7495 ELECTRIC ROPE SHOVEL

Simple, Safe and Robust Electrics

BENEFITS AND FEATURES

Tried and True AC IGBT Electric Drive System You will experience greater machine uptime, lower operating costs, and faster cycle times via our AC electric rope shovel designs that leverage institutional knowledge built on 30 years of experience commissioning more than 200 AC equipped machines worldwide.

A Simpler System A streamlined AC system design that runs smoother, has fewer parts, and is easier to maintain, are the benefits you will realize, and the result of three decades of continuous improvement.

• A single, centralized control rack reduces parts requirements, eliminates communication issues between racks, and simplifies maintenance
• A single, compact drive cabinet houses the controller and drives to simplify assembly, troubleshooting, and maintenance
• Fuses, circuit breakers, and line filters have been eliminated reducing potential points of failure and overall parts requirements
• Parallel inverters have been removed to prevent uneven loading and to reduce the number of inverters required by the system
• The IGBT modules have been designed to be interchangeable between inverters and Active Front Ends (AFEs) and between motions and machines

A Safer System Your safety remains our highest priority, and is evident in our AC system design.

• The high voltage DC bus is located in the back of the drive cabinet and is never exposed during maintenance or troubleshooting
• The centralized control rack keeps maintenance personnel away from high voltage components when troubleshooting the controller
• Shielding blocks induced currents eliminating the need for high frequency bonding

A Robust System Helping to ensure your rope shovel remains in service, our AC system is designed to perform in the toughest mining conditions.

• The robust, welded drive cabinet was designed to withstand severe and consistent vibration
• An isolated, positive-pressure room houses the drive/controller cabinet to protect it from dust and debris
• Mine-grade components are used to ensure system performance and long, trouble-free life

Maximize Operator Comfort and Safety to Boost Productivity

BENEFITS AND FEATURES

Comfort Infused, State-of-the-art Operator’s Cab and Station Providing more comfort, added safety, and greater reliability, our newly designed state-of-the-art operator’s cab will help you produce more. The product of a multi-year collaboration with mining companies and rope shovel operators from across the globe, our Design Engineers, armed with insights into the aspects most desired by you, have designed what we believe to be the most comfortable and productivity-enhancing operator’s cab in the industry.

Improved Performance Increase productivity, and your bottom line, with our comfort-infused cab.

• Reduced fatigue-causing vibration resulting from bolstered support and stability of extended machinery house underneath isolator mounted cab
• Operator seat, armrests, and footrest adjust to perfectly fit a wide-range of body sizes
• Effortless operation and improved control response resulting from new, Hall Effect joysticks (patent pending), with custom-designed ergonomic handles and “finger touch control” spring tension
• Reduced cognitive fatigue and enhanced productivity via the intuitive and visually aesthetic display screens
• Display screens adjust for brightness and contrast to meet operator preference
• Climate control system automatically maintains a preset temperature

Enhanced Safety Ensure the safety of your operators with industry-leading cab safety features.

• For safer double-side loading and reduced crawler link damage, the large windshield, side windows, and floor window provide superior far-side and vertical line of sight for industry-leading visibility
• Augmented line of sight and improved operator situational awareness via external camera system with direct feed to five overhead monitors in cab
• Dual door design facilitates easy entry and exit from the cab and provides for rapid escape in case of highwall collapse or other emergencies
• Reduced trip hazards with no-step floor
• Enhanced safety during operator training with additional emergency stop button within reach of trainer seat

Better Training Reap learning and performance benefits from the enhanced training environment of our first-in-industry three-seat cab design.

• State-of-the-art, ergonomic operator’s seat maximizes operator comfort and productivity
• Adjacently positioned trainer seat provides optimal view of working face, facilitates communication during training, and provides ready access to the trainer emergency stop button
• Elevated observer’s work station, positioned behind the operator seat, provides space for laptop and optimum visibility of operator station and digging environment

More Reliability To ensure consistent and reliable performance in the harshest mining conditions, cab components were carefully selected for ruggedness.

• Custom cabinets designed to eliminate rattling
• Heavy-duty refrigerator built to withstand shovel vibrations
• High efficiency, adjustable LED lights optimize visibility

Reduced Front-end Weight, Reliable Structural Strength

BENEFITS AND FEATURES

Safety, Reliability and Productivity Advantages Afforded by Our Unique Design Greatly improved digging efficiency, safety, and component life are the results of our unique, yet robust front-end design, particularly when compared to rack-and-pinion systems.

