Service Trainning

SERVICE TRAINING CATALOG NEW SURFACE & UNDERGROUND MINING PRODUCTS • • • • • • • • •

Hydraulic Shovels Electric Rope Shovels Draglines Highwall Miners Unit Rig Trucks Surface Drills Room & Pillar Mining Longwall Mining Conveyor Systems

CATERPILLAR GLOBAL MINING

February 2013

Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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Process Overview Hydraulic Shovels • 2013 Training Schedule • 6015 - Service Training • 6015 - Training Time Schedule • 6018 - Service Training • 6018 - Training Time Schedule • 6030 - Service Training • 6040 - Service Training • 6050 - Service Training • 6060 - Service Training • 6090 - Service Training • 6030 to 6090 - Training Time Schedule • 6018 AC - Service Training • 6030 AC - Service Training • 6040 AC - Service Training • 6050 AC - Service Training • 6060 AC - Service Training • 6090 AC - Service Training • 6030 AC to 6090 AC - Training Time Schedule • 60XX Electrical Training - ‘CAMP’ - Control and Monitoring Platform • 60XX Electrical Training – ‘Regular’ • Training available on Dealer Performance Center (DPC) • Conditions and Rates for Training ‘Out of the Office’ Electric Rope Shovels • 7495 Electrical Training Plan • 7495 Maintenance Training Plan • 7495 Operator Training Plan • SIEMENS IGBT Standard Training Course Outline • Training available on Dealer Performance Center (DPC) Draglines Highwall Miners Unit Rig Trucks • Training Syllabus – Structure and Function • Training Syllabus – General Electric AC Drive System • Training Syllabus – General Atomics AC Drive System • Training available on Dealer Performance Center (DPC) Surface Drills • 2013 Training Schedule • Training Program Syllabus – Rotaries SKF/SKS Large Blasthole Drill • Hydraulic Percussive Track Drill Technical Training Program Room & Pillar • Continuous Miner Service Training – Program Overview • Coal Hauler Service Training – Program Overview • Scoop Utility Vehicle Service Training – Program Overview • Feeder Breaker Service Training – Program Overview • Roof Bolter Service Training – Program Overview • Continuous Haulage Service Training – Program Overview • Sheild Hauler Service Training – Program Overview • Training available on Dealer Performance Center (DPC) Plow/Shearer Longwall Conveyor Systems Asia Pacific 2013 Dealer Training Schedule Contacts Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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Process Overview Service Training for Bucyrus products will be provided in both Instructor-led and Web Based formats. Most of the Instructor-led training will be delivered by Factory Instructors from the Product Groups during the delivery, assembly and machine commissioning process of a machine model within a product family. The training will typically take place at the mine site on the machine for Dealer Training Instructors, Technical Communicators, and Technicians from the selling dealer. Other Dealer Training Instructors will be encouraged to attend the training to gain in-the-iron exposure to the product and service requirements to enable them to train their dealer technicians. Caterpillar Global Manpower Development will work with the product groups and regions to determine when machines from the product families will be scheduled for commissioning within a region. Other training opportunities could occur when machines operating under MARCs are scheduled for repair/overhaul. Based on machine availability, a training session will be scheduled to coincide with the commissioning or repair process and dealers will be advised on the timing and location to enable training instructors to attend. Additional Instructor-led training for some products is also available and is described below. To determine their training needs, dealers should use the following steps: 1) Dealer determines the current level of service support today. 2) Dealer determines the future level of service support, what training is needed, what training is available based on the skills within their dealership 3) Dealer communicates gaps in skills to their DSD. 4) DSD communicates the gaps to the Product Groups and determines the strategy to fill those gaps. The DSD and Product Groups may contact GMD and Global Mining for assistance.


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The Dealer, DSD, and the Product Group will provide the training. The Product Families are: o Hydraulic Shovels o Surface Drills o Unit Rig Trucks o Room & Pillar Mining o Electric Rope Shovels o Draglines o Longwall Mining o Highwall Mining o Conveyor Systems

Dealers will have access to the Dealer Performance Center, their Distribution Services Divisions, and Machine specific training through each Product Group.

Dealer Performance Center (DPC): https://dlms.logicbay.com


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Hydraulic Shovels The regular training courses are conducted in our training center in the Dortmund Factory. We also offer the same training course to be conducted at the dealer location or customer site. To schedule these ‘on site trainings’ please contact us to discuss the details of the request. For more individual information, please contact us direct: Matthias Aust – Training Manager [email protected] +49 231 922 4932

Training Schedule 1st Half of 2013 for - CAT® 60xx - Hydraulic Mining Shovels Participants attending this course should have a technical education as mechanical or electrical apprenticeship, or technical background such as technical training instructor, technical communicator, shovel expert or service manager. We are planning to offer the following trainings: SUBJECT

LOCATION LANGUAGE

WEEK

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CAT 6030 Dortmund English 4 21.01.-25.01.2013 1 Tinaja Hills CAT 6030 English 5 28.01.-01.02.2013 2 Tinaja Hills CAT60xx CAMP Electrics English 6 04.02.-06.02.2013 3 CAT 6040 Dortmund English 8 18.02.-22.02.2013 4 CAT60xx CAMP Electrics Dortmund English 9 25.02.-27.02.2013 5 Tinaja Hills CAT 6030 English 10 04.03.-08.03.2013 6 Tinaja Hills CAT60xx CAMP Electrics English 11 11.03.-13.03.2013 7 CAT 6015 + 6018 Dortmund Russian 12 18.03.-22.03.2013 8 CAT 6060 Dortmund English 12 18.03.-22.03.2013 9 CAT60xx CAMP Electrics Dortmund English 13 25.03.-27.03.2013 10 CAT 6050 Dortmund English 15 08.04.-12.04.2013 11 CAT 6060 Dortmund Russian 15 08.04.-12.04.2013 12 CAT60xx CAMP Electrics Dortmund Russian 16 16.04.-18.04.2013 13 CAT 6030 Dortmund Russian 17 22.04.-26.04.2013 14 CAT 6050AC + 6060AC (e-drive) Dortmund English 17 22.04.-26.04.2013 15 CAT 6090 Dortmund English 20 13.05.-17.05.2013 16 CAT60xx CAMP Electrics Dortmund English 23 05.06.-07.06.2013 17 CAT 6030 + CAT 6040 compact Dortmund English 24 10.06.-14.06.2013 18 CAT 6015 + CAT 6018 compact Dortmund English 25 17.06.-21.06.2013 19 CAT 6050AC + 6060AC (e-drive) Dortmund Russian 25 17.06.-21.06.2013 20 Standard cost for each training session incl. material is 750,- EUR per participant incl. lunch in our canteen. Costs for accommodation, flight, etc. are to be borne by the participant. Hotel payment has to be done at check-out.

Please note that the minimum number of participants is 4 persons and the maximum limited to 8 persons. Registration is requested to arrive at the latest 5 weeks prior to training starting date to ensure correct planning and optimal utilization. Please also bear in mind that visa application may be very time consuming. Please consider to bring your own safety shoes. To register yourself, please fill in the attached registration form and send it to: Attn.: e-mail:

Mrs. Dana Dietrich [email protected]


Copy: e-mail:

Mr. Matthias Aust [email protected]

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6015 – Service Training



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6018 – Time Schedule


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6030 to 6090 – Time Schedule


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6018 AC – Service Training



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6030 AC to 6090 AC – Training Time Schedule

Electrical Training – Control and Monitoring Platform (CAMP)


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CAMP – Electrical Training Time Schedule

Electrical Training - Regular


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Electrical Training Time Schedule

Training Available on Dealer Performance Center (DPC) Cat 6030 - Service and Maintenance Training - 40240 This module is for mechanical and electrical skilled people who can explain the basic operation of the Cat 6030, to provide a detailed explanation of hydraulic and electrical circuits. Description: This module is for mechanical and electrical skilled people who can explain the basic operation of the Cat 6030, to provide a detailed explanation of hydraulic and electrical circuits. During this module participants acquire detailed knowledge and skills to carry out troubleshooting on the hydraulic and electrical systems. Learning Objectives: Upon completion of this course, participants should be able to have a better understanding of basic knowledge to properly maintain and perform minor repair on Caterpillar Hydraulic Mining Excavator Cat 6030 and will be able to perform the following tasks: • Explain common machine features on Cat 6030 Hydraulic Mining Excavator. • Explain the safety precautions and procedure while working on the machine. • Find necessary information in delivered technical documentation. • Identify & explain the function of the major components of the machine systems. • Identify & explain the different functions of the pilot or servo circuit. • Identify the components and explain system operation of power train and PMS system. • Identify the components and explain system operation of attachment/travel/swing. • Identify the components and explain system operation of Board Control System. Perform machine startup and shutdown procedures. • Perform daily inspection and preventive maintenance as per the operating instructions. Approval Required: No - but approval may be required to register for a class. Length: 5 days


