CATERPILLAR TRUCK BODY PROGRAM

Overview

Global Mining Division

April 2009

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 Meeting Agenda

Engineering
Design
Analysis
Products & Applications
MSDII Body
X Body
Dual Slope Body
Gateless Coal Body
Mine Specific Design
FACLT
Mine site profile
Manufacturing
Shipping Configurations
Quality & control
Body Maintenance Program
Inspection Tools/Forms
Best Practices
Summary

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TRUCK BODY ENGINEERING
Design & Analysis

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S ystems S tructural A nalysis /
V irtual P roduct E nvironment

SSA/VPE

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Truck System Simulations

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PRODUCTS & APPLICATIONS
MSDII Body, X Body, Gateless Coal Body, & Dual Slope Body

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 Applications

Lightweight

Which type of body do I need for my mine site?

Standard (heavy duty) body

Gateless coal (high volume) body

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 Light Weight Body - Applications

Mature Mines (well established)*

Operational Considerations Body at 16,000 hrs
Excellent loading practice
Good blasting practice
Solid maintenance program
Maintenance resources
Facilities
Personnel
Expertise
Typical body requirements
Optimize payload
Lightweight body
20,000 hours minimum
Mine specific liner package

*797 & 795 are the exception see 797 MSDII section
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 785-793 MSDII Body Feature Overview

10mm
frontwall

8mm

5mm 8mm 16mm

8mm

8mm
floor rib

Mine Specific Design (application specific body packages)

Efficient use of steel (floor, sidewalls, frontwall, canopy, & ribs)
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785-793 MSDII Body Size Options

793 Available in 3 sizes:

209 cu yd (160 cu m)
230 cu yd (176 cu m)
250 cu yd (191 cu m)

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 Front to Rear Body Flare

1 o flare front interior

6982 mm
body width to rear interior
body width
Improved material flow /
release
Front to Reduces wear on rear
Rear sidewalls (less material
Flare contact

7265 mm
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 Structural Advantage

8mm
Floating sidewall
6mm wrapper eliminates the
need for under utilized
sections of 8mm sidewall &
16mm floor
Maintains durability 16mm
Efficient use of steel (weight)
16mm
6mm

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 Body Exhaust Heat

Exhaust
Highly cohesive applications Outlet
Carry back reduction system
Hot surface improves material flow
Targets problem areas CATERPILLAR:
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 Pivot Area and Hoist Brackets

Factory pre-assembled and installed

Internal and external gussets provide full support
Solid piece pivot bracket CATERPILLAR:
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 Understructure Gussets & Rib Coverage

Internal and external gussets optimize stress distribution

Minimizes impact damage to floor
Analyzed and tested for optimal floor rib coverage
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 Guards, Lifting Points, & Loading Target

Upper sidewall lifting eyes

Loading target

Complete forward machine coverage

Canopy rock shedders
Rock ejectors

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 785-789 MSDII Body Feature Overview

5mm
8mm

8mm
10mm

16mm
8mm

8mm
floor rib

Mine Specific Design (application specific body packages)

Efficient use of steel (floor, sidewalls, frontwall, canopy, & ribs)
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785-789 MSDII Body Size Options

789 Available in 4 sizes:

165 cu yd (126 cu m)
175 cu yd (134 cu m)
185 cu yd (141 cu m)
195 cu yd (149 cu m)
785 Available in 3 sizes:
130 cu yd (99 cu m)
140 cu yd (107 cu m)
150 cu yd (115 cu m)

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 Front to Rear Body Flare

1 o flare front interior

body width to rear interior
body width
Improved material flow /
release
Front to Reduces wear on rear
Rear sidewalls (less material
Flare contact

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 Structural Advantage

8mm
Floating sidewall
6mm wrapper eliminates the
need for under utilized
sections of 8mm sidewall &
16mm floor
Maintains durability 16mm
Efficient use of steel (weight)
16mm
6mm

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 Body Exhaust Heat

Exhaust
Outlet

Highly cohesive applications

Carry back reduction system
Hot surface improves material flow
Targets problem areas CATERPILLAR:
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 Pivot Area and Hoist Brackets

Factory pre-assembled and installed

Internal and external gussets provide full support
Solid piece pivot bracket CATERPILLAR:
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 Understructure Gussets & Rib Coverage