Faster Cycle-times, Improved Line-of-sight, and Safer Maintenance Enhance both loading safety and productivity at your mine with a lighter front-end that affords better line-of-sight and serviceability.

• Faster swing times resulting from reduced swing inertia of lighter front-end
• Improved left-hand line-of-sight with deck-mounted crowd machinery that reduces visibility-impeding components on the boom
• Reducing fall hazards, deck-mounted crowd machinery allows the majority of crowd maintenance to be completed from the protection of the machinery house deck

Reduced Cracking and Extended Component Life Experience greater uptime and component reliability with our unique, yet robust front-end design.

• Highly crack resistant one-piece, forged dipper handle
• Extending boom and dipper handle life, rotating handle design transmits torsional stress into the hoist ropes
• Reducing wear and cracking at the boom/dipper handle junction, crowd and retract ropes or hydraulic fluid absorb kickback force caused by dipper colliding with poorly shot material
• Reduced lube usage by replacing racks and pinions with tubular handle and ropes or hydraulic cylinder greatly reduces lube usage

Easier, More Efficient Digging Realize more productive and efficient digging facilitated by our wide-set boom point sheaves. • Twin hoist ropes balance dipper pull in the bank via wide-set boom point sheaves, automatically distributing digging force where it is needed most

Simplified Maintenance Get your primary loading tool back to work quickly with simpler, more straight-forward maintenance.

• Design facilitates handle installation and requires fewer adjustments
• Crowd and retract rope adjustments are made from the safety of the machinery house roof - rather than on the boom, as required by rack and pinion systems
• Elimination of bi-annual, major maintenance handle re-racking procedure with tubular handle instead of racks

Description of Cat Front-end:

• Stress-relieved, impact resistant steel boom with twin box girder design - 100% penetration and UT quality welds on all major splice joints
• Modular, deck-mounted crowd assembly includes AC motor, spring-set air-release disc brake, and hydraulic power pack
• Maintenance-free, one-piece, high-alloy, forged steel handle designed to rotate freely in the saddle block
• Saddle block, with one-piece liner, rotates about shipper shaft on a manganese bronze bushing, guiding the longitudinal movement of the handle

Reduce Torsional Stress and Extend Component Life with Our Innovative Design

BENEFITS AND FEATURES

Results Are What You’ll Get from the HydraCrowd System The HydraCrowd system provides outstanding performance and high reliability. This innovative system goes a step further than the Rope Crowd system, making maintenance more predictable and keeping your rope shovel in production longer.

Eliminates Routine Crowd/Retract Rope Replacements HydraCrowd extends maintenance intervals and improves your overall productivity with a patented innovative design that replaces crowd and retract ropes with a hydraulic cylinder.

• Increases uptime and enhances productivity via reduced scheduled maintenance hours
• Eliminates routine crowd/retract rope changes
• Extends major maintenance interval to two years
• Maintains the benefits of our unique front-end design

Description of HydraCrowd

• Four bent-axis, fixed-displacement pumps feed a single cylinder inside the tubular dipper handle
• Hydraulic power pack located in the front of the machinery house
• System controlled by proven Cat IGBT technology
• Large-capacity, dirt-tolerant cartridge valves provide high reliability and long service life
• Diagnostic software and troubleshooting system with step-by-step instructions inherent in the PLC controls

Preventing Downtime with a Revolutionary Approach

BENEFITS AND FEATURES

Avoid the Leading Cause of Rope Shovel Downtime for Over a Century Spend more time digging, and less time performing unplanned dipper maintenance with the LatchFree Dipper System. The first successful solution to the number-one cause of rope shovel downtime, the LatchFree Dipper System replaces the maintenance-intensive latch assembly with a strong steel link mounted to the dipper back, away from material flow. To ensure you achieve maximum benefits, the system comes complete with a comprehensive training program.