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Cat 60xx (6015, 6018 6030, 6040, 6050, 6060, 6090) CAMP Electric Training - 40239 This module is for mechanical and electrical skilled people who can explain the basic operation of the Cat 60xx machines, to provide a detailed explanation of electrical circuits and systems used on those machines. Description: This module is for mechanical and electrical skilled people who can explain the basic operation of the Cat 60xx machines, to provide a detailed explanation of electrical circuits and systems used on those machines. During this module participants acquire detailed knowledge and skills to carry out troubleshooting on the and electrical and electronic systems of machines equipped with CAMP electric system. Learning Objectives: Upon completion of this course, participants should be able to properly maintain and perform major faultfinding and repair on Caterpillar Hydraulic Mining Excavator Cat 60xx machines equipped with CAMP electric system and will be able to perform the following tasks: • Explain common machine features on Cat 60xx Hydraulic Mining Excavator. • Explain the safety precautions and procedure while working on the machine. • Find necessary information in delivered technical documentation. • Identify & explain the function of the major components of the electric/electronic machine systems. • Identify & explain the different functions of these systems. • Identify the components and explain the operation of different controller boxes/systems. • Identify the components and explain system operation of Board Control System. • Perform daily inspection and preventive maintenance as per the operating instructions. Approval Required: No - but approval may be required to register for a class. Length: 3 days


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Conditions and Rates for Training ‘Out of the Office’ in 2013 Ladies and Gentlemen, These are our regulations for your individual ‘on-site training’. Prerequisite for a training course is the availability of the following:

Training: Technical Training for Maintenance + Service Personnel Training room with projector and white screen. White board and flip-chart with markers in different colors. Access to the internet if possible. Trainees should be free for 5 complete days. The excavator should be available for the time of the training to get more practical know how. For the technical trainer, costs are 1.200,- EUR per day (travel day: 900,- EUR). Additional costs for hotel accommodation, flights, handouts for training, etc.

Training: Operator Training Training room with projector and white screen. White board and Flip-chart with markers in different colors. Access to the internet if possible. Trainees should be free for the complete training or as long as needed. The excavator must be available for the time of the training. For the operator trainer, costs are 900,- EUR per day (travel day: 700,- EUR). Additional costs for hotel accommodation, flight, material for training, etc. In case you have any questions, please do not hesitate to contact us.

To register yourself, please fill in the attached registration form and send it to: Contact details: Attn.: Mrs. Dana Dietrich e-mail: [email protected]

Copy: e-mail:

Mr. Matthias Aust [email protected]

In case you have any questions, please do not hesitate to contact us. We look forward to receiving your registration soon.


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ELECTRIC ROPE SHOVELS For more information and quote, please contact: Mark Smith – Technical Training Manager [email protected] (414) 768-4785 2013 Training Rates Travel Daily Rates Instructor Rates (8 hours/day, Mon. - Fri.) Overtime Rates Per Hour Daily Standby Fee when not required

Over 8 hrs. & Sat. Over 8 hrs. & Sun./U.S. Holidays Standby

$ 1,000.00 $ 2,489.00 $ 466.69 $ 622.25 $ 1,991.00

Requirements: • Minimum of 5 days of training. Training days are to be consecutive. • Training day is defined as 8 hours, day shift only. • If the trainer works more than 8 hours per day, or works on Saturday, Sunday or a U.S. Holiday, customer is responsible for payment according to above rates. • Any training done on a Saturday, Sunday or U.S. Holiday counts towards the total days.


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7495 Electrical Training Plan


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7495 Maintenance Training Plan


