F-Series Training – 795F AC

Caterpillar Global Mining –

Tinaja Hills Training Center
August 10-13, 2010
 Safety Share

2
 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
795F AC Introduction
 New market class segment for Caterpillar…

785C / D 789 793D / F 795F-AC 797B / F

EH3000 EH3500-AC EH4500-2 EH5000

HD 1500 -7 730E 830E - AC 860E 930E-4 960E

930E-4SE

MT300 MT3300A MT3600 MT3700AC MT4400AC MT5500 MT6300A

Unit Rig

T252 T262 TI274 T282

7513 7530 7560

SF31904 SF32601

Short Tons 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 3200 330 340 350 360 370 380 390 400 410 420
Metric Tons 100 109 1188 127 136 145 154 163 172 181 191 200 209 218 2277 236 245 254 263 272 281 290 299 308 318 327 336 345 354 363 372 381
3
 Overview of Coverage

• 795F AC - “Built on Strength”

– Our Heritage
• Safety
• Serviceability
• Performance
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 dealer
support
 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)
 795F AC Reliability: “Built on Strength”

797F Commonality “New” Content

• Wet Multi-Disc Brakes • AC Powertrain

• C-175 Engine Platform • Inverter (MELCO Phase Modules)

• Struts, Wheels & Tires • Generator (EPG Experience)

• 4 Bar Rear Linkage

• Operator Cab
• Main Frame Design
• MSD Bodies
 Common/Similar designs

Design 793F 795F AC 797F

Front Wheel - Common Common
Front Front brake pack - Common Common
Brake cooling pump - Common Common
Cab Common Common Common
Common
Engine (C175-16) Common -
(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
Similar Similar Similar
(Four bar link design)
Rear struts - Common Common
Rear wheel casting - Common Common
Rear wheel bearings - Common Common
Rear
Rear brake pack - Common Common
 C-175 Engine

• Cat is a leader in Electric

Power Generation

• 695 C175 engines Built to date

for all applications
– Over 500 C175-16 Built
– 260 for Mining Trucks
– 250 for Power Generation

C175-16 Engine
 Power Inverter – Mitsubishi Electric Collaboration

• MELCO #1 supplier of IGBT phase

modules in the world

• Proven Leader in Inverter systems for

heavy duty electric drive applications

• Same Phase Module used in EMD

locomotives

Power inverter:
Collaboration with Mitsubishi Electric

MELCO Phase Module

 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
795F AC Pilot build - Decatur
 Hi level specifications

Specification 795F AC
Engine C175 –16
Power (HP) 3400

Target Payload 345 T* / 360

T**
313 mt / 326 mt
TGMW 1,257,000 lb
570,166 kg
Standard Top speed 40 mph
64 kph
Speed on grade 7+ mph
(12% effective) 11.3 kph
Retarding 19.28 mph
(10% effective) 31.03 kph
Tires 55/80R63
56/80R63
59/80R63 BFOR
*As per Cat std.
**As per electric drive industry practice
 795F AC Specifications

Specification 793F 795F AC 797F

Engine C175 –16 C175 –16 C175 –20
Power (HP) 2650 3400 4000
Target Payload 250 T 345 T 400 T
227 mt 313 mt 362 MT
GMW 860,000 lb 1,257,000 lb 1,375,000 lbs
390,100 kg 570,166 kg 623,690 Kg
Standard Top speed 37 mph 40 mph 42 mph
60 kph 64 kph 68 kph
Speed on grade 8 mph 7 mph 8 mph
(12% effective) 13 kph 11.3 kph 13 kph
Retarding 18 mph 21.5 mph 9.5 mph
(9% effective) 29 kph 34.6 kph 15.3 mph
Tires 40.00R57 55/80R63 59/80R63
46/90R57 56/80R63
50/80R57 59/80R63 BFOR
 F-Series - Critical Customer Requirements
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 Large Mining Truck Initiatives

Critical Customer Requirements

• Safety
• Serviceability
• Performance
• Reliability
• Additional Features
 Safety in Operator Environment

• All new Cab

– Larger cab (10%)
– Improved control
ergonomics
– Reduced operator
vibration
– ROPS capacity
increase
– Improved visibility
 New Cab

Cat 795F visibility

• Improved Ergonomics
– Larger cab than 793 (10%)
– Adjustable steering column
– New transmission control with
“park” position
– Hoist lever moved to center console

