Cat® Electric Rope Shovels can move more material with optimum efficiency and more cost-effectively. With industry-leading visibility and ideally pass-matched for Cat ultra-class trucks, backed by the TIPL’s service excellence. The Cat® 7495 HF has the same industry-leading features as that of Cat 7495, but comes with a configuration that includes a high-flotation undercarriage designed specifically for oil sand mining applications where low ground-bearing pressure is required.
The Cat® 7495 HF offers all of the same industry-leading features as the 7495, but comes with a configuration that includes a high-flotation undercarriage designed specifically for oil sand mining applications where low ground-bearing pressure is required. Consistent with the standard 7495, the HF configuration provides a maximum payload capacity of 109 tonnes (120 tons) and pairs well with the Cat 795F, 797F and MT5300D AC trucks for 3 and 4 pass loading capability.
Dipper payload 100.0 tonnes Dipper capacity 30.6-61.2 m3 (40-80 yd3) Dipper payload (Available dipper payloads up to 109 tonnes [120 tons] when specified) 100.0 tonnes Effective length of dipper handle 10.9 m Length of boom 20.4 m Overall length of dipper handle 14.3 m
Working weight, with dipper and standard links 1369246.0 kg Ballast (furnished by customer) 302614.0 kg General purpose dipper – 56 m3 (73 yd3) 80603.0 kg Net weight, domestic, without ballast or dipper 988100.0 kg Note These weights will vary slightly depending upon dipper and optional equipment selection.
Crawler Mounting – Number and diameter of rollers: Lower (16) 78.0 cm Crawler Mounting – Number and diameter of rollers: Lower rear (2) 106.7 cm Crawler Mounting – Number and diameter of rollers: Upper Slides Crawler Mounting – Number and pitch of treads (94) 50.8 cm Crawler Mounting – Overall length of mounting 11.43 m Crawler Mounting – Overall width 200.7 cm (79 in) treads, standard 11.0 m Crawler Mounting – Overall width 259.1 cm (102 in) treads 13.5 m Crawler Mounting – Take-up tumblers diameter 162.0 cm Crawler Mounting – Total effective bearing area (200.7 cm treads) 36.1 m2 (372 kPa); 388.6 ft2 (53.9 psi) Crawler Mounting – Total effective bearing area (259.1 cm treads) 46.6 m2 (288 kPa); 501.7 ft2 (41.8 psi) Hoist A planetary gearbox with dual-output pinions provides the hoist torque transfer from the electric motor to the hoist drum gear. Planetary Propel Dual-motor independent drive Revolving Frame (Center Section) – Welded, impact-resistant steel: Length 8.38 m Revolving Frame (Center Section) – Welded, impact-resistant steel: Width 3.68 m Swing Two planetary gearboxes, each driven by a vertically mounted motor, are mounted on either side of the revolving frame. Swing (cont’d) Dual-output pinion shafts from each gearbox engage the swing rack. Turntable – Forged rim, alloy steel swing rack pitch diameter 5.26 m Turntable – Number of tapered rollers 50 Turntable – Tapered rollers diameter 27.31 cm Turntable – Tapered, forged alloy steel roller rails diameter 4.52 m Turntable – Teeth external cut (face) 24.13 cm
Components Six pumps (four for lubricant and two for grease) located in an insulated, double-walled lube room Type Single-line system applies lubricant and grease via the PLC
Distribution System Requirements – Machine on separate system 4000 kVA Drive IGBT Acutrol drive system Lights HPS lights on boom feet, top of A-frame, machinery house, lube room, control room, and utility room. Lights Incandescent lights for ground lights and on walkways. Main Electrical Systems – Lighting transformer 25 kVA, 120/240V secondary Main Electrical Systems – System voltage (nominal) 50/60 Hz, 7200V Main Electrical Systems – Trail cable (furnished by customer) SHD-3-#1/0 at 8000V Main Electrical Systems – Transformer, auxiliary 350 kVA, 7200V primary Power Requirements – Average 15-minute demand 926-1297 kW Power Requirements – Peak power 3706 kW Power Requirements – Voltage 3 phase, 50/60 Hz, 7200V (Other voltage options available to suit customer requirements.) System voltage (nominal) 50/60 Hz, 7200V Trail cable (supplied by customer) SHD-3-#1/0 at 8000V Transformer, auxiliary 350 kVA, 7200V primary