Internal and external gussets optimize stress distribution

Minimizes impact damage to floor
Analyzed and tested for optimal floor rib coverage
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 Guards, Lifting Points, & Loading Target

Upper sidewall lifting eyes

Loading target

Complete forward machine coverage

Canopy rock shedders
Rock ejectors

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 797F & 795F AC MSDII Body Feature Overview

5mm

10mm

14mm 10mm

20mm
10mm

Enhanced design versus smaller trucks

Floor, sidewall, & frontwall plate thickness increased
Heavier floor structure
Why?
Wide application range (green field mature mine)
Larger loading tools CATERPILLAR:
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797F & 795F AC MSDII Body Options

797 Available in 4 sizes:

288 cu yd (220 cu m)
315 cu yd (241 cu m)
330 cu yd (252 cu m)
350 cu yd (268 cu m)
795 Available in 5 sizes:
237 cu yd (181 cu m)
270 cu yd (206 cu m)
288 cu yd (220 cu m)
310 cu yd (237 cu m)
330 cu yd (252 cu m)

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 Body Exhaust Heat

Exhaust
Outlets

Highly cohesive applications

Carry back reduction system
Hot surface improves material flow
Targets problem areas CATERPILLAR:
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 Rounded Rear Ribs

Maximize berm clearance

Enhanced impact resistance
Reduces stress under racking conditions CATERPILLAR:
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 Pivot Area and Hoist Brackets

Factory pre-assembled and installed

Internal and external gussets provide full support
Solid piece pivot bracket

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 Understructure Gussets & Rib Coverage

Internal and external gussets optimize stress distribution

Minimizes impact damage to floor
Analyzed and tested for optimal floor rib coverage

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 Body Chassis Guards

Complete forward machine coverage

Canopy rock shedders
Rear tire rock shedders

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Lifting Options & Loading Target

Lower sidewall lifting lugs*

Upper sidewall lifting eyes
Loading target

*797 315 cu yd (241 cu m) MSDII Body only

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 Floor & Rib Seam

Rib seam offset from floor seam

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MSDII Half-Life Study

Proven design validated by a substantial field population

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Initial expectations
Excellent payload
20,000 hour life
Improved understructure
No pivot & hoist bracket
cracking
Application specific body program
Volume Requirements
Effective wear & impact
protection
MSDII Half-Life Study
Delivered Results
Over 2000 MSDII Bodies in the
field
600+ bodies reviewed
NACD, LACD, APD, & EAME
15,000 to 30,000 hours
Understructure excellent condition
Target payload achieved in all cases
MSD liner system improved payload
& body service life
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 MSDII Body Locations 2003-2008

850

World wide 2000+

140

650 50 330

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 Heavy Duty - Applications

Greenfield sites (new projects)

Contractor Mining
Operational Considerations
New operators
New practices
New maintenance program
Limited facilities and resources
Durability valued over payload

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 785 793 X Body Feature Overview

5mm
8mm

12mm
16mm

Top Rail
20mm Cross Section
12mm

8mm
floor rib

Toughest Option in the CAT Truck Body Line Up

Excellent durability & good payload performance for tough applications

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785-793 X Body Size Options

793 Available in 3 sizes:

195 cu yd (149 cu m)
204 cu yd (156 cu m)
210 cu yd (161 cu m)
789 Available in 3 sizes:
156 cu yd (119 cu m)
163 cu yd (125 cu m)
175 cu yd (134 cu m)
785 Available in 3 sizes:
111 cu yd (85 cu m)
125 cu yd (96 cu m)
135 cu yd (103 cu m)
Next up: 777 (est. 2010)
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 Sidewall to Floor Integration

Improved structural integrity thru

Cross Section
Direct sidewall floor integration
Direct sidewall rib floor rib
termination
Tapered sidewall ribs added flexibility &
durability

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 Body Exhaust Heat

Exhaust
Outlet
Highly cohesive applications
Carry back reduction system
Hot surface improves material flow
Targets problem areas CATERPILLAR:
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 Understructure Gussets & Rib Coverage
Internal and external gussets optimize stress distribution
Minimizes impact damage to floor
Analyzed and tested for optimal floor rib coverage

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 Pivot Area and Hoist Brackets

Factory pre-assembled and installed

Internal and
external gussets
provide full support
Solid piece pivot
bracket

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 Guards, Lifting Points, & Loading Target

Upper sidewall lifting eyes

Loading Target

Complete forward machine coverage

Canopy rock shedders
Rock ejectors
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 X Body Field Information

