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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and Machine specific training through each Product Group. their Distribution Services Divisions. DSD. and the Product Group will provide the training. 4 . Dealer Performance Center (DPC): https://dlms.com Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.• • The Dealer.logicbay. 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.

2013 9 CAT60xx CAMP Electrics Dortmund English 13 25.2013 20 Standard cost for each training session incl. please contact us direct: Matthias Aust – Training Manager Matthias.2013 16 CAT60xx CAMP Electrics Dortmund English 23 05. material is 750.06.com Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. are to be borne by the participant.-25.06.02. We are planning to offer the following trainings: SUBJECT LOCATION LANGUAGE WEEK DATE CAT 6030 Dortmund English 4 21.02.05.03.com Copy: e-mail: Mr. Please also bear in mind that visa application may be very time consuming.02.-01.04.: e-mail: Mrs.2013 12 CAT60xx CAMP Electrics Dortmund Russian 16 16.2013 11 CAT 6060 Dortmund Russian 15 08.-13.06. Please consider to bring your own safety shoes.02.2013 8 CAT 6060 Dortmund English 12 18.-27.-27.-08.-17.04.-06.05.03. We also offer the same training course to be conducted at the dealer location or customer site.04.-07.03.2013 5 Tinaja Hills CAT 6030 English 10 04. 5 .03.2013 1 Tinaja Hills CAT 6030 English 5 28. please fill in the attached registration form and send it to: Attn.04.04.-21. shovel expert or service manager.01.-12.Aust@cat.-21.03.2013 10 CAT 6050 Dortmund English 15 08.-26.02.2013 18 CAT 6015 + CAT 6018 compact Dortmund English 25 17. Please note that the minimum number of participants is 4 persons and the maximum limited to 8 persons.03.-22.01.2013 6 Tinaja Hills CAT60xx CAMP Electrics English 11 11. or technical background such as technical training instructor.2013 4 CAT60xx CAMP Electrics Dortmund English 9 25.03. Costs for accommodation.02.04.01. technical communicator.2013 13 CAT 6030 Dortmund Russian 17 22.EUR per participant incl.2013 15 CAT 6090 Dortmund English 20 13.-22.04.2013 3 CAT 6040 Dortmund English 8 18.2013 2 Tinaja Hills CAT60xx CAMP Electrics English 6 04. Matthias Aust matthias. flight. For more individual information. lunch in our canteen. To schedule these ‘on site trainings’ please contact us to discuss the details of the request.02. etc. Hotel payment has to be done at check-out.06. Registration is requested to arrive at the latest 5 weeks prior to training starting date to ensure correct planning and optimal utilization.-12.2013 17 CAT 6030 + CAT 6040 compact Dortmund English 24 10.2013 19 CAT 6050AC + 6060AC (e-drive) Dortmund Russian 25 17.06.06.-26. To register yourself.Hydraulic Shovels The regular training courses are conducted in our training center in the Dortmund Factory.04.aust@cat.06.-14.03.03.06. Dana Dietrich dana.Hydraulic Mining Shovels Participants attending this course should have a technical education as mechanical or electrical apprenticeship.04.03.-22..dietrich@cat.04.2013 7 CAT 6015 + 6018 Dortmund Russian 12 18.com +49 231 922 4932 Training Schedule 1st Half of 2013 for .2013 14 CAT 6050AC + 6060AC (e-drive) Dortmund English 17 22.CAT® 60xx .-18.

6015 – Service Training 6015 – Service Training Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. 6 .

7 .6018 – Service Training 6018 – Time Schedule Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

8 .6030 – Service Training 6040 – Service Training Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

9 .6050 – Service Training 6060 – Service Training Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

6090 – Service Training 6030 to 6090 – Time Schedule Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. 10 .

6018 AC – Service Training 6030 AC – Service Training Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. 11 .

6040 AC – Service Training 6050 AC – Service Training Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. 12 .

13 .6060 AC – Service Training 6090 AC – Service Training Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

6030 AC to 6090 AC – Training Time Schedule Electrical Training – Control and Monitoring Platform (CAMP) Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. 14 .

15 .Regular Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.CAMP – Electrical Training Time Schedule Electrical Training .

• Explain the safety precautions and procedure while working on the machine. • Identify & explain the function of the major components of the machine systems. Learning Objectives: Upon completion of this course. • Find necessary information in delivered technical documentation. • Identify the components and explain system operation of Board Control System. Description: This module is for mechanical and electrical skilled people who can explain the basic operation of the Cat 6030. 16 .but approval may be required to register for a class. Approval Required: No . 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.40240 This module is for mechanical and electrical skilled people who can explain the basic operation of the Cat 6030. • 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. • Perform daily inspection and preventive maintenance as per the operating instructions. Perform machine startup and shutdown procedures. to provide a detailed explanation of hydraulic and electrical circuits. 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. Length: 5 days Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.Service and Maintenance Training .Electrical Training Time Schedule Training Available on Dealer Performance Center (DPC) Cat 6030 .