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7495 Operator Training Plan


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SIEMENS IGBT Standard Training Course Outline IGBT Standard Training Course Schedule Class Length 5 Days Scope of Class: This class is being given for IGBT Standard Shovel customers. It is assumed that the people in class will be familiar with electrical shovels and basic electrical fundamentals. This class will introduce the student to the technology as applied on the standard IGBT shovels. 1. Documentation and Software furnished to the students: A. Class Schedule B. IGBT Shovel Systems Class Manual C. General electrical schematics for shovels (SIEMENS & BUCYRUS) D. General Information and Procedures for the SiBas control system E. Shovel electronic devices manual F. CDA / ANF Fault Manual G. SIB Fault Manual H. SIRAS remote logon information I. SiBas Monitor software for connecting to SiBas32 program Basic Outline: I. System Overview A. OBJECTIVES: Upon completion of this section, the student will be able to :  Introduce the major technologies used in the standard IGBT System  List the power connections and lock-out safety points for the cabinet  Explain the operation of components used on the shovel “skid”  List the three classes of faults that annunciate on the shovel  Read schematics and locate components based on device name  Maneuver through the various HMI screens found on the skid  Research faults in both the HMI and the troubleshooting manuals  Locate devices and characteristic in the Device Manual B. MATERIALS:  Class Manual  Siemens Schematics  Bucyrus Schematics  Device Manuals  Troubleshooting Manuals C. INTRODUCTION: Provides an overview of the technologies used in the Siemens IGBT shovel family. The instructor introduces the major black boxes used in controlling the system. Discusses the functions and responsibilities of each, as well as the interfaces between them. D. SIEMENS SCHEMATICS: Introduction to the schematic style used for the IGBT system. Covers Print Sections, Cross-Referencing, Tracing. Exercises include tracing control loops, component locations, Cable Detail Identification, etc. E. BUCYRUS SCHEMATICS: Explanation of the different style of drawing used in the Bucyrus schematics. Identifying components and identifying interface points between the BI and SE&A schematics. F. SYSTEM COMPONENTS: Describes some of the important system devices, their operation and their specifications. Comparison of device specifications from the vendors vs. those in the application. Use of the Device Manual. G. TYPES OF FAULT MESSAGES:  ANF – PLC  CDA – PLC  SIB – SiBas II. Component Identification – Practical A. OBJECTIVES: Upon completion of this section, the student will be able to:  Locate any component in the Siemens cabinet based upon information from the Siemens schematic.  Locate any component in the Siemens schematic based upon its markings in the drive cabinet. Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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 Locate and Identify all connections points for field wiring to the drive cabinet B. MATERIALS:  Class Manual  Siemens Schematics  Bucyrus Schematics  Device Manuals  Troubleshooting Manuals  Shovel drive cabinet – Power Disconnected III. HMI Operation A. OBJECTIVES: Upon completion of this section, the student will be able to:  Monitor feedback values from the PLC and drive systems.  Locate the various screens for Active Logic for monitoring and troubleshooting.  Read faults from the Active Alarms screen.  Read and Save faults from the Fault History screen.  Follow faults to the on-line Troubleshooting Manual. B. MATERIALS:  Maintenance Station Owner’s Manual IV. HMI Operation – Practical A. OBJECTIVES: Upon completion of this section, the student will be able to:  Monitor feedback values from the PLC and drive systems.  Locate the various screens for Active Logic for monitoring and troubleshooting.  Read faults from the Active Alarms screen.  Read and Save faults from the Fault History screen.  Follow faults to the on-line Troubleshooting Manual.  Use Footprints screen to locate system components.  Locate and view Synchronizing voltages ULRT & ULST B. MATERIALS:  Maintenance Station Owner’s Manual  Shovel drive cabinet – Power ON V. SiBas 32 A. OBJECTIVES: Upon completion of this section, the student will be able to:  Explain the functions of the ZR and SIP processors  Explain the difference between the PLC and SiBas scan logic  Explain different block types, connector types, and scan times in the SiBas program.  Trace the signal flow through the speed regulator function package.  Explain the functions of each card in the SiBas rack.  Explain the different protection levels in the UWS cards.  Start the Monitor program.  Start the Monitor program to load the ZR and SIP programs.  Start the Monitor program to read faults and clear faults.  Start the Monitor program to read and record values.  Start the Monitor program to change connectors and edit changes in the buffer  Explain the functions of the SIP Traco and how to set up and trigger record on fault conditions.  Set the system to Manual mode (for hoist & crowd). B. MATERIALS:  SiBas Rack  Laptop with SiBas Monitor program installed  Interface cable  Class Manual  Microsoft Excel  Manual General Information and Procedures for SiBas 32 Control System C. SiBas OVERVIEW:  SiBas as a motion control system, the differences between SiBas and earlier control systems. Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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D. READING SiBas PROGRAM LISTING:  Reading Function Packages; block types, scan rates, scan sequence, connector and data types. E. SiBas RACK CARDS:  Functionality and interchangeability of SiBas rack cards. Different levels of protection in the UWS cards and their reset routine. F. SiBas HARDWARE LIST:  Guide to reading the SiBas Hardware List; information contained. G. SiBas MONITOR:  Installation, startup and configuration. Observing connectors and changing values.  Creating, opening and saving files and data  Loading programs into the ZR and SIP cards. SIP Traco functions. A. SiBas MONITOR PRACTICE  Exercises for the installation, startup and configuration of the software on the laptop.  Creating, opening and saving files and data. VI. SiBas 32 – Practical A. OBJECTIVES: Upon completion of this section, the student will be able to:  Creating, opening and saving files and data.  Trapping signal values in the Monitor program.  Graphing signal values in Excel  Practice in troubleshooting SiBas faults B. MATERIALS:  SiBas Monitor Software with Interface cable and Microsoft Excel programs  Shovel drive cabinet – Power ON VII. Step 7 PLC and ET200 Stations A. OBJECTIVES: Upon completion of this section, the student will be able to:  Understand the topology of the S7 network and its stations  Understand and Edit the S7 Hardware Configuration  Understand basics of Profibus communication  Work between the ON line / OFF Line windows  Use the Simatic Manager to check system information  Use the Simatic Manager to observe and change PLC values  Use the Simatic Manager to search for variables and I/O  Download & Upload programs  Archive & Retrieve projects  Configure individual ET200 stations  Understand PLC program structure B. MATERIALS:  Class Manual  Laptop with Simatic Manager installed C. PLC HARDWARE: Explanation of PLC network configuration. Differences between earlier network with Host PC / Slot PLC and the new system with Rocky. Explanation of ET200 cards and setup. Setting network addresses at stations and terminating resistors. D. PROFIBUS: Basic steps in setting up Profibus networks. E. STEP 7 INTRODUCTION F. STEP 7 SIMATIC MANAGER  Using the Simatic Manager to open PLC projects  Viewing and setting up the Hardware Configuration  Object properties of the hardware components  Searching for I/O and variables in the Step 7 program  Comparing I/O addresses in the PLC program and the Siemens schematics  Troubleshooting from the HMI – System Ready screen and the Simatic Manger G. SETTING IP ADDRESS IN STEP 7  Setting the internal Ethernet address for the PLC Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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VIII. Step 7 PLC - Practical A. OBJECTIVES: Upon completion of this section, the student will be able to:  Troubleshoot problems via the System Ready screen, the Simatic Manager and around the network. B. MATERIALS:  Shovel drive cabinet – Power ON  HMI screens and the preinstalled Simatic Manager IX. Shovel Command / Control Structure A. OBJECTIVES: Upon completion of this section, the student will be able to:  List the steps in the DC Buss ON/OFF sequence  List the steps in the Motion ON/OFF sequence B. MATERIALS:  Class Manual  PLC Listing X. AC Motors & Controls A. OBJECTIVES: Upon completion of this section, the student will be able to:  Explain the motor nameplate information  Understand the difference between real power and reactive power and describe power factor  Explain the three basic methods of motor speed control B. MATERIALS:  Class Manual  Step 2000 series guide C. BASICS OF AC MOTORS  Nameplate data and slip  Real power, reactive power and power factor  Volts per Hertz relationship D. BASIC DRIVE OPERATION  Modes of open-loop and closed-loop control for variable speed motors  The SiBas implementation of control  Torque and flux generation  Functions of the SIP’s and ZR XI. AFE Operation & Space Vector Control A. OBJECTIVES: Upon completion of this section, the student will be able to:  List the advantages of the AFE’s compared to other rectification systems  Describe the purpose of the choppers  Describe the difference between chopper firing and AFE firing  Describe the operation of Ground Fault detection in the IGBT system B. MATERIALS  Class Manuals and Overheads C. BASICS OF AFE POWER SECTION OPERATION  AFE Block Diagram  State Vector Modulation (SVM) D. BASIC AFE MONITORING  Monitoring through the SiBas and the test points.  Observation of the chopper operation E. GROUND FAULT DETECTION  Explanation of Ground Fault protection XII. AFE Operation & Control – Practical A. OBJECTIVES  Troubleshoot faults initiated in SiBas B. MATERIALS  Siemens Schematics  Voltmeter XIII. Midas and Siras Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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A. OBJECTIVES  Understand the differences between MIDAS and SIRAS and how they work together  Understand Maintenance tools vs. Operations tools  Become familiar with the various screens and information presented in the MIDAS DesktopR B. MATERIALS  Class Manual  Laptop with MIDAS files stored for viewing XIV. Review A. OBJECTIVES  Summary of presented material  Open question and answer period

Training Available on Dealer Performance Center (DPC) 7495 MECHANICAL SYSTEMS OVERVIEW - 41590 The CAT 7495 Electric Rope Shovel Mechanical Systems Overview course is a foundational level course developed to introduce the service & maintenance personnel to the CAT 7495 mechanical systems, circuits and components Description: The CAT 7495 Electric Rope Shovel Mechanical Systems Overview course is a foundational level course developed to introduce the service & maintenance personnel to the CAT 7495 mechanical systems, circuits and components. Through lectures, classroom discussions and exposure to a 7495 shovel the participants are provided with learning experiences that will enable them to identify, locate and describe the CAT 7495 Electric Rope Shovel mechanical system. In addition the participants will be exposed to the machine mechanical schematics, machine support websites and documents. There is a maximum of 10 students per class. Approval Required: No - but approval may be required to register for a class.

7495 ELECTRICAL SYSTEMS OVERVIEW - 41591 The CAT 7495 Electric Rope Shovel Electrical Systems Overview course is a foundational level course developed to introduce the service & maintenance personnel to the CAT 7495 electrical systems, circuits and components. Description: The CAT 7495 Electric Rope Shovel Electrical Systems Overview course is a foundational level course developed to introduce the service & maintenance personnel to the CAT 7495 electrical systems, circuits and components. Through lectures, classroom discussions and exposure to a 7495 shovel the participants are provided with learning experiences that will enable them to identify, locate and describe the CAT 7495 Electric Rope Shovel electrical system. In addition the participants will be exposed to the machine electrical schematics, machine support websites and documents. Approval Required: No - but approval may be required to register for a class.