Cat 793D visibility

• Increased Visibility
– 40% more window area
– Center mounted gauge cluster
– 15% improvement in visibility
 Visibility - Operator

•Enhanced Visibility
Attachments

•WAVS (Camera)

•CIODS (Camera +
Radar)
 Operator Controls

• New Shift Cane

& Hoist Lever
 Safety in Access Systems

• 2’ (600 mm) wide

walkway to cab
Improved
• Improved Secondary Egress

Secondary Egress
• Powered Stair
Attachment
• Flat & Open Deck 600 mm Wide
Access to Cab
Eliminated
Step Down to
Catwalk
 Access / Egress

• Powered Access Stair

(attachment)
 Safety in Serviceability
F793F
Series
• Ground Level
Maintenance
– Bottom-loading
filters
– Fluid filter drains Generator Service Platform

• Service platforms
• Propel & Starter
lockout
• Fewer service
areas Engine Service Platform

795F AC Rear Platform

 Modular Powertrain

C175-16 Engine

Control/Power Radial Grid

Converter Cabinet

Cooling air
duct
Blower &
Hydraulic
Motor
Driveshaft

Generator

Wheel motors
 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 Strategy

•Highest 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
 Braking; Retarding; and Control – Development

10% Development Ramp at TPG

Super Slick Clay Overlay
Add Water

Software and Test Engineers

Tried Many Scenarios
Developed the best Braking,
Retarding, and Control Strategy
 Braking; Retarding; and Control – Proof

795F AC Operators are our Best

Promoters – the Truck has won them
over.
Blended Retarding Operation
795F AC vs. 793 MD
 Retarding and Braking Control

•1 – Front Brake Assist -

On/Off Switch

•2 – Retarder Lever

•3 – Retarding Speed
Control Toggle

•4 - Automatic Retarder
Control (ARC) – On/Off
Switch
 Retarder Lever Operation

0% 100%

Retarder Lever

795F AC (Front Brake Switch OFF)

Electric Retarding
(rear wheels)
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
Note: actual front/rear split varies
793 MD based on payload weight

Service Brakes
(front wheels)
Service Brakes
(rear wheels)
 Retarder Lever Operation

0% 100%

Retarder Lever

795F AC (Front Brake Switch ON)

Electric Retarding
(rear wheels)
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
Note: actual front/rear split varies
793 MD based on payload weight

Service Brakes
(front wheels)
Service Brakes
(rear wheels)
 ARC Operation

0% 100%

ARC Demand

795F AC (Front Brake Switch OFF)

Electric Retarding
(rear wheels)
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
Note: actual front/rear split varies
793 MD based on payload weight

Service Brakes
(front wheels)
Service Brakes
(rear wheels)
 ARC Operation

0% 100%

ARC Demand

795F AC (Front Brake Switch ON)

Electric Retarding
(rear wheels)
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
Note: actual front/rear split varies
793 MD based on payload weight

Service Brakes
(front wheels)
Service Brakes
(rear wheels)
 Traction Control System
(TCS)
Operation

795F AC vs. 793 MD


793F
• Operates in propel only
• Uses the rear brakes to limit
speed differences between
rear wheels
• No steering sensor – allowed
slip must accommodate
steering
• No ground speed reference;
only relative wheel speed is
controlled
Comparison of Systems
795F AC
• Operates in propel and electric
retard
• Limits wheel slips and slides
by reducing electrical torque to
each motor independently
• Use of steering sensor
improves sensitivity to wheel
slips and slides
• Uses front wheel speeds as a
ground speed reference to
improve overall traction
 Mechanical Drive Traction Control

Brake

Engine TC Trans Diff

Brake
Speed sensors

Right wheel
speed

Left wheel
speed

time
 795F AC Traction Control

Rectifiers
Power converter
Engine Alt. Speed sensors

Power converter
M

Right wheel
speed

Left wheel
speed

time
 Performance: Caterpillar C175 Engine
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 using
ACERT Technology with ATAAC
Benefits
• Power Increase
• Lower Owning & Operating Costs
• Improved Fuel Consumption
• Improved Serviceability
• Increased Service Life

