f-series training 795f ac participants copy 810
TRANSCRIPT
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F-Series Training 795F AC
Caterpillar Global MiningTinaja Hills Training Center
August 10-13, 2010
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2
Safety Share
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Safety
795F AC Walkaround
Hardhat
Safety Boots
Safety Glasses
Keep Hydrated
If you are not feeling well , please speak up
Cool air conditioned area
Medical attention
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795F AC Introduction
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Short Tons
Metric Tons
795F-AC785C / D
100 109 1188 127 154 172 209 218 2277 236 245 254 272
263 281 290 299 308 318 327136 163 191145 181 200 354336 345 372363 381
110 120 130 140 170 190 230 240 250 260 270 280 300
290 310 3200 330 340 350 360150 180 210160 200 220 390370
380 410400 420
T252
Unit Rig
MT300 MT3600 MT5500
T262 T282
789 793D / F
797B / F
HD 1500 -7 730E 930E-4830E - AC
930E-4SE
EH3000 EH3500-AC EH4500-2 EH5000
MT6300AMT4400ACMT3700ACMT3300A
TI274
960E860E
75137530
7560
SF32601SF31904
New market class segment for Caterpillar
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Overview of Coverage
795F AC - Built on Strength
Our Heritage
Safety
Serviceability
Performance
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795F AC Foundation: Built on Strength
Cat Mechanical Drive Tradition Four Corner Wet-Disk Brakes
Engine FD Structures - Bodies
Dealer Strength Parts - Service
Cat Product Development
Proven Components Proprietary electric drive system
AC Efficiency
Cat Vertical Integration 100% Caterpillar Design Control
Engine Powertrain Braking
Bumper to bumper Cat dealersupport
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New Product Introduction (NPI) Overview and Update
NPI programs executed using 6 Sigma DMEDI
Define Measure Explore Develop Implement
Process requirements & conformance indices
5 Phases
8 leadership Reviews (Gates)
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795F AC Reliability: Built on Strength
797F Commonality
Wet Multi-Disc Brakes
C-175 Engine Platform
Struts, Wheels & Tires
4 Bar Rear Linkage
Operator Cab
Main Frame Design
MSD Bodies
New Content
AC Powertrain
Inverter (MELCO Phase Modules)
Generator (EPG Experience)
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Common/Similar designs
Design 793F 795F AC 797F
Front Wheel - Common Common
Front brake pack - Common Common
Brake cooling pump - Common Common
Cab Common Common Common
Engine (C175-16) CommonCommon
(except for turbos)-
Frame Similar design Similar design -
Steering pump - Common Common
Pump drive Common Common Common
Pump drive shaft Common Common Common
Rear suspension
(Four bar link design)Similar Similar Similar
Rear struts - Common Common
Rear wheel casting - Common Common
Rear wheel bearings - Common Common
Rear brake pack - Common Common
Front
Rear
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C-175 Engine
Cat is a leader in ElectricPower Generation
695 C175 engines Built to datefor all applications
Over 500 C175-16 Built
260 for Mining Trucks
250 for Power Generation
C175-16 Engine
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Power Inverter Mitsubishi Electric Collaboration
MELCO #1 supplier of IGBT phase
modules in the world
Proven Leader in Inverter systems forheavy duty electric drive applications
Same Phase Module used in EMDlocomotives
Power inverter:Collaboration with Mitsubishi Electric
MELCO Phase Module
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795F AC Significant Accomplishments
Two TPG Development Units
AC Powertrain Development (Drive Train Simulator)Integration of Engine-PT-Braking/Retarding
Passed Internal/External Safety Audits
Product Support
OMM & Service Manual
Special Tooling
Parts in place
Field Follow Program
4 running 4 more this year
HAA Units Later This Year
Well Accepted
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795F AC Pilot build - Decatur
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Specification 795F AC
Engine C17516Power (HP) 3400
Target Payload 345 T* / 360T**
313 mt / 326 mt
TGMW 1,257,000 lb570,166 kg