Boom – Boom welded, impact-resistant steel Boom – Boom point sheave diameters 243.84 cm Boom – Boom point sheaves twin-grooved, flame-hardened Boom – Handle diameter 86.36 cm Boom – Wall thickness (nominal) 7.62 cm Crowd Plastic coated crowd and retract ropes are used to move the dipper handle fore and aft. Crowd Rope Crowd consists of motor, brake, drum and gearing. Crowd Rope Crowd with the crowd machinery is located at the front center of the revolving frame. Rope Data – Boom susp. – Construction struct. strand Rope Data – Boom susp. – Diameter 82.6 mm Rope Data – Boom susp. – No. 4 Rope Data – Boom susp. – Type equalized Rope Data – Crowd – Construction 8 × 37 Rope Data – Crowd – Diameter 63.5 mm Rope Data – Crowd – No. 1 Rope Data – Crowd – Type single dual Rope Data – Dipper trip – Construction 7 x 25 Rope Data – Dipper trip – Diameter 19.1 mm Rope Data – Dipper trip – No. 1 Rope Data – Dipper trip – Type single Rope Data – Hoist – Construction 8 x 37 Rope Data – Hoist – Diameter 69.8 mm Rope Data – Hoist – No. 2 Rope Data – Hoist – Type twin dual Rope Data – Retract – Construction 8 × 37 Rope Data – Retract – Diameter 63.5 mm Rope Data – Retract – No. 1 Rope Data – Retract – Type single dual
Dipper capacities 30.6-61.2 m3 (40-80 yd3) Dipper payload 109.0 tonnes Maximum dumping height 10.06 m Maximum dumping radius 21.64 m Operating weight 1369246.0 kg
DIMENSIONS – OPTIMAL WORKING RANGES
Clearance height (boom point sheaves) 20.87 m Clearance radius (boom point sheaves) 19.65 m Clearance under frame (to ground) 3.76 m Clearance under lowest point in truck frame/propel gearcase 0.9 m Dumping height 10.06 m Dumping height at maximum electric crowd limit 8.61 m Height of A-frame 14.0 m Maximum clearance radius (revolving frame) 9.34 m Maximum cutting height 17.8 m Maximum cutting radius 25.2 m Maximum dumping radius 21.64 m Operator’s eye level 10.61 m Overall width 13.11 m Radius of level floor 17.47 m
High-flotation undercarriage custom designed for soft ground conditions
- Best-in-class operator’s cab, equipped with excellent visibility, dual egress, ergonomic and fully adjustable operator’s seat with custom designed joysticks
- LatchFree dipper system (optional), which enables you to avoid rope shovel downtime by removing the maintenanceintensive latch bar assembly
- Safety is in-built into the machine design, with excellent line of sight, 45-degree rear-facing boarding stairs, platforms and walkways, as well as stored energy signs
- Reliable and simple AC system
- Robust front end design with a free-floating handle, which eliminates torsional loading
- Maintenance-friendly, deck-mounted crowd machinery, which reduces front-end weight
Rope Crowd System
The Rope Crowd system provides outstanding performance and high reliability. Rack and pinion misalignment challenges are eliminated with our tubular handle design Front-end cracking is reduced, as crowd and retract ropes absorb shock . Reduced Torsional Stress and Extended Component Life.
AC IGBT ELECTRICS
TRIED AND TESTED AC IGBT ELECTRIC DRIVE SYSTEM
Cat AC electric rope shove bring you higher r machine uptime, lower operating costs, and faster cycle times.
A SIMPLER ,SAFER & ROBUST SYSTEM
- Streamlined AC system that runs smoother, and is easier to maintain.
- A single, centralized control rack reduces parts requirements A single, compact drive cabinet houses the controller and drives to simplify assembly, troubleshooting, and maintenance
- Fuses, circuit breakers, and line filters are eliminated to reduce potential failure issues 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
- 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 AC system is designed to perform in the toughest mining conditions
- The robust, welded drive cabinet is 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.
COMFORTABLE , STATE-OF-THE-ART OPERATOR’S CAB AND STATION
Providing more comfort, added safety, and greater reliability, the newly designed state-of-the-art operator’s cab of 7495 is a true performer. The machine helps you produce more. increase productivity and your profit.