• Identify the components and explain system operation of Board Control System.Cat 60xx (6015. Description: This module is for mechanical and electrical skilled people who can explain the basic operation of the Cat 60xx machines. 6050. Learning Objectives: Upon completion of this course. to provide a detailed explanation of electrical circuits and systems used on those machines. • Identify & explain the different functions of these systems. to provide a detailed explanation of electrical circuits and systems used on those machines. Length: 3 days Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. • Identify & explain the function of the major components of the electric/electronic machine systems. • Explain the safety precautions and procedure while working on the machine. • Find necessary information in delivered technical documentation.but approval may be required to register for a class. 6090) CAMP Electric Training . 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. Approval Required: No . 6040. • Perform daily inspection and preventive maintenance as per the operating instructions.40239 This module is for mechanical and electrical skilled people who can explain the basic operation of the Cat 60xx machines. • Identify the components and explain the operation of different controller boxes/systems. 6018 6030. 17 . 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. 6060.

Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. These are our regulations for your individual ‘on-site training’.. Additional costs for hotel accommodation.EUR). We look forward to receiving your registration soon. costs are 1. To register yourself. etc. material for training. please fill in the attached registration form and send it to: Contact details: Attn. The excavator should be available for the time of the training to get more practical know how. Matthias Aust matthias. please do not hesitate to contact us. Training: Operator Training Training room with projector and white screen.Conditions and Rates for Training ‘Out of the Office’ in 2013 Ladies and Gentlemen. White board and flip-chart with markers in different colors.: Mrs. Trainees should be free for the complete training or as long as needed.. please do not hesitate to contact us. etc.200. handouts for 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. flights. Dana Dietrich e-mail: dana. In case you have any questions.com In case you have any questions. Access to the internet if possible. flight.. The excavator must be available for the time of the training. Trainees should be free for 5 complete days. For the operator trainer.EUR per day (travel day: 900.. White board and Flip-chart with markers in different colors.aust@cat.EUR).com Copy: e-mail: Mr. 18 . For the technical trainer. costs are 900. Access to the internet if possible.EUR per day (travel day: 700.dietrich@cat. Additional costs for hotel accommodation.

19 .M. Sunday or a U. • If the trainer works more than 8 hours per day. Holiday counts towards the total days. & Sat.S.000.ELECTRIC ROPE SHOVELS For more information and quote. Training days are to be consecutive. • Training day is defined as 8 hours. Sunday or U.Smith@cat.com (414) 768-4785 2013 Training Rates Travel Daily Rates Instructor Rates (8 hours/day.S. Mon. Holiday.25 $ 1. & Sun.00 $ 466. • Any training done on a Saturday./U. day shift only. Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.489.) Overtime Rates Per Hour Daily Standby Fee when not required Over 8 hrs. customer is responsible for payment according to above rates.S. Holidays Standby $ 1.00 $ 2.00 Requirements: • Minimum of 5 days of training. . or works on Saturday.Fri.69 $ 622. please contact: Mark Smith – Technical Training Manager Mark.991. Over 8 hrs.

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25 .7495 Maintenance Training Plan Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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32 .7495 Operator Training Plan Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.

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SIB Fault Manual H. Class Schedule B. It is assumed that the people in class will be familiar with electrical shovels and basic electrical fundamentals. OBJECTIVES: Upon completion of this section. OBJECTIVES: Upon completion of this section. System Overview A. Cable Detail Identification. Identifying components and identifying interface points between the BI and SE&A schematics. E. the student will be able to:  Locate any component in the Siemens cabinet based upon information from the Siemens schematic. 35 . F. IGBT Shovel Systems Class Manual C. SIRAS remote logon information I. MATERIALS:  Class Manual  Siemens Schematics  Bucyrus Schematics  Device Manuals  Troubleshooting Manuals C. 1. as well as the interfaces between them. Covers Print Sections. Tracing. SiBas Monitor software for connecting to SiBas32 program Basic Outline: I. Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. component locations. SYSTEM COMPONENTS: Describes some of the important system devices. etc. Exercises include tracing control loops. INTRODUCTION: Provides an overview of the technologies used in the Siemens IGBT shovel family.  Locate any component in the Siemens schematic based upon its markings in the drive cabinet.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. This class will introduce the student to the technology as applied on the standard IGBT shovels. Documentation and Software furnished to the students: A. their operation and their specifications. TYPES OF FAULT MESSAGES:  ANF – PLC  CDA – PLC  SIB – SiBas II. Cross-Referencing. General Information and Procedures for the SiBas control system E. 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. Comparison of device specifications from the vendors vs. CDA / ANF Fault Manual G. BUCYRUS SCHEMATICS: Explanation of the different style of drawing used in the Bucyrus schematics. D. Shovel electronic devices manual F. Component Identification – Practical A. G. Discusses the functions and responsibilities of each. those in the application. Use of the Device Manual. SIEMENS SCHEMATICS: Introduction to the schematic style used for the IGBT system. General electrical schematics for shovels (SIEMENS & BUCYRUS) D. The instructor introduces the major black boxes used in controlling the system.

