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Safety Share
Safety
795F AC Walkaround
Hardhat Safety Boots Safety Glasses
Keep Hydrated
795F AC Introduction
785C / D
789
793D / F
795F-AC
797B / F
EH3000
EH3500-AC
EH4500-2
EH5000
HD 1500 -7
730E
830E - AC
860E
930E-4
960E
930E-4SE
MT300
MT3300A
MT3600 MT3700AC
MT4400AC
MT5500
MT6300A
Unit Rig
T252 T262 TI274 T282
7513
7530
7560
SF31904
SF32601
110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 3200 330 340 350 360 370 380 390 400 410 420 100 109 1188 127 136 145 154 163 172 181 191 200 209 218 2277 236 245 254 263 272 281 290 299 308 318 327 336 345 354 363 372 381 3
Overview of Coverage
797F Commonality
Wet Multi-Disc Brakes C-175 Engine Platform Struts, Wheels & Tires 4 Bar Rear Linkage Operator Cab
New Content
AC Powertrain Inverter (MELCO Phase Modules) Generator (EPG Experience)
Common/Similar designs
Front
Design Front Wheel Front brake pack Brake cooling pump Cab Engine (C175-16) Frame Steering pump Pump drive Pump drive shaft Rear suspension (Four bar link design) Rear struts Rear wheel casting Rear wheel bearings Rear brake pack
795F AC Common Common Common Common Common (except for turbos) Similar design Common Common Common Similar Common Common Common Common
797F Common Common Common Common Common Common Common Similar Common Common Common Common
Rear
C-175 Engine
Cat is a leader in Electric Power Generation 695 C175 engines Built to date for all applications
Over 500 C175-16 Built 260 for Mining Trucks 250 for Power Generation
C175-16 Engine
Proven Leader in Inverter systems for heavy duty electric drive applications
Same Phase Module used in EMD locomotives
Power inverter:
Collaboration with Mitsubishi Electric
Hi level specifications
Specification
Engine Power (HP) Target Payload
795F AC
C175 16 3400 345 T* / 360 T** 313 mt / 326 mt 1,257,000 lb 570,166 kg 40 mph 64 kph 7+ mph 11.3 kph 19.28 mph 31.03 kph 55/80R63 56/80R63 59/80R63 BFOR
TGMW Standard Top speed Speed on grade (12% effective) Retarding (10% effective) Tires
*As per Cat std. **As per electric drive industry practice
795F AC Specifications
Specification
Engine Power (HP) Target Payload GMW Standard Top speed Speed on grade (12% effective) Retarding (9% effective) Tires
793F
C175 16 2650 250 T 227 mt 860,000 lb 390,100 kg 37 mph 60 kph 8 mph 13 kph 18 mph 29 kph 40.00R57 46/90R57 50/80R57
795F AC
C175 16 3400 345 T 313 mt 1,257,000 lb 570,166 kg 40 mph 64 kph 7 mph 11.3 kph 21.5 mph 34.6 kph 55/80R63 56/80R63 59/80R63 BFOR
797F
C175 20 4000 400 T 362 MT 1,375,000 lbs 623,690 Kg 42 mph 68 kph 8 mph 13 kph 9.5 mph 15.3 mph 59/80R63
Profitable Business
New Cab
Cat 795F visibility
Improved Ergonomics
Larger cab than 793 (10%) Adjustable steering column New transmission control with park position Hoist lever moved to center console
Increased Visibility
40% more window area Center mounted gauge cluster 15% improvement in visibility
Visibility - Operator
Operator Controls
2 (600 mm) wide walkway to cab Improved Secondary Egress Powered Stair Attachment Flat & Open Deck
Eliminated Step Down to Catwalk 600 mm Wide Access to Cab Improved Secondary Egress
Safety in Serviceability
F793F Series
Modular Powertrain
C175-16 Engine
Radial Grid
Generator
Wheel motors
Software and Test Engineers Tried Many Scenarios Developed the best Braking, Retarding, and Control Strategy
795F AC Operators are our Best Promoters the Truck has won them over.
