SERVICE TRAINING CATALOG
NEW SURFACE & UNDERGROUND MINING PRODUCTS
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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
Matthias.Aust@cat.com
+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
DATE
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
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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
dana.dietrich@cat.com
Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.
Copy:
e-mail:
Mr. Matthias Aust
matthias.aust@cat.com
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6015 – Service Training
6015 – Service Training
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6018 – Service Training
6018 – Time Schedule
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6030 – Service Training
6040 – Service Training
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6050 – Service Training
6060 – Service Training
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6090 – Service Training
6030 to 6090 – Time Schedule
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6018 AC – Service Training
6030 AC – Service Training
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6040 AC – Service Training
6050 AC – Service Training
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6060 AC – Service Training
6090 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
Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.
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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
Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.
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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:
dana.dietrich@cat.com
Copy:
e-mail:
Mr. Matthias Aust
matthias.aust@cat.com
In case you have any questions, please do not hesitate to contact us.
We look forward to receiving your registration soon.
Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING.
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ELECTRIC ROPE SHOVELS
For more information and quote, please contact:
Mark Smith – Technical Training Manager
Mark.M.Smith@cat.com
(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.
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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.
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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
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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
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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
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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
diane.spearsanicola@cat.com
(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
Frank.Nett@cat.com
(304) 253-0216
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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
Travis.Houser@cat.com
(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
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SURFACE DRILLS
Contact:
Osvaldo Pires – Technical Training Manager
Osvaldo.Pires@cat.com
(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
joyce.chambers@cat.com 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 )
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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)
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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
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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
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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
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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
matt.phillips1@cat.com
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
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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
Dietmar.Wegner@cat.com
+49 2306 709 1946
Hans Leppkes - Technical Training Manager
Hans.Leppkes@cat.com
+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
Peter.Coffey@cat.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
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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: Ricardo_Rebecca@cat.com
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
NOTES:
This Course Description is subject to change due to product design changes and
individual attendee needs and experience.
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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
NOTES:
This Course Description is subject to change due to product design changes and
individual attendee needs and experience.
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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
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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
O & K Electrical
Training Notebook
Electrical Schematics
Data Projector
White Board
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.
O & K Electrical
Training Notebook
Electrical Schematics
Data Projector
White Board
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.
O & K Electrical
Training Notebook
Electrical Schematics
Data Projector
White Board
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
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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”
O & K Electrical
Training Notebook
Electrical Schematics
Data Projector
White Board
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.
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Contacts
Global Manpower Contact:
Mark W. Crandall – Service Training Supervisor
Crandall_Mark_W@cat.com
(309) 494-5493
Global Mining Contact:
Martin F Young – Product Support Project Manager
Young_Martin_F_JR@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.com
(507) 305 2307
Asia Pacific Division
Asia Pacific
Kim Bak Chua – Training Manager
Chua_K_B@cat.com
+65 6828 7256
China
Steven Li – Training Manager
Li_Steven@cat.com
+86 21 2408 5307
Australia
Warwick Newson – Training Manager
Newson_Warwick_A@cat.com
+61 3 9953 9963
Japan
Tomohiko Yuda – Training Manager
Yuda_Tomohiko@cat.com
+81 42 7637144
EAME
Maurice Manders – Training Manager
Manders_Maurice@cat.com
+34 95 2418740 ext 8740
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