®®

Machine CompatibilityMachine Family Scrapers, Loaders, Dozers,

Shovels, Motor Graders,Hydraulic Excavators,Track-Type Tractors

CAESultrafor Mining

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CAESultra for MiningCAESultra for Mining is a versatile technology tool that can help miners maximize their operation.

Maximize your mining operation byusing CAESultra to improve orerecovery, decrease survey costs andincrease productivity and profitability.

Off-Board Components

CAES off-board components ensurecommunication with operators,planning for projects, and productionreporting. pg. 7

On-Board Components

CAES on-board components keepthe operator informed with real-timeinformation, which provides greatercontrol and empowerment. pg. 6

CAESultra for Mining

Advanced GNSS technologies formining equipment improve machineefficiency, maximize mining potential,increase productivity and improve minesafety. pg. 4

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Features and Benefits

The CAESultra for Mining system linksthe operator to the office, improvingproductivity and profitability. pg. 9

Applications

CAESultra for Mining can be used inmany applications to increase machineproductivity, decrease costs andimprove ore recovery. pg. 8

Caterpillar is helping customersrevolutionize the way they mine andmanage their operation with technologysolutions that provide greater accuracy,higher productivity, lower operatingcosts and increased profitability.

The CAES system is one such solution.It is a high-technology earthmoving toolthat allows mines to operate moreproductively and safely.

Using Global Navigation SatelliteSystem (GNSS) technology, machine-mounted components, a radio networkand office management software,this state-of-the-art machine guidancesystem delivers real-time productivityinformation to machine operators onan in-cab display.

By monitoring ore bodies, bench height,volume of material cut and filled,and cycle times, operators have theinformation they need to maximizethe efficiency of the machine.

Applications. The CAES system is anideal tool for mine planning, engineering,surveying, grade control and productionmonitoring applications. For example,the CAES system can be used for:

• Haul road and bench constructionand maintenance

• Production dozing

• Leach pad construction andmaintenance

• Reclamation

• Ore grade control and materialidentification

• Coal load out terminals

The system is meant for use onscrapers, loaders, dozers, shovels, motorgraders, hydraulic excavators and track-type tractors.

Operation. The CAES system usesGNSS technology, a wireless radiocommunication network, and officesoftware to map mines, create terrainmodels, locate a machine’s positionand track volume and productivitywith complete accuracy.

The receiver uses signals fromGPS and GLONASS satellites todetermine precise machine positioning.Two receivers are used to capture andcollect satellite data – one located at astationary spot on the site, anotherlocated on the machine.

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Allows machine operators to mine more safely, efficiently and accurately.

CAESultra for Mining

Signals from the ground-basedreference station and on-boardcomputer are combined to removeerrors in satellite measurementsfor centimeter-level accuracy.

Using the radio network and officesoftware, terrain data is transmittedfrom the machine to the office.Terrain data may also be sharedfrom machine to machine.

The in-cab display then provides theoperator with an overhead and cross-sectional three-dimensional surfaceview of the color-coded work plan andprecise machine location. The softwarecontinuously updates terrain andmachine position information as themachine traverses the site.

The CAES system gives the operatorthe ability to control production bymonitoring progress on the in-cabdisplay, which is configurable forvarious mining applications.

In ore control applications, the colordisplay graphically shows the operatorore boundaries and bench height.

In grade control applications, the colordisplay graphically shows the operatorcut, fill and grade work to be doneaccording to plan. As the machineworks, the screen changes color.Green indicates when the operatorhas achieved plan grade.

By providing immediate feedbackon the accuracy of each pass, CAESoperators have the information andconfidence they need to work moreefficiently, productively and profitably.

Office Software. CAESoffice software,productivity tools and METSmanagerwork together to convert, verify, andtransmit design data. Productivitytools allow users to create reports onutilization, materials and volumes.METSmanager allows communicationamong machines and the office,and converts files from mineplanning software.

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GPS Receiver. The all-new MS990C isthe next generation GNSS receiver fromCaterpillar. The antenna and receiverhardware have been combined into onedurable component built to withstandworking in the harsh miningenvironment.

This base station GNSS receiver isused to send corrections across the radionetwork. The system computes positionswith centimeter-level accuracies toensure precise machine location.Mines with deep pits or locations in thefar northern and southern hemisphereswill benefit from the receiver’s abilityto use satellites in both the GPS andGLONASS constellations, providingincreased position availability forthe system.

The new design of the MS990C alsoincludes faster RTK initializationtimes, better tracking and accuracycharacteristics over a broader range ofoperating environments, and featuresto use the new modernized U.S.-basedGPS satellite constellation.

Communications Radio. The ruggedradio is used for transmitting andreceiving real-time data. The radio isused to send design data to machines,and receive terrain files, diagnostics andproductivity information from machines.It also sends GNSS corrections fromthe base station to the machine receiveron a dedicated channel. Under normalconditions, the 900 MHz radiobroadcasts data up to 10 km (6.2 miles)line-of-sight. Coverage can be enhancedwith a network of repeaters, whichallows coverage over a broader area.Optimized for mining applications, theradio features error correction and high-speed data transfer, ensuring optimumperformance.