 Explain the different protection levels in the UWS cards. the differences between SiBas and earlier control systems. the student will be able to:  Monitor feedback values from the PLC and drive systems. Locate and Identify all connections points for field wiring to the drive cabinet 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. OBJECTIVES: Upon completion of this section.  Start the Monitor program to read faults and clear faults. HMI Operation – Practical A.  Read and Save faults from the Fault History screen.  Follow faults to the on-line Troubleshooting Manual.  Start the Monitor program. OBJECTIVES: Upon completion of this section.  Locate the various screens for Active Logic for monitoring and troubleshooting.  Read faults from the Active Alarms screen. the student will be able to:  Monitor feedback values from the PLC and drive systems. SiBas OVERVIEW:  SiBas as a motion control system. connector types. B. MATERIALS:  Maintenance Station Owner’s Manual IV.  Follow faults to the on-line Troubleshooting Manual.  Use Footprints screen to locate system components.  Set the system to Manual mode (for hoist & crowd).  Read faults from the Active Alarms screen. 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. 36 .  Explain the functions of each card in the SiBas rack.  Trace the signal flow through the speed regulator function package. MATERIALS:  Class Manual  Siemens Schematics  Bucyrus Schematics  Device Manuals  Troubleshooting Manuals  Shovel drive cabinet – Power Disconnected III. SiBas 32 A.  Locate and view Synchronizing voltages ULRT & ULST B. B.  Start the Monitor program to load the ZR and SIP programs. HMI Operation A.  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.  Start the Monitor program to read and record values.  Locate the various screens for Active Logic for monitoring and troubleshooting. and scan times in the SiBas program. Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.  Read and Save faults from the Fault History screen. MATERIALS:  Maintenance Station Owner’s Manual  Shovel drive cabinet – Power ON V. OBJECTIVES: Upon completion of this section.

the student will be able to:  Creating. OBJECTIVES: Upon completion of this section. startup and configuration. READING SiBas PROGRAM LISTING:  Reading Function Packages.D. opening and saving files and data. MATERIALS:  Class Manual  Laptop with Simatic Manager installed C. SiBas MONITOR PRACTICE  Exercises for the installation. D. 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. information contained. OBJECTIVES: Upon completion of this section. opening and saving files and data.  Trapping signal values in the Monitor program. startup and configuration of the software on the laptop. SETTING IP ADDRESS IN STEP 7  Setting the internal Ethernet address for the PLC Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. PLC HARDWARE: Explanation of PLC network configuration. SiBas RACK CARDS:  Functionality and interchangeability of SiBas rack cards. SiBas 32 – Practical A. Step 7 PLC and ET200 Stations A. Differences between earlier network with Host PC / Slot PLC and the new system with Rocky. E. SIP Traco functions. Setting network addresses at stations and terminating resistors.  Creating. connector and data types.  Graphing signal values in Excel  Practice in troubleshooting SiBas faults B. Explanation of ET200 cards and setup. 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. scan sequence. E.  Creating. opening and saving files and data  Loading programs into the ZR and SIP cards. SiBas MONITOR:  Installation. STEP 7 INTRODUCTION F. Different levels of protection in the UWS cards and their reset routine. SiBas HARDWARE LIST:  Guide to reading the SiBas Hardware List. 37 . scan rates. Observing connectors and changing values. MATERIALS:  SiBas Monitor Software with Interface cable and Microsoft Excel programs  Shovel drive cabinet – Power ON VII. G. F. VI. PROFIBUS: Basic steps in setting up Profibus networks. A. block types.

the Simatic Manager and around the network. MATERIALS:  Class Manual  Step 2000 series guide C. 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. Midas and Siras Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.  Observation of the chopper operation E. 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:  Shovel drive cabinet – Power ON  HMI screens and the preinstalled Simatic Manager IX. the student will be able to:  Troubleshoot problems via the System Ready screen. B. OBJECTIVES: Upon completion of this section. Shovel Command / Control Structure A. 38 . BASIC AFE MONITORING  Monitoring through the SiBas and the test points. GROUND FAULT DETECTION  Explanation of Ground Fault protection XII. Step 7 PLC . OBJECTIVES: Upon completion of this section. MATERIALS:  Class Manual  PLC Listing X. reactive power and power factor  Volts per Hertz relationship D. AFE Operation & Control – Practical A.Practical A. MATERIALS  Siemens Schematics  Voltmeter XIII. 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. 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. AFE Operation & Space Vector Control A. AC Motors & Controls A.VIII. BASICS OF AC MOTORS  Nameplate data and slip  Real power. BASICS OF AFE POWER SECTION OPERATION  AFE Block Diagram  State Vector Modulation (SVM) D. OBJECTIVES: Upon completion of this section. OBJECTIVES  Troubleshoot faults initiated in SiBas B. OBJECTIVES: Upon completion of this section. MATERIALS  Class Manuals and Overheads C.

OBJECTIVES  Summary of presented material  Open question and answer period Training Available on Dealer Performance Center (DPC) 7495 MECHANICAL SYSTEMS OVERVIEW . circuits and components.Be able to perform various inspections on the HydraCrowd system. classroom discussions and exposure to a 7495 shovel the participants are provided with learning experiences that will enable them to identify. Approval Required: No .but approval may be required to register for a class. mechanical maintenance personnel and anyone interested in learning more about this product. Through lectures. Please refer to your service manual for further specifications. 7495 HydraCrowd Inspection and Service Schedule course . 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. Approval Required: No . machine support websites and documents.A.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. In addition the participants will be exposed to the machine electrical schematics. circuits and components. Review A. Operations tools  Become familiar with the various screens and information presented in the MIDAS DesktopR B. In addition the participants will be exposed to the machine mechanical schematics. circuits and components. Be familiar with what a Preventive Maintenance Program is and why it is important. There is a maximum of 10 students per class.00 Length: 00:30 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. machine support websites and documents. Through lectures. locate and describe the CAT 7495 Electric Rope Shovel electrical system.but approval may be required to register for a class. The HydraCrowd system is found on Cat Electric Rope Shovels. classroom discussions and exposure to a 7495 shovel the participants are provided with learning experiences that will enable them to identify.41873 This course is intended for field representatives. MATERIALS  Class Manual  Laptop with MIDAS files stored for viewing XIV.Understand the important safety risks associated with the HydraCrowd system. Approval Required: No Cost: $0. locate and describe the CAT 7495 Electric Rope Shovel mechanical system.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. OBJECTIVES  Understand the differences between MIDAS and SIRAS and how they work together  Understand Maintenance tools vs. . Description: This course will provide knowledge on inspecting and servicing the HydraCrowd system. Learning Objectives: After completing this course you will: . 7495 ELECTRICAL SYSTEMS OVERVIEW . 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. 39 .