7495 HydraCrowd Inspection and Service Schedule course - 41873 This course is intended for field representatives, mechanical maintenance personnel and anyone interested in learning more about this product. Description: This course will provide knowledge on inspecting and servicing the HydraCrowd system. The HydraCrowd system is found on Cat Electric Rope Shovels. Please refer to your service manual for further specifications. Learning Objectives: After completing this course you will: - Be able to perform various inspections on the HydraCrowd system. Be familiar with what a Preventive Maintenance Program is and why it is important. - Understand the important safety risks associated with the HydraCrowd system. Approval Required: No Cost: $0.00 Length: 00:30 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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7495 HydraCrowd Service Procedures Course - Part 1 - 41871 This course is intended for field representatives, mechanical maintenance personnel and anyone interested in learning more about this product. Learning Objectives: After completing this course you will be able to: - Identify contaminants and maintain cleanliness of HydraCrowd parts and the surrounding area. - Understand the importance of cleanliness in HydraCrowd procedures. - Flush, fill or filter necessary oils. - Replace the Auxiliary Power Unit filter. - Clean the Crowd Cooler. Approval Required: No Cost: $0.00 Length: 1:00

7495 HydraCrowd Service Procedures Course - Part 2 - 41872 This course is intended for field representatives, mechanical maintenance personnel and anyone interested in learning more about this product. Description: This course will provide knowledge on service procedures required for the HydraCrowd system, which is found on Cat Electric Rope Shovels Please refer to your service manual for further specifications. Learning Objectives: After completing this course you will be able to: - Purge air from the Main Pumps. - Clean the Upper Tank return filters. - Remove, drain and reassemble the Isolators. - Replace Boom pressure and return hoses. - Replace the Main Pump pressure hose. Approval Required: No Cost: $0.00 Length: 1:00

7495 HydraCrowd System™ and Component Overview - 41663 This course will provide knowledge about the HydraCrowd system, which is found on Cat Electric Rope Shovels. Please refer to your Service Manual for further specifications. Description: This course is intended for field representatives and anyone interested in learning more about 7495 HydraCrowd System™ and Components. Learning Objectives: After completing this course you will be able to: - Identify the advantages of the HydraCrowd system. - Recognize the basic components of the HydraCrowd system. - Familiarize yourself with components location and their functions Approval Required: No Cost: $0.00 Length: 1:00


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7495 Series Electric Rope Shovel Air Filtration Training - 40242 This course will provide knowledge about the 7495 Series Electric Rope Shovel Air Filtration System. This course contains information on house filter fans, the different parts of the air filtration system and how to maintain it. You will also find information on the air conditioning/heater units Description: This course is intended for anyone interested in learning more about this product such as Cat® dealer sales professionals or field representatives. Learning Objectives: After completing this course you will be able to: Explain how to maintain the parts in the house filter fans. Summarize the maintenance process for the different parts in air filtration system. Describe the maintenance and cleaning process of the air conditioner/heater system. Approval Required: No Cost: $0.00 Length: 00:45

7495 Series Electric Rope Shovel Brakes - 41807 This course will provide knowledge about the 7495 Series Electric Rope Shovel Brakes. This course contains disc brake operation, maintenance, hoist, crowd, propel, and swing brake maintenance procedures. Please refer to the Service Manual for further specifications. Description: This course is intended for Caterpillar dealer’s sales professionals, field representatives and anyone interested in learning more about this product. Learning Objectives: After completing this course you will be able to: - Understand the disc brake operation. - Explain how to maintain the hoist, crowd, propel and swing brake. - Summarize the maintenance procedures for spring, friction disc and O-ring replacement. - Describe the safety considerations for brake maintenance. Approval Required: No Cost: $0.00 Length: 01:00

7495 Series Electric Rope Shovel Couplings Training - 41867 This course will provide knowledge about the 7495 Series Electric Rope Shovel Couplings. This course contains grid and gear coupling maintenance procedures. Please refer to the Service Manual for further specifications. Description: This course is intended for Caterpillar dealer’s sales professionals, field representatives and anyone interested in learning more about this product. After taking the course, you should be able to explain the different procedures for grid and gear couplings, summarize the maintenance procedures for couplings and describe the safety considerations for coupling maintenance. Learning Objectives: After completing this course you will be able to: • Explain the different procedures for grid and gear couplings. • Summarize the maintenance procedures for couplings. • Describe the safety considerations for coupling maintenance. Approval Required: No Cost: $0.00 Payment Status: No payment required


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7495 Series Electric Rope Shovel Overview - 40281 This course is intended for anyone interested in learning more about this product such as Cat dealer sales professionals or field representatives. Description: This course will cover History, Mechanical Features, Lower Works, Electrical Features, Operator's Cab and the Theory of Operation of the 7495 Series Electric Rope Shovel. Learning Objectives: The goal of this course is to provide basic knowledge and a core understanding of the Cat 7495 Series Electric Rope Shovel. Approval Required: No Cost: $0.00 Length: 01:00

CAT 7495 Electric Rope Shovel Electrical Systems Overview - 42355 This training course is designed to introduce electrical service personnel to the CAT 7495 Electric Rope Shovel. It is especially suited to service technicians who are unfamiliar with the particular electrical and control systems of the 7495. Description: This course includes systems descriptions, specifications, capabilities and theory of operation. In addition, the learner will become familiar with the documents, manuals and schematics used to maintain and service the CAT 7495. This course includes the following topics: 1.0. ERS E01.0-7495 INTRODUCTION 2.0. ERS E02.0-7495 ELECTRICAL SAFETY 3.0 ERS E03.0-7495 POWER DISTRIBUTION 4.0 ERS E04.0-7495 POWER CONVERSION 5.0 ERS E05.0-7495 CONTROL & COMMUNICATIONS 6.0 ERS E06.0-7495 AUXILIARY & SUPPORT SYSTEMS 7.0 ERS E07.0-7495 HYDRACROWD SYSTEM Language: English Minimum #: 4 students (Class will cancel 30 days prior to course date is enrollment is less than 4 students) Maximum #: 10 students Lunch: Provided at Cafeteria FAQ Sheet: Will be sent via email to registered student. Course Materials: Provided NOTE: Laptop Computer: Student must bring their own laptop Lodging: A primary hotel will be recommended that provides shuttle service to and from class< Learning Objectives: After successful completion of this training the learner will be able to: • Identify & locate the main systems, circuits and components of the CAT 7495 electrical systems. • Describe the operational capabilities and specifications of the CAT 7495 electrical systems. • Utilize the documents and references materials used to maintain service and troubleshoot the CAT 7495 electrical systems. Approval Required: No - but approval may be required to register for a class. Length: 5 days

DRAGLINES For more information, please contact:

Diane Spear Sanicola – Team Leader [email protected] (414) 768-4988

Highwall Miner Electrical Maintenance Training – 2 day class. Hydraulic Maintenance Training – 2 day class. Both classes are taught at the Beckley WV Facility. Contact: Frank Nett – Product Health Manager [email protected] (304) 253-0216 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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UNIT RIG TRUCKS Training is provided on site in English. For more information and quote, please contact: Travis Houser – Technical Training Manager [email protected] (414) 768-4097 Training Syllabus – Structure and Function Location: on mining site


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Training Syllabus - General Electric AC Drive System


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Training Syllabus - General Atomics AC Drive System Location: on mining site

Training Available on Dealer Performance Center (DPC) 2012 - Unit Rig MT4400 AC Off-Highway Truck - SERV1950 Description: This Unit Rig MT4400 AC Machine Service Training course is designed to prepare participants to demonstrate knowledge of the methods and strategies used in all of the major systems of the Unit Rig MT4400 AC Off-Highway Truck.MODULE 1 - Operator's Station MODULE 2 - Structure MODULE 3 - Electrical System MODULE 4 - Engine and Support Systems MODULE 5 - Steering System MODULE 6 - Hoist System MODULE 7 - Brake System MODULE 8 - Running Gear MODULE 9 - Electric Drive Train MODULE 10 - Automatic Lubrication System MODULE 11 - Weigh System Location(s): STMG Documents >> 2012 - Unit Rig MT4400 AC Off-Highway Truck - SERV1950 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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SURFACE DRILLS Contact:

Osvaldo Pires – Technical Training Manager [email protected] (903) 337-4554


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Training Program Syllabus – Rotaries SKF/SKS Large Blasthole Drill This Training is intended for Technical Personnel who are directly involved in maintenance and operation of the Caterpillar Drilling units. It is intended for dealer or customer participants. Knowledge of basic hydraulics and applied electricity is a prerequisite. Course is on an advanced level. • Training will be conducted at the Drill Factory in Denison, TX. The classes are no cost to Cat Dealers. Travel related expenses are the responsibility of the Dealer/participant. Training material and Lunch will be provided. • Training will start each day at 8:00 a.m. and finish at 5:00 p.m. Participants should plan to arrive the Sunday before and depart after 12:00 p.m. on Friday. • The Factory is located approximately 70 miles North of DFW Airport. Hotel(s) are approximately 10 minutes from the Factory. • Classes will cover; Safety, Drill Application, Main Components & Layout, Operating Systems, Operating Controls, Maintenance and Options. • Registration is required (2) two weeks prior to the class. To register contact Joyce Chambers at [email protected] Joyce will also have information regarding accommodations.

