Cat® Electric Rope Shovels are built specifically for removing large amounts of overburden and ore, at a fraction of the cost per. Cat 7495 HD offers a payload of 82 tonnes (90 tons), providing 3 and 4 pass loading capability with both Cat (793D / 795F) and MT4400D AC / MT5300D AC mining trucks for an optimal loading and hauling operation. This powerful and reliable machine is the only electric rope shovel offered in this size class.
Cat® Electric Rope Shovels: The ultimate in power and performance for removing overburden and ore.
Dipper payload 81.8 tonnes Dipper capacity 19.1-61.2 m3 (25-80 yd3) 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 1306346.0 kg Ballast (furnished by customer) 260362.0 kg General purpose dipper – 49.78 m3 (65 yd3) 73482.0 kg Net weight, domestic, without ballast or dipper 972502.0 kg Note These weights will vary slightly depending upon dipper and optional equipment selection.
Crawler Mounting – Number and diameter of rollers: Lower (8) 139.7 cm Crawler Mounting – Number and diameter of rollers: Upper (10) 60.96 cm Crawler Mounting – Number and pitch of treads (74) 61.91 cm Crawler Mounting – Overall length of mounting 10.41 m Crawler Mounting – Overall width 213.36 cm (84 in) treads, standard 9.98 m Crawler Mounting – Overall width 274.32 cm (108 in) treads 10.44 m Crawler Mounting – Take-up tumblers diameter 157.48 cm Crawler Mounting – Total effective bearing area (213.36 cm/84 in treads) 32.0 m2 (344 ft2); 401 kPa (58.1 psi) Crawler Mounting – Total effective bearing area (274.32 cm/108 in treads) 41 m2 (442.3 ft2); 311 kPa (45.2 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 4.29 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 5.18 m Turntable – Number of tapered rollers 56 Turntable – Tapered, forged alloy steel roller rails diameter 4.5 m Turntable – Teeth external cut (face) 24.13 cm
OPTIMAL WORKING RANGES
Clearance height (boom point sheaves) 20.1 m Clearance radius (boom point sheaves) 19.74 m Clearance radius (revolving frame) 8.67 m Clearance under frame (to ground) 3.45 m Clearance under lowest point in truck frame/propel gearcase 0.86 m Cutting height (maximum) 17.3 m Cutting radius (maximum) 23.97 m Dumping height 10.6 m Dumping height at maximum electric crowd limit 8.45 m Dumping radius (maximum) 21.0 m Height of A-frame 13.3 m Operator’s eye level 8.64 m Overall width 13.01 m Radius of level floor 16.92 m
Components 6 pumps (4 for lubricant and 2 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 large system 2000 kVA Distribution System Requirements – Machine on separate system 3500 kVA Drive IGBT Acutrol drive system. Main Electrical Systems – Lighting transformer 25 kVA, 120/240V secondary Main Electrical Systems – System voltage (nominal) 50/60 Hz, 7,200V Main Electrical Systems – Trail cable (furnished by customer) SHD-3-#1/0 at 8,000V Main Electrical Systems – Transformer, auxiliary 350 kVA, 7,200V primary Power Requirements – Average 15-minute demand 832-1165 kW Power Requirements – Peak power 3330 kW Power Requirements – Voltage 3 phase, 50/60 Hz, 7,200V (Other voltage options available to suit customer requirements.)
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 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 x 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 15.9 mm Rope Data – Dipper trip – No. 1 Rope Data – Dipper trip – Type single Rope Data – Hoist – Construction 8 × 37 Rope Data – Hoist – Diameter 69.8 mm Rope Data – Hoist – No. 2 Rope Data – Hoist – Type twin dual Rope Data – Retract – Construction 8 x 37 Rope Data – Retract – Diameter 63.5 mm Rope Data – Retract – No. 1 Rope Data – Retract – Type single dual
Types Incandescent lights on ground lights, walkways and operator’s cab. Types HPS lights on boom feet, top of A-frame, machinery house, lube room, control room, utility room and flood lights.
Ideal for long life mines with bench heights of 59 ft (about 18 m)
- Optimum pass match capabilities with Cat 793F AC, 795F AC, MT4400D AC and MT4300D AC trucks
- Safety as integral part of machine design, with excellent visibility, non-slip stairs, platforms and walkways, as well as stored energy signs
- Over 30 years of experience commissioning more than 200 machines worldwide, with a reliable and simple AC system
- The only 90-ton (81.8-tonne) AC machine available in the market
- Robust front end design with a free-floating handle, which eliminates torsional loading
- Maintenance-friendly, deck-mounted crowd machinery, which reduces front-end weight
MACHINE SERVICE & SUPPORT
TIPL has 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.
AC IGBT ELECTRICS
With over 30 years of AC experience and over 200 operating AC machines, Bucyrus led the industry in AC electric rope shovels. Caterpillar will carry on this proud tradition.
Since its launch in 1981, the AC electric rope shovel has gained strong industry acceptance due to its clear benefits over DC machines, including:
- Higher productivity: AC machines are faster than DC machines due to an absence of commutation limits, which enables AC machines to operate with a greater area under the speed torque curve. This translates to faster lowering speeds and reduced swing times
- Superior availability: AC IGBT electric rope shovels have routinely demonstrated electrical availabilities of greater than 98%. Compared to DC machines, mean time between failures is extended and mean time to repair is reduced
- Greater reliability: AC machines are less vulnerable to input voltage variation. They continue to operate with instantaneous voltages from -20% to -30%, ranges which cause DC shovels to shut down
- More efficient: AC drives provide 10% energy savings over DC over the life of the shovel. AC drives maintain a power factor of 1.0 (zero efficiency loss), compared to 0.95 with DC drives
- Reduced maintenance: No regular maintenance is required on IGBT power control modules. Motor maintenance on AC machines is reduced to greasing and replacing bearings every 30,000 hours
- Reduced inventory: AC machines do not require a RPC, motor brushes or motor commutors. IGBT modules are interchangeable between AFEs, inverters, motions and machines
AccessDirect is an electrical interface system that facilitates remote access to a machine’s onboard computer via the Internet.