Improved Safety • Enhances safety by eliminating daily maintenance on the latch bar, latch keeper, shims, and inserts

Greater Uptime • Improves reliability by eliminating the electric rope shovels’ leading downtime occurrence: the latch assembly

More Productive Digging/Loading • Increases efficiency by reducing lost loads

Better Component Life • Reduces component wear by repositioning components away from the harsh conditions of the lower dipper door

Description of LatchFree Dipper System

• A strong steel holding link and eccentric replace the traditional dipper latch assembly
• Components are mounted to dipper back, rather than dipper door, away from the material flow
• The door closes by gravity as the dipper is lowered
• Available on both FastFil™ and Straight-Side dipper designs
• Comes complete with a comprehensive training program

Longer Dipper Life

BENEFITS AND FEATURES

Meet the Challenges of any Mining Environment with Two Design Options Providing extended dipper life and optimal fit with your application, our FastFil and Straight-Side Dippers help you move more.

• Manufactured from cold-weather, impact-resistant, high strength steel for strength and durability
• Stress relieved dipper back to prevent cracking
• Key welds inspected using nondestructive testing
• Expertly sized for your application
• Designed for easy repair

Straight-Side Dipper - Maximized Payload Capability Offering a larger payload range, our Straight-Side Dipper maintains quality and reliability of our FastFil Dipper design.

• Box shape design accommodates larger dipper sizes
• Available in sizes up to 61.2 m3 (80 yd3)

FastFil Dipper - Faster, Fuller Dipper Loads Improving fill factors and helping you hit your productivity targets the trapezoidal shape of our FastFil Dipper accommodates the natural configuration of the load, eliminating voids that occur with box-shaped dippers.

• Trapezoidal shape eliminates the void that occurs at the back of the dipper with the traditional dipper shapes
• Improved maneuverability and faster swing times resulting from reduced dipper size and weight
• Improved bank penetration and elimination of bulldozing for material turbulence due to optimized lip and rake angles
• Reduced load and dump times facilitated by shorter dipper body
• Fill factors average > 100% (110% typical)
• Available in sizes up to 49.7 m3 (65 yd3)

Move More Material with Optimal Pass Match Pairings

BENEFITS AND FEATURES

Achieve Targeted Loading/Hauling Production with Perfectly Paired Cat Rope Shovels and Mining Trucks For full truck payloads with minimum loading time, an efficient loading/hauling system begins with an optimized equipment match. Cat electric rope shovels are matched with Cat mining trucks to maximize volume of material moved at the lowest operating cost per ton.

Faster Cycle Times and Extended Component Life

BENEFITS AND FEATURES

Providing optimum speed and cycle time, all while extending component life, our swing system is designed to help keep your rope shovel swinging longer and filling trucks faster.

Even Loading Achieve maximum component life with our swing system design that ensures reduced and even swing rack wear.

• Eliminating the need to rotate the swing rack, two swing gearcases, positioned 180° apart, produce even swing rack wear
• Reducing wear on the swing rack and swing pinions, straddle-mounted, dual-output pinions decrease tooth loading

Better Serviceability Mean-time to repair is reduced, as most repairs involve the third rail, rather than the rollers.

• The easy-to-replace third rail, rather than roller flanges or the swing rack, serves as the primary wearing part in the system, greatly simplifying maintenance
• Provides roller access without jacking up the upper half of the machine

Evolving Your Mine for Greater Safety and Productivity

BENEFITS AND FEATURES

Helping you Enhance Safety and Productivity Through Technology Aimed at enhancing the productivity and profitability of your rope shovel, we currently offer a combination of Cat MineStar System offerings and Cat rope shovel technology solutions.

Cat MineStar System Helping you achieve your goals for enhanced mine site safety, improved efficiency, reduced operating costs, and greater profitability, the Cat MineStar System provides the most comprehensive suite of mining technology products in the industry. It consists of a number of configurable capability sets - Fleet, Terrain, Detect, Health, and Command - that allow you to scale the system to your mine site needs. Cat MineStar System helps you manage everything from material tracking to sophisticated real-time fleet management, machine health systems, autonomous equipment, and more. The Cat 7495 is currently able to utilize two of the Cat MineStar System capability sets:

• Fleet - Fleet provides real-time machine tracking, assignment and productivity management, providing a comprehensive overview of all your asset operations from anywhere in the world.
• Terrain

- Terrain enables high-precision management of drilling, dragline, grading and loading operations through the use of guidance technology. It increases machine productivity and provides you real-time feedback for improved efficiency. The remaining Cat MineStar System capability sets are currently under development for the Cat rope shovel product line.