A. 1– Maintainers Program Syllabus 1) Theoretical Technical Training, including functionality explanation of different Systems, such as: air,water, hydraulic, electrical and mechanical (Mechanics and Operators) 2) Practical Training combined with assembly and identification of components and it’s functionality (Mechanics and Operators – Field Only ) 3) Operators Theoretical and Practical Training ( Field Only ) OVERVIEW MAJOR COMPONENT LOCATIONS  Using - (Locator Chart .Dwg) or actual unit when available OVERVIEW OF POTENTIAL HAZARDS  Safety - Before Operation  Minimum Clearances from High Voltage Lines  Safety - Operation & After Operation  Safety - Maintenance & Equipment Transfer OPERATOR CONTROLS  Graphic Symbol Legend DRILLING FUNDAMENTALS (PRINCIPIOS DE BARRENACION)  Pull-down ( Carga sobre la Barrena )  Rotation ( Rotacion )  Hoist ( Izado de barras )  Tram ( Desplazamiento )  Bailing air ( Velocidad de Barrido ) SAFETY INSTRUCTIONS (INSTRUCCIONES DE SEGURIDAD)  Warning ( Advertencia )  Caution ( Precaucion )  Danger ( Peligro ) OPERATOR’S CAB (CABINA DEL OPERADOR)  Operators console ( Tablero de operacion )  Drill gauges ( Manometros de barrenacion, Rotacion, Pull-down, Bomba auxiliar, Presion de aire )  Engine and compressor gauges ( Manometros del motor y compresor )  Fuses ( Fusibles )  Drill Controls ( Controles de Barrenacion, Pull-down / Hoist, Rotacion Der./ Izq.)  Tram Controls ( Controles de desplazamiento, Oruga Izq., Oruga Der ). POWER TRAIN (CONJUNTO DE POTENCIA)  Motor Caterpillar and Cummins  Pump Gear Box and Pumps ( Caja de engranes y bombas )  Compressor Sullair ( Compresor Sull-Air )  Centamax Coupling ( Cople Centamax ) Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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MAIN AIR SYSTEM (SISTEMA DE AIRE PRINCIPAL)  Sull-Air Compressor Components ( Componentes del compresor Sull- Air )  Sull-Air Compressor Control System ( Sistema de control del compresor Sull-Air )  Lubrication Charts and Maintenance ( Pautas de lubricaion y Mantenimiento ) DUST CONTROL SYSTEM (SISTEMA DE CONTROL DE POLVO)  Water Injection Pump ( Bomba de inyeccion de agua )  Lubrication and Maintenance ( Lubricaicon y mantenimiento ) MAST (Mastil)  Vertical Drilling ( Barrenacion Vertical )  Angle Drilling ( Barrenacion en Angulo )  Lock pins ( Seguro del mastil )  In the Hole Drill Pipe Interlock ( Seguro de Barra en el Barreno ) ROTARY DRIVE ( Cabezal de Rotacion )  Hydraulic Motors ( Motores Hidraulicos )  Swivel Seal ( Sello del Aire )  Main Bearing Preload ( Precarga de los rodamientos )  Rotary Head Supports and slicers ( Soprtes y Deslizaderas del Cabezal )  Lubricaion y matenimiento PIPE RACK ( Cargador de barras )  Pipe rack interlock ( Seguro del Cargador de Barras )  Pipe rack operation and maintenance ( Operacion y Mantenimiento del Cargador de Barras ) HYDRAULIC SYSTEM ( Sistema Hidraulico )  Basic Hydraulics ( Hidraulica Basica )  Drill Tram selector Valve ( Selector de Desplazamiento o Perforacion )  Main Hydraulic Pumps Charge Loop ( Circuito de Carga de las Bombas Pricipales )  Close Loop, Right and Left Main Pumps, Drill / Tram .( Cicuito Cerrado de las Bombas Der. e Izq.Perforacion / Desplazamiento )  Auxiliary Pump, Pull-Down System and Positioning functions. ( Bomba Auxiliar, Sistema del Pull-Down y Funciones de Posicionamiento )  Fan Pump, Single and Double Speed Circuits. (Bomba del Ventilador (s) ( Circuitos de uno o dos motores )  Leveling Jacks ( Gatos de Nivelacion )  Mast Lift Cylinders ( Gatos de Levante del Mastil )  Mast Lock Pins ( Seguros del Mastil )  Main Air Valve ( Valvula del Aire )  Winch ( Guincho o Malacate )  Deck Wrench ( Llave de Mesa )  Carrousel Swing in and Out / Interlock, ( Cargador de Barras Adentro y Fuera / Interlock )  Carrousel lock ( Seguro de giro del cargagador )  Carrousel rotation right or left ( Giro del Cargador Der. o Izq. )  Pipe position guide in or out ( Guia de Barras Adentro y Fuera )  Dust curtain ( Faldon )  Water Pump Circuit ( Circuito de la Bomba de Agua )  Main Hydraulic Schematic ( Circuito Hidraulico Princpal )  Auxiliary Hydraulic Schematic ( Circuito Hidraulico Auxiliar ) ELECTRIC SYSTEMS  Components ( Componentes )  Electric Schematic 24 DC ( Diagrama Electrico )  Tram Interlock System ( Sistema de Seguridad de Desplazamiento )  Drill Pipe Interlock ( Seguro de Barra en el Barreno ) LUBRICATION AND PREVENTIVE MAINTENANCE ( Lubricacion y mantenimiento preventivo)  Lubrication Chart ( Cuadros de Lubricaion )  Preventive Maintenance Chart ( Cuadros de mantenimiento preventivo)  Cuadros Lubricacion y Mantenimiento WARNING DECALS  Operator Control Panel (standard) Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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 Instrument Panel (standard)  Instrument Panel (optional)  Operator Control Panel (optional)  System Pressure Gauge Panel  Switch Panel  Lights, Circuit Breakers, & Heater/AC Controls.  Cab Heater Fault Isolation  AC/Heater/Pressurizer Unit  Air Conditioner  Maintenance and Servicing Schedule  Troubleshooting LUBRICATION & PREVENTIVE MAINTENANCE  Service Points - Mainframe  Auto Lube System  Service Points - Mast  Lubrication - General  Equipment Lubrication  Care of Lubrication Points  Lubrication & Maintenance Chart  Lubricant Specifications  Hydraulic System  Compressor  Compressor Lubrication Procedure  Lubricating Grease  Gear Lubricant  Lubrication - Winch  Water Pump (Cat pump Model 1050)  Cat Pump Crankcase Oil  Engine Oil Specifications  Preventive Maintenance  Hydraulic System Maintenance  Cooling System Maintenance (Cummins)  Air Cleaners  Air Filter Elements  Electrical System  Scheduled Oil Sampling Analysis  Extended Machine Shutdown OPERATING INSTRUCTIONS  Commissioning a New Machine  Walk Around Checks  Pre-Start Checklist  Fire Extinguisher Specifications  Fire Suppression System (optional)  Start-Up Procedure  To Start Engine:  After Start Checks  Normal Shut Down  Ground Level Engine Stop (optional)  Cold Weather Start-up  Hydraulic System Warm-Up  Compressor Warm-Up  Propelling Machine  Propelling Up, Down and Across Grades  Propelling Over Cables  Leveling Machine Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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 Re-Leveling Machine  Raising Mast  Lowering Mast  Loading Drill Pipe  Preparing to Drill  Installing and Removing Drill Bit  Drilling Procedures  Multiple Pass Drilling  Adding Drill Pipe  Retracting Drill Pipe B.2 Operator Program Syllabus 1. Safety Personal protective equipment Lock-outs Noise Hazards Electrical Contact Hazards Contaminated Air Hazards Machine Stability Moving Rotary Parts Hazards Safe Working Practices Blind Spots on Drill Rig 2. Drill Movement Propelling the rig Raise and lower jacks Raise and lower mast Mast locks Hobo and Pipe Positioner Positioning Pipe Rack positioning Transient Stability 3. Operator's Cab Overall structure Control console Pipe rack Pressure gauges 4. Main Frame & Undercarriage Intertractor Tracks/Crawlers Idler Roller Track Adjustment Track assembly Final Drives Towing the Drill Rig Tram Motor Assembly Rollers (upper and lower) Pivot and equalizer bar Leveling Jack Assembly Mast Elevating Cylinder Assembly 5. Power Train Centaflex Drive Line Pump Drive Box Compressor Coupling Compressor and Controls Compressor - cooler/thermal by-pass valve Compressor oil filter Compressor compression cycle Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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Compressor shaft seals Compressor pressure regulators Compressor blow down valve Compressor discharge system Compressor oil/cooling system Compressor Inlet controls 6. Dust Control Dry Dust Suppression Water Injection Systems 7. Mast & Rotary Drive Structure & main components A-frame Mast Locking Mast Pivot Caps Mast Elevating Cylinders Mast Elevating/Raise Cylinder Pins Feed System Sheaves Guide Assembly Cable Adjustment Rotary head Rotary head wear pads/shims Rod Handling - Carousel Pipe Rack - break-out arrangements Carousel - indexing motor assembly Drill Deck - A tool arrangement 8. Hydraulics Closed Loop - Open Loop Circuits Hydraulic Tank Return Filters Pump Layout Main Pump Left hand tram and rotation pump Gear Pumps - auxiliary Adjustments Charge Circuit Charge Filters Diverter Valve Loop Filters Rotation Circuit Rotation Motors Feed and Rotation Levers Tram Motors - Final Drives Auxiliary Functions Jacks and Mast Raise Circuits Pulldown & Hoist Valve Dust Collector & water injection valve Mast Valving Rod Handler - Hobo Cooling Fans and Cooling Circuits 9. Electrical General Component Overview Adjusting Joystick Output Troubleshooting Schematic Overview 10. Lubrication & Maintenance Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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Preventive Maintenance Safety Overview Maintenance Chart Daily Checks