C175 3500B
 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
 Scale Truck

KUCC S97- BC07 Waste Haul

Production Study Week of May 3, 2010

Speed Trap 4
2855 ft 8.3%
Speed Trap 3
866 ft 8.32%

Wheeler Trailer

Truck Shop

Speed Trap 2
743 ft 8.22%

Speed Trap 1
719 ft 9.78%

S97
 Actual Study Cycle - Profile

KUC S97-BC07 Waste Haul

Week of May 3-7, 2010 - Cat 795F AC Productivity Study

6800
BC07
6700

6600

6500

6400
Approx.8.3%
Distance

6300

6200

6100 Approx.8.3%
6000

5900
Approx.10.0%
5800

5700 S97
0 2000 4000 6000 8000 10000 12000 14000
Elevation
Scale Truck and Tray Scan
 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

793D 795F AC
tons/cycle 254 342
tons/hr 321 440
 Performance: 795F AC Operator Comments

• Quiet
– No ear protection
required
• Smooth
• Braking and
Retarding are
Great
– Effortless
– Can sit back in
the seat while
retarding
 Operator Comments

•“I’m a Komatsu operator, but in slick

conditions the 795F is really stable, a
lot 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 is
great, simple to operate. Build them
faster, make me a personal one.”
G. Turley
•In a downpour at the Arch Black Thunder
Mine the 795F AC was the only truck that
was able to continue running due to
confidence of traction control and four
corner blended retarding.
 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
Safety
• Ground Level Access: Fluid Levels
and Filters
• Platforms: for Working at Heights
• Visibility: HID, WAVES, CIODS
• Access/Egress: 600mm stairs, PAS
• Blended Four Corner Retarding
• Traction Control
Serviceability
• Modular Power Train: Lower R&I
• Ground Level; Platforms
• Ground Level (Bumper) Service
Center, LOTO, Batteries
• 1000 hour filter life
• Turbos: good access
• Drain Plugs; SOS Ports
Performance
• 345 ton Payload
• 7.0–7.5 mph @12% effective grade
• Blended Four-Corner Retarding
• Traction Control
• GVW within Tire Specs
• Quiet Cab (76dBa)
• Mine Specific Design Bodies
Reliability
• Rear mounted Generator
• Continuous Rear Axle Filtration
• Fewer external hoses
• Component Diagnostics On-Board
• Operator Advisor / Test Features
• Frame – casting and mild steel
795F AC Virtual Walk Around
Caterpillar AC Electric Drive
 Electric Drive Fundamentals

Powertrain… a group of components used to transmit

engine power to the driving wheels.

Mechanical Drive AC Electric Drive

Electric Drive - Recap
 Cat Proprietary Electric Drive System

Generator: Power inverter:

Capitalize on Cat’s leadership in Collaboration with Mitsubishi Electric
electric power generation
Caterpillar
integration

Controls and Hardware: Motors:

Cat designed and developed Designed and built to Cat’s
specifications
 Drive System Comparison

Mechanical Drive Train AC Electric Drive Train

 Caterpillar AC drive truck chassis

C175-16 Engine

Control/Power Radial Grid

Converter Cabinet

Cooling air
duct
Blower &
Hydraulic
Motor
Driveshaft

Generator

Wheel motors
 AC System Basics – Engine & Generator

Electric drive relies on a diesel engine to turn a generator providing electric

power for traction motors turning the rear wheels

• Engine / Generator
– Engine powers the generator
– Generated AC voltage is converted then
used to power wheel motors
– Excitation regulator and Inverter draw
power out of the generator
– Engine speed becomes independent of
power generated
• Available power still based on rpm
– 2-3 Megawatts can be generated
• 30-40 Trucks = Small Town
 AC System Basics – DC Recitifer

3-phase AC voltage from the generator is routed to the Inverter cabinet where
it is converted to DC for use by the Inverters

• In the Inverter cabinet, a

rectifier converts AC voltage
from the generator into DC
voltage
• The DC voltage is further
smoothed via large capacitors
which form the DC bus. 3-phase AC from alternator

Converted DC
from rectifier
 AC System Basics – AC Inverter

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 wheel motors

• The DC Bus is connected to

both Inverters
• Voltage from the DC Bus is
used by the inverters to
output AC voltage variable in
amplitude and frequency for
controlling wheel motor Converted DC from rectifier
speed