2 years solid field performance

200 + units in the field
Replaced flat floor body
Payload & volume advantage
validated
Result of mine specific approach
Design enhancements identified &
implemented

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 785 789 DS Body Feature Overview

5mm
8mm

12mm
14mm

20mm

12mm
floor rib

40 Years of solid performance

A versatile body with a robust design for green field and contractor
applications
A long life body (typically life of chassis) & low maintenance CATERPILLAR:
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785-789 DS Body Size Options

789 Available in 2 sizes:

137 cu yd (105 cu m)
157 cu yd (120 cu m)*
785 Available in 2 sizes:
102 cu yd (78 cu m)
119 cu yd (91 cu m)*
777 Available in multiple sizes:
78 cu yd (59.5 cu m)
84-105 cu yd (64-80 cu m)*

*with sideboard & tail extension

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 Sidewall to Floor Integration

In addition to 12mm thick sidewall plates

More support structure than any other option (vertical & horizontal)
Low loading height Cross Section
5 sided beam - sidewall to floor integration 12 mm side wall

16 mm transition

20 mm floor
5 sided beam

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 Body Exhaust Heat

Exhaust
Highly cohesive applications Outlet
Carry back reduction system
Hot surface improves material flow
Targets problem areas CATERPILLAR:
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 Understructure & Rib Coverage

More rib coverage than any body in the industry

Reinforced rear rib to minimize berm contact damage
20mm
12mm thick

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 8 Degree V Floor & 16 Degree Ducktail
V-shaped floor
Maintains low center of gravity
Reduces shock from loading
Ducktail improves load retention

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 Guards, Lifting Points, & Loading Target

Upper sidewall lifting eyes

Loading Target

Complete forward machine coverage

Canopy rock shedders
Rear tire rock shedders
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 New Canopy Design

2000 mm from catwalk

(old design was only 1760 mm)

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 Gateless Coal Body

Coal or High Volume Applications

Attain target payload in coal

Maintain proper center of gravity
Maximize payload (less weight
than other modified body options
i.e. tailgates)
Minimize maintenance
(eliminates cost & downtime
associated with tailgates)
Covers combi applications with
the addition of mine specific liner
options
Available: 785, 789, 793, & 795
NOW available: 777F
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 Gateless Coal Body Feature Overview

Application specific options

Sideboard options to maximize volume

Capture target payload

& volume without the
costs of a tailgate

MSDII understructure Solid piece pivot bracket

Rear 2/3 of the floor kick-up
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 Why a Gateless Coal Body?

Tailgates cause
Damage & downtime
Additional weight (payload reduction)
Maintenance costs
CG (center of gravity) problems

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 Gateless Coal Body Field Performance
Payload Summary*
Average Payload (Tonne)
# of loads 29 15 9 5
100

95

90
91 6 ton advantage
85
tons 85
80

75
tons 73
70 tons
All Loads Gateless Coal Body Dual Slope + 610mm Dual Slope + 610mm
sideboards + Philippi tail gate sideboards + 381mm tail
extension

*January 2009 scale study results CATERPILLAR: 67

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Gateless Coal Body Field Performance

Average Weight Splits*

Load Distribution
Empty Loaded
Front Rear Front Rear
45.6% 54.4% 33.1% 66.9%

*January 2009 scale study results

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 Body Options By Truck Model

Body
777F 785C/D 789C 793F 797F
Type

MSDII

Coming
X Body Soon
(2010)

Dual
Slope

Gateless
Coal
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TRUCK BODY MANUFACTURING
General Overview

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 Steel Inventory (prior to first operations)

10 digit material control system - classification of steel type &

size

Material heats analyzed against CAT specifications prior to

acceptance & use

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 Plate Cleaning Machine

Plate cleaning - steel shot (multiple impeller machine) prior to first operations

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 Plate Cutting (first operations)

Oxy-fuel cutting - 12+ mm thick material

Articulation plasma cutting Plasma arc cutting - material under 12 mm thick

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 Forming Press

6.2 m (20 ft), 750 ton press brake 6 m (19.8 ft ), 2000 ton press brake

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 Welder Qualification

All welders pass several welder qualification tests (Caterpillar

MC1000-105, AWS D1.1 & ISO 9606)
Weld processes: GMAW, FCAW, & SAW
Welders qualify for the weld position required for the job (flat,
horizontal, vertical up, etc)
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 Sub-Assembly