Hydraulic Percussive Track Drill Technical Training Program Location : Denison. This Training is intended for Technical Personnel who are directly involved in maintenance and operation of the Caterpillar Drilling units. It is intended for dealer or customer participants. Knowledge of basic hydraulics and applied electricity is a prerequisite. Course is on an advanced level. Models: MD5050-MD5050T-MD5075-MD5090-MD505125 Coverage: Safety, Drilling Application, Main Components & Layout, Operating Systems, Operating Controls, Maintenance, Can-Bus, Carrousel, Rod Changer and options.

DAY 1 INTRODUCTION  Safety  Model Overview - Layout  Application & Operation  Key Components

DAY 2 SYSTEMS  Hydraulics  Function  Settings

DAY 3 SYSTEMS  Electrical  Pneumatics  Function  Settings

DAY 4 HYDRAULIC ROCK DRILLS  HPR – 4519  HPR – 5123  HPR – 5128  HPR – 6030  HPR – 6832  Theory – Function – Overhaul

DAY 5 MECHANICS  Booms  Feeds  Rod Changer  Carousel  Practical Identification of Components –  Depending on machine availability  Maintenance Schedules  End of Training


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ROOM AND PILLAR Training organized on requests. Training can be provided either at our facility or on site Contact person: Matt Phillips M: (+1) 724.249.4861 O: (+1) 724.743.1549 [email protected] Continuous Miner Service Training – Program Overview Scheduled Time: 5 days Purpose: 1. Provide an overview of the machine and machine operation 2. Provide a detailed explanation of the machine control system 3. Provide a detailed explanation of the electrical, hydraulic, and water systems 4. Provide an overview of preventative maintenance required 5. Provide an overview of major mechanical assemblies Required Experience: Course attendees should have a strong mechanical background and have an advanced understanding of hydraulic and electrical systems. Typical Class Structure: Day 1 Day 2 Introduction Control System Overview/Operation Control System

Day 3 Control System Electrical System

Day 4 Maintenance Hydraulics

Day 5 Mechanical Wrap-Up

Coal Hauler Service Training – Program Overview Scheduled Time: 2 days Purpose: 1. Provide an overview of machine operation, machine hydraulics, and maintenance 2. Provide a detailed explanation of both AC and DC control systems 3. Provide a detailed explanation of battery maintenance and charging Required Experience: Course attendees should have a strong mechanical background and have an advanced understanding of hydraulic and electrical systems. Typical Class Structure: Day 1 Introduction AC Motor Control AC Machine Operation and Maintenance

Day 2 DC Motor Control DC Machine Operation Battery and Battery Charging


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Scoop Utility Vehicle Service Training – Program Overview Scheduled Time: 4 days Purpose: 1. Provide an overview of machine operation, control system, maintenance, electrical permissibility, and hydraulics for diesel powered scoops, AC battery powered scoops, and DC battery powered scoops. 2. Provide a detailed explanation of battery maintenance and charging Required Experience: Course attendees should have a strong mechanical background and have an advanced understanding of hydraulic and electrical systems. Typical Class Structure: Day 1 – Diesel Introduction Control System, Electrical System Operation Maintenance and Permissibility Hydraulics

Day 2 – Dual Motor DC DC Control System Electrical System Operation Hydraulics Maintenance

Day 3 – Single Motor AC AC Control System Electrical System Operation Hydraulics Maintenance

Day 4 Battery Maintenance Battery Chargers Scoop Wrap-up

Feeder Breaker Service Training – Program Overview Scheduled Time: 2 days Purpose: 1. Provide an overview of machine operation and control system, electrical system, hydraulic system, and maintenance for a PLC controlled machine. 2. Provide an overview of machine operation, electrical system, hydraulic system, and maintenance for a simple electrics machine. Required Experience: Course attendees should have a strong mechanical background and have an advanced understanding of hydraulic and electrical systems. Typical Class Structure: Day 1 – PLC Introduction Operation & PLC Control Electrical System Hydraulic System Maintenance

Day 2 – Non-PLC Introduction Operation Electrical System Hydraulic System Maintenance


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Roof Bolter Service Training – Program Overview Scheduled Time: 1 day Purpose: 1. Provide an overview of machine operation, electrical system, hydraulic system, and maintenance. Required Experience: Course attendees should have a strong mechanical background and have an advanced understanding of hydraulic and electrical systems. Typical Class Structure: Day 1 Introduction Operation Maintenance Electrical System Hydraulic System

Continuous Haulage Service Training – Program Overview Scheduled Time: 1 day Purpose: 1. Provide an overview of machine operation, electrical system, hydraulic system, and maintenance. Required Experience: Course attendees should have a strong mechanical background and have an advanced understanding of hydraulic and electrical systems. Typical Class Structure: Day 1 Introduction Overview of Layout, Attached vs. Detached Systems, etc. Operation Maintenance Electrical System Hydraulic System


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Shield Hauler Service Training – Program Overview Scheduled Time: 4 days Purpose: 1. Provide an overview of machine operation, control system, maintenance, electrical permissibility, and hydraulics for diesel powered shield haulers, AC battery powered shield haulers, and DC battery powered shield haulers. 2. Provide a detailed explanation of battery maintenance and charging Required Experience: Course attendees should have a strong mechanical background and have an advanced understanding of hydraulic and electrical systems. Typical Class Structure: Day 1 - Diesel

Day 2 - DC

Day 3 - AC

Day 4

Introduction

DC Control System

AC Control System

Battery Maintenance

Control System, Electrical System

Electrical System

Electrical System

Battery Chargers

Operation

Operation

Operation

Shield Hauler Wrap-Up

Maintenance and Permissibility

Hydraulics

Hydraulics

Hydraulics

Maintenance

Maintenance

Training Available on Dealer Performance Center (DPC) Room and Pillar Mechanical Mining - 40974 This course will provide an overview of the Cat Room and Pillar Mechanical Mining System. This includes an explanation of how an underground room and pillar mine operates and the various types of equipment used. Description: This course will provide an overview of the Cat Room and Pillar Mechanical Mining System. This includes an explanation of how an underground room and pillar mine operates and the various types of equipment used. Learning Objectives: After completing the course, you should be able to: Identify the components of an underground room and pillar mine layout Identify Room and Pillar equipment also used in Longwall development Identify the equipment power systems available Explain how the various machine types are used in a room and pillar mine site Identify the manufacturing locations for room and pillar equipment Current Status: Not Started Approval Required: No Cost: $0.00 Payment Status: No payment required Length: 1:00