Rope Shovel Technology Solutions To help increase productivity, reduce unplanned downtime, and improve planning accuracy, our electric rope shovel technology package collects, transmits, stores and analyzes key data. The technology package includes AccessDirect™, MIDAS, AccuLoad, and Bearing Temperature Monitoring.

AccessDirect Expedite maintenance with remote access to your rope shovel data in real-time.

• Enables factory experts to join the local maintenance team
• Prepares maintenance personnel to go to the machine ready to correct rather than analyze the problem
• Reduces daily maintenance efforts

MIDAS Maintain constant awareness of machine health with MIDAS, our health monitoring software that provides, logs, and analyzes data on a variety of machine variables.

• Broadens understanding of machine performance
• Delivers insight into how best to utilize machines in mine operations
• Generates reports that can be easily analyzed to identify opportunities to improve machine performance

AccuLoad Improve productivity with real-time dipper load feedback directly to operators.

• Improves productivity by allowing operator to monitor load and shift performance
• Reduces machine and truck overloading

Bearing Temperature Monitoring Better maintenance predictability and reduced risk of failure via bearing temperature monitoring, a system that monitors bearing temperature and alerts operator of high temperatures.

• Helps predict maintenance through bearing temperature trending
• Reduces risk of major failure

Bolstering Your Investment with Robust and Durable Structures

BENEFITS AND FEATURES

Rugged Structures Designed and Fabricated to Withstand your Extreme Mining Conditions To extend service life and ultimately reduce your maintenance cost, all major rope shovel structures are designed for durability and dependability. Extended performance in the harsh mining conditions you face daily is accomplished through selection of high-strength steels, and rugged castings, joined and thermally stress-relieved to create a reliable shell capable of one of the most productive loading tools in the industry.

• Manufactured from cold-weather, impact-resistant, high strength steel for strength and durability
• Full penetration, profiled and ground welds at critical junctures
• MT, UT, and X-ray inspections on select welds ensure quality
• Entire structures are stress relieved to prevent cracking
• Factory installed manholes and ladders assist inspection
• White painted interiors facilitate crack inspection

Keep Moving in All Mining Conditions

BENEFITS AND FEATURES

Enhanced Maneuverability, Extended Component Life, and Consistent Reliability are the Foundation of this Powerful Machine Intended to enhance digging/loading capability, ground footing, and mobility, a newly designed propel system and battle tested crawlers come standard on all Cat electric rope shovels.

• Stress relieved crawler frames resist cracking
• Lower rollers design withstands periodic single-point ground reaction caused by uneven pit floors
• Crawler-mounted propel motors facilitate maintenance and reduce misalignment
• Upward slanted propel motor shelves protect components from rocks and water
• Elevated drive tumbler isolates planetary drive from ground impact shock loads
• Sprocket-style drive tumbler lugs provide a large area of contact against the crawler links for extended tumbler and link life
• Straddle-mounted rollers improve component wear and extend life

Designed with Your Safety as Our Top Priority

BENEFITS AND FEATURES

Sharing your commitment to safety, and driven by our commitment to Zero Harm, we work tirelessly to design the safest machines possible to protect your most important asset; your employees.

Machine Access

• Forty-five degree rear facing boarding stair provides fast and convenient access to the machine
• Grip-strut stairs, platforms and walkways facilitate safe movement around the machine

Visibility

• Panoramic view from the operator’s seat offers the best far-side visibility in the industry
• Cameras feed five in-cab, overhead monitors to augment line of sight and elevate situational awareness

Operator Environment

• Dual door design facilitates entry and exit from cab and provides a quick escape in case of a high wall collapse
• No-step floor reduces trip hazards
• Operator training seat facilitates safe operator training
• Second emergency stop button allows the trainer to stop the machine to avoid an accident

Stored Energy Warning Signs • Stored energy locations are clearly marked with signs warning personnel of danger

Maintenance

• Reduced number of maintenance events afforded by HydraCrowd and the LatchFree Dipper System
• Easier maintenance and reduced fall hazard with deck-mounted front-end machinery

Designed to Get You Back to Work Fast

BENEFITS AND FEATURES

Lowering your operating costs and maximizing your rope shovel’s uptime and productivity is of supreme importance to us. To that end, we continually strive to automate maintenance procedures, extend maintenance intervals, and simplify maintenance activities for our electric rope shovels.