.41663 This course will provide knowledge about the HydraCrowd system.Understand the importance of cleanliness in HydraCrowd procedures. Learning Objectives: After completing this course you will be able to: .Clean the Crowd Cooler. . .41871 This course is intended for field representatives. Description: This course will provide knowledge on service procedures required for the HydraCrowd system. mechanical maintenance personnel and anyone interested in learning more about this product. . . Learning Objectives: After completing this course you will be able to: .Purge air from the Main Pumps. . . which is found on Cat Electric Rope Shovels Please refer to your service manual for further specifications.Identify the advantages of the HydraCrowd system. . Approval Required: No Cost: $0. 40 .Part 2 . Description: This course is intended for field representatives and anyone interested in learning more about 7495 HydraCrowd System™ and Components. which is found on Cat Electric Rope Shovels. fill or filter necessary oils.00 Length: 1:00 7495 HydraCrowd Service Procedures Course .00 Length: 1:00 7495 HydraCrowd System™ and Component Overview .Flush.Replace the Auxiliary Power Unit filter.7495 HydraCrowd Service Procedures Course . Please refer to your Service Manual for further specifications. drain and reassemble the Isolators.Replace Boom pressure and return hoses. Approval Required: No Cost: $0.Recognize the basic components of the HydraCrowd system.Familiarize yourself with components location and their functions Approval Required: No Cost: $0. .41872 This course is intended for field representatives.Replace the Main Pump pressure hose.Remove.Identify contaminants and maintain cleanliness of HydraCrowd parts and the surrounding area.Part 1 .00 Length: 1:00 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. mechanical maintenance personnel and anyone interested in learning more about this product. Learning Objectives: After completing this course you will be able to: .Clean the Upper Tank return filters. .

00 Length: 00:45 7495 Series Electric Rope Shovel Brakes .Understand the disc brake operation. 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. friction disc and O-ring replacement. Approval Required: No Cost: $0. propel and swing brake. • Summarize the maintenance procedures for couplings. . • Describe the safety considerations for coupling maintenance. Summarize the maintenance process for the different parts in air filtration system.Summarize the maintenance procedures for spring. Please refer to the Service Manual for further specifications. Learning Objectives: After completing this course you will be able to: . After taking the course. This course contains information on house filter fans. Approval Required: No Cost: $0.7495 Series Electric Rope Shovel Air Filtration Training . field representatives and anyone interested in learning more about this product.Describe the safety considerations for brake maintenance. the different parts of the air filtration system and how to maintain it. hoist. This course contains disc brake operation. Describe the maintenance and cleaning process of the air conditioner/heater system. Learning Objectives: After completing this course you will be able to: Explain how to maintain the parts in the house filter fans. field representatives and anyone interested in learning more about this product. crowd. Please refer to the Service Manual for further specifications. Description: This course is intended for Caterpillar dealer’s sales professionals. propel.00 Length: 01:00 7495 Series Electric Rope Shovel Couplings Training . summarize the maintenance procedures for couplings and describe the safety considerations for coupling maintenance. Approval Required: No Cost: $0. 41 .00 Payment Status: No payment required Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.Explain how to maintain the hoist.41867 This course will provide knowledge about the 7495 Series Electric Rope Shovel Couplings. crowd. Learning Objectives: After completing this course you will be able to: • Explain the different procedures for grid and gear couplings. . . This course contains grid and gear coupling maintenance procedures.40242 This course will provide knowledge about the 7495 Series Electric Rope Shovel Air Filtration System. maintenance. Description: This course is intended for Caterpillar dealer’s sales professionals. and swing brake maintenance procedures. you should be able to explain the different procedures for grid and gear couplings.41807 This course will provide knowledge about the 7495 Series Electric Rope Shovel Brakes.