2012 - CM235 Continuous Miner - SERV1963 Description: It is necessary for participants to be able to quickly and accurately diagnose problems to test and properly adjust components, and to know the methods and strategies used in all of the major systems of the CM235 Continuous Miner. Use of the knowledge gained in this course will ensure participants will be able to provide more effective customer service, which enhances customer satisfaction. Location(s): STMG Documents >> 2012 - CM235 Continuous Miner - SERV1963 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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Cat CM235 Continuous Miner Overview - 41886 This course will provide an overview of the Cat CM235 Continuous Miner, how it operates, its main components, and its service points. Description: This is a foundational level course. This course provides a review of the CM235 Continuous Miner. The component locations and service points are identified and the basic systems operation are discussed. When used in conjunction with the service manual, the information in this course should permit the technician to analyze problems in any of the major systems on these machines. Learning Objectives: After completing the course, you should be able to: - Identify the various systems and components of a CM235 Continuous Miner - Identify the machine's key service points - Explain the basic operation of the machine Approval Required: No Cost: $0.00 Payment Status: No payment required Length: 00:45

2012 - FH120 Room Pillar Mining - SERV1962 Description: This FH120 Face Hauler Machine Service Training Course is designed to prepare participants to quickly and accurately diagnose problems, to test and properly adjust components, and to demonstrate knowledge of the methods and strategies used in all of the major systems of the FH120 Face Hauler. Location(s): STMG Documents >> 2012 - FH120 Room Pillar Mining - SERV1962

FH120 Face Hauler Service Training Course - 41869 This course will provide an overview of the FH120 Face Hauler machine. This includes the basic machine functions and the location of service points around the machine, components in the operator’s station, the electrical system, the HiPAC 10 display, and the hydraulic system. Description: This course provides an overview of the FH120 Face Hauler. The basic machine functions, component locations and service points are identified and the basic systems operation are discussed. When used in conjunction with the service manual, the information in this course should permit the technician to analyze problems in any of the major systems on these machines. Always use the latest Service Information to ensure that the most current specifications and test procedures are used. Learning Objectives: After completing the course, you should be able to: - Identify basic machine functions and the location of service points around the machine - Identify components in the operator's station - Identify components of the electric system - Identify the features of the HiPAC 10 display - Identify components of the hydraulic system Current Status: Not Started Approval Required: No Cost: $0.00


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PLOW / SHEARER/ LONGWALL Training organized on requests, available from February 2013. Training will be provided in factory facility in Luenen (Germany) Contact person: Dietmar Wegner – Product Support Manager [email protected] +49 2306 709 1946 Hans Leppkes - Technical Training Manager [email protected] +49 2306 709 1264 This module will comprise a general introduction of underground mining and then the different applications of the plow, shearer and longwall. 1. Course data Underground longwall mining methods by shearer and plow systems. System and product introduction (scheduled time 6h) 2. Purpose This module is for dealer audience to become acquainted with underground longwall mining infrastructure and the systems in general. It gives an overview of the machines and main components a longwall system consists of. Furthermore an indication about possible required services like maintenance, typical parts replacements and repair requirements will be given. 3. Required experience Participants attending this course should be of a basic technical background. 4. Summary of content Basic introduction of underground longwall mining. General explanation of a longwall system, the main application requirements, the system components and general service requirements. 5. Resources Exemplary user manuals. Exemplary parts books.


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Conveyor Systems Training delivered to the mine site. Contact:

Peter Coffey – Technical Documentation Cordinator [email protected] (724) 743-1396

Operation • Basic Conveyor operation • Power pack operation • VFD controller operations • REGEN Controller operation • Belt scale operation Service • Pillow Block Bearing replacement • B-Lock replacement • T- lock replacement • Engineered Pulley replacement • Idler replacement


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Asia Pacific 2013 Dealer Training Schedule


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To register yourself, please fill in the attached registration form and send it to: Attention: Ms Rebecca Ricardo Email: [email protected] Note: Venue information for training will be provided upon registration. Course Enrollement Form


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Hydraulic Rotary Drill-Move & Test - Operator Training DURATION : 2 Hours PREREQUISITES There are no minimum prerequisites for attending the Caterpillar Hydraulic Rotary Drill Move & Test training. The course is designed for maintenance and/or build staff, that need to move a machine and test its functionality: COURSE OUTLINE The course covers the following: • • • • • • • •

Safe working area evaluation Pre-start inspection Emergency stop system Operator cab controls and switches Machine start-up Tramming the machine Setup for drilling Electronic Interface System

LEARNING OUTCOMES On completion of this course, participants will learn to: • • • • •

Identify the operators controls and switches Safely start the drill Safely tram the drill Safely set the machine up for drilling Stop the drill in an emergency

COURSE PROGRAM This training is one on one with the trainer and takes approximately 2 hours to complete, dependant on the prior knowledge of the student. NOTES: This Course Description is subject to change due to product design changes and individual attendee needs and experience.


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SK Series Rotary Blast Hole Drill Mechanical Maintenance Training INTERMEDIATE LEVEL Drill Models: MD6240, MD6290, MD6420, MD6540 DURATION : 1 Day PREREQUISITES The minimum prerequisites for attending an Intermediate Technical Training Course for Caterpillar Rotary Blast Hole Drills are: • •

Participants must have a Mechanical or Electrical Trade background Some experience maintaining Heavy Mining Equipment will be helpful to the participant

COURSE OUTLINE The Course is divided into nine (9) modules: • Module 1 – Drill Safety • Module 2 – Operators Cab & Controls • Module 3 – Undercarriage and Mainframe • Module 4 – Engine, Drive-Train, Compressor • Module 5 – Dust Control • Module 6 – Mast, Rotary Head & Pipe Handling • Module 7 – Hydraulics • Module 8 – Electrical &PLC • Module 9 – Lubrication, Preventative Maintenance LEARNING OUTCOMES On completion of this course, participants will learn to: • Identify and explain Major Components • Demonstrate an understanding of machine systems • Diagnose basic faults • Explain preventative maintenance requirements. COURSE PROGRAM Day 1

Modules 1 - 9

NOTES: This Course Description is subject to change due to product design changes and individual attendee needs and experience.


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SK Series Rotary Blast Hole Drill Mechanical Maintenance Training ADVANCED LEVEL Drill Models: MD6240, MD6290, MD6420, MD6540 DURATION : 1 Day PREREQUISITES The minimum prerequisites for attending the Advanced Technical Training Course for Caterpillar Rotary Blast Hole Drills are: •

Participants must have attended the Intermediate SK Series Rotary Blast Hole Drill Mechanical Maintenance Training.

COURSE OUTLINE The Course is divided into four (4) modules: • Module 1 – Hydraulic Pump Functions, Adjustment & Troubleshooting • Module 2 – Hydraulic Circuit Description, Function & Diagnostic Procedures • Module 3 – Compressor Diagnostics & Troubleshooting Procedures • Module 4 – Reliability Study and Repetitive Fault Identification & Rectification LEARNING OUTCOMES On completion of this course, participants will be able to: • • •

Explain how to adjust the functions of the hydraulic pump Read circuit schematics and diagnose faults in the hydraulic system Identify and rectify faults in the compressor system

COURSE PROGRAM Day 1

Modules 1 - 4



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Excavator Mechanical Maintenance Training Models: 6030, 6040, 6050, 6060 DURATION : 2 days PREREQUISITES The minimum prerequisites for attending a Technical Training Course for Caterpillar Excavators are: • •

Participants must have a Mechanical or Electrical Trade background Some experience maintaining Heavy Mining Equipment will be helpful to the participant

COURSE OUTLINE The Course is divided into eight (8) modules: • • • • • • • •

Module 1 - Introduction Module 2 – Operator Cab & Controls Module 3 – Undercarriage Module 4 – Engine, Drive Train Module 5 – Hydraulic System Module 6 – Electrical System Module 7 – Lubrication, Preventative Maintenance Module 8 – Slew System

LEARNING OUTCOMES On completion of this course, participants should be able to: • Identify and explain Major Components • Demonstrate an understanding of machine systems • Diagnose basic faults • Explain preventative maintenance requirements COURSE PROGRAM Day 1 Day 2