Mine sites may also use an internetprotocol radio network to connectCAES-equipped machines. A ruggedizedEthernet port on the CAES touch screendisplay is available for easy connectionto third party radios.

CAES Touch Screen Display. The in-cabgraphical display provides real-timeoperating information to the operator.Designed for simple operation, the264 mm (10.4 in) custom configurable,integrated touch screen display allowsoperators to easily interface with theCAES system. The display uses thelatest infrared touch screen andtransflective backlight technology forsuperior viewing in bright light conditionsand a broad-range dimmable backlightfor viewing in low light conditions.Designed for reliable performance inextreme operating conditions, the unit isbuilt to withstand shock and vibrationand sealed to keep out dust and moisture.

Harnesses and Cables. Integratedharnesses and cables connect componentsto the machine’s main electrical systemsand are designed for easy installation.

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On-Board ComponentsCAES on-board components are built-to-last and provide operators with real-timeinformation.

CAESoffice Software. The Caterpillardesigned CAESoffice software enablesmine management to monitor CAES-equipped machines and work progressthroughout the site in near real-time.CAESoffice software uses maps,profiles, gauges and text displays inorder to show the current state of work.CAESoffice software continuouslyupdates and displays as-built surfaceinformation, including current elevationand mined material.

Productivity Tools. Productivity toolsallows mine office personnel to tracka multitude of productivity informationabout an individual machine or groupsof machines. Examples of the types ofproductivity information availableinclude volume of material cut andfilled, machine utilization, cycles perhour and number of loads of eachmaterial type. As events happen, theyare recorded in the CAES applicationso that both the machine operator andoffice personnel can view them.Using the CAES Productivity ReportGenerator program, reports can becreated and archived at any time, aswell as recalled and compared toimprove machine use and miningefficiency. Report templates areprovided and may be easily modified.New reports may be created usingCrystal Reports.

METSmanager. This software packageprovides the user interface for theCAES system and controls allcommunications over the wirelessradio network. It includes on-boardfile management, file conversions andmachine configurations. METSmanagerreads design files, converts them andsends them to the on-board display onthe machine over the radio network.METSmanager also maintains the sitemodels using data transmissions frommachine to office and can be used toexport terrain and progress lines,continuously updating the plan usingdata transmissions from machineto office.

GNSS Reference Station. A GNSSreference station is used to achieve thecentimeter-level accuracy needed ina mining application. The referencestation sends GNSS information over aradio link to the receiver on the CAES-enabled machine. Depending on whichbase station is used, a mine will be ableto use satellites in both the GPS andGLONASS constellations to enhancesignal availability and strength.

Radio Network. The off-board radiosare used to seamlessly connect theoffice network to the on-board systems.The network contains one channel usedfor timely delivery of GNSS correctionsto the on-board GNSS receiver. Anotherchannel is available to send site plans tomachines and receive productivity anddiagnostic information from machines.The 900 Mhz network can work aroundhills or buildings reducing the necessaryinfrastructure and the range can befurther extended by adding repeaters.

The CAES system has also beendesigned to work with mine-suppliedinternet protocol radio systems.

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Off-Board ComponentsCAES off-board components monitor progress and ensure communication withmachine operators.

CAESultra is a technology system thatcan augment nearly any mining processin which a grade or slope is desired.The additional ore control feature allowsmines to identify material at the face.Mines can achieve greater accuracy andproductivity by using the CAES systemin multiple applications, from draglinepad construction to reclamation. Someexample applications include:

• Production Dozing. The CAES systemis used in production dozing to removeoverburden quickly and accurately.Using the CAES system, the operatorcuts the overburden until achievingtop-of-coal. This improves machineutilization and increases productivity.

CAES application machine types:Dozers and Track-Type Tractors.

• Leach Pad Construction andMaintenance. The CAES system, whenused in this application, ensures that theleach pad is built and maintained at thedesired grade, improving ore recoveryand minimizing dilution.

CAES application machine types:Scrapers, Dozers and Track-TypeTractors.

• Reclamation. The CAES system,when used in reclamation operations,helps ensure the right amount of materialis moved to return the surface to thedesired topography. This allows for afaster reclamation process, loweringcosts and improving profitability.

CAES application machine types:Scrapers, Loaders, Dozers, MotorGraders, Hydraulic Excavators andTrack-Type Tractors.

• Ore Grade Control and MaterialIdentification. The CAES system usedfor ore grade control provides accurateprofile and plan views of ore bodies,minimizing time spent to map oregrades. Ore control leads to betteridentification of loaded material,minimizing misrouted material andimproving ore recovery and profitability.

CAES application machine types:Loaders, Shovels and HydraulicExcavators.

• Coal Load Out Terminals. In coal loadout terminals, material is pushed into adeep cone-shaped pit, often times, withoverhead conveyor systems in area.Using the 3D avoidance zones feature,the CAES system alerts the operator ofobstacles and hazards, increasing safetywhile simultaneously providinginformation about volume ofmaterial moved.

