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F-Series Training 795F AC

Caterpillar Global Mining Tinaja Hills Training Center

August 10-13, 2010

Safety Share


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


793D / F


797B / F





HD 1500 -7


830E - AC







MT3600 MT3700AC




Unit Rig
T252 T262 TI274 T282






Short Tons Metric Tons

110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 3200 330 340 350 360 370 380 390 400 410 420 100 109 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
Wet Multi-Disc Brakes C-175 Engine Platform Struts, Wheels & Tires 4 Bar Rear Linkage Operator Cab

New Content
AC Powertrain Inverter (MELCO Phase Modules) Generator (EPG Experience)

Main Frame Design

MSD Bodies

Common/Similar designs


Design Front Wheel Front brake pack Brake cooling pump Cab Engine (C175-16) Frame Steering pump Pump drive Pump drive shaft Rear suspension (Four bar link design) Rear struts Rear wheel casting Rear wheel bearings Rear brake pack

793F Common Common Similar design Common Common Similar -

795F AC Common Common Common Common Common (except for turbos) Similar design Common Common Common Similar Common Common Common Common

797F Common Common Common Common Common Common Common Similar Common Common 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
Engine Power (HP) Target Payload

795F AC
C175 16 3400 345 T* / 360 T** 313 mt / 326 mt 1,257,000 lb 570,166 kg 40 mph 64 kph 7+ mph 11.3 kph 19.28 mph 31.03 kph 55/80R63 56/80R63 59/80R63 BFOR

TGMW Standard Top speed Speed on grade (12% effective) Retarding (10% effective) Tires

*As per Cat std. **As per electric drive industry practice

795F AC Specifications
Engine Power (HP) Target Payload GMW Standard Top speed Speed on grade (12% effective) Retarding (9% effective) Tires

C175 16 2650 250 T 227 mt 860,000 lb 390,100 kg 37 mph 60 kph 8 mph 13 kph 18 mph 29 kph 40.00R57 46/90R57 50/80R57

795F AC
C175 16 3400 345 T 313 mt 1,257,000 lb 570,166 kg 40 mph 64 kph 7 mph 11.3 kph 21.5 mph 34.6 kph 55/80R63 56/80R63 59/80R63 BFOR

C175 20 4000 400 T 362 MT 1,375,000 lbs 623,690 Kg 42 mph 68 kph 8 mph 13 kph 9.5 mph 15.3 mph 59/80R63

F-Series - Critical Customer Requirements

Top Customer Needs
Reliability Unscheduled Downtime Durability Parts Availability Rebuild Costs Production Safety Beyond Regulations Unscheduled Downtime Reliability Operator Visibility Remove & Install Times Ease of Maintenance Initial Price Access / Egress Remove & Install Times Safety Beyond Regulations Ease of Maintenance

Cat Gaps vs. Needs

Cat Gaps vs. Competition

Cat Business Needs

Profitable Business

F Series Large Mining Truck Initiatives

Critical Customer Requirements

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

Access / Egress Powered Access Stair (attachment)

Safety in Serviceability

Ground Level Maintenance

Bottom-loading filters

F793F Series

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 Converter Cabinet

Radial Grid

Cooling air duct Blower & Hydraulic Motor Driveshaft


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% Retarder Lever 795F AC (Front Brake Switch OFF) Electric Retarding (rear wheels) Service Brakes (front wheels) Service Brakes (rear wheels) 793 MD Service Brakes (front wheels) Service Brakes (rear wheels)


Note: actual front/rear split varies based on payload weight

Retarder Lever Operation

0% Retarder Lever 795F AC (Front Brake Switch ON) Electric Retarding (rear wheels) Service Brakes (front wheels) Service Brakes (rear wheels) 793 MD Service Brakes (front wheels) Service Brakes (rear wheels)


Note: actual front/rear split varies based on payload weight

ARC Operation

0% ARC Demand 795F AC (Front Brake Switch OFF) Electric Retarding (rear wheels) Service Brakes (front wheels) Service Brakes (rear wheels) 793 MD Service Brakes (front wheels) Service Brakes (rear wheels)


Note: actual front/rear split varies based on payload weight

ARC Operation

0% ARC Demand 795F AC (Front Brake Switch ON) Electric Retarding (rear wheels) Service Brakes (front wheels) Service Brakes (rear wheels) 793 MD Service Brakes (front wheels) Service Brakes (rear wheels)


Note: actual front/rear split varies based on payload weight

Traction Control System (TCS) Operation

795F AC vs. 793 MD

Comparison of Systems

Operates in propel only

795F AC
Operates in propel and electric retard Limits wheel slips and slides by reducing electrical torque to each motor independently