Modules 1 - 4 Modules 5 - 8



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O & K Excavator Electrical Systems DURATION : 2 days PREREQUISITES The minimum prerequisites for attending a Technical Training course for Bucyrus Excavators are: • Candidates must have a mechanical or electrical trade background • Some experience maintaining heavy mining equipment will be helpful to the candidate. COURSE OUTLINE This course is intended for dealer/customer personnel who have responsibility for troubleshooting and maintaining the excavator electrical systems, typically workshop supervisors, technical communicators and experienced servicemen. The course focuses on the electrical systems operation and controls of main pump regulation, lubrication system control and the monitoring system. After instruction in these basics, students then learn to apply the fundamentals to analyse and test the electrical components and electrical system. The course consists of classroom instruction and on the job practical testing and adjusting. LEARNING OUTCOMES • Learning Outcome 1 - Identify major Electrical/Electronic components, using correct terminology, which are applicable to the O&K hydraulic excavator. The course participants must be able to list 4 main electrical areas of the machine and identify components that are located in these areas. • Learning Outcome 2 - Describe the function of major components and be able to explain or demonstrate how they work. The course participant must be able to state the function and briefly explain how the components interact within the Electrical System. • Learning Outcome 3 – Demonstrate the ability to interpret electrical drawings and charts. The course participant will need to demonstrate an understanding of the Electrical schematics and charts. • Learning Outcome 4 – Demonstrate an understanding of the principals behind Pump Management Systems and be able to explain the process of this system Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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The course participant must be able to briefly explain the principal of Pump Management System and list the steps in this process. • Learning Outcome 5 - Have an understanding of the Board Control System (BCS), Pump Management System (PMS) and the Stored Programmable Control (SPC) and apply these systems to diagnose machine faults and problems. The course participant must be able to explain the difference between Board Control System (BCS), Pump Management System (PMS) and the Stored Programmable Control (SPC). They must demonstrate how to use these systems to diagnose machine faults and problems. •

Learning outcome 6 – Have an understanding of the latest BCSIII system along with the Drive controller the new Servo controller and the Auxiliary Control. To use the BCS to view the controllers through the BCS for correct control functions.

The course participant must be able to explain how to select the various menus through the BCS to view the various controls and their functions on the BCS screen. • Learning Outcome 7- Analyze and diagnose performance related problems with possible solutions, which apply to the electrical and central lubrication system. The course participant must be able to diagnose and provide possible solutions to a given machine performance related problem of the lubrication system. COURSE PROGRAM Time

Task/Activity

Main Points

Resources

7.30 am

Introduction to the facilitator, to safety requirements, to the course requirements and to the examination requirements, candidates to complete attendants form. Commence Power Point, Introduction

Outline classroom time and requirement Outline practical requirement Check to see if any special requirements

01 Introduction Power point

Power Point Slideshow O & K Electrical System

Electrical System Major components X1, X15 & X150 Cabinets, two power Supplies, BCS CAN Bus components, J1939 engine CAN Bus, PLC,CMS, PMS, DER cards. Components, addresses. Component Interaction.

O & K Electrical Training Notebook Electrical Schematics Data Projector White Board

10.00 am Power Point Continues Power Point Slideshow O & K Electrical System

How to set addresses of components Describe how incorrect addresses can result in Electronic Conflict & Ghost faults Explain how to use the BCS for Diagnosing Bus faults


8.00 am

Brief overview of the machine. Explain layout of components and Electrical Schematic.


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Electrical system faults and diagnosis. Selection and use of “Test Mode” Dangers of chemical cleaning agents

11.00 am Power Point Continues Power Point Slideshow O & K Electrical System

12.15am 12.45 am

3.45 pm

5.00pm

Review

Break Explain the Board Control System (BCS), O & K Electrical Pump Management System (PMS), Training Notebook Stored Programmable Control (SPC/PLC), Computer Electrical Schematics Management System (CMS), Data Projector Data Acquisition Processor White Board (DAR/DER) Cards and apply this System to diagnose machine faults and problems. Lunch Break Demonstrate use of BCS to analyze Bus Faults, missing addresses & Control current to Proportional Solenoid Valves Locate address of solenoid connections. CAN BUSS harness measurement. Selection of “Test Mode” Via BCS Question & answer session on the days activities

BCS Demonstrator

Electrical System Questionnaire

Close

DAY TWO Time

Task/Activity

Main Points

Resources

7.30 am

CAMP O & K Electrical System Commence Power Point, Introduction

Outline classroom time and requirement Outline practical requirement Check to see if any special requirements

01 Introduction Power point

Power Point Slideshow CAMP O & K Electrical System

Electrical System Major components X1, X10 X24 X30 & X40 Cabinets, three power Supplies, 30, 15 & VIQ. BCS CAN Bus components, J1939 engine CAN Bus, Servo, Auxiliary and Drive controllers Component Interaction.


Explanation of latest electrical drawings, the use of VIQ power to run Drive controllers and Servo Control. Emergency shut down now without the loss of Main Power supply.


8.00 am

10.00 am Power Point Continues Power Point Slideshow CAMP O & K Electrical System

Brief overview of the machine. Explain layout of components and new Electrical Schematic. Comparison of earlier/later system and advantages

Break Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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11.00am Power Point Continues

New BCS III, explain how to use the BCS to diagnose Buss faults, viewing the names and location of components and terminal connections of Components. Electrical system faults and diagnosis. The alternative method of creating “Test Mode” for hydraulic set up.

O & K Electrical Training Notebook Electrical Schematics Data Projector White Board BCS III demonstrator

Lunch Break 1.00 pm

Power Point Continues Power Point Slideshow CAMP O & K Electrical System

2.45 pm

3.45 pm

5.00pm

Review

Explain the operation of the Servo Controller, the Auxiliary Controller, and the Drive controller settings and functions. Explanation of “Pulse Width Modulation”


Demonstrate use of BCS to analyze Bus Faults, missing addresses & Control current to Proportional Solenoid Valves Locate address of solenoid connections. CAN BUSS harness measurement.

BCS III Demonstrator

Question & answer session on the days activities

Electrical System Questionnaire

Close

ASSESSMENT Assessment of each Performance Criteria will be by written examination or if possible observation and questioning of the participants in the field during the practical exercises. The participant will be asked to demonstrate or complete a written examination. Notes and reference materials may be used. All questions or demonstrations must be correct to obtain a certificate of competency. Any question answered incorrectly shall be reviewed with the participant and the correct answer explained or demonstrated. NOTES: This Course Description is subject to change due to product design changes and individual attendee needs and experience.


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MT4400 Mining Truck Mechanical Maintenance Training DURATION: 2 days PREREQUISITES The minimum prerequisites for attending a Technical Training Course for Caterpillar MT4400 trucks are: • •

Participants must have a Mechanical or Electrical Trade background Some experience maintaining Heavy Mining Equipment will be helpful to the participant.

COURSE OUTLINE The Course is divided into twelve (12) modules: • Module 1 – Introduction & Safety • Module 2 – Major Structures • Module 3 – Operator Controls • Module 4 – Frame & superstructure • Module 5 – Running Gear • Module 6 – Suspension • Module 7 – Brake system • Module 8 – Steering system • Module 9 – Hoist system • Module 10 – 24V system • Module 11 – Lube system • Module 12 – Weigh system LEARNING OUTCOMES On completion of this course, participants will learn to: • Identify and explain Major Components • Demonstrate an understanding of machine systems • Diagnose basic faults • Explain preventative maintenance requirements

COURSE PROGRAM Day 1 Day 2

Modules 1 - 6 Modules 7 -12

NOTES: This Course Description is subject to change due to product design changes and individual attendee needs and experience. Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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Contacts Global Manpower Contact: Mark W. Crandall – Service Training Supervisor [email protected] (309) 494-5493 Global Mining Contact: Martin F Young – Product Support Project Manager [email protected] (309) 636-5563 Regional Service Training Contacts: Americas North Kelley Maxwell – Service Training Consultant [email protected] (309) 675-4975 Americas South Oscar Negrini – Service Training Manager [email protected] (507) 305 2307 Asia Pacific Division Asia Pacific Kim Bak Chua – Training Manager [email protected] +65 6828 7256 China Steven Li – Training Manager [email protected] +86 21 2408 5307 Australia Warwick Newson – Training Manager [email protected] +61 3 9953 9963 Japan Tomohiko Yuda – Training Manager [email protected] +81 42 7637144 EAME Maurice Manders – Training Manager [email protected] +34 95 2418740 ext 8740 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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Service Trainning

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