Standard Top speed 40 mph
64 kph
Speed on grade
(12% effective)
7+ mph
11.3 kph
Retarding
(10% effective)
19.28 mph
31.03 kph
Tires 55/80R63
56/80R63
59/80R63 BFOR
Hi level specifications
*As per Cat std.**As per electric drive industry practice
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Specification 793F 795F AC 797F
Engine C17516 C17516 C17520Power (HP) 2650 3400 4000
Target Payload 250 T
227 mt
345 T
313 mt
400 T
362 MT
GMW 860,000 lb
390,100 kg
1,257,000 lb
570,166 kg
1,375,000 lbs
623,690 Kg
Standard Top speed 37 mph
60 kph
40 mph
64 kph
42 mph
68 kph
Speed on grade
(12% effective)
8 mph
13 kph
7 mph
11.3 kph
8 mph
13 kph
Retarding
(9% effective)
18 mph
29 kph
21.5 mph
34.6 kph
9.5 mph
15.3 mph
Tires 40.00R57
46/90R57
50/80R57
55/80R63
56/80R63
59/80R63 BFOR
59/80R63
795F AC Specifications
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Top Customer Needs Reliability
Unscheduled Downtime Durability Parts Availability Rebuild Costs Production Safety Beyond Regulations
Cat Gaps vs. Needs
Unscheduled Downtime Reliability Operator Visibility Remove & Install Times Ease of Maintenance
Cat Gaps vs. Competition
Initial Price Access / Egress Remove & Install Times Safety Beyond Regulations Ease of Maintenance
Cat Business Needs Profitable Business
F-Series - Critical Customer Requirements
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Safety
Serviceability
Performance
Reliability
Additional Features
Critical Customer Requirements
F Series Large Mining Truck Initiatives
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All new Cab Larger cab (10%)
Improved controlergonomics
Reduced operatorvibration
ROPS capacityincrease
Improved visibility
Safety in Operator Environment
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New Cab
Improved ErgonomicsLarger cab than 793 (10%)Adjustable steering column
New transmission control with
park position
Hoist lever moved to centerconsole
Increased Visibility
40% more window area
Center mounted gauge cluster
15% improvement in visibility
Cat 793D visibility
Cat 795F visibility
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Visibility - Operator
Enhanced Visibility
Attachments
WAVS (Camera)
CIODS (Camera +
Radar)
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Operator Controls
New Shift Cane
& Hoist Lever
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2 (600 mm) wide
walkway to cab
ImprovedSecondary Egress
Powered StairAttachment
Flat & Open Deck
Safety in Access Systems
600 mm WideAccess to Cab
Eliminated
Step Down toCatwalk
ImprovedSecondary Egress
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Access / Egress
Powered Access Stair(attachment)
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Ground Level
Maintenance Bottom-loading
filters
Fluid filter drains
Service platforms Propel & Starter
lockout
Fewer service
areas
Safety in Serviceability
Engine Service Platform
Generator Service Platform
795F AC Rear Platform
793F793FF Series
M d l P t i
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Modular Powertrain
Blower &Hydraulic
Motor
Generator
Cooling airduct
Driveshaft
C175-16 Engine
Radial GridControl/PowerConverter Cabinet
Wheel motors
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Braking; Retarding; and Control #1 Differentiator
Truck will Stop Every Time Under Control
For Operators this is a Home Run
Confidence in the Cab under all operating
conditions
Why? Four-Corner Blended-Retarding StrategyHighest Dynamic Retarding HP in the Industry
797F Four-Corner / Oil-Cooled / Multi-Disk Brakes
With Retarding Capability
Result: Maximized Traction and Control
Superior Handling on Slick Roads
Verified and Optimized Through Testing
Operator Selectable Turned on as Needed
C
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Braking; Retarding; and Control Development
10% Development Ramp at TPG
Super Slick Clay OverlayAdd Water
Software and Test Engineers
Tried Many Scenarios
Developed the best Braking,Retarding, and Control Strategy
B ki R di d C l P f
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Braking; Retarding; and Control Proof
795F AC Operators are our Best
Promoters the Truck has won themover.
