Quick Couplers improve operator safety by
replacing the need of leaving the cab in order
to exchange work tools. The Cat Rip and Load
packages for excavators provide an alternative
for blasting in quarries, improving the quality
of the extracted materials and protecting
the environment against high noise and dust
levels, generated usually by blasts. Caterpillar
delivers solutions that help customers become
sustainable in their respective industries.