7495 HD Rope Shovels TechSalesPres 032212

Cat® 7495 HD
Electric Rope Shovels
Presenter Name
Month DD, YYYY
1 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Safety Briefing
Emergency Contacts Emergency Information
Fire Alarm Description

• Building: <phone #> • Evacuate
• Municipal: <phone #> • Take cover
• All clear
Medical
• Building: <phone #> Unique Hazards
• Municipal: <phone #> • Room
• Floor/Building
First Responders
• Room <identify> Emergency Procedures
• Building <location & name> • Equipment locations
• Evacuation routes

Cat® 7495 HD: Agenda

Agenda
• History/Overview
• Manufacturing & Distribution
• Specifications
• Features & Benefits
• Sustainability & Safety
• Equipping Your Electric Rope Shovel
• Productivity
• Serviceability
• Product Support

Cat® 7495 HD: History/Overview

Rope Shovel Evolution
1880 Bucyrus Foundry and Manufacturing Company is established

1882 The first Bucyrus steam shovel is manufactured
1904 Bucyrus supplies 77 of the 102 steam shovels that dig the Panama canal. Marion supplies an additional 24.
1927 Bucyrus merges with the Erie Steam Shovel Company, America’s leading manufacturer of small excavators
1930 Bucyrus expands internationally by joining Ruston & Homsby, Britain's top excavating machinery manufacturer
1935 Rope Crowd is introduced

1981 The first Bucyrus manufactured AC drive shovel goes to work
1990 The 7495 series of electric rope shovels is launched
1997 Bucyrus acquires Marion Power Shovel Company First Bucyrus model to
incorporate AC Drives
2000 Bucyrus upgrades to AC IGBT drives
Bucyrus Machine digging

the Panama Canal First Bucyrus model to
incorporate Rope Crowd

Rope Shovel Evolution
2002 Models 7495 and 7495 HF, which incorporate the best Bucyrus and Marion product features are released
2008 HydraCrowd™, the first new crowd technology developed in 70 years, is launched
2009 Bucyrus releases its first LatchFree™ Dipper System
2010 After months of customer collaboration, Bucyrus launches its new cab design – the most operator
oriented cab on the market
LatchFree Dipper
HydraCrowd
New Operator’s Cab

Electric rope shovels: Product overview
7395
MID-RANGE
7295
45.4 t (50 tons) 63.5 t (70 tons)

18.4-39 m³ (24-51 yd3) 19.1-49.7 m³ (25-65 yd3)
789,251 kg (1,740,000 lbs) 1,179,340 kg (2,600,000 lbs)
ULTRA CLASS
7495 HD 7495 / 7495 HF

81 t (90 tons) 109 t (120 tons)
19.1-49.7 m³ (25-65 yd3) 30.6-62.6 m³ (40-82 yd3)
1,306,346 kg (2,880,000 lbs) 1,382,400 kg (3,047,670 lbs)*
* Stated weight is for 7495. 7495 HF operating weight is 1,442,274 kg (3,179,670 lbs)

Manufacturing facilities
United States
South Milwaukee
Rope Shovels

Electric rope shovels: Pass match
Model 785 789 793 795 797

Tons 150 200 250 345 400
3-4 pass 3-4 pass 3-4 pass 3-4 pass
Model 7295 7395 7495 HD 7495/7495 HF

Tons 50 70 90 120

Caterpillar ERS Field Population
(Active machines as of 11/29/2011)
Total active machines = 227

Loading Tool Market
7295 7395 7495 HD 7495 HF 7495
2300XPC 2800XPC 4100C 4100C BOSS 4100XPC
WK-20 WK-27 WK-35 WK-55
EKG-18 EKG-32 EKG-50
6040 6050 6060 6090
EX3600 EX5500 EX8000
PC4000
PC5000 PC8000
9350 R9400 R995 R996 R9800

Cat® 7495 HD: Manufacturing & Distribution

Experience
• 85 years of experience building electric rope shovels

• More than 600 electric rope shovels built over the past 50 years
• ISO 9001 quality system

7495 HD
• Product Development
– Partner with customers
– Learn from experience
– Utilize technologies &
innovations from
Caterpillar’s wide array of
mining equipment

Superior Quality – Thermal Stress Relief
• Eliminates residual stress in complex weld structures

• Large furnaces are used to relieve entire weldments
• Stress-relieved structures
– Boom
– Crawler frames
– Revolving frame
– Front and rear
A-frame legs
– Truck frame center
core and wings

Superior Quality - Weldments
• Full penetration, profiled and ground welds used in select

areas
• Enhanced design for extended performance

Superior Quality – Weld Inspections
• All welds are visually inspected by

union inspectors
• Union inspectors are required to be
(or become) AWS weld inspector
certified
• Ultrasonic weld testing is
performed on most weldments
• Magnetic particle inspection used
on select welds

Cat® 7495 HD: Specifications

7495 HD Dimensions

7495 HD Specifications

Cat® 7495 HD: Features & Benefits

Major Features
• AC IGBT Electrics • Swing Machinery

– Drives – Planetary Gearcases
– Motors – Swing Rack
• Lube System • Hoist Machinery
• Major Structures • Crowd Machinery
– Truck Frame – Rope Crowd
– Revolving Frame • Front End
– Crawlers – Handle/Saddle block
– Cab – Boom
– Machinery House – Dipper
• Planetary Propel

AC IGBT Electrics
• Caterpillar Experience
– 30 years in AC drives
– 200+ AC drive shovels operating
• AC Benefits
– Fast
• Shorter cycle time than DC
– Reliable
• MTBF in the thousand of hours
• MTTR averages <1 hour
– Less Maintenance
– Worldwide customer service
support
– Strong industry acceptance