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Blended Retarding Operation795F AC vs. 793 MD
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Retarding and Braking Control
1 Front Brake Assist -On/Off Switch
2 Retarder Lever
3 Retarding SpeedControl Toggle
4 - Automatic Retarder
Control (ARC) On/OffSwitch
R t d L O ti
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Retarder Lever Operation
Retarder Lever
Service Brakes(front wheels)
Electric Retarding
(rear wheels)
Service Brakes(rear wheels)
0% 100%
795F AC (Front Brake Switch OFF)
Service Brakes(front wheels)
Service Brakes(rear wheels)
793 MD
Note: actual front/rear split varies
based on payload weight
R t d L O ti
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Retarder Lever Operation
Retarder Lever
Service Brakes(front wheels)
Electric Retarding
(rear wheels)
Service Brakes(rear wheels)
0% 100%
795F AC (Front Brake Switch ON)
Service Brakes(front wheels)
Service Brakes(rear wheels)
793 MD
Note: actual front/rear split varies
based on payload weight
ARC Operation
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ARC Operation
ARC Demand
Service Brakes(front wheels)
Electric Retarding
(rear wheels)
Service Brakes(rear wheels)
0% 100%
795F AC (Front Brake Switch OFF)
Service Brakes(front wheels)
Service Brakes(rear wheels)
793 MD
Note: actual front/rear split varies
based on payload weight
ARC Operation
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ARC Operation
ARC Demand
Service Brakes(front wheels)
Electric Retarding
(rear wheels)
Service Brakes(rear wheels)
0% 100%
795F AC (Front Brake Switch ON)
Service Brakes(front wheels)
Service Brakes(rear wheels)
793 MD
Note: actual front/rear split varies
based on payload weight
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Traction Control System(TCS)Operation
795F AC vs. 793 MD
C i f S
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Comparison of Systems
793F
Operates in propel only
Uses the rear brakes to limitspeed differences between
rear wheels
No steering sensor allowedslip must accommodatesteering
No ground speed reference;only relative wheel speed iscontrolled
795F AC
Operates in propel and electricretard
Limits wheel slips and slidesby reducing electrical torque to
each motor independently
Use of steering sensorimproves sensitivity to wheelslips and slides
Uses front wheel speeds as aground speed reference toimprove overall traction
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Mechanical Drive Traction Control
Engine TC Trans Diff
Brake
BrakeSpeed sensors
time
Left wheelspeed
Right wheelspeed
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795F AC Traction Control
time
Left wheelspeed
Right wheelspeed
Engine Alt.
M
M
Power converter
Power converterRectifiers
Speed sensors
M
P f C t ill C175 E i
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New Engine Family
5.3 liters displacement per cylinder:
C-175 x 16 / 85L
High Pressure Fuel System
Cross Flow Design
ACERT Technology
Tier II EPA Emissions Compliant usingACERT Technology with ATAAC
Benefits
Power Increase
Lower Owning & Operating Costs
Improved Fuel Consumption
Improved Serviceability
Increased Service Life
3500BC175
Performance: Caterpillar C175 Engine
P f St d t KUCC
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Performance Study at KUCC
KUCC Concerned the 795F AC was Slower than 793D
Speed on Grade
Compare 793D and 795F AC
Productivity Measures
Tons per Cycle
Tons per Hour
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S97
KUCC S97- BC07 Waste Haul
Production Study Week of May 3, 2010
Truck Shop
Wheeler Trailer
Scale Truck
Speed Trap 1719 ft 9.78%
Speed Trap 3866 ft 8.32%
Speed Trap 2743 ft 8.22%
Speed Trap 42855 ft 8.3%
A l S d C l P fil
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KUC S97-BC07 Waste HaulWeek of May 3-7, 2010 - Cat 795F AC Productivity Study
5700
5800
5900
6000
6100
6200
6300
6400
6500
6600
6700
6800
0 2000 4000 6000 8000 10000 12000 14000
Elevation
Distance
S97
BC07
Approx.8.3%
Approx.10.0%
Approx.8.3%
Actual Study Cycle - Profile
S l T k d T S
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Scale Truck and Tray Scan
Speed on Grade Results
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Speed on Grade Results
Speed Trap Description Speed on Grade Comparison
Trap Distance(ft) Grade 793D (All) 795F AC (#300)
1 719.3 9.78% 8.2 7.6
2 743.0 8.22% 8.3 8.7
3 866.5 8.32% 8.5 8.7
4 2854.5 8.30% 8.7 9.2
793D excelled on Steeper Grade
Sweet spot for Mechanical Drive
795F AC excelled on Shallower Grade
795F AC operates at constant HP
This was a gear hole for 793D
Shallower Grade was most of this cycle.
