SURFACE MINING EXTRACTION EQUIPMENT · Electric rope shovels are one of the largest loading tools on the market. They run in a truck-shovel opera-tion with mining trucks in order

© 2014 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

800.437.4228www.hawthornecat.com

Caterpillar® Performance

Handbook Edition 44

SURFACE MINING

EXTRACTION EQUIPMENT

PART C

16

Edition 44 16-29

CONTENTS

ELECTRIC ROPE SHOVELSIntroduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-29Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-29Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-32Digging Envelopes. . . . . . . . . . . . . . . . . . . . . . . . 16-35General Dimensions . . . . . . . . . . . . . . . . . . . . . . 16-42Ground Bearing Pressure . . . . . . . . . . . . . . . . . . 16-49Dipper Selection . . . . . . . . . . . . . . . . . . . . . . . . . 16-50Truck Match . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-51

INTRODUCTIONElectric rope shovels are one of the largest loading

tools on the market. They run in a truck-shovel opera-tion with mining trucks in order to move large quan-tities of material at a low cost per ton. Electric rope shovels are used to mine a variety of minerals including oil sands, coal overburden, copper, gold, iron ore, etc. They operate at extreme climates in tough surface min-ing applications all over the world.

FEATURES

AC IGBT ElectricsWith 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.

● Superior availability: AC IGBT electric rope shovels have routinely demonstrated electrical availabilities of greater than 98%.

● Greater reliability: Fewer components including inter-changeable inverters. IGBT systems require no fuses or circuit breakers.

● 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: Cat IGBT is a mine quality system with rugged welded cabinets to withstand harsh min-ing conditions.

ELECTRIC ROPE SHOVELS

PHB-Sec16-ElectricRopeShovels(pg029-052).indd 29PHB-Sec16-ElectricRopeShovels(pg029-052).indd 29 12/20/13 8:54 AM12/20/13 8:54 AM

16-30 Edition 44

Electric Rope Shovels

Robust Front End DesignThe Cat free-floating tubular handle design presents

many benefits over traditional rack-and-pinion systems, including:

● Fast swing times: The Cat deck-mounted, rather than boom-mounted, crowd machinery greatly reduces front end weight for reduced swing inertia and fast swing times.

● Elimination of torsional loading: The free-floating han-dle design allows the Cat handle to rotate under tor-sional stress, transferring stress into the ropes rather than into the boom.

● Improved line of sight: Cat machines provide opera-tors with a much-improved left-hand line of sight by moving around the crowd machinery from the boom to the deck.

● Efficient digging: Wide-set boom point sheaves stabi-lize the dipper as it engages the bank for easier and more efficient digging.

Cat CabCaterpillar’s state-of-the-art operator’s cab is the prod-

uct of a multi-year collaboration between Caterpillar, mining companies and shovel operators. The cab pro-vides 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 avail able with an ergonomic, adjustable operator’s seat with a fully pneumatic suspension system, low-effort joysticks and dual display screens optimized for opera-tor comfort.

Power Demand Management SystemCaterpillar’s exclusive Power Demand Management

System for 7495 Series machines allows an electric rope shovel to operate in spite of electrical infrastructure challenges. This patented energy storage and power management technology reduces the number of gen-erators required to run an electric rope shovel, giving mines the option of production without grid power. Additionally, this technology lowers the machine’s peak power requirement, resulting in more alternatives when mines plan for power.

HydraCrowd™HydraCrowd represents the first new crowd technol-

ogy 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. HydraCrowd cuts down time 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™The LatchFree Dipper System is Caterpillar’s solu-

tion 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 enhances safety by reducing the number of maintenance events required to maintain the system and increase 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 DesignThe unique FastFil dipper provides customers with

faster and fuller dipper loads where the application per-mits. Its trapezoidal 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 dip-per body cuts load and dump time. Combined, FastFil features optimize fill factor.

Features


Edition 44 16-31


16

AccessDirect™AccessDirect is an electrical interface system that

facilitates remote access to a machine’s onboard com-puter via the Internet. With AccessDirect, maintenance personnel can analyze faults from off-site locations and arrive on-site prepared to resolve the issues — lead-ing to reduced machine downtime. AccessDirect also enables factory experts to remote-access and trouble-shoot faults, resulting in superior response times and reduced mean time to repair.

MIDASThe 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 gen-erator 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 operation and provides users with a 3D model to watch the shovel in motion.

AccuLoadAccuLoad is a data analysis system that provides

real-time feedback on dipper loads. AccuLoad’s load calculation is accomplished without mechanical sen-sors, eliminating the need for recalibration, a common problem with other load-weighing systems. The system can be employed to calculate material moved, to moni-tor overloading of trucks or to allow operators to study their load and shift performance. It can also log opera-tor performance data which, when paired with MIDAS, can generate reports to help identify training opportuni-ties to increase shift production.