Benefits of AC over DC Electrics
• Less vulnerable to input voltage variation

– Operating from -30% to +10% while DC operates from -20% to +10%
• Less harmonic distortion provides cleaner energy
– <8% for AC compared to 11% for DC
• No RPC due to use of AFE rather than rectifiers
• No efficiency loss – drives maintain a power factor of 1.0
• No fuses due to use of IGBT switches
• Interchangeable components
– IGBT modules are interchangeable between AFEs, inverters, motions,
and machines
• Longer lasting, easier to maintain motors

AC IGBT Electrics – Acutrol III™ Drives
• Fuseless regenerative IGBT AC drives

• Fully digital integrated maintenance
display
• Common components (AFE/inverter)
– Interchangeable between AFE, inverter
motions and machines

AC IGBT Electrics - Motors
• Design
– Simple squirrel cage induction
motor
– No brushes
– No commutator
– No flashover
• Reduced Maintenance
– Grease and replace gearing every
30,000 hours

AC IGBT Electrics – On-board Maintenance Computer
• Provides to easy to troubleshoot screens

• Connects to SiBAS drive computer and PLC
• Capable of loading all drive and PLC software (Application software
resident)
• Contains troubleshooting and device manuals
• Eliminates the need for a laptop
• Accessible from remote locations

AC IGBT Electrics
Diagnostic Computer (Deck View)

Lube System
• Lube Room
– Insulated, double walled
– 907 kg (2000 lbs) monorail
mounted electric chain hoist for
lifting supplies is included
• Automatic lubrication
– Single-line automatic lube system
applies open gear lubricant and
grease via a programmable logic
controller
– Six separately controlled lube
circuits provide selective
distribution frequency and quantity
resulting in reduced lubricant
usage and cost

Major Structures – Truck Frame & Revolving Frame
• Rugged thermally
stress-relieved
structures
• Cold-weather impact
resistant ASTM A-633
grade steel on outside
skin plates
• White painted interiors
for ease of field
inspection

Major Structures – Truck Frame & Revolving Frame
Bolted and welded front edge joint transmits

digging and steering loads
Key type hook joint at crawler/truck frame edge assures

high quality reliable connection

Major Structures – Crawlers
Cantilever roller design

Easy tumbler access for
inspection & maintenance

Major Structures – Crawlers

Major Structures – Crawler Links
Link Offerings:
• 213 cm (84 in)
• 274 cm (108 in)
• Made from heat-treated cast alloy

• Stretch-resistant
• Induction hardened pins
• Manual hydraulic take-up adjustment
provided
• Manganese bushings available for hard
rock applications

Major Structures – Operator’s Cab
• Broad line of site for excellent

operator situational awareness
• Touch-screen display for real-
time information
• On-board phone
communications
• Efficient layout for easy access
to storage and workstations
• Adjacent positioned trainer
seat
• Fingertip control of
environmental system to
maximize cab comfort
• Rheostat lighting control for
optimum light levels
• dBA from 74 to 80
Storage
Lockers
Trainer
Seat
Exit
Touch screen
Display

• Operator Seat & Controls:

– Ergonomically positioned controls to
reduce operator fatigue
– Adjustable joysticks
– Motorized seat, console, and foot rest
– Flip-up armrest with height and angle
adjustment

Major Structures – Machinery House
• Improved machinery house layout

– Designed with efficient shovel
maintenance in mind
– Completely enclosed, self-supporting
steel panels with built-in framing
– Dynavane air filtering and pressurizing
system to inhibit influx of dust and dirt

Planetary Propel
• Dual independent drive trains

• Steering on-the-go for faster shovel positioning
• Maximizes reliability
• Supports reduced maintenance

Planetary Propel
Gearcase or drive tumbler

independently removable
DUOCONE SEAL
DRIVE TUMBLER
BEARING

Swing – Dual Output Planetary Gearcase
• Optimum cycle times
• Improved swing rack and pinion life as compared

to single pinion design
• Improved reliability and reduced maintenance
Dual output pinions

Swing Rack
• Forged/fabricated construction
extends life.
• Dual output swing pinions provide

even wear and eliminate the need to
rotate the rack
• Design allows for minor roller

maintenance and single roller
replacement without removing the
upper works

Hoist Machinery
• Superior load capacity

• Improved drum gear and pinion life
• Increased rope life as compared to smaller drums
• Roof hatches facilitate motor, drum and gear case removal
• Planetary gearcase with dual output pinions

Crowd Machinery
• Deck-mounted crowd machinery

for:
– Lower swing inertia & faster
cycle time
– Less stress on boom structures
– Ease of maintenance and
improved safety
• Ropes attached to drum by
furrele-becket anchors for
easier rope changes
• Pinions carbureted for
extended life
• Crowd drum enlarged 152 cm
(60 in) for extended rope life

Crowd Machinery
New standard rope crowd machine includes the
Automated Electro/Hydraulic Crowd Rope Take-up System
previously quoted as an option
SHIPPER SHAFT
RETRACT ROPE
CROWD ROPE
CROWD DRUM
152.4 cm (60")

Crowd Machinery
Automated Electro/Hydraulic Crowd Rope Take-up System
• Reduces machine maintenance preparation time and
downtime during tightening sessions
• Increased safety because adjustments are made from
the top of the machinery house instead of the top of
the dipper
• Eliminates the need for retract rope hydraulic
cylinders and shims
• Auxiliary equipment needed for making rope
adjustments are no longer necessary

Front End
• Front end geometry maximizes
payloads and productivity
• Design minimizes front end

weight
• Lightweight front end reduces