With AccessDirect, maintenance personnel can analyze faults from off-site locations and arrive on-site prepared to resolve the issue – leading to reduced machine downtime. AccessDirect also enables factory experts to remote-access and troubleshoot faults, resulting in superior response times and reduced mean time to repair.
Celebrating its tenth anniversary on the market, the MIDAS health monitoring system continues to optimize machine performance by providing, logging and analyzing data on a variety of machine variables.
MIDAS comes complete with a built-in report generator that outputs data in a format that can be easily analyzed to identify opportunities to improve machine performance. When paired with AccessDirect, MIDAS provides real-time monitoring of shovel operations and provides users with a 3D model to watch the shovel in motion.
AccuLoad is a data analysis system that provides real-time feedback on dipper loads with industry leading accuracy of ±4% on greater than 90% of all loads. AccuLoad’s load calculation is accomplished without mechanical sensors, eliminating the need for recalibration, a common problem with other load-weighing systems.
The system can be employed to calculate material moved, to monitor overloading of trucks or to allow operators to study their load and shift performance. It can also log operator performance data which, when paired with MIDAS, can generate reports to help identify training opportunities to increase shift production.
Cat major structures are designed for extended performance in harsh mining conditions. Structures are manufactured using cold-weather, impact-resistant, high-strength steel with select welds of full-penetration, profiled and ground type.
All welds undergo visual inspection, with critical welds also receiving MT, UT or X-ray inspection. Large furnaces are used to stress-relieve entire weldments for reduced susceptibility to cracking. Interiors of finished structures are painted white to facilitate field inspection.
ROBUST FRONT END DESIGN
The Cat free-floating tubular handle design presents many benefits over traditional rack-and-pinion systems.
These benefits include:
- Faster swing times: the Cat deck-mounted, rather than boom-mounted, crowd machinery greatly reduces front end weight for reduced swing inertia and faster swing times
- Elimination of torsional loading: The free-floating handle design allows the Cat handle to rotate under torsional stress, transferring stress into the ropes rather than into the boom and handle
- Crowd cushioning: With all electric rope shovels, as the dipper crowds the bank the handle recoils slightly. On Cat shovels, this force is absorbed in the ropes (rope crowd) or
hydraulic fluid (HydraCrowdTM), reducing stress on the handle. On a rack-and-pinion system, the force is absorbed where the rack and pinions mesh, leading to broken teeth
and increased handle cracking
- Improved line of sight: Cat machines provide operators with a much-improved left-hand line of sight by moving the crowd machinery from the boom to the deck
- Efficient digging: Wide-set boom point sheaves stabilize the dipper as it engages the bank for easier and more efficient digging
Caterpillar’s new state-of-the-art operator’s cab is the product of a multi-year collaboration between Caterpillar, mining companies and shovel operators. It has secured one patent and has an additional five patents pending.
The cab provides industry-leading visibility with excellent line of sight supplemented by five optimally-mounted cameras and display screens. It provides enhanced safety through dual access/egress doors and an optimally-placed trainer seat with independent emergency stop. Additionally, the new cab offers the smoothest, most comfortable ride available with an ergonomic, adjustable operator’s seat with fully pneumatic suspension system, low-effort joysticks and dual display screens optimized for operator comfort.
HydraCrowd represents the first new crowd technology developed in the past 70 years. A hydraulic cylinder inside the tubular dipper handle maintains all the benefits of the Cat front end while eliminating the need for routine crowd/retract rope replacements.
With a two-year major maintenance interval, HydraCrowd improves safety and cuts downtime by reducing the number of maintenance events needed to keep the machine operational. HydraCrowd is controlled with proven Cat IGBT technology and has complete diagnostic and troubleshooting information with step-by-step instructions. It is designed to operate in all climates to ensure each shovel will be able to deliver maximum productivity in the harshest conditions.
LATCHFREE™ DIPPER SYSTEM
The LatchFree Dipper System is Caterpillar’s solution to customers’ number-one cause of downtime – the latch assembly. The LatchFree dipper eliminates the latch assembly, replacing it with a strong steel link mounted to the dipper back – away from material flow.
The system improves safety by reducing the number of maintenance events required to maintain the system and increases reliability by reducing unplanned downtime. The LatchFree dipper system comes complete with a comprehensive training program to ensure customers achieve maximum system benefits.
FASTFIL™ DIPPER DESIGN
The unique FastFil dipper provides customers with faster and fuller dipper loads. Its trapezodial shape accommodates the natural configuration of the load, eliminating voids that occur with box-shaped dippers for improved fill factors.
The trapezoidal shape also reduces dipper size and weight for improved maneuverability and faster swing times. Additionally, optimized lip and rake angles lead to improved bank penetration and eliminate bulldozing for reduced material turbulence. Finally, a shorter dipper body cuts load and dump time. Combined, FastFil features optimize fill factor and maximize productivity.
Safety is integral to our commitment to mining. Product designs undergo risk assessments and meet strict codes and regulations. Examples of safety focus include the development of a new cab with dual egress doors and flat floors to provide stretcher-to-operator access, LatchFree dipper and HydraCrowd for reduced unplanned maintenance.
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.
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