Hydraulic Maintenance Training – 2 day class. Approval Required: No Cost: $0. Operator's Cab and the Theory of Operation of the 7495 Series Electric Rope Shovel. please contact: Diane Spear Sanicola – Team Leader diane. ERS E01.0-7495 POWER DISTRIBUTION 4. Electrical Features. Contact: Frank Nett – Product Health Manager Frank. In addition.7495 Series Electric Rope Shovel Overview .00 Length: 01:00 CAT 7495 Electric Rope Shovel Electrical Systems Overview . ERS E02. circuits and components of the CAT 7495 electrical systems.0 ERS E07. capabilities and theory of operation. Description: This course will cover History. 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.0-7495 INTRODUCTION 2. • Utilize the documents and references materials used to maintain service and troubleshoot the CAT 7495 electrical systems.0-7495 CONTROL & COMMUNICATIONS 6. specifications.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.0 ERS E05.0 ERS E04.0. manuals and schematics used to maintain and service the CAT 7495.0 ERS E03. Mechanical Features. This course includes the following topics: 1. 42 . Lower Works. • Describe the operational capabilities and specifications of the CAT 7495 electrical systems. Both classes are taught at the Beckley WV Facility.42355 This training course is designed to introduce electrical service personnel to the CAT 7495 Electric Rope Shovel. Approval Required: No . Description: This course includes systems descriptions.0 ERS E06. It is especially suited to service technicians who are unfamiliar with the particular electrical and control systems of the 7495. Length: 5 days DRAGLINES For more information.but approval may be required to register for a class. the learner will become familiar with the documents.40281 This course is intended for anyone interested in learning more about this product such as Cat dealer sales professionals or field representatives.spearsanicola@cat.0.0-7495 POWER CONVERSION 5. Learning Objectives: The goal of this course is to provide basic knowledge and a core understanding of the Cat 7495 Series Electric Rope Shovel.0-7495 AUXILIARY & SUPPORT SYSTEMS 7.com (304) 253-0216 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.com (414) 768-4988 Highwall Miner Electrical Maintenance Training – 2 day class.0-7495 ELECTRICAL SAFETY 3.Nett@cat.

com (414) 768-4097 Training Syllabus – Structure and Function Location: on mining site Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.UNIT RIG TRUCKS Training is provided on site in English. For more information and quote. 43 .Houser@cat. please contact: Travis Houser – Technical Training Manager Travis.

Training Syllabus .General Electric AC Drive System Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. 44 .

Operator's Station MODULE 2 .Hoist System MODULE 7 .Running Gear MODULE 9 . 45 .Electrical System MODULE 4 .General Atomics AC Drive System Location: on mining site Training Available on Dealer Performance Center (DPC) 2012 .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.Electric Drive Train MODULE 10 .Structure MODULE 3 .Training Syllabus .Automatic Lubrication System MODULE 11 .Unit Rig MT4400 AC Off-Highway Truck .Engine and Support Systems MODULE 5 .Brake System MODULE 8 .Unit Rig MT4400 AC Off-Highway Truck .Weigh System Location(s): STMG Documents >> 2012 .SERV1950 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.Steering System MODULE 6 .MODULE 1 .

46 .Pires@cat.com (903) 337-4554 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.SURFACE DRILLS Contact: Osvaldo Pires – Technical Training Manager Osvaldo.

Dwg) or actual unit when available OVERVIEW OF POTENTIAL HAZARDS  Safety . It is intended for dealer or customer participants. Rotacion Der. Operating Systems. Operating Controls. Pull-down / Hoist. Travel related expenses are the responsibility of the Dealer/participant. and finish at 5:00 p.com Joyce will also have information regarding accommodations.chambers@cat. Hotel(s) are approximately 10 minutes from the Factory. • Classes will cover.)  Tram Controls ( Controles de desplazamiento.. Main Components & Layout. To register contact Joyce Chambers at joyce. Safety.Before Operation  Minimum Clearances from High Voltage Lines  Safety . 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. Bomba auxiliar. Oruga Izq. Participants should plan to arrive the Sunday before and depart after 12:00 p. such as: air. The classes are no cost to Cat Dealers. Drill Application. TX. Rotacion.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.Operation & After Operation  Safety . • Training will be conducted at the Drill Factory in Denison. • Training will start each day at 8:00 a. 1– Maintainers Program Syllabus 1) Theoretical Technical Training.m. Training material and Lunch will be provided. on Friday. Pull-down. 47 . Maintenance and Options.water. • Registration is required (2) two weeks prior to the class.m. A. Knowledge of basic hydraulics and applied electricity is a prerequisite. • The Factory is located approximately 70 miles North of DFW Airport.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. Presion de aire )  Engine and compressor gauges ( Manometros del motor y compresor )  Fuses ( Fusibles )  Drill Controls ( Controles de Barrenacion. including functionality explanation of different Systems. Oruga Der ). 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 . Course is on an advanced level.m.(Locator Chart ./ Izq. hydraulic.

48 . )  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.MAIN AIR SYSTEM (SISTEMA DE AIRE PRINCIPAL)  Sull-Air Compressor Components ( Componentes del compresor Sull. Single and Double Speed Circuits. ( Bomba Auxiliar. Sistema del Pull-Down y Funciones de Posicionamiento )  Fan Pump.Perforacion / Desplazamiento )  Auxiliary Pump.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. o Izq.( Cicuito Cerrado de las Bombas Der. Right and Left Main Pumps. ( Cargador de Barras Adentro y Fuera / Interlock )  Carrousel lock ( Seguro de giro del cargagador )  Carrousel rotation right or left ( Giro del Cargador Der. Drill / Tram . (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. e Izq. Pull-Down System and Positioning functions.

 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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Maintenance. Models: MD5050-MD5050T-MD5075-MD5090-MD505125 Coverage: Safety. It is intended for dealer or customer participants. DAY 1 INTRODUCTION  Safety  Model Overview . Main Components & Layout. 52 . This Training is intended for Technical Personnel who are directly involved in maintenance and operation of the Caterpillar Drilling units.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 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. Drilling Application. Rod Changer and options. Can-Bus. Operating Controls. Operating Systems. Carrousel.Preventive Maintenance Safety Overview Maintenance Chart Daily Checks Hydraulic Percussive Track Drill Technical Training Program Location : Denison. Knowledge of basic hydraulics and applied electricity is a prerequisite. Course is on an advanced level.

machine hydraulics. Provide an overview of machine operation.1549 matt.4861 O: (+1) 724. Provide a detailed explanation of the machine control system 3. 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 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. 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. and maintenance 2. 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.com Continuous Miner Service Training – Program Overview Scheduled Time: 5 days Purpose: 1.249. Training can be provided either at our facility or on site Contact person: Matt Phillips M: (+1) 724.ROOM AND PILLAR Training organized on requests. Provide a detailed explanation of both AC and DC control systems 3. 53 . Provide an overview of the machine and machine operation 2.743. 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. and water systems 4.phillips1@cat. hydraulic. Provide a detailed explanation of the electrical. Provide an overview of preventative maintenance required 5.

