F-Series Training 795F AC Participants Copy 810

8/3/2019 F-Series Training 795F AC Participants Copy 810

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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


4/96

795F AC Introduction


5/96

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


6/96

Overview of Coverage

795F AC - Built on Strength

Our Heritage

Safety

Serviceability

Performance


7/96

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


8/96

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)


9/96

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)


10/96

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


11/96

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


12/96

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


13/96

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


14/96

795F AC Pilot build - Decatur


15/96

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


19/96

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)


22/96

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


28/96

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


29/96

Braking; Retarding; and Control Proof

795F AC Operators are our Best

Promoters the Truck has won themover.


30/96

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)



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


Electric Retarding

(rear wheels)


0% 100%

795F AC (Front Brake Switch ON)



793 MD



ARC Operation


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ARC Operation

ARC Demand


Electric Retarding

(rear wheels)


0% 100%

795F AC (Front Brake Switch OFF)



793 MD



ARC Operation


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ARC Operation

ARC Demand


Electric Retarding

(rear wheels)


0% 100%

795F AC (Front Brake Switch ON)



793 MD




36/96

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


41/96

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%




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


49/96

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


50/96

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


51/96

795F AC Virtual Walk Around


52/96

Caterpillar AC Electric Drive

Electric Drive Fundamentals


53/96

Electric Drive Fundamentals

AC Electric DriveMechanical Drive

Powertrain a group of components used to transmit

engine power to the driving wheels.


54/96

Electric Drive - Recap

Cat Proprietary Electric Drive System


55/96

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


56/96

Drive System Comparison

Mechanical Drive Train AC Electric Drive Train

Caterpillar AC drive truck chassis


57/96

Blower &Hydraulic

Motor

Generator

Cooling airduct

Driveshaft

C175-16 Engine

Radial GridControl/PowerConverter Cabinet

Wheel motors

AC System Basics Engine & Generator


58/96

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


60/96

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


61/96

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


62/96

y g

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


63/96

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


64/96

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


65/96

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


66/96

795F AC Performance Differentiation


67/96

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


68/96

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!


69/96

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


70/96

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
http://www.peabodyenergy.com/default.asp


71/96

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
http://www.codelco.com/english/index1.asp


72/96

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


73/96

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


74/96

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


75/96

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






795F Availability


76/96

795F Running MTBS


77/96

ERM154Released

ERM157Released

60 = WorldClass

Performance

ERM156Released

795F Availability Drivers


78/96

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%)


79/96

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


80/96

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


81/96

795F AC Product Support & Pilot StatusParts Stocking

Name: John Bauler/Erik TautkusGlobal Mining Division

Parts Stocking


82/96

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


83/96

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


84/96

795F AC Product Support & Pilot StatusService Training


795F AC Service Training Prerequisites


85/96

Web Based Training (WBT)

Teaches basic electric concepts

Consists of seven courses available on DLMS

795F AC Service Training Prerequisites


86/96

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


87/96

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


88/96

795F AC Product Support & Pilot StatusService Literature


Service Literature


89/96

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


90/96

795F AC Product Support & Pilot StatusTooling


R&I, Maintenance & Diagnostic Tooling


91/96

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


92/96

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


93/96

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


94/96

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


95/96

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


96/96

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

Documents

F-Series Training 795F AC Participants Copy 810