Productivity Measure
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Productivity Measure
793D 795F AC
tons/cycle 254 342tons/hr 321 440
Performance: 795F AC Operator Comments
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Performance: 795F AC Operator Comments
Quiet
No ear protectionrequired
Smooth
Braking and
Retarding areGreat Effortless
Can sit back in
the seat whileretarding
Operator Comments
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Operator Comments
Im a Komatsu operator, but in slick
conditions the 795F is really stable, alot more stable than Komatsu.
D.Winnet after driving on 2 of snow on
Nov. 12, 2009
Beautiful, smooth, quiet I love this
machine, unbelievable, braking isgreat, simple to operate. Build themfaster, make me a personal one.
G. Turley
In a downpour at the Arch Black ThunderMine the 795F AC was the only truck that
was able to continue running due toconfidence of traction control and fourcorner blended retarding.
Cat Mine Specific Design (MSD) Bodies
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Cat Mine Specific Design (MSD) Bodies
Cat bodies: Designed to work with Cat trucks
Engineered to Fit the Caterpillar Chassis Truck Body Options: Application Specific (Lightweight, HD, Coal)
Mine Specific Design: liner system optimization
795F AC vs. Critical Customer Requirements
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Safety
Ground Level Access: Fluid Levelsand Filters
Platforms: for Working at Heights
Visibility: HID, WAVES, CIODS
Access/Egress: 600mm stairs, PAS
Blended Four Corner Retarding
Traction Control
795F AC vs. Critical Customer Requirements
Reliability
Rear mounted Generator
Continuous Rear Axle Filtration
Fewer external hoses
Component Diagnostics On-Board
Operator Advisor / Test Features
Frame casting and mild steel
Serviceability
Modular Power Train: Lower R&I
Ground Level; Platforms
Ground Level (Bumper) ServiceCenter, LOTO, Batteries
1000 hour filter life
Turbos: good access
Drain Plugs; SOS Ports
Performance
345 ton Payload
7.07.5 mph @12% effective grade Blended Four-Corner Retarding
Traction Control
GVW within Tire Specs
Quiet Cab (76dBa)
Mine Specific Design Bodies
795F AC Virtual Walk Around
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795F AC Virtual Walk Around
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Caterpillar AC Electric Drive
Electric Drive Fundamentals
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Electric Drive Fundamentals
AC Electric DriveMechanical Drive
Powertrain a group of components used to transmit
engine power to the driving wheels.