Major StructuresCat major structures are designed for extended per-

formance in harsh mining conditions. Structures are manufactured using cold-weather, impact-resistance, 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.

SafetySafety plays an integral role in everything we do

at Caterpillar, from our factory floors to our service centers to our clients’ mine sites. Caterpillar’s commit-ment to safety is apparent in our product designs, which undergo risk assessments and are designed to meet strict codes and regulations. Examples of our safety focus include the development of a cab with dual egress doors and flat floors to provide stretcher-to-operator access, LatchFree dipper and HydraCrowd for reduced unplanned maintenance, and extensive training pro-grams to help keep your operators and maintenance per-sonnel out of harm’s way. Additionally, the electric rope shovel product line has incorporated additional safety product enhancements as part of Caterpillar’s engage-ment and dedication to the Earth Moving Equipment Safety Round Table or EMESRT.

Features


16-32 Edition 44


Specifications

MODEL 7295 7395Payload 45 tonnes 50 tons 64 tonnes 70 tonsOperating Weight 789 251 kg 1,740,000 lb 1 288 656 kg 2,841,000 lbDipper Range 19.1-38.3 m³ 25-50 yd³ 20.7-55.8 m³ 27-73 yd³Drive AC IGBT AC IGBTDistribution System Requirements (separate system) 2000 kVA 3500 kVADistribution System Requirements (large system) 1320 kVA 2000 kVAAverage 15 Minute Demand 538-753 kW 777-1087 kWPeak Power 2152 kW 3106 kWCrowd Type Tubular handle rope crowd Tubular handle rope crowdHoist Ropes

Number 2 2Diameter 57 mm 2.25" 70 mm 2.8"Type Twin dual Twin dualConstruction 6×41 8×37

Crowd/Retract RopesNumber 1 crowd, 1 retract 1 crowd, 1 retractDiameter 60 mm 2.4" 64 mm 2.5"Type Single dual Single dualConstruction 8×37 8×37


Edition 44 16-33


Specifications

16

MODEL 7495 HD 7495 7495 HydraCrowdPayload 82 tonnes 90 tons 109 tonnes 120 tons 109 tonnes 120 tonsOperating Weight 1 306 346 kg 2,880,000 lb 1 369 246 kg 3,018,670 lb 1 382 400 kg 3,047,670 lbDipper Range 27.5-60.4 m³ 36-79 yd³ 30.6-62.7 m³ 40-82 yd³ 30.6-62.7 m³ 40-82 yd³Drive AC IGBT AC IGBT AC IGBTDistribution System Requirements

(separate system) 3500 kVA 4000 kVA 4000 kVADistribution System Requirements

(large system) 2000 kVA — —Average 15 Minute Demand 832-1165 kW 926-1297 kW 945-1322 kWPeak Power 3330 kW 3706 kW 3778 kWCrowd Type Tubular handle rope crowd Tubular handle rope crowd Tubular handle HydraCrowdHoist Ropes

Number 2 2 2Diameter 70 mm 2.8" 70 mm 2.8" 70 mm 2.8"Type Twin dual Twin dual Twin dualConstruction 8×37 8×37 8×37

Crowd/Retract RopesNumber 1 crowd, 1 retract 1 crowd, 1 retract N/ADiameter 64 mm 2.5" 64 mm 2.5" N/AType Single dual Single dual N/AConstruction 8×37 8×37 N/A

N/A = Not Available.


16-34 Edition 44


Specifications

MODEL 7495 HF 7495 HF HydraCrowdPayload 109 tonnes 120 tons 109 tonnes 120 tonsOperating Weight 1 429 120 kg 3,150,670 lb 1 442 274 kg 3,179,670 lbDipper Range 30.6-62.7 m³ 40-82 yd³ 30.6-62.7 m³ 40-82 yd³Drive AC IGBT AC IGBTDistribution System Requirements (separate system) 4000 kVA 4000 kVAAverage 15 Minute Demand 926-1297 kW 945-1322 kWPeak Power 3706 kW 3778 kWCrowd Type Tubular handle rope crowd Tubular handle HydraCrowdHoist Ropes

Number 2 2Diameter 70 mm 2.8" 70 mm 2.8"Type Twin dual Twin dualConstruction 8×37 8×37

Crowd/Retract RopesNumber 1 crowd, 1 retract N/ADiameter 64 mm 2.5" N/AType Single dual N/AConstruction 8×37 N/A

N/A = Not Available.