1 Front Brake Assist On/Off Switch 2 Retarder Lever 3 Retarding Speed Control Toggle 4 - Automatic Retarder Control (ARC) On/Off Switch
0% Retarder Lever 795F AC (Front Brake Switch OFF) Electric Retarding (rear wheels) Service Brakes (front wheels) Service Brakes (rear wheels) 793 MD Service Brakes (front wheels) Service Brakes (rear wheels)
100%
0% Retarder Lever 795F AC (Front Brake Switch ON) Electric Retarding (rear wheels) Service Brakes (front wheels) Service Brakes (rear wheels) 793 MD Service Brakes (front wheels) Service Brakes (rear wheels)
100%
ARC Operation
0% ARC Demand 795F AC (Front Brake Switch OFF) Electric Retarding (rear wheels) Service Brakes (front wheels) Service Brakes (rear wheels) 793 MD Service Brakes (front wheels) Service Brakes (rear wheels)
100%
ARC Operation
0% ARC Demand 795F AC (Front Brake Switch ON) Electric Retarding (rear wheels) Service Brakes (front wheels) Service Brakes (rear wheels) 793 MD Service Brakes (front wheels) Service Brakes (rear wheels)
100%
Comparison of Systems
793F
Operates in propel only
795F AC
Operates in propel and electric retard Limits wheel slips and slides by reducing electrical torque to each motor independently
Uses the rear brakes to limit speed differences between rear wheels No steering sensor allowed slip must accommodate steering No ground speed reference; only relative wheel speed is controlled
Use of steering sensor improves sensitivity to wheel slips and slides Uses front wheel speeds as a ground speed reference to improve overall traction
Brake
Engine
TC
Trans
Speed sensors
Diff
Brake
time
Rectifiers
M
Speed sensors
Engine
Alt.
time
C175
3500B
KUCC Concerned the 795F AC was Slower than 793D Speed on Grade
Compare 793D and 795F AC
Productivity Measures
Tons per Cycle Tons per Hour
Scale Truck
S97
BC07
Approx.8.3%
Distance
Approx.8.3%
Approx.10.0%
5800 5700 0
S97
2000 4000 6000 8000 10000 12000 14000
Elevation
Productivity Measure
tons/cycle tons/hr
Quiet
No ear protection required
Operator Comments
Im a Komatsu operator, but in slick conditions the 795F is really stable, a lot more stable than Komatsu. D.Winnet after driving on 2 of snow on Nov. 12, 2009 Beautiful, smooth, quiet I love this machine, unbelievable, braking is great, simple to operate. Build them faster, make me a personal one. G. Turley In a downpour at the Arch Black Thunder Mine the 795F AC was the only truck that was able to continue running due to confidence of traction control and four corner blended retarding.
Cat Mine Specific Design (MSD) Bodies Cat bodies: Designed to work with Cat trucks
Engineered to Fit the Caterpillar Chassis Truck Body Options: Application Specific (Lightweight, HD, Coal) Mine Specific Design: liner system optimization
Performance
345 ton Payload 7.07.5 mph @12% effective grade Blended Four-Corner Retarding Traction Control GVW within Tire Specs Quiet Cab (76dBa) Mine Specific Design Bodies
Serviceability
Modular Power Train: Lower R&I Ground Level; Platforms Ground Level (Bumper) Service Center, LOTO, Batteries 1000 hour filter life Turbos: good access Drain Plugs; SOS Ports
Reliability
Rear mounted Generator Continuous Rear Axle Filtration Fewer external hoses Component Diagnostics On-Board Operator Advisor / Test Features Frame casting and mild steel
Mechanical Drive
AC Electric Drive
Generator:
Capitalize on Cats leadership in electric power generation
Power inverter:
Collaboration with Mitsubishi Electric
Caterpillar integration
Motors:
Designed and built to Cats specifications
C175-16 Engine
Radial Grid
Generator
Wheel motors
Electric drive relies on a diesel engine to turn a generator providing electric power for traction motors turning the rear wheels
Engine / Generator
Engine powers the generator Generated AC voltage is converted then used to power wheel motors Excitation regulator and Inverter draw power out of the generator Engine speed becomes independent of power generated
Available power still based on rpm
3-phase AC voltage from the generator is routed to the Inverter cabinet where it is converted to DC for use by the Inverters
In the Inverter cabinet, a rectifier converts AC voltage from the generator into DC voltage The DC voltage is further smoothed via large capacitors which form the DC bus.