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Electric Drive - Recap
Cat Proprietary Electric Drive System
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Cat Proprietary Electric Drive System
Motors:Designed and built to Cats
specifications
CaterpillarintegrationCaterpillarintegration
Generator:
Capitalize on Cats leadership inelectric power generation
Controls and Hardware:Cat designed and developed
Controls and Hardware:Cat designed and developed
Power inverter:
Collaboration with Mitsubishi Electric
Drive System Comparison
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Drive System Comparison
Mechanical Drive Train AC Electric Drive Train
Caterpillar AC drive truck chassis
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Blower &Hydraulic
Motor
Generator
Cooling airduct
Driveshaft
C175-16 Engine
Radial GridControl/PowerConverter Cabinet
Wheel motors
AC System Basics Engine & Generator
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y g
Engine / Generator Engine powers the generator
Generated AC voltage is converted thenused to power wheel motors
Excitation regulator and Inverter draw
power out of the generator
Engine speed becomes independent ofpower generated
Available power still based on rpm
2-3 Megawatts can be generated
30-40 Trucks = Small Town
Electric drive relies on a diesel engine to turn a generator providing
electric power for traction motors turning the rear wheels
AC System Basics DC Recitifer
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AC System Basics DC Recitifer
In the Inverter cabinet, arectifier converts AC voltagefrom the generator into DCvoltage
The DC voltage is furthersmoothed via large capacitorswhich form the DC bus.
3-phase AC voltage from the generator is routed to the Inverter cabinet
where it is converted to DC for use by the Inverters
Converted DC
from rectifier
3-phase AC from alternator
AC System Basics AC Inverter
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The DC Bus is connected toboth Inverters
Voltage from the DC Bus is
used by the inverters tooutput AC voltage variable inamplitude and frequency forcontrolling wheel motorspeed
3-phase AC from the generator is routed to the Inverter cabinet
where it is converted to DC, then back to AC for use by the wheelmotors
Variable AC
from Inverter
Converted DC from rectifier
AC System Basics Wheel Motors
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Inner workings:
Stator: Frame & Windings
Rotor: Rotating component
On AC trucks, the voltage and
frequency determine the speed andtorque of the wheel motors
The AC voltage from the inverter is sent to the wheel motor where its
amplitude and frequency results in torque and speed on the motors driveshaft.
The amount of torque and speed is based on operator inputs
AC System Basics Retarding Grids
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Retard Mode
The voltage and frequency sent to thewheel motors result in them behaving likegenerators
Generated voltage from the wheel motorsgoes back into the inverter cabinet on ontothe DC Bus
The excess voltage is then routed toretarding grid
Voltage is absorbed by the resistor grids
then dissipated as heat Similar to a big toaster
A large cooling fan is needed to force theheat out
Electric trucks use their wheel motors for dynamic retarding, using
electric current to slow the rear wheels
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AC Drive Train Development
2005
797 MuleTruck
797 modified w/ Electric
Drive
3524 Engine
Primary Use Software
Propulsion
Retarding
Traction Control
Anti-Rollback
Troubleshooting
Purpose To test
ECM and software
linked to computer
generated component
models
Production intent
Software/Controls
Machine and System
Level set ups
(HIL)Hardware in
Loop
Caterpillar Technical Center
C175 Engine NPI intent Generator
and Motors
CAT Proprietary
electric drive controls
Component Validation
Software testing andvalidation
Continues to be
utilized into production
DrivetrainSimulator
Prototype/Pilot
Trucks
Tucson Proving
Grounds -
Engineering
Product Support &
Marketing
Field Development
Pilot truck in
operation at
Kennecott Utah
Copper.