Automated Maintenance Procedures

• Automatic lubrication system covers all regular lube points
• HydraCrowd system self-monitors pressure, contamination, and pump condition

Extended Maintenance Intervals

• HydraCrowd eliminates routine crowd/retract rope changes extending the major maintenance interval to two years
• LatchFree dipper eliminates the daily hassle of maintaining a latch bar assembly and extends the major maintenance interval

Simplified Maintenance Activities

• Walkways provided for major service points
• Additional platforms provided for gear inspection
• Factory installed ladders inside boom for easy access
• White painted interiors in major structures to facilitate crack inspections
• Easy-to-remove roof hatches offer access to machinery house components
• Electro-hydraulic crowd rope take-up system simplifies crowd rope tightening
• On board accessible diagnostic system identifies faults and gives instructions to resolve issues
• Third-rail swing system offers access to center rollers without jacking up the shovel’s upper works
• Lock out tag out points for safer maintenance

Stay Up and Running with Service and Support from Our Unmatched Global Network

BENEFITS AND FEATURES

Providing You a Unified Team Unlike Any Other in the Mining Industry While the Caterpillar acquisition of Bucyrus is complete, we are still in the process of integrating the two companies. However, you can rest assured that both your Cat and Bucyrus products will continue to be supported and that there will be no disruption in the service you have come to expect from both organizations. We are committed to business as usual - with sales, parts fulfillment, technical support, and all other customer services continuing uninterrupted. For the time being, Caterpillar Global Mining will operate from two distinct distribution channels:

• Legacy Bucyrus products, including the electric rope shovel, will continue factory direct with support from former Bucyrus employees
• Traditional Cat products will continue through Cat dealers with support from Global Mining

We Will Transition Products to the Cat Dealer Network With the goal of providing you with one face and the distribution approach that positions you best for success, we will leverage the strength of the Cat dealer network. All products will eventually be sold and serviced by Cat dealers; however, the transition will occur in phases until complete.

We Will Create an Unparalleled Source for Support The expertise you have come to depend on will continue in the Caterpillar organization, whether through a Cat dealer or from Caterpillar - combining the best of both organizations to create one unparalleled source for support.

Until the Transition is Complete… To ensure you have the support necessary to meet your production requirements, experienced and knowledgeable Cat Service Engineers are available throughout the world.

Maximize Your Investment

BENEFITS AND FEATURES

Aimed at advancing a novice operator to expert levels in a rapid time frame, our combination of on-site and computer-based training provides all the tools your staff will need. To help maximize your investment in a Cat electric rope shovel, we provide on-site operator training assessments, on-site electrical and mechanical maintenance training, and a variety of computer-based training options.

Customized Training

• On-site and/or classroom training for rope shovel operators and mine operation supervisors
• Aimed at developing internal training competency for your operation
• Designed in module form to target key production issues specific to your operation
• Trainers have years of experience with hands-on and classroom training, offering the necessary skills to implement changes on all aspects of operation, machine management, and maintenance
• Utilizes cutting-edge technologies to improve knowledge retention, increase training efficiency, and create a safer learning environment via machine simulation

VAST (Value-Added Simulation Training)

• Exclusive Cat electric rope shovel simulator which replicates machine controls, responses and typical sensors found in mining operations
• Minimizes interruptions in mine productivity due to operator training while reducing shovel damage, repair costs and overall training costs
• Tracks and evaluates user progress
• Available in English, Spanish and French

Higher Standards for a Better Tomorrow

BENEFITS AND FEATURES

Meeting the needs of today without compromising the needs of tomorrow is the goal for all Cat machinery. The commitment to helping you operate safely and sustainably is affirmed in the production of the 7495 rope shovel.

Cat Rope Shovel Sustainability - Electric Power More efficient than diesel powered machines, Cat electric rope shovels are entirely electric and therefore experience less heat loss.

Cat Rope Shovel Sustainability - Regenerative Power Cat electric rope shovels use regenerative braking technology to convert kinetic energy from shovel motions into electrical energy when braking. The electrical energy that is generated is then fed back to the grid. Without regenerative braking, the kinetic energy would be burned off as heat.

Cat Rope Shovel Sustainability - Long Life Cycles Fewer component change-outs result in less waste. Component change-out intervals for electric rope shovels are generally longer than those for similar-sized hydraulic machines.

Cat Rope Shovel Sustainability - Rebuilds Saving you money and reducing waste in the environment, electric rope shovel motors and gearcases can be rebuilt.