Tack weld station

Finish weld station CATERPILLAR:

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 Main Tack Fixture

Center, right sidewall, left sidewall,

& front wall tacked together
(verification of alignment)

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 End Over End Weld Station

Body rotated tail over front wall

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 Side Over Side Weld Station

Body rotated side over side

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 Paint Process

3 step process / facility layout:

(1) wash room
(2) paint room
(3) heated curing room

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 Shipping

Shipping configurations
Single piece shipping arrangement
Multi-piece shipping options

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 Caterpillar Body Manufacturing
Design

Raw Material

Manufacturing

Shipping

Quality & control through the entire process

Industry & Caterpillar certifications
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MINE SPECIFIC DESIGN
Application specific liner systems

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 F.A.C.LT Available: MSDII & X Bodies

Impact & wear protection that maximizes body life & performance

F ragmentation
A brasion
C ohesion
L oading
T ool
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 FACLT & Body Liner Segmentation

L1 L1

L2 L1 L2

L4 L3 L4

L5 L3 L5

L8 L8
L7 L 11 L 13 L 11 L7

L9 L6 L6 L9
L 12 L 14 L 12

L 10 L 10

L 15
L 15
L 15
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 Material Fragmentation

Small to moderate size rocks

How big are your rocks?

Large rocks

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 FACLT - Fragmentation

Material Size How big are your rocks?

Golf balls

Baseballs

Footballs (soccer)

Basketballs
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 FACLT - Fragmentation

Will the rock fit thru a goal post?

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Fragmentation Liner Placement

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 FACLT - Abrasion

Wear Protection

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 Wear Indicators

Tip Life

Truck Body Liner Life

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Abrasion Liner Placement

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 Cohesion

CARRY BACK CAN BE A HUGE

WASTE OF LABOR & EQUIPMENT

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Material Cohesion is a problem

What can we do about it?

Exhaust body heat
Liner Design (smooth plate)
Body geometry changes
Stop sign plates
Curved transition plates

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 CURVED FRONTWALL TRANSITION

CARRY BACK REDUCTION SYSTEM

Curved transition eliminates

front corner deep pocketing
Allows material to flow and
release more freely
Exhaust heat utilized to dry &
release material in conjunction
with the geometry change
Available on the CATERPILLAR Cross section
X BODY

Green line represents curved transition

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Cohesion Liner Placement

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 Caterpillar Body Liner Options - Types

Smooth Plate for

cohesive materials
Zipper Grid for
semi-cohesive materials

Rock Box for dry and

non-cohesive materials

Mechanically Attached Wear

Plate System (MAWPS)
semi-cohesive to non-cohesive materials

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 Loading Tools

Rope Shovel Wheel Loader

Hydraulic Face Shovel Hydraulic Back Hoe

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Loading Tool Liner Placement

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 Body Application Form

How do we gather mine specific information?

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Body Application Form Cont

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TRUCK BODY MAINTENANCE
Tools & Best Practices

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 Truck Body Maintenance

Tools
Body inspection forms
Body inspection checklist
Body wear map & spread sheet
Body maintenance guidelines
Body inspection images/examples
Best practices
WNGM - 50,000hr body care &
maintenance program
Bed on Wheels maintenance program
Body wear management best practice

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Body Inspection Forms

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 Body Inspection Forms

Modified for wear package

management

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Body Inspection Checklist

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Body Wear Map

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Body Wear Spread Sheet

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 Body Maintenance Guidelines

Develop & follow a BODY MAINTENANCE PROGRAM

Operator walk around inspection every shift change
Body washed & thoroughly examined every PM
Identify any damage & assess degree of importance
Repair any critical problems to prevent further
damage
Track and monitor minor cracking in non critical
areas
Wear liner maintenance is site specific & should be
driven by wear measurements conducted during PM
inspections

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 Develop a Body Maintenance Program

Regular inspections & documentation of results

Notify CAT Dealer if any failure can be attributed to
product quality
CAT Dealer involvement will result in effective
repairs based on proper weld procedures
Continual coordination with the Dealer
Include Caterpillar & the Dealer prior to any
structural changes to Caterpillar truck bodies

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 Body Washed & Thoroughly Examined Every PM