Variable AC
from Inverter
 AC System Basics – Wheel Motors

The AC voltage from the inverter is sent to the wheel motor where it’s amplitude and
frequency results in torque and speed on the motor’s driveshaft. The amount of
torque and speed is based on operator inputs
• Inner workings:
– Stator: Frame & Windings
– Rotor: Rotating component
• On AC trucks, the voltage and
frequency determine the speed and
torque of the wheel motors
 AC System Basics – Retarding Grids

Electric trucks use their wheel motors for dynamic retarding, using
electric current to slow the rear wheels

• Retard Mode
– The voltage and frequency sent to the
wheel motors result in them behaving like
generators
– Generated voltage from the wheel motors
goes back into the inverter cabinet on onto
the DC Bus
– The excess voltage is then routed to
retarding 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 the
heat out
 ’08-’09
AC Drive Train Development Drivetrain
Simulator
(HIL)
Hardware in
797 Mule Loop Prototype/Pilot
Truck Trucks
Caterpillar Technical Center
• Tucson Proving
• C175 Engine
Grounds -
• NPI intent Generator
Engineering
and Motors
2005 • Product Support &
• CAT Proprietary
Marketing
electric drive controls
• Purpose – To test • Field Development
• 797 modified w/ Electric ECM and software • Pilot truck in
• Component Validation
Drive linked to computer operation at
• Software testing and
• 3524 Engine generated component Kennecott Utah
validation
• Primary Use – Software “models” Copper.
• Continues to be utilized
• Propulsion • Production intent
into production
• Retarding Software/Controls
• Traction Control • Machine and System
• Anti-Rollback Level set ups
• Troubleshooting
 AC Drivetrain Simulator

Rubber
Couplings
Motor
Inertia
Dyno Weights Alternator

C175-16 Engine

Cooling Air Drivetrain Simulator Build

Blower
Hot Air Return
Fan Inverter
[picture from early Jan 07]

Drivetrain Simulator Plan

• C-175 Engine
• NPI representative drivetrain components Drivetrain Simulator for components
(Alternator, motors, inverter)
and controls validation
• CAT Proprietary Electric drive controls
 Caterpillar AC Integrated Drive Train

Caterpillar Grids Planetary

Caterpillar & Mitsubishi Inverter
AC Motor

MP – Inverter Speed Sensor

Control Temperature
Engine Alternator Rectifier

MP – Engine Voltage Speed Sensor

Control Regulator Temperature
Inverter
Grids AC Motor
Truck MP – Inverter
Controls Planetary
Control

Machine
Control
Software
 795F AC Performance Differentiation

• 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
CAT Komatsu Hitachi
CCRs ITEM 795F AC 930E-4 930E-4SE 960E EH5000 795F AC Notes:
Access / Egress PAS, Rear Access, CSGA, 600mm
SAFETY

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
SERVICEABILITY

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)
PERFORMANCE

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/ coolers…to evaluate
Stall Torque Gradeability 23% Std, 26.5% Opt
Tires Slight underload of rated capacity with 56/80R63
Body Mine specific design body

Program objective – Pure differentiation!

795F AC Product Support & Pilot Status
Target Site and Pilot Truck Update

Name: John Bauler/Erik

Bauler Tautkus
Global Mining Division
 AC Drive Field Follow Target Sites – 2010

Four Trucks Running: 2 Bingham Canyon; 1 Arch

Black Thunder; 1 Barrick Cortez Hills
4 Additional Trucks in NA

Teck Resources Ltd. – Fording River

• Overburden; Flat to Downhill
• 2 units – ERM158/159

Arch – Black Thunder

• Coal; Flat/High Speed
• 1 unit – ERM157 (Running)
             
Newmont – Phoenix    
• Gold; Uphill/ Seasonal Hot
• 1 unit – ERM160

Rio Tinto / KUCC – Bingham Canyon

• Copper/Overburden; Flat/Med Speed
Barrick – Cortez Hills
• 2 units (ERM153/154 on site running)
• Gold; Uphill/Downhill; Seasonal Hot
• 2 Units – ERM155/156 (One Running)
 AC Drive Field Follow Target Sites – Overseas 2010
Truck SN Customer SOL Date RTS Date
• Boliden-Aitik – units are sold 1. ERM161 Boliden 8/04/2010 9/07/2010
2. ERM162 Boliden 8/18/2010 9/21/2010
• LACD-Chile – Finning-owned 3. ERM163 ? 10/05/2010 11/08/2010
– High Altitude Application 4. ERM164 ? 10/19/2010 11/16/2010
5. ERM165 ? 11/02/2010 12/08/2010