- 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 fit various body types
- 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
- Intuitive and visually aesthetic display screen help reduce cognitive fatigue and enhance productivity
- Display screens can be adjusted for brightness and contrast as per operator’s preference
- Climate control system maintains a preset temperature
- Industry-leading cab safety features make sure your operators are always safe. The large windshield, side windows, and floor window provide superior far-side and vertical line of sight for greater visibility . This also helps in safer double-side loading and reduced crawler link damage
- External camera system with direct feed to five overhead monitors improve the line of sight and operator awareness
- Dual door design facilitates easy entry and exit and has provision for rapid escape in case of highwall collapse or other emergencies
- Reduced trip hazards with no-step floor
- State-of-the-art, ergonomic operator’s seat for maximum operator comfort and productivity
- Adjacently positioned trainer seat provides greater view, facilitates communication and provides ready access to the trainer emergency stop button
- Elevated observer’s work station, provides space for laptop and optimum visibility of operator station and digging environment
- Carefully selected Cab components for ruggednessa nd reliable performance even in the harshest mining conditions,
- Custom cabinets designed to eliminate rattling
- Heavy-duty refrigerator built to withstand shovel vibrations
- High efficiency, adjustable LED lights optimize visibility
DESIGNED FOR SAFETY, RELIABILITY AND PRODUCTIVITY
Superior and efficient digging , safety, and component life are the results of a robust front-end design
FASTER CYCLE-TIMES, IMPROVED LINE-OF-SIGHT, AND SAFER MAINTENANCE
- A lighter front-end that affords better line-of-sight and serviceability that will help you increase both loading safety and productivity at your mine site
- 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
- Deck-mounted crowd machinery allows the majority of crowd maintenance to be completed from the protection of the machinery house deck, thus reducing fall hazards
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
Get more productive and efficient digging facilitated by the 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
Designed to facilitate handle installation requiring 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
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
The Rope Crowd system provides outstanding performance and high reliability. This traditional system is a tried-and-true design, proven reliable in mine sites across the globe for three-quarters of a century.
CONSISTENT PERFORMANCE, TRUSTED RELIABILITY
Our traditional rope crowd provides predictable and reliable performance
Rack and pinion misalignment challenges are eliminated with our tubular handle design
Front-end cracking is reduced, as crowd and retract ropes absorb shock
Torsional stress is eliminated with our rotating dipper handle, reducing cracking and extending component life
LATCHFREE DIPPER SYSTEM
Spend more time digging, and less time on unplanned dipper maintenance with the LatchFree Dipper System. It is a highly successful solution to prevent 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.
Enhances safety by eliminating daily maintenance on the latch bar, latch keeper, shims, and inserts
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
TWO DESIGN OPTIONS FASTFILTM and STRAIGHT-SIDE Dippers.
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
FastFil™ Dipper – For Small to medium payloads (up to 49.7 m3 (65 yd3). Optimal for hard rock applications
Straight-Sided Dipper- Small to large payloads. Optimal for coal applications
Optimal Pass Match Pairings
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.
THIRD RAIL SWING SYSTEM
For Faster Cycle Times and Extended Component Life
Provides optimum speed and cycle time, the swing system is designed to help keep your rope shovel swinging longer and filling trucks faster. The swing system also ensures even loading and better serviceability.
CAT MINESTAR SYSTEM AND TECHNOLOGY SOLUTIONS
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. Cat 7495 HF currently utilizes 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 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.
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
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
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
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.
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
HIGH-FLOATATION (HF) UNDERCARRIAGE DESIGN
Designed specifically for soft ground conditions, like those found in the Canadian oil sands mines, our high-floatation undercarriage ensures low ground-bearing pressure for improved digging, loading, and productivity.
Safety is integral to our commitment to mining. Product designs undergo risk assessments and meet strict codes and regulations. From machine access with grip strut stairs,platfprms and walkways for safe movement , to visibility that takes into account cameras , overhead monitors to augment line of sight and elevate situational awareness; to operator environment that provides dual door design useful for quick escape in case of a high wall collapse,second emergency button- all are made with one goal: to protect your employees.
Stored energy locations are clearly marked with signs warning personnel of danger . Reduced number of maintenance events afforded by the LatchFree Dipper System
Easier maintenance and reduced fall hazard with deck-mounted front-end machinery
We are committed to maximizing your rope shovel’s uptime and productivity and lowering your operating costs . That is why continually strive to simplify maintenance activities,make the maintenance procedures like the lubrication system automated,and ensure extended maintenance intervals with Latch Free dipper..
SIMPLIFIED MAINTENANCE ACTIVITIES INCLUDE:
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 TIPL. We have trained service engineers available to provide you with the support necessary to meet your production requirements, help you maximize productivity and minimize costs.We are built to help you succeed; with parts, service support; ensuring you operate safely, sustainably, productively and profitably.
Maximize Your Investment.The ability of your mining equipment to achieve promised production levels is as dependent on the operator’s knowledge and skill as it is on the equipment itself. TIPL has the required expertise to provide on-site operator training and assessments, on-site electrical and mechanical maintenance training, and a variety of computer-based training options. The Computer based training (CBT) modules provide convenient 24/7 access to training on a variety of topics ranging from safety and operation to mechanical and electrical repairs. Contact TIPL to know more.
Higher Standards for a Better Tomorrow. We are committed to helping you operate safely and sustainably.
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.
7495 Electric Rope Shovels specalogs Click here to download
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1800 419 3356