08-09
AC Drivetrain Simulator
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Drivetrain Simulator Plan
C-175 Engine NPI representative drivetrain components
(Alternator, motors, inverter)
CAT Proprietary Electric drive controls
RubberCouplings
Dyno
C175-16 Engine
Inertia
Weights
Motor
Blower
Fan Inverter
Cooling Air
Hot Air Return
Drivetrain Simulator Build
[picture from early Jan 07]
Drivetrain Simulator for componentsand controls validation
Alternator
Caterpillar AC Integrated Drive Train
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Caterpillar
Caterpillar & Mitsubishi
Grids
VoltageRegulator
TruckControls
MachineControl
Software
MP EngineControl
Engine
Grids
Speed SensorTemperature
MP Inverter
Control
Inverter
MP Inverter
Control
Alternator Rectifier
Inverter
AC Motor
Planetary
Planetary
AC Motor
Speed SensorTemperature
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795F AC Performance Differentiation
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Competitive Propel Performance
C175
100% Cat AC Powertrain Features: Anti-rollback; Excellent Inching Control and Response
Braking; Retarding and Control
Stops Every Time
Operator Confidence
Best Retarding Payload
True 345-350 tons (313-318 tonnes)
Product Support
Serviceability
Modular Powertrain Cat Vertical Integration
Competitive comparison
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CAT Hitachi
795F AC 930E-4 930E-4SE 960E EH5000
Access / Egress PAS, Rear Access, CSGA, 600mm
Working at Heights Engine Bay, Tie Off points, Center torque tube etc.
Operator Sound 76 dba vs. 81dba
Operator Visibility WAVS, HID lighting
Hydraulic Filter Life 1000 hours vs. 500 hours
Major Component R&I Generator, WM, and FD component R&I...industry best
Ground Level Maintenance Filters, SOS ports, sight glasses, pressure ports
AST (HVOF) Hoist cylinders and struts
Ecology drains Filters, pans, etc.
System integration Supportability with bumper to bumper
Complexity System complexity - Hydraulics
VIMS Advisor A single source for diagnostics, all critical functions
Payload 345sT, w/ liners, 100% fuel/lubes, 4% debris, field options
Propulsion SOG (12%) 7.0-7.5 mph (11.3-12.1 kph)
Retarding SOG (-10%) 6,400hp in retarding; 19.28 mph (31.03 kph)
Braking Four corner oil cooled brakes
Retarding Blended retarding (Front brakes & Rear dynamics)AC Drive System Evaluate features during field program
Final Drives Onboard filtration, added complexity w/ coolersto evaluate
Stall Torque Gradeability 23% Std, 26.5% Opt
Tires Slight underload of rated capacity with 56/80R63
Body Mine specific design body
ITEM 795F AC Notes:
Komatsu
CCRs
SAFETY
SERVICEABILITY
PERFORMANCE
Program objective Pure differentiation!
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795F AC Product Support & Pilot StatusTarget Site and Pilot Truck Update
Name: John BaulerGlobal Mining DivisionName: John Bauler/Erik TautkusGlobal Mining Division
AC Drive Field Follow Target Sites 2010
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Teck Resources Ltd. Fording River
Overburden; Flat to Downhill
2 units ERM158/159
Barrick Cortez Hills
Gold; Uphill/Downhill; Seasonal Hot
2 Units ERM155/156 (One Running)
Arch Black Thunder
Coal; Flat/High Speed
1 unit ERM157 (Running)
Rio Tinto / KUCC Bingham Canyon
Copper/Overburden; Flat/Med Speed
2 units (ERM153/154 on site running)
Four Trucks Running: 2 Bingham Canyon; 1Arch Black Thunder; 1 Barrick Cortez Hills
4 Additional Trucks in NA
Newmont Phoenix