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

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




Speed sensors


Right wheel speed Left wheel speed


795F AC Traction Control


Power converter Power converter

Speed sensors



Right wheel speed Left wheel speed


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



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%


Actual Study Cycle - Profile

KUC S97-BC07 Waste Haul
Week of May 3-7, 2010 - Cat 795F AC Productivity Study

6800 6700 6600 6500 6400




6300 6200 6100 6000 5900


5800 5700 0

2000 4000 6000 8000 10000 12000 14000


Scale Truck and Tray Scan

Speed on Grade Results

Speed Trap Description Trap 1 2 3 4 Distance(ft) 719.3 743.0 866.5 2854.5 Grade 9.78% 8.22% 8.32% 8.30% Speed on Grade Comparison 793D (All) 8.2 8.3 8.5 8.7 795F AC (#300) 7.6 8.7 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

tons/cycle tons/hr

793D 254 321

795F AC 342 440

Performance: 795F AC Operator Comments

No ear protection required

Smooth Braking and Retarding are Great

Effortless Can sit back in the seat while retarding

Operator Comments
Im 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

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

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

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

Capitalize on Cats leadership in electric power generation

Power inverter:
Collaboration with Mitsubishi Electric

Caterpillar integration

Controls and Hardware:

Cat designed and developed

Designed and built to Cats specifications

Drive System Comparison

Mechanical Drive Train

AC Electric Drive Train

Caterpillar AC drive truck chassis

C175-16 Engine

Control/Power Converter Cabinet

Radial Grid

Cooling air duct Blower & Hydraulic Motor Driveshaft


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 speed

Converted DC from rectifier

Variable AC from Inverter

AC System Basics 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 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

AC Drive Train Development

797 Mule Truck
(HIL) Hardware in Loop


Drivetrain Simulator
Prototype/Pilot Trucks

Caterpillar Technical Center C175 Engine NPI intent Generator and Motors CAT Proprietary electric drive controls Component Validation Software testing and validation Continues to be utilized into production

Tucson Proving Grounds Engineering Product Support & Marketing Field Development Pilot truck in operation at Kennecott Utah Copper.

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

AC Drivetrain Simulator

Rubber Couplings Motor Dyno Inertia Weights Alternator

C175-16 Engine

Cooling Air Hot Air Return

Blower Fan


Drivetrain Simulator Build [picture from early Jan 07]

Drivetrain Simulator Plan

C-175 Engine NPI representative drivetrain components (Alternator, motors, inverter) CAT Proprietary Electric drive controls

Drivetrain Simulator for components and controls validation

Caterpillar AC Integrated Drive Train

Caterpillar Caterpillar & Mitsubishi


Planetary Inverter AC Motor MP Inverter Control

Speed Sensor Temperature

Engine MP Engine Control

Alternator Voltage Regulator

Rectifier Speed Sensor Temperature AC Motor MP Inverter Control Planetary

Inverter Grids

Truck Controls

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

True 345-350 tons (313-318 tonnes)

Product Support
Serviceability Modular Powertrain

Cat Vertical Integration

Competitive comparison

ITEM Access / Egress Working at Heights Operator Sound Operator Visibility Hydraulic Filter Life Major Component R&I Ground Level Maintenance AST (HVOF) Ecology drains System integration Complexity VIMS Advisor Payload Propulsion SOG (12%) Retarding SOG (-10%)



Komatsu 930E-4SE


Hitachi EH5000 795F AC Notes: PAS, Rear Access, CSGA, 600mm Engine Bay, Tie Off points, Center torque tube etc. 76 dba vs. 81dba WAVS, HID lighting 1000 hours vs. 500 hours Generator, WM, and FD component R&I...industry best Filters, SOS ports, sight glasses, pressure ports Hoist cylinders and struts Filters, pans, etc. Supportability with bumper to bumper System complexity - Hydraulics A single source for diagnostics, all critical functions 345sT, w/ liners, 100% fuel/lubes, 4% debris, field options 7.0-7.5 mph (11.3-12.1 kph) 6,400hp in retarding; 19.28 mph (31.03 kph) Four corner oil cooled brakes Blended retarding (Front brakes & Rear dynamics) Evaluate features during field program Onboard filtration, added complexity w/ coolersto evaluate 23% Std, 26.5% Opt Slight underload of rated capacity with 56/80R63 Mine specific design body



Braking Retarding AC Drive System Final Drives Stall Torque Gradeability Tires Body

Program objective Pure differentiation!

795F AC Product Support & Pilot Status

Target Site and Pilot Truck Update
Name: John Bauler Bauler/Erik 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 Barrick Cortez Hills Gold; Uphill/Downhill; Seasonal Hot 2 Units ERM155/156 (One Running) Copper/Overburden; Flat/Med Speed 2 units (ERM153/154 on site running)

AC Drive Field Follow Target Sites Overseas 2010 Boliden-Aitik units are sold LACD-Chile Finning-owned
High Altitude Application
1. 2. 3. 4. 5. Truck SN ERM161 ERM162 ERM163 ERM164 ERM165 Customer Boliden Boliden ? ? ? SOL Date 8/04/2010 8/18/2010 10/05/2010 10/19/2010 11/02/2010 RTS Date 9/07/2010 9/21/2010 11/08/2010 11/16/2010 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 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

795F Running MTBS

ERM154 Released

ERM157 Released

ERM156 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.

Mine 6.7 (30%)

Engine 4.5 (20%)

PM 4.3 (19%)

LPT 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 Cat Man Onsite #1 rated activity that could ensure a successful field follow program!
John Bauler Supervisor Erik Tautkus NPI List Manager 795F AC Product Support

Dealer Commitment / Involvement Dedicated management level person Dedicated, qualified, service technician for each shift
Lead man Mechanic

Greg Hulva

Zack Palmquist

Lee Tolzdorf

Richard Ortecho





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 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

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

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 3367250 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 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)