Typical Class Structure: Day 1 – Diesel Introduction Control System. electrical system. 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. 2. electrical permissibility. and maintenance for a PLC controlled machine. hydraulic system. 2. 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. 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 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. Provide an overview of machine operation. and DC battery powered scoops. AC battery powered scoops. Provide an overview of machine operation and control system. maintenance. and hydraulics for diesel powered scoops.Scoop Utility Vehicle Service Training – Program Overview Scheduled Time: 4 days Purpose: 1. Provide an overview of machine operation. and maintenance for a simple electrics machine. 54 . hydraulic system. Required Experience: Course attendees should have a strong mechanical background and have an advanced understanding of hydraulic and electrical systems. electrical system. control system.

hydraulic system. and maintenance. Provide an overview of machine operation. 55 . electrical system. Typical Class Structure: Day 1 Introduction Overview of Layout. Provide an overview of machine operation. Operation Maintenance Electrical System Hydraulic System Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. hydraulic system. electrical system. Required Experience: Course attendees should have a strong mechanical background and have an advanced understanding of hydraulic and electrical systems. etc. and maintenance. Typical Class Structure: Day 1 Introduction Operation Maintenance Electrical System Hydraulic System Continuous Haulage Service Training – Program Overview Scheduled Time: 1 day Purpose: 1. Required Experience: Course attendees should have a strong mechanical background and have an advanced understanding of hydraulic and electrical systems.Roof Bolter Service Training – Program Overview Scheduled Time: 1 day Purpose: 1. Attached vs. Detached Systems.

CM235 Continuous Miner . maintenance. Learning Objectives: After completing the course. This includes an explanation of how an underground room and pillar mine operates and the various types of equipment used. Electrical System Operation Maintenance and Permissibility Hydraulics Day 2 .00 Payment Status: No payment required Length: 1:00 2012 . and to know the methods and strategies used in all of the major systems of the CM235 Continuous Miner. 2. Use of the knowledge gained in this course will ensure participants will be able to provide more effective customer service. and DC battery powered shield haulers. Typical Class Structure: Day 1 . Provide an overview of machine operation. and hydraulics for diesel powered shield haulers. AC battery powered shield haulers. electrical permissibility. which enhances customer satisfaction. control system. 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.CM235 Continuous Miner . 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. Description: This course will provide an overview of the Cat Room and Pillar Mechanical Mining System.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.Shield Hauler Service Training – Program Overview Scheduled Time: 4 days Purpose: 1. 56 .AC AC Control System Electrical System Operation Hydraulics Maintenance Day 4 Battery Maintenance Battery Chargers Shield Hauler Wrap-Up Training Available on Dealer Performance Center (DPC) Room and Pillar Mechanical Mining .DC DC Control System Electrical System Operation Hydraulics Maintenance Day 3 .SERV1963 Description: It is necessary for participants to be able to quickly and accurately diagnose problems to test and properly adjust components.SERV1963 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. Location(s): STMG Documents >> 2012 .Diesel Introduction Control System.

the electrical system. you should be able to: . Location(s): STMG Documents >> 2012 .Identify components of the hydraulic system Current Status: Not Started Approval Required: No Cost: $0. Description: This is a foundational level course. Description: This course provides an overview of the FH120 Face Hauler. its main components. and its service points.FH120 Room Pillar Mining .SERV1962 FH120 Face Hauler Service Training Course . When used in conjunction with the service manual.FH120 Room Pillar Mining .Identify basic machine functions and the location of service points around the machine .Identify the machine's key service points .00 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. the HiPAC 10 display. This course provides a review of the CM235 Continuous Miner. to test and properly adjust components. Always use the latest Service Information to ensure that the most current specifications and test procedures are used.Identify components of the electric system .Identify components in the operator's station . and the hydraulic system. Learning Objectives: After completing the course.Explain the basic operation of the machine Approval Required: No Cost: $0. The basic machine functions.SERV1962 Description: This FH120 Face Hauler Machine Service Training Course is designed to prepare participants to quickly and accurately diagnose problems. When used in conjunction with the service manual. how it operates. component locations and service points are identified and the basic systems operation are discussed.Identify the features of the HiPAC 10 display . components in the operator’s station. 57 . This includes the basic machine functions and the location of service points around the machine. the information in this course should permit the technician to analyze problems in any of the major systems on these machines.Cat CM235 Continuous Miner Overview . and to demonstrate knowledge of the methods and strategies used in all of the major systems of the FH120 Face Hauler.41886 This course will provide an overview of the Cat CM235 Continuous Miner.00 Payment Status: No payment required Length: 00:45 2012 .Identify the various systems and components of a CM235 Continuous Miner . Learning Objectives: After completing the course. The component locations and service points are identified and the basic systems operation are discussed. you should be able to: .41869 This course will provide an overview of the FH120 Face Hauler machine. the information in this course should permit the technician to analyze problems in any of the major systems on these machines.