PM inspection includes: pivot structure, hoist

brackets, field joints, sidewall top rail, rear floor
bolster, main rails, front body rest pads, & any
areas that could affect service
All findings need to be documented
Ultrasonic measurement of wear package & any
unprotected base body material
Examine general body mounting/shimming
PM includes routine welding repairs
Major repairs scheduled for planned downtime if
possible

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 Operator Walk Around Inspection

Visual inspection & notify foreman of any damage or

areas of concern before operating vehicle
Look for cracks in structural welds of main rails & ribs
Look specifically at the pivot structure & hoist brackets
Look for loose or missing wear components
Check body to chassis alignment

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 Wear Package Maintenance

Maintenance of the wear package is site specific

PM Ultrasonic Measurement of wear package &
any unprotected base body material will allow
the calculation of a life expectancy for all areas
of the package

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 Body Inspection

What to look for

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 Side Wall Structure Review
Visual inspection indicates
Typical rail cap condition
Minimal impact damage
Structure & base plate
Good condition overall (Example MSDII Body at 20,000 hrs)

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 Rock Shedders

(Example MSDII Body at 10,000 hrs)

Visual inspection indicates
Rock shedder (eyebrow) damage
Damage caused by material contact
Loading practice & fragmentation
need to be evaluated
Repair as needed

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 Canopy & Frontwall

(Example MSD II body at 12,000 hrs)

Visual inspection indicates

Top side review

Some canopy loading
Risk of structural damage
Typical impact damage on
frontwall & sidewall
Minor plate deformation
(No cracking)

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 Canopy & Frontwall
(Example MSD II body at 10,000 hrs)

Visual inspection indicates

Bottom side review

Some canopy loading
Minor plate deformation
Check for structural weld
cracking
Consider liner plate for
improved impact protection
star burst (deformation
causing paint separation)

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 Verify Proper Body Shimming
(Example unit at 81,135 hrs)

Visual inspection indicates

Body pads deteriorated & need replaced
Grease lines out of retainers (crushed by pads)

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 Verify Proper Body Shimming

(Example MSD II body at 18,150 hrs)

Visual inspection indicates

Unit is light in the rear & LH

front
Uneven stress result: front
support & body structure
damage

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 Body Pivot Pin & Hoist Bracket
(Example MSD II body at 18,000 hrs)

Visual inspection indicates

No cracking in the pivot

No cracking in the hoist
bracket
Critical area
If visible cracking is present,
damage should be repaired
as soon as possible

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 Center Floor Ribs (between main rails)
(Example MSD II body at 20,000 hrs)

Visual inspection indicates

Top images
No deformation
Bottom image
(Example MSD II body at 10,000 hrs)
Significant deformation
Loading practice &
fragmentation need to
be evaluated

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 Body Field Seam (weld joint)
(Example MSD II body at 20,000 hrs)

Visual inspection indicates

Top 2 images show LH & RH

body ribs no cracking in the
field seam
Bottom image is an example
of a field seam crack
Repair required

Crack highlighted by
exhaust gas
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 Sidewall Plate & Liner
(Example MSD II body at 16,000 hrs)

Visual inspection indicates

Minimal impact damage

Liner & sidewall design are
adequate for the application
If damage were evident
Loading practice &
fragmentation need to be
evaluated
Increase or add liner plate

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 Floor Area (base plate & liner)
(Example MSD II body at 20,000 hrs)

Visual inspection indicates

Top image
Minimal impact damage
Adequate for the application
Bottom image
Base floor plate
deformation (Example MSD II body at 10,000 hrs)

Loading practice &

fragmentation need to
be evaluated
Increase or add liner
plate

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 Wear Package (rear 1/3 of the body)
(Example MSD II body at 7,000 hrs)

Visual inspection indicates

Zipper grid (top image)

25% wear - continue to
monitor
Rock box (bottom image)
80% wear replace
immediately
Application dependent (Example MSD II body at 10,000 hrs)
Liner wear rates vary by
more than 100%
depending on material
hauled

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 Body Tail Structure Review

(Example MSD II body at 22,000 hrs)

Visual inspection indicates

Gussets intact
Minor deformation
Minimal berm contact
Excellent dumping practice
Minimal body
understructure stress &
fatigue

End rib gussets

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 Safety Cable Bracket & Cable Review
(Example MSD II body at 23,000 hrs)

Visual inspection indicates

No weld cracking
Main bracket & tie off bracket in
sound condition
Cable appears undamaged
Overall condition: good

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 Post Inspection (What next?)