CAES application machine types:Dozers and Track-Type Tractors.

• Haul Road and Bench Constructionand Maintenance. A CAES equippedmachine helps create and maintain haulroads and benches by providing a real-time design plan, reducing the need forsurveying costs. Roads and benchescreated using the CAES system aresmoother, at the right grade and slope,with minimal rework. These conditionsaid in minimizing truck maintenancecosts, extending machine tire life,improving water run-off and increasingfleet productivity.

CAES application machine types:Scrapers, Loaders, Dozers, Shovels,Motor Graders and Track-Type Tractors.

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ApplicationsCAESultra for Mining can be used in many applications to increase machine productivity,decrease costs and improve ore recovery.

The CAESultra for Mining systemis a robust technology system thatempowers the operator in the cab tomove the right material the first time,ultimately improving productivity andprofitability. Using this system,machines and the mine office are linked– ensuring the design as created by themine engineers is being accuratelyexecuted in the pit. The CAES systemis a versatile solution with multiplefeatures and capabilities available tosuit nearly any mining application.

Features of the CAESultra for Miningsystem include:

• Configurable on-board display forspecific application

• “Virtual plan” visible at all times

• Color-coded cut and fill mapsshowing design vs. as-built surfaces

• Real-time productivity and volumecalculations

• Color-coded ore bodies

• Operator login, job codes, delaycodes and activity codes

• 3D avoidance zones and surfaces

• Ability to view other machinepositions on the in-cab display

• Terrain modifications used andviewed by other machines

• Operator-determined points ofinterest for display and reporting

• GNSS receiver using both GPS andGLONASS satellite constellations

• Easy connection to 3rd party internetprotocol communication network

• Machine production data foroperator and office

• Near real-time terrain updatesin office

• Interface with the Caterpillar®

MineStar™ system

• Archived productivity data for officereporting

CAESultra is a technology systempurpose-built to help miners improveproductivity and profitability. Using theCAES system, mining customersexperience productivity improvementsof more than 25%.

Benefits of the CAESultra for Miningsystem include:

• Reduces rework by moving materialright the first time

• Reduces ore dilution throughmaterial identification at the face

• Reduces operating costs

• Reduces survey costs

• Optimizes machine use

• Improves safety by reducing theneed for survey ground personnelin the vicinity of machines

• Empower operators by puttingdesign in the cab

• Increases productivity more than 25%

Customer Support. For more than25 years, Caterpillar has been providingelectronic and electrical componentsand systems for the earthmovingindustry – real-world technologysolutions that enhance the value ofCat® products, making customers moreproductive and profitable. Your Catdealer is ready to assist you withmatching machine guidance systemsto the application and obtainingresponsible, knowledgeable support.

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Features and BenefitsCAESultra for Mining allows operators to mine more safely, efficiently and accurately.

10 CAESultra for Mining specifications

CAES Touch Screen Display

Display screen 264 mm (10.4 in) LCDdisplay, 640 � 480transflective color VGA

Electrical input 9 to 32 V DCMemory drive 64 MB Ram, solid state

disk: internal 128 MB,external compact flash

Operating temperature –20° C to 70° C –4° F to 185° F

Storage temperature –50° C to 85° C –58° F to 185° F

Humidity 100%Width 315 mm 12.4 inHeight 261 mm 10.28 inWeight 3.17 kg 8.5 lbDepth 93 mm 3.66 in

CAESoffice/METSmanager

PC requirements Current PC configuration(minimal P4, 512 MB RAM,80G hard drive, CDROM,dedicated serial port,Ethernet port 10/100, XP)

Machine Compatibility

Machine Family Scrapers, Loaders,Dozers, Shovels, MotorGraders, HydraulicExcavators, Track-TypeTractors

Communications Radio

Operating range Up to 10 km (6.2 miles)Technology Spread spectrumData rate High speedOperating temperature –40° C to 70° C

–40° F to 158° FStorage temperature –55° C to 70° C

–67° F to 158° FHumidity 100%Height 216 mm 8.5 inWidth 86 mm 3.4 inLength 260 mm 10.3 inWeight 0.9 kg 2 lb

GPS Receiver

Horizontal accuracy 10 mm 0.39 inVertical accuracy 20 mm 0.79 inOperating range Up to 10 km (6.2 miles)Network connector 16-pinElectrical input 9 to 32 V DCOperating temperature –40° C to 70° C

–40° F to 158° FStorage temperature –50° C to 85° C

–67° F to 185° FHeight 147 mm 5.8 inWidth 232 mm 9.1 inDepth 251 mm 9.9 inWeight 3.8 kg 8.3 lb

CAESultra for Mining specifications 11

Notes

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For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at www.cat.com

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Printed in U.S.A.

Materials and specifications are subject to change without notice.Featured machines in photos may include additional equipment.

See your Caterpillar dealer for available options.

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are trademarks of Caterpillar and may not be used without permission.AEHQ5595 (11-06)

CAESultra for Mining