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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
February 2013
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
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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.
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.
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 20 Standard cost for each training session incl. material is 750,- EUR per participant incl. lunch in our canteen. Costs for accommodation, flight, etc. are to be borne by the participant. Hotel payment has to be done at check-out.
Please note that the minimum number of participants is 4 persons and the maximum limited to 8 persons. Registration is requested to arrive at the latest 5 weeks prior to training starting date to ensure correct planning and optimal utilization. Please also bear in mind that visa application may be very time consuming. Please consider to bring your own safety shoes. To register yourself, please fill in the attached registration form and send it to: Attn.: e-mail: Mrs. Dana Dietrich dana.dietrich@cat.com Copy: e-mail: Mr. Matthias Aust matthias.aust@cat.com
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Cat 60xx (6015, 6018 6030, 6040, 6050, 6060, 6090) CAMP Electric Training - 40239
This module is for mechanical and electrical skilled people who can explain the basic operation of the Cat 60xx machines, to provide a detailed explanation of electrical circuits and systems used on those machines. Description: This module is for mechanical and electrical skilled people who can explain the basic operation of the Cat 60xx machines, to provide a detailed explanation of electrical circuits and systems used on those machines. During this module participants acquire detailed knowledge and skills to carry out troubleshooting on the and electrical and electronic systems of machines equipped with CAMP electric system. Learning Objectives: Upon completion of this course, participants should be able to properly maintain and perform major faultfinding and repair on Caterpillar Hydraulic Mining Excavator Cat 60xx machines equipped with CAMP electric system and will be able to perform the following tasks: Explain common machine features on Cat 60xx Hydraulic Mining Excavator. Explain the safety precautions and procedure while working on the machine. Find necessary information in delivered technical documentation. Identify & explain the function of the major components of the electric/electronic machine systems. Identify & explain the different functions of these systems. Identify the components and explain the operation of different controller boxes/systems. Identify the components and explain system operation of Board Control System. Perform daily inspection and preventive maintenance as per the operating instructions. Approval Required: No - but approval may be required to register for a class. Length: 3 days
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Conditions and Rates for Training Out of the Office in 2013 Ladies and Gentlemen, These are our regulations for your individual on-site training. Prerequisite for a training course is the availability of the following:
Training: Technical Training for Maintenance + Service Personnel Training room with projector and white screen. White board and flip-chart with markers in different colors. Access to the internet if possible. Trainees should be free for 5 complete days. The excavator should be available for the time of the training to get more practical know how. For the technical trainer, costs are 1.200,- EUR per day (travel day: 900,- EUR). Additional costs for hotel accommodation, flights, handouts for training, etc.
Training: Operator Training Training room with projector and white screen. White board and Flip-chart with markers in different colors. Access to the internet if possible. Trainees should be free for the complete training or as long as needed. The excavator must be available for the time of the training. For the operator trainer, costs are 900,- EUR per day (travel day: 700,- EUR). Additional costs for hotel accommodation, flight, material for training, etc. In case you have any questions, please do not hesitate to contact us.
To register yourself, please fill in the attached registration form and send it to: Contact details: Attn.: Mrs. Dana Dietrich e-mail: dana.dietrich@cat.com
Copy: e-mail:
In case you have any questions, please do not hesitate to contact us. We look forward to receiving your registration soon.
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Over 8 hrs. & Sat. Over 8 hrs. & Sun./U.S. Holidays Standby
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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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 Owners 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 Owners 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 SIPs 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 AFEs 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
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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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SURFACE DRILLS
Contact: Osvaldo Pires Technical Training Manager Osvaldo.Pires@cat.com (903) 337-4554
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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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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 5 MECHANICS
Booms Feeds Rod Changer Carousel Practical Identification of Components Depending on machine availability Maintenance Schedules End of Training
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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
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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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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
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 7.30 am Task/Activity 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 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. Explain layout of components and Electrical Schematic. Resources 01 Introduction Power point
8.00 am
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. 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
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Electrical system faults and diagnosis. Selection and use of Test Mode Dangers of chemical cleaning agents 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
11.00 am Power Point Continues Power Point Slideshow O & K Electrical System
12.15am 12.45 am
BCS Demonstrator
3.45 pm
Review
5.00pm
Close
DAY TWO
Time 7.30 am Task/Activity CAMP O & K Electrical System Commence Power Point, Introduction Main Points Outline classroom time and requirement Outline practical requirement Check to see if any special requirements Brief overview of the machine. Explain layout of components and new Electrical Schematic. Comparison of earlier/later system and advantages Electrical System Major components X1, X10 X24 X30 & X40 Cabinets, three power Supplies, 30, 15 & VIQ. BCS CAN Bus components, J1939 engine CAN Bus, Servo, Auxiliary and Drive controllers Component Interaction. Explanation of latest electrical drawings, the use of VIQ power to run Drive controllers and Servo Control. Emergency shut down now without the loss of Main Power supply. Break
Caterpillar Confidential: GREEN / WHEREVER THERES MINING.
8.00 am
O & K Electrical Training Notebook Electrical Schematics Data Projector White Board
10.00 am Power Point Continues Power Point Slideshow CAMP O & K Electrical System
O & K Electrical Training Notebook Electrical Schematics Data Projector White Board
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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. Lunch Break
O & K Electrical Training Notebook Electrical Schematics Data Projector White Board BCS III demonstrator
1.00 pm
Power Point Continues Power Point Slideshow CAMP O & K Electrical System
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 BCS III Demonstrator
2.45 pm
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. Review Question & answer session on the days activities
3.45 pm
5.00pm
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. 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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