Edition 44 16-35


16

Digging Envelopes● 7295

MODEL 7295Dumping Height 9.22 m 30'3"Dumping Height at Maximum Crowd Limit 7.00 m 23'0"Dumping Radius 18.69 m 61'4"Cutting Height 15.56 m 51'1"Cutting Radius 21.78 m 71'5"Effective Length of Dipper Handle 9.45 m 31'0"

m

m

ft

ft


16-36 Edition 44




m

m

ft

ft


Edition 44 16-37


16

Digging Envelopes● 7495 HD

MODEL 7495 HDDumping Height 10.60 m 34'10"Dumping Height at Maximum Crowd Limit 8.45 m 27'9"Dumping Radius 21.00 m 69'0"Cutting Height 17.30 m 56'10"Cutting Radius 23.97 m 78'8"Effective Length of Dipper Handle 14.30 m 47'0"

m

m

ft

ft


16-38 Edition 44




m

m

ft

ft


Edition 44 16-39


16

Digging Envelopes● 7495 HydraCrowd

MODEL 7495 HydraCrowdDumping Height 10.06 m 33'0"Dumping Height at Maximum Crowd Limit 8.61 m 28'3"Dumping Radius 21.64 m 71'0"Cutting Height 17.80 m 58'5"Cutting Radius 25.20 m 82'8"Effective Length of Dipper Handle 14.30 m 47'0"

m

m

ft

ft


16-40 Edition 44


Digging Envelopes● 7495 HF

MODEL 7495 HFDumping Height 10.06 m 33'0"Dumping Height at Maximum Crowd Limit 8.61 m 28'3"Dumping Radius 21.64 m 71'0"Cutting Height 17.80 m 58'5"Cutting Radius 25.20 m 82'8"Effective Length of Dipper Handle 14.30 m 47'0"

m

m

ft

ft


Edition 44 16-41


16

Digging Envelopes● 7495 HF HydraCrowd

MODEL 7495 HF HydraCrowdDumping Height 10.06 m 33'0"Dumping Height at Maximum Crowd Limit 8.61 m 28'3"Dumping Radius 21.64 m 71'0"Cutting Height 17.80 m 58'5"Cutting Radius 25.20 m 82'8"Effective Length of Dipper Handle 14.30 m 47'0"

m

m

ft

ft


16-42 Edition 44


MODEL 7295Boom Length 18.00 m 59'0"

A Height 18.15 m 59'7"B A-Frame Height 11.94 m 39'2"C Overall Width 12.39 m 40'8"D Tail Swing Radius 7.98 m 26'2"E Clearance Radius 17.48 m 57'4"F Radius of Level Floor 15.58 m 51'1"G Minimum Ground Clearance 0.78 m 2'6"H Track Length 10.26 m 33'8"I Operator Eye Level 8.20 m 26'11"

General Dimensions● 7295

C L R

OTAT

ION

C L R

OTAT

ION


Edition 44 16-43


16





16-44 Edition 44


General Dimensions● 7495 HD

MODEL 7495 HDBoom Length 20.40 m 67'0"



Edition 44 16-45


16





16-46 Edition 44


MODEL 7495 HydraCrowdBoom Length 20.40 m 67'0"


General Dimensions● 7495 HydraCrowd


Edition 44 16-47


16

MODEL 7495 HFBoom Length 20.40 m 67'0"


General Dimensions● 7495 HF


16-48 Edition 44


General Dimensions● 7495 HF HydraCrowd

MODEL 7495 HF HydraCrowdBoom Length 20.40 m 67'0"



Edition 44 16-49


16

MODEL 7295 7395 7495 HD 7495Standard Link Length 140 cm 55" 213 cm 84" 213 cm 84" 200 cm 79"Ground Bearing Pressure 372 kPa 53.9 psi 395 kPa 57.4 psi 401 kPa 58.1 psi 372 kPa 53.9 psiOptional Link Length 183 cm 72" 274 cm 108" 274 cm 108" 259 cm 102"Ground Bearing Pressure 284 kPa 41.2 psi 308 kPa 44.6 psi 311 kPa 45.2 psi 288 kPa 41.8 psi

MODEL 7495 HydraCrowd 7495 HF 7495 HF HydraCrowdStandard Link Length 200 cm 79" 318 cm 125" 318 cm 125"Ground Bearing Pressure 374 kPa 54.2 psi 245 kPa 35.6 psi 248 kPa 35.9 psiOptional Link Length 259 cm 102" 356 cm 140" 356 cm 140"Ground Bearing Pressure 289 kPa 50 psi 219 kPa 31.8 psi 221 kPa 32.1 psi

Ground Bearing Pressure

GROUND BEARING PRESSUREGround bearing pressure, or the amount of weight

that can be supported by ground conditions, determines the link width (and occasionally the machine model) that can be used at a mine site. Softer ground conditions require wider links while the softest conditions (i.e. oil sands) require a specific model (7495 HF) which was designed to operate under low ground bearing pressure

conditions. Selecting links that require higher ground bear-ing pressure than what exists at site will make propelling the machine difficult. A link too narrow for the applica tion may even cause the crawlers to sink into the ground.