Technical Training Manager Hans. Required experience Participants attending this course should be of a basic technical background. the main application requirements. 3. the system components and general service requirements. It gives an overview of the machines and main components a longwall system consists of. Course data Underground longwall mining methods by shearer and plow systems. Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.Wegner@cat. Purpose This module is for dealer audience to become acquainted with underground longwall mining infrastructure and the systems in general.com +49 2306 709 1946 Hans Leppkes . 58 .PLOW / SHEARER/ LONGWALL Training organized on requests. Training will be provided in factory facility in Luenen (Germany) Contact person: Dietmar Wegner – Product Support Manager Dietmar. 5. General explanation of a longwall system. Resources Exemplary user manuals. Furthermore an indication about possible required services like maintenance. 1. 4. shearer and longwall.Leppkes@cat. Exemplary parts books. typical parts replacements and repair requirements will be given. System and product introduction (scheduled time 6h) 2.com +49 2306 709 1264 This module will comprise a general introduction of underground mining and then the different applications of the plow. Summary of content Basic introduction of underground longwall mining. available from February 2013.

Contact: Peter Coffey – Technical Documentation Cordinator Peter.com (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 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.Coffey@cat.Conveyor Systems Training delivered to the mine site. 59 .

Asia Pacific 2013 Dealer Training Schedule Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. 60 .

please fill in the attached registration form and send it to: Attention: Ms Rebecca Ricardo Email: Ricardo_Rebecca@cat.com Note: Venue information for training will be provided upon registration.To register yourself. Course Enrollement Form Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. 61 .

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. dependant on the prior knowledge of the student.Hydraulic Rotary Drill-Move & Test . 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.Operator Training DURATION : 2 Hours PREREQUISITES There are no minimum prerequisites for attending the Caterpillar Hydraulic Rotary Drill Move & Test training. Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. 62 . The course is designed for maintenance and/or build staff. NOTES: This Course Description is subject to change due to product design changes and individual attendee needs and experience.

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. 63 . Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. MD6290. participants will learn to: • Identify and explain Major Components • Demonstrate an understanding of machine systems • Diagnose basic faults • Explain preventative maintenance requirements. Preventative Maintenance LEARNING OUTCOMES On completion of this course.SK Series Rotary Blast Hole Drill Mechanical Maintenance Training INTERMEDIATE LEVEL Drill Models: MD6240. Rotary Head & Pipe Handling • Module 7 – Hydraulics • Module 8 – Electrical &PLC • Module 9 – Lubrication. Compressor • Module 5 – Dust Control • Module 6 – Mast. Drive-Train. 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.

SK Series Rotary Blast Hole Drill Mechanical Maintenance Training ADVANCED LEVEL Drill Models: MD6240. 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. MD6420. 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. 64 . Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. COURSE OUTLINE The Course is divided into four (4) modules: • Module 1 – Hydraulic Pump Functions. 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 . MD6290.4 NOTES: This Course Description is subject to change due to product design changes and individual attendee needs and experience. Adjustment & Troubleshooting • Module 2 – Hydraulic Circuit Description.

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 . 6050. Drive Train Module 5 – Hydraulic System Module 6 – Electrical System Module 7 – Lubrication.Introduction Module 2 – Operator Cab & Controls Module 3 – Undercarriage Module 4 – Engine.8 NOTES: This Course Description is subject to change due to product design changes and individual attendee needs and experience.4 Modules 5 . 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 . Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. 6040. 65 .Excavator Mechanical Maintenance Training Models: 6030. Preventative Maintenance Module 8 – Slew System LEARNING OUTCOMES On completion of this course.

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. The course consists of classroom instruction and on the job practical testing and adjusting. typically workshop supervisors. 66 . students then learn to apply the fundamentals to analyse and test the electrical components and electrical system. After instruction in these basics.Identify major Electrical/Electronic components.Describe the function of major components and be able to explain or demonstrate how they work. lubrication system control and the monitoring system. The course participant must be able to state the function and briefly explain how the components interact within the Electrical System. using correct terminology. 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 OUTCOMES • Learning Outcome 1 . • 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. The course focuses on the electrical systems operation and controls of main pump regulation. technical communicators and experienced servicemen. The course participant will need to demonstrate an understanding of the Electrical schematics and charts. which are applicable to the O&K hydraulic excavator. • Learning Outcome 2 . • Learning Outcome 3 – Demonstrate the ability to interpret electrical drawings and charts. COURSE OUTLINE This course is intended for dealer/customer personnel who have responsibility for troubleshooting and maintaining the excavator electrical systems.