Gold; Uphill/ Seasonal Hot
1 unit ERM160
AC Drive Field Follow Target Sites Overseas 2010
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Codelco Andina
High Altitude 4,000 m (13,125 ft)
Temp = -15 to 30 C
Copper; Flat to Uphill
Boliden-Aitik units are sold
LACD-Chile Finning-owned
High Altitude Application
Anglo American Los Bronces High Altitude 3,600-4,000 m (11,800-13,125 ft)
Temp = -15 to 30 C
Copper; Downhill
Truck SN Customer SOL Date RTS Date
1. ERM161 Boliden 8/04/2010 9/07/2010
2. ERM162 Boliden 8/18/2010 9/21/2010
3. ERM163 ? 10/05/2010 11/08/2010
4. ERM164 ? 10/19/2010 11/16/20105. ERM165 ? 11/02/2010 12/08/2010
ERM153/154 CMS Stats
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Stats for Dec 5 August 6 (5,218 hours)
Total payload hauled = 1,799,377 t
(1,983,474 tons) Average payload = 314.7 t (346.9 tons)
Cycles = 5,717
Cycles / hr = 1.3
t / hr = 411.7 (453.8 tons/hr)
Stats for May 29 August 6 (1,485 hours) Total payload hauled = 626,725 t (690,846
tons)
Average payload = 316.7 t (349.1 tons)
Cycles = 1,979
Cycles / hr = 1.43 t / hr = 444.0 (498.4 tons/hr)
ERM156 CMS Stats
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Stats for August 2 August 6(225 hours)
Total payload hauled = 56,417 t(62,189 tons)
Average payload = 331.8 t(365.8 tons)
Cycles = 170
Cycles / hr = 1.93
t / hr = 641.1 (706.7 tons/hr)
ERM157 CMS Stats
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Stats for July 1 August 6 (788 hours)
Total payload hauled = 308,808 t
(340,402 tons) Average payload = 316.4 t (348.8 tons)
Cycles = 542
Cycles / hr = 1.5
t / hr = 462.6 (509.9 tons/hr)
795F Hour Accumulation
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Program Goal is 500 Hours/Month
Current Fleet Avg = 561 Hours/Month
ERM153Released 12/5/10 w/ 758 SMUs Current SMU = 5128
544 Hours/Month current avg
ERM154 Released 5-29-10 w/ 35 SMUs Current SMU = 1421
616 Hours/Month current avg
ERM156 Released 8-2-10 w/ 40 SMUs Current SMU = 128
677 Hours/Month current avg
ERM157 Released 7-1-10 w/ 28 SMUs Current SMU = 696
561 Hours/Month current avg
795F Availability
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795F Running MTBS
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ERM154Released
ERM157Released
60 = WorldClass
Performance
ERM156Released
795F Availability Drivers
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Current Physical Availability is 76.7% / Mechanical Availability is 84.0%
1. Mine weather, shift change, accident damage, tires, etc., No operator
2. Lower PT Axle Thrusting (January 2010 44DH) (March 2010 23 DH) , Rear Brake Anchor Bolts ( March 2010 -
91 DH), 4 Link Bearing (July 2010 - 182 DH)3. Engine HPFP (February 2010 52 DH) , exhaust manifold (January 2010 50 DH), Software/Electrical (33 DH) ,
PTO idler shaft (June 2010 94 DH), Head Leak (August 2010 31 DH)
4. PM includes all backlog work order work, software, inspections, etc.
Mine
6.7 (30%)
Engine
4.5 (20%)
PM
4.3 (19%)
LPT
4.-0 (18%)
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795F AC Product Support & Pilot StatusField Support for Field Follow Program
Name: John BaulerGlobal Mining DivisionName: John Bauler/Erik TautkusGlobal Mining Division
Field Follow Site Personnel Concept 2010
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795F AC ProductSupport
ZackPalmquist
RichardOrtecho
Finning WyomingCashman
GregHulva
LeeTolzdorf
Wheeler
Cat Man Onsite
#1 rated activity that could ensurea successful field follow program!