The chart below lists the link length options for each electric rope shovel model as well as the corresponding minimum ground bearing pressures.


16-50 Edition 44


MODEL 7295 7395 7495 HD 7495Dipper Range 19.1-

38.3 m³25-

50 yd³20.7-

55.8 m³27-

73 yd³27.5-

60.4 m³36-

79 yd³30.6-

62.7 m³40-

82 yd³

MODEL 7495 HydraCrowd 7495 HF 7495 HF HydraCrowdDipper Range 30.6-62.7 m³ 40-82 yd³ 30.6-62.7 m³ 40-82 yd³ 30.6-62.7 m³ 40-82 yd³

Dipper Selection

DIPPER SELECTIONSelecting the correct dipper size plays an integral role

in maximizing productivity from a truck shovel opera-tion. Optimal dipper size is a function of truck size, material loose density, and fill factor.

The first step in calculating dipper size is to deter-mine the machine’s optimal payload based on truck size. To calculate this, divide truck payload by three and four (three or four pass even loading is ideal for high productivity). Compare these values to the machine’s maximum payload. The machine’s optimal payload is the largest value that is less than the maximum payload.

For example, consider a mine operating a 7495 shovel (maximum payload = 120 tons) and 797 trucks (pay-load = 400 tons). 400 ÷ 3 = 133.3 and 400 ÷ 4 = 100. 133.3 can be eliminated as it is greater than the shovel’s maximum payload (120 tons). 100 tons is the largest value less than the machine’s maximum payload, and therefore, is the machine’s optimal payload.

Once optimal machine payload is determined, mate-rial loose density and fill factor are used to calculate the optimum dipper size. To calculate material loose

density, divide insitu (undisturbed material density) by 1 + swell factor.

Material loose density =

Insitu(1 + swell factor)

Once material loose density is calculated, use the equation below to find the optimal dipper size.

Optimal dipper size =

Optimal machinepayload

Material loosedensity

× Fill factor

For example: For a mine with the following conditions:

Insitu: 2.276 ton/yd³Swell factor: 35%Fill factor: 95%Optimal machine payload: 100 tons

Optimal dipper size =

100 tons2.276 ÷

(1 + 0.35)

× .95 = 62.5 yd³


Edition 44 16-51


16

Truck Match

MODEL

Payload 7295 7395 7495 HD 7495 7495 HFtonne (ton) 45 (50) 64 (70) 82 (90) 109 (120) 109 (120)

772G 45 (50)

773G 57 (63)

775G 65 (72)

777G 97 (107) 2

MT3300 AC 136 (150) 3 2 2

785D 136 (150) 3 2 2

789D 181 (200) 4 3 2

MT3700 AC 186 (205) 4 3 2

MT4400 AC 221 (244) 5 4 3 2 2

793F 227 (250) 5 4 3 2 2

795F AC 313 (345) 5 4 3 3

MT5500 AC 326 (360) 5 4 3 3

MT6300 AC 363 (400) 4 4 4

797F 363 (400) 4 4 4

TRUCK MATCHTruck shovel match, or the number of passes necessary

to load a truck, has a major impact on an operation’s productivity. To optimize productivity, 3 to 4 even pass loading of trucks is ideal. The chart below shows pass match between Cat electric rope shovels and Cat trucks.


16-52 Edition 44

Notes —


SURFACE MINING EXTRACTION & CONVEYING EQUIPMENT/Conveyor Systems/Draglines/Electric Rope Shovels/Hydraulic Mining ShovelsCONVEYOR SYSTEMS:IntroductionSpecifications:Surface IdlersEngineered Class PulleysEngineered BTGsPre-Engineered BTGs

DRAGLINES:Introduction8000SpecificationsDimensions/Working Ranges

8200SpecificationsDimensions/Working Ranges

8750 – 22.9 m (75 ft) BaseSpecificationsDimensions/Working Ranges

8750 – 25.6 m (84 ft) BaseSpecificationsDimensions/Working Ranges

ELECTRIC ROPE SHOVELS:IntroductionFeaturesSpecificationsDigging EnvelopesGeneral DimensionsGround Bearing PressureDipper SelectionTruck Match

HYDRAULIC MINING SHOVELS:General IntroductionFeaturesSpecificationsDigging Envelopes/Working Range/Digging ForcesGeneral DimensionsGround PressuresBucket SelectionCycle TimesProduction Overviews

Documents

SURFACE MINING EXTRACTION EQUIPMENT · Electric rope shovels are one of the largest loading tools on the market. They run in a truck-shovel opera-tion with mining trucks in order