After the inspection

Establish priority & timing for
repairs
Utilize scheduled down time
for any non-critical repair
Contact your Caterpillar dealer
for service or information for the
most efficient repair
Understand root cause
Adjust operational contributor
if appropriate
Loading practice
Material fragmentation
(size)
Dumping practice

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 CAT Body Repair Information
Welding Procedure Special Instruction REHS1841
Operation & Maintenance Guide AEDK0627
Body Assembly Special Instructions (helpful reference)
MSDII Body
797B REHS0963
795F AC REHS4413
793C/D/F REHS2437
789C REHS2777
785D REHS4412 ( 785C REHS3714)

X Body
793C/D/F REHS3713
789C REHS3718

Dual Slope Body

793C/D SEHS9315
789C SEHS9539
785D REHS4415 (785C SEHS9996)
777F REHS2653 (777D REHS0033)

Gateless Coal Body

789C REHS3270
777D/F REHS4424 CATERPILLAR:
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 Body Maintenance - Best Practice

Western Nevada Gold Mine (WNGM)

50,000 hour Truck Body Care & Maintenance Program

Presentation provided by customer (name removed upon their request)

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 WNGM Body Presentation

Lightweight bodies make WNGM money, pay back is

less than 2 years
Tonnage increased without truck overloads
Spill rock is less due to no overloading
Spot time and dump times the same as Rock body
Fuel consumption is lower on return trip as truck is
lighter
Life is 30,000 hours before rebuild

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 WNGM Key Components to Bed Survival

Inspections are performed every 60 days by a NDT (Non

Destructive Test) person.
We use a person who has no interest in any welding
conflicts. His only job is to find problems, not repair them.
Understands some cracks are critical and others are not
Expertise to make the distinction is key to repairing only
when needed
Welders work from his inspection. Details are written in
work orders.
Body inspection sheets are kept on file for all to view.
Work orders are written beside needed repairs.

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 WNGM Key Components to Bed Survival

One dedicated welder who is responsible for welding

during PM. He keeps running lists on each bed and
repairs what he has time for.
He works closely with the NDT inspector and the Weld
Shop Supervisor.
He has all the tools and prepares for each job well in
advance to the truck arrival.
He schedules his time and has the ability to move trucks
around to make sure he has the time to repair the
problems.

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MSD Body Inspection Form

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WNGM Unit 4 Most Recent Inspection

Manage Cracks
(length & time)

Manage Wear

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MSD Body Inspection Form View 2

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WNGM Unit 4 Most Recent Inspection

Drawn in tumble
bars managing
all onsite additions

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MSD Body Inspection Form View 3

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 WNGM Unit 4 Most Recent Inspection

New or existing
If existing change

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MSD Body Inspection Form View 4

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 WNGM Unit 4 Most Recent Inspection

Work order number

- document fixes

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 WNGM Key Components to Bed Survival

Weld shop repairs work PM shop welder can not

handle.
Minor repairs to structure. PM shop is too small
to lift the bed, making body frame repairs more
difficult.
Hinge and hoist bores. We have a Boreteck and
every welder is trained to run it efficiently.

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 WNGM Key Components to Bed Survival

Body rebuilds are done by our weld shop.

There are two stages of rebuild.

A. On truck rebuild, less than two days. Grid

replacement, plate replacements, and cosmetic
repairs.
B.Major rebuild. Usually done around 30,000
hours. We dedicate 3 welders until bed is
complete. Usually takes 3 weeks and costs less
than half of replacements.

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 WNGM Current Body Hours

HOURS BEFORE REBUILD HOURS SINCE REBUILD

Unit 1 - 34,223 + Unit 1 - 12,921 = 47,000
Unit 2 - 31,309 Unit 2 - 15,014
Unit 3 - 36,913 Unit 3 - 7,638
Unit 4 - 32,752 Unit 4 - 14,274
Unit 5 - 30,286 Unit 5 - 15,926
Unit 6 - 34,637 Unit 6 - 11,380
Unit 7 - 34,566 Unit 7 - 11,893
Unit 8 - 36,355 Unit 8 - 9,928
Unit 9 - 31,512 Unit 9 - 6,335
Unit 10- 32,239 Unit 10- 5,454
Unit 11- 33,862 Unit 11- 3,691
Unit 12- 32,462 Unit 12- 4,824
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WNGM Cumulative Truck Body Life is expected to
exceed 50,000 hours.