BCS CAN Bus components. DER cards. Component Interaction. addresses. 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 O & K Electrical Training Notebook Electrical Schematics Data Projector White Board 10.00 am Power Point Continues Power Point Slideshow O & K Electrical System O & K Electrical Training Notebook Electrical Schematics Data Projector White Board Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING. to safety requirements. 67 .Have an understanding of the Board Control System (BCS). to the course requirements and to the examination requirements.Analyze and diagnose performance related problems with possible solutions. Pump Management System (PMS) and the Stored Programmable Control (SPC). The course participant must be able to explain the difference between Board Control System (BCS). Introduction Power Point Slideshow O & K Electrical System Main Points Outline classroom time and requirement Outline practical requirement Check to see if any special requirements Brief overview of the machine. two power Supplies.00 am Electrical System Major components X1. • Learning Outcome 5 . J1939 engine CAN Bus. Resources 01 Introduction Power point 8. • Learning outcome 6 – Have an understanding of the latest BCSIII system along with the Drive controller the new Servo controller and the Auxiliary Control. candidates to complete attendants form.CMS. X15 & X150 Cabinets. Pump Management System (PMS) and the Stored Programmable Control (SPC) and apply these systems to diagnose machine faults and problems. Commence Power Point. The course participant must be able to diagnose and provide possible solutions to a given machine performance related problem of the lubrication system. 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. which apply to the electrical and central lubrication system.The course participant must be able to briefly explain the principal of Pump Management System and list the steps in this process. PMS. To use the BCS to view the controllers through the BCS for correct control functions. They must demonstrate how to use these systems to diagnose machine faults and problems. Explain layout of components and Electrical Schematic. COURSE PROGRAM Time 7. Components.30 am Task/Activity Introduction to the facilitator. PLC.

Data Projector Data Acquisition Processor White Board (DAR/DER) Cards and apply this System to diagnose machine faults and problems. Computer Electrical Schematics Management System (CMS). Comparison of earlier/later system and advantages Electrical System Major components X1. J1939 engine CAN Bus. Training Notebook Stored Programmable Control (SPC/PLC).15am 12. 30. Auxiliary and Drive controllers Component Interaction. missing addresses & Control current to Proportional Solenoid Valves Locate address of solenoid connections.45 pm Review Electrical System Questionnaire 5.00 am Power Point Continues Power Point Slideshow O & K Electrical System 12. Emergency shut down now without the loss of Main Power supply. Explanation of latest electrical drawings. 15 & VIQ. Selection and use of “Test Mode” Dangers of chemical cleaning agents Break Explain the Board Control System (BCS). Selection of “Test Mode” Via BCS Question & answer session on the days activities 11. Lunch Break Demonstrate use of BCS to analyze Bus Faults.30 am Task/Activity CAMP O & K Electrical System Commence Power Point. O & K Electrical Pump Management System (PMS). Introduction Main Points Outline classroom time and requirement Outline practical requirement Check to see if any special requirements Brief overview of the machine.00 am Power Point Continues Power Point Slideshow CAMP O & K Electrical System O & K Electrical Training Notebook Electrical Schematics Data Projector White Board 68 . the use of VIQ power to run Drive controllers and Servo Control. Servo. CAN BUSS harness measurement.00pm Close DAY TWO Time 7.00 am Power Point Slideshow CAMP O & K Electrical System O & K Electrical Training Notebook Electrical Schematics Data Projector White Board 10. Explain layout of components and new Electrical Schematic. three power Supplies. Break Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.Electrical system faults and diagnosis.45 am BCS Demonstrator 3. Resources 01 Introduction Power point 8. BCS CAN Bus components. X10 X24 X30 & X40 Cabinets.

00am Power Point Continues New BCS III. All questions or demonstrations must be correct to obtain a certificate of competency. the Auxiliary Controller. Explanation of “Pulse Width Modulation” O & K Electrical Training Notebook Electrical Schematics Data Projector White Board BCS III Demonstrator 2.45 pm Electrical System Questionnaire 5. 69 . and the Drive controller settings and functions.45 pm Demonstrate use of BCS to analyze Bus Faults.00 pm Power Point Continues Power Point Slideshow CAMP O & K Electrical System Explain the operation of the Servo Controller. Electrical system faults and diagnosis. Review Question & answer session on the days activities 3. 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. The participant will be asked to demonstrate or complete a written examination. The alternative method of creating “Test Mode” for hydraulic set up. Notes and reference materials may be used. Any question answered incorrectly shall be reviewed with the participant and the correct answer explained or demonstrated. viewing the names and location of components and terminal connections of Components. explain how to use the BCS to diagnose Buss faults. CAN BUSS harness measurement.00pm 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. Lunch Break O & K Electrical Training Notebook Electrical Schematics Data Projector White Board BCS III demonstrator 1. missing addresses & Control current to Proportional Solenoid Valves Locate address of solenoid connections.11.

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 . 70 .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. Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.6 Modules 7 -12 NOTES: This Course Description is subject to change due to product design changes and individual attendee needs and experience. 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.

com (507) 305 2307 Asia Pacific Division Asia Pacific Kim Bak Chua – Training Manager Chua_K_B@cat.com +61 3 9953 9963 Japan Tomohiko Yuda – Training Manager Yuda_Tomohiko@cat.com +86 21 2408 5307 Australia Warwick Newson – Training Manager Newson_Warwick_A@cat.com +81 42 7637144 EAME Maurice Manders – Training Manager Manders_Maurice@cat.com +65 6828 7256 China Steven Li – Training Manager Li_Steven@cat.com (309) 494-5493 Global Mining Contact: Martin F Young – Product Support Project Manager Young_Martin_F_JR@cat.com +34 95 2418740 ext 8740 Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.Contacts Global Manpower Contact: Mark W. 71 . Crandall – Service Training Supervisor Crandall_Mark_W@cat.com (309) 636-5563 Regional Service Training Contacts: Americas North Kelley Maxwell – Service Training Consultant Maxwell_Kelley_G@cat.com (309) 675-4975 Americas South Oscar Negrini – Service Training Manager Negrini_Oscar@cat.

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