Dealer Commitment / Involvement
Dedicated management levelperson
Dedicated, qualified, servicetechnician for each shift
Lead man
Mechanic
John BaulerSupervisor
Erik Tautkus
NPI List Manager
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795F AC Product Support & Pilot StatusParts Stocking
Name: John Bauler/Erik TautkusGlobal Mining Division
Parts Stocking
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Pilot long lead major components first requested 4th Qtr 2007
Pilot parts stocking turned in Dec 2008
All AC drive major components in Morton
All other major components in Morton Engine in Schilli
Major components / long lead items submitted Jan 15, 2010
Included Boliden & Chile
Revised parts stocking list completed Jan 28, 2010
Included Boliden & Chile
Current Activity
Electric components updates
Critical engine component strategy
Weekly status report on major components
Parts Stocking Status
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82% of the major components and critical parts in stock (51 pns)
Of these not in stock (9 pns), 67% can be service from factory (6 pns)
Weekly reports on stocking levels and deliverables
1 HA Engine Ar is due December 2010
91.6% of all parts are in stock with a 1 day supply
90.8% of all parts are in stock with a 30 day supply
By September 5, 2010 NACD will have 97% of all parts in stock
Grimbergen will have 100% of all parts in stock
Melbourne will have 99% of all parts in stock
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795F AC Product Support & Pilot StatusService Training
Name: John Bauler/Erik TautkusGlobal Mining Division
795F AC Service Training Prerequisites
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Web Based Training (WBT)
Teaches basic electric concepts
Consists of seven courses available on DLMS
795F AC Service Training Prerequisites
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Instructor Led Training (ILT) Electrical / Electronics (Course 26679)
Sign up through DLMS 5 day course
Electrical & electronics troubleshooting and repair techniques
Hands on to demonstrate inspection, service and required tools
Alternative: Dealer instructor is trained and has necessary training aids,then he can teach the course at dealership
Recommended C175 Engine Training (Course 32302)
5 day course
795F AC Service Training
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ITTP complete
Used on ERM153
Revised for ERM154
Performing on site at:
KUCC-Bingham Canyon
Barrick-Cortez Hills
Arch-Black Thunder
Teck-Fording River
Newmont-Phoenix
Boliden-Aitik
Chile
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795F AC Product Support & Pilot StatusService Literature
Name: John Bauler/Erik TautkusGlobal Mining Division
Service Literature
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90% available on SISweb
10% in process or near completion
OMM Completed
Assembly SI final revision
Commissioning final revision
Power Train Electrical SO/TA/TS Completed
VIMS & Payload SO/TA/TS Completed Schematics: Hydraulic and 24V Electrical Complete
Frame Inspection SI
Full build of ERM152 in Decatur
Allowed for initial documentation
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795F AC Product Support & Pilot StatusTooling
Name: John Bauler/Erik TautkusGlobal Mining Division
R&I, Maintenance & Diagnostic Tooling
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All prototype tooling built and validated
All service tooling as requested to properly support the pilot truck
Pon Tooling Status
Participated in Dealer Advisory
Committee
Received tooling list Indicated tooling required
Order tooling after July 2010
Tooling Allocated to NA FD
Engine RemovalLoad Leveler Only
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Removing the engine using the 309-2793 LoadLeveler Group.
Required for the lift is one of the lifting eyes from
the 323-1146 Lifting Eye Group and one 336-7250 Lifting Eye Assembly (adjustable)
309-2793 Engine Stand used to hold, store andtransport used engine
Wheel Station Removal
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Remove axle through small coverby using 315-2607 adapter and
315-2605 handle (outer sun gearcan be removed and reinstalled)
Remove the wheel station
by using the 173-6624Wheel Carrier Bracket
202-2053 Wheel StationShipping Stand used tohold, store and transport
used wheel station
Traction Motor Removal
A i f h ill d i id h
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A view of the motor still mounted inside the rearaxle housing. The axle coupling is shown.
Connect 295-6471 lifting fixture (motor removaltool) and pull motor from axle housing
Pictures of the motor mounted to the toolingafter removal
Generator Removal
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A 6V-3145 load leveler (6,000 lb.)was used on the front of the
generator to protect the highvoltage box.
A 6V-6146 load leveler (10,000lb.) was used to span thegenerator fore- aft.
A 2-leg chain was used betweenthe load leveler and the rear of thegenerator.
Generator & Motor Stand
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329-5130 Stand Includes:
Enclosure to protect component
Brackets to support either generator ormotor
Desiccant to ensure a clean, dryenvironment
Access to perform required maintenanceduring storage (rotate every 6 months)
Front