3-phase AC from the generator is routed to the Inverter cabinet where it is converted to DC, then back to AC for use by the wheel motors
The DC Bus is connected to both Inverters Voltage from the DC Bus is used by the inverters to output AC voltage variable in amplitude and frequency for controlling wheel motor speed
The AC voltage from the inverter is sent to the wheel motor where its amplitude and frequency results in torque and speed on the motors driveshaft. The amount of torque and speed is based on operator inputs Inner workings:
Stator: Frame & Windings Rotor: Rotating component On AC trucks, the voltage and frequency determine the speed and torque of the wheel motors
Electric trucks use their wheel motors for dynamic retarding, using electric current to slow the rear wheels Retard Mode
The voltage and frequency sent to the wheel motors result in them behaving like generators Generated voltage from the wheel motors goes back into the inverter cabinet on onto the DC Bus The excess voltage is then routed to retarding grid Voltage is absorbed by the resistor grids then dissipated as heat
Similar to a big toaster
08-09
Drivetrain Simulator
Prototype/Pilot Trucks
Caterpillar Technical Center C175 Engine NPI intent Generator and Motors CAT Proprietary electric drive controls Component Validation Software testing and validation Continues to be utilized into production
Tucson Proving Grounds Engineering Product Support & Marketing Field Development Pilot truck in operation at Kennecott Utah Copper.
2005
797 modified w/ Electric Drive 3524 Engine Primary Use Software Propulsion Retarding Traction Control Anti-Rollback Troubleshooting Purpose To test ECM and software linked to computer generated component models Production intent Software/Controls Machine and System Level set ups
AC Drivetrain Simulator
C175-16 Engine
Blower Fan
Inverter
Grids
Inverter Grids
Truck Controls
Payload
True 345-350 tons (313-318 tonnes)
Product Support
Serviceability Modular Powertrain
Competitive comparison
CCRs
SAFETY
ITEM Access / Egress Working at Heights Operator Sound Operator Visibility Hydraulic Filter Life Major Component R&I Ground Level Maintenance AST (HVOF) Ecology drains System integration Complexity VIMS Advisor Payload Propulsion SOG (12%) Retarding SOG (-10%)
CAT 795F AC
930E-4
Komatsu 930E-4SE
960E
Hitachi EH5000 795F AC Notes: PAS, Rear Access, CSGA, 600mm Engine Bay, Tie Off points, Center torque tube etc. 76 dba vs. 81dba WAVS, HID lighting 1000 hours vs. 500 hours Generator, WM, and FD component R&I...industry best Filters, SOS ports, sight glasses, pressure ports Hoist cylinders and struts Filters, pans, etc. Supportability with bumper to bumper System complexity - Hydraulics A single source for diagnostics, all critical functions 345sT, w/ liners, 100% fuel/lubes, 4% debris, field options 7.0-7.5 mph (11.3-12.1 kph) 6,400hp in retarding; 19.28 mph (31.03 kph) Four corner oil cooled brakes Blended retarding (Front brakes & Rear dynamics) Evaluate features during field program Onboard filtration, added complexity w/ coolersto evaluate 23% Std, 26.5% Opt Slight underload of rated capacity with 56/80R63 Mine specific design body
PERFORMANCE
SERVICEABILITY
Braking Retarding AC Drive System Final Drives Stall Torque Gradeability Tires Body
AC Drive Field Follow Target Sites 2010 Four Trucks Running: 2 Bingham Canyon; 1 Arch Black Thunder; 1 Barrick Cortez Hills 4 Additional Trucks in NA