We dont know how many hours these

bodies will run.
We dont think a second rebuild will be
cost effective.

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WNGM has a few operational items that help our
body life exceed normal life expectancy.

We use small loading equipment, we have less impact

related problems.
We have a great blasting program.
We are comfortable taking a truck out of service to
repair bodies with other scheduled work.
We have support from our management on our
maintenance decisions.
We added a body up indicator that indicates the body is
high enough to release material but low enough to not
contact the berm.
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 WNGM Unit 2 15,014 Hours Since Rebuild

The outside of a Caterpillar lightweight body at 46,000+

hours at WNGM?

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 WNGM Unit 2 15,014 Hours Since Rebuild

The inside of a Caterpillar lightweight body at 46,000+

hours at WNGM?

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What does WNGMs truck body program demonstrate?

Body longevity is beyond the product

Operations has a major impact
Blasting
Loading & Dumping
Maintenance has a major impact
Crack Management
Wear Management
Coordinating repairs effectively
Management buy in is absolutely critical
Ensure operations & maintenance share goals in
terms of equipment utilization and condition
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 Body Maintenance - Best Practice

Bed on Wheels Program

Large fleets demand creative solutions to maximize fleet up time
and minimize cost per hour

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 Bed On Wheels Platform

Safety first
Handrails and covers
Bed is raised to provide flat
working surface
Efficiency
Moveable
Tooling stored & ready to go
Every 1500 hours
8 hour shift
Any internal repairs replace

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 Entry Point Into Rear Of The Bed

Large flat entry point plank

Rear of the body is sectioned off to prevent potential injury
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 Welders

Dedicated to Bed on
Wheels Program
Trained
Establish & maintain core
expertise
Creative solutions to wear
problems resulting in
extended body life

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 Tooling & Supplies

Located on the upper

platform
Accessible to reduce
excess motion
Safer by reducing
movement to and
from the machine
(specifically less
ladder work)

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 Body Wear Management - Best Practice

Telfers Body Maintenance Program

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 Front End of The Tool

Locally developed tool

Excel based electronic
records & analysis
(trending is done)
Tracks different truck
components
Frame & body
Different body types

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 Truck Body Crack Management Tool

Data storage by unit Structural weld locations

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 Telfers Wear Measurement
Data Sheet DT01 DT02 DT03 DT04 DT05 DT06 DT07 DT08 DT09 DT10 DT11 DT12 DT13 DT14 Nominal

Return to
Menu Aug-05 Nov-05 Aug-05 Aug-05 Nov-05 Jul-05 Nov-05 Jul-05 Aug-05 Sep-05 Aug-05 Nov-05 Jul-05 Jul-05

F1 10.5 10.1 9.7 10.7 10 10.7 10 7.1 9.9 10.4 10.5 10.6 10.3 10.1 12

F2 14.5 13.8 12.8 14.2 13.4 14.2 13.7 14.4 14 14 13.6 14.5 14.2 14.9 16
Substantial wear - Increase Inspections F3 10.2 10.5 9.7 10.7 9.9 10.7 9.5 10.8 9.9 10.6 10.1 10.5 10.6 11 12

F4 8.8 7.1 8.1 8.6 6.9 8.4 7.8 8.1 6.5 5.7 8.6 7.4 9 9.4 12

Excessive Wear - schedule for repairs to that area F5 12.1 10.5 12.2 11.7 10.6 13.0 11.7 12.3 9.9 11.6 11.3 10.8 12 12.1 16

F6 9.2 6.8 8 8.8 7.2 8.9 7.6 8.8 7.4 7.4 8.7 7.7 9.5 9.2 12

F7 9 6.8 9.6 8.1 8.9 9.4 9.4 9.2 8.1 8.2 7.6 8.2 9.3 9.1 12
Highest wear in the fleet for this area
F8 12.7 10.8 13.2 11.8 12 11.9 11.6 11.5 11.3 12.1 10.7 12.1 13.1 13.4 16

F9 9.1 8.7 9.6 8.8 9 9.1 8.6 9.2 8.7 9 7.2 8.5 9.5 9.4 12

L1 5.6 5.3 5.4 5.5 5.6 5.6 5.5 5.6 5.5 5.5 5.4 5.6 5.3 5.8 6

L2 4.9 4.9 4.9 4.9 4.9 5.3 4.8 5.4 5.1 5.3 4.9 4.7 5.1 5.5 6

L3 10.2 4.9 7.2 4.8 5.1 10.4 10.1 7.9 9.7 10.3 5.1 5.2 10.3 7.1 12

R1 5.6 5.5 5.4 5.6 5.6 5.6 5.6 5.6 5.5 5.6 5.5 5.6 5.5 5.1 6

R2 5.2 4.6 4.6 4.8 4.4 5.1 4.8 5.4 4.8 5.1 5 4.7 5 5.7 6

R3 10.5 5 9.7 5 4.9 11.2 10.1 8.7 10.2 9.8 5.2 4.8 10.2 10.5 12

H1 11.5 11.6 11.5 11.6 11.6 11.7 11.6 11.6 11.3 11.2 11.5 11.5 11.5 11.7 12

H2 7.4 7 7.3 7.2 7.2 7.6 7.3 7.6 7.2 7.4 7.1 7.1 7.3 7.6 8

H3 11.7 11.5 11.6 11.4 11.6 11.7 11.7 11.7 11.4 11.6 11.5 11.5 11.5 11.8 12

H4 11.5 11.5 11.5 11.4 11.5 11.7 11.5 11.7 11.2 11.6 11.7 11.5 11.6 11.6 12

H5 7.3 7.3 7.3 7.3 7.3 7.4 7.4 7.6 7.5 7.4 7.2 7.1 7.3 7.5 8

H6 11.7 11.6 11.6 11.4 11.6 11.7 11 11.7 11.6 11.6 11.6 11.5 11.8 11.7 12

G1 34 22.3 27.1 27.9 20 25.4 27.4 17 28.4 23.8 26 25 16.3 10.1 41

G2 25 19.8 28 21.2 19.7 27.9 21.4 16.1 23.1 22.7 25 26.6 16.5 12.4 41

G3 30 22.3 27.8 27.3 24.9 27.4 25.2 17.1 27.1 23.7 27 26.2 16.2 9.1 41

T1 12 11 12 12 10.8 12.0 10.5 12 12 12 12 10.8 12 12 12

T2 16 14.3 16 16 14.6 16.0 14.4 16 16 16 16 14.7 16 16 16
T3 16 14.4 16 16 14.5 16.0 14.6 16 16 16 16 14.6 16 16 16
T4 12 10.7 12 12 10.8 12.0 10.7 12 12 12 12 10.7 12 12 12
T5 12 3.8 12 12 7.2 12.0 9.7 12 12 12 12 2.3 12 12 12
T6 16 10.5 16 16 8 16.0 9.8 16 16 16 16 8.6 16 16 16
T7 16 10.6 16 16 7.3 16.0 8.5 16 16 16 16 11.7 16 16 16
T8 12 6.1 12 12 6.6 12.0 11.5 12 12 12 12 2.7 12 12 12
T9 12 6.2 12 12 4.8 12.0 11.9 12 12 12 12 5.5 12 12 12
T10 12 10.7 12 12 5.8 12.0 7.8 12 12 12 12 11.7 12 12 12
T11 12 10.8 12 12 5.5 12.0 7.9 12 12 12 12 6.1 12 12 12

T12 16 6 16 16 5.1 16.0 11.3 16 16 16 16 4.1 16 16 16

T13 16 5.8 16 16 6.4 16.0 11.8 16 16 16 16 6.1 16 16 16
T14 16 10.5 16 16 5.5 16.0 7.9 16 16 16 16 5.2 16 16 16
T15 16 10.4 16 16 6.4 16.0 8 16 16 16 16 6.6 16 16 16
T16 12 5.8 12 12 5.5 12.0 8.4 12 12 12 12 4 12 12 12

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CAT TRUCK BODY PROGRAM
Recap & Summary

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 CAT Truck Body Program Recap

Engineering: dynamic system approach

Truck body options: application specific

Mine specific design: liner system optimization

Manufacturing: quality (design thru finished product)

Body maintenance program: best practices & tools

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 Summary

The Caterpillar Body Program

Adds value to the chassis through products that
are the right fit for the operation
Adds value to the chassis through mine specific
body options and expertise that optimizes the
balance of payload and durability
Minimizes cost/risk to customers through truck
body products designed to maximize chassis
life through system structural analysis (system
approach to design

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