Anglo American – Los Bronces

• High Altitude – 3,600-4,000 m (11,800-13,125 ft)
• Temp = -15 to 30 C
• Copper; Downhill

Codelco – Andina
• High Altitude – 4,000 m (13,125 ft)
• Temp = -15 to 30 C
• Copper; Flat to Uphill
 ERM153/154 CMS Stats

• 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

• 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

• 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

• Program Goal is 500 Hours/Month

• Current Fleet Avg = 561 Hours/Month

• ERM153 – Released 12/5/10 w/ 758 SMU’s

– Current SMU = 5128
– 544 Hours/Month current avg

• ERM154 – Released 5-29-10 w/ 35 SMU’s

– Current SMU = 1421
– 616 Hours/Month current avg

• ERM156 – Released 8-2-10 w/ 40 SMU’s

– Current SMU = 128
– 677 Hours/Month current avg

• ERM157 – Released 7-1-10 w/ 28 SMU’s

– Current SMU = 696
– 561 Hours/Month current avg
795F Availability
 795F Running MTBS

ERM154 ERM157 ERM156

Released Released Released

60 = World
Class
Performance
 795F Availability Drivers

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.

Engine
Mine
4.5 (20%)
6.7 (30%)

PM LPT

4.3 (19%) 4.-0 (18%)

795F AC Product Support & Pilot Status
Field Support for Field Follow Program

Name: John Bauler

Bauler/Erik Tautkus
Global Mining Division
 Field Follow Site Personnel Concept – 2010
John Bauler –
Supervisor
Cat Man Onsite 795F AC Product
Erik Tautkus – Support
• #1 rated activity that could ensure NPI List Manager
a successful field follow program!

Greg Zack Lee Richard

Dealer Commitment / Involvement Hulva Palmquist Tolzdorf Ortecho
• Dedicated management level
person
Cashman Finning Wheeler Wyoming
• Dedicated, qualified, service
technician for each shift
– Lead man
– Mechanic
795F AC Product Support & Pilot Status
Parts Stocking

Name: John Bauler/Erik Tautkus

Global Mining Division
 Parts Stocking

• 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

• 82% of the major components and critical parts in stock (51 pn’s)
– Of these not in stock (9 pn’s), 67% can be service from factory (6 pn’s)
– 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
795F AC Product Support & Pilot Status
Service Training

Name: John Bauler/Erik Tautkus

Global Mining Division
 795F AC Service Training – Prerequisites

• Web Based Training (WBT)

– Teaches basic electric concepts
– Consists of seven courses available on DLMS
 795F AC Service Training – Prerequisites

• 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

• 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
795F AC Product Support & Pilot Status
Service Literature

Name: John Bauler/Erik Tautkus

Global Mining Division
 Service Literature

• 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
795F AC Product Support & Pilot Status
Tooling

Name: John Bauler/Erik Tautkus

Global Mining Division
 R&I, Maintenance & Diagnostic Tooling

• 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 Removal – Load Leveler Only

• Removing the engine using the 309-2793 Load

Leveler 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 and
transport used engine
 Wheel Station Removal

• Remove axle through small cover

by using 315-2607 adapter and
315-2605 handle (outer sun gear
can be removed and reinstalled)

• Remove the wheel station

by using the 173-6624
Wheel Carrier Bracket
• 202-2053 Wheel Station
Shipping Stand used to
hold, store and transport
used wheel station
 Traction Motor Removal
• A view of the motor still mounted inside the rear
axle housing. The axle coupling is shown.
• Connect 295-6471 lifting fixture (motor removal
tool) and pull motor from axle housing
• Pictures of the motor mounted to the tooling
after removal
 Generator Removal

• A 6V-3145 load leveler (6,000 lb.) was

used on the front of the generator to
protect the high voltage box.
• A 6V-6146 load leveler (10,000 lb.)
was used to span the generator fore-
aft.
• A 2-leg chain was used between the
load leveler and the rear of the
generator.
 Generator & Motor Stand

• 329-5130 Stand Includes:

– Enclosure to protect component
Front
– Brackets to support either generator or
motor
– Desiccant to ensure a clean, dry
environment
– Access to perform required maintenance
during storage (rotate every 6 months)