Teck Resources Ltd. Fording River Overburden; Flat to Downhill 2 units ERM158/159 Arch Black Thunder Coal; Flat/High Speed 1 unit ERM157 (Running) Newmont Phoenix Gold; Uphill/ Seasonal Hot 1 unit ERM160 Rio Tinto / KUCC Bingham Canyon Barrick Cortez Hills Gold; Uphill/Downhill; Seasonal Hot 2 Units ERM155/156 (One Running) Copper/Overburden; Flat/Med Speed 2 units (ERM153/154 on site running)
AC Drive Field Follow Target Sites Overseas 2010 Boliden-Aitik units are sold LACD-Chile Finning-owned
High Altitude Application
1. 2. 3. 4. 5. Truck SN ERM161 ERM162 ERM163 ERM164 ERM165 Customer Boliden Boliden ? ? ? SOL Date 8/04/2010 8/18/2010 10/05/2010 10/19/2010 11/02/2010 RTS Date 9/07/2010 9/21/2010 11/08/2010 11/16/2010 12/08/2010
Anglo American Los Bronces High Altitude 3,600-4,000 m (11,800-13,125 ft) Temp = -15 to 30 C Copper; Downhill
Codelco Andina High Altitude 4,000 m (13,125 ft) Temp = -15 to 30 C Copper; Flat to Uphill
Program Goal is 500 Hours/Month Current Fleet Avg = 561 Hours/Month ERM153 Released 12/5/10 w/ 758 SMUs
Current SMU = 5128 544 Hours/Month current avg
795F Availability
ERM154 Released
ERM157 Released
ERM156 Released
PM 4.3 (19%)
Field Follow Site Personnel Concept 2010 Cat Man Onsite #1 rated activity that could ensure a successful field follow program!
John Bauler Supervisor Erik Tautkus NPI List Manager 795F AC Product Support
Dealer Commitment / Involvement Dedicated management level person Dedicated, qualified, service technician for each shift
Lead man Mechanic
Greg Hulva
Zack Palmquist
Lee Tolzdorf
Richard Ortecho
Cashman
Finning
Wheeler
Wyoming
Parts Stocking Pilot long lead major components first requested 4th Qtr 2007 Pilot parts stocking turned in Dec 2008 All AC drive major components in Morton All other major components in Morton
Engine in Schilli
Current Activity
Electric components updates Critical engine component strategy Weekly status report on major components
Parts Stocking Status 82% of the major components and critical parts in stock (51 pns)
Of these not in stock (9 pns), 67% can be service from factory (6 pns) Weekly reports on stocking levels and deliverables 1 HA Engine Ar is due December 2010
91.6% of all parts are in stock with a 1 day supply 90.8% of all parts are in stock with a 30 day supply By September 5, 2010
NACD will have 97% of all parts in stock Grimbergen will have 100% of all parts in stock Melbourne will have 99% of all parts in stock
ITTP complete
Used on ERM153 Revised for ERM154
R&I, Maintenance & Diagnostic Tooling All prototype tooling built and validated All service tooling as requested to properly support the pilot truck Pon Tooling Status
Participated in Dealer Advisory Committee Received tooling list Indicated tooling required Order tooling after July 2010
Tooling Allocated to NA FD
Removing the engine using the 309-2793 Load Leveler Group. Required for the lift is one of the lifting eyes from the 323-1146 Lifting Eye Group and one 3367250 Lifting Eye Assembly (adjustable) 309-2793 Engine Stand used to hold, store and transport used engine
Wheel Station Removal Remove axle through small cover by using 315-2607 adapter and 315-2605 handle (outer sun gear can be removed and reinstalled)
Remove the wheel station by using the 173-6624 Wheel Carrier Bracket 202-2053 Wheel Station Shipping Stand used to hold, store and transport used wheel station
Generator Removal A 6V-3145 load leveler (6,000 lb.) was used on the front of the generator to protect the high voltage box. A 6V-6146 load leveler (10,000 lb.) was used to span the generator fore- aft. A 2-leg chain was used between the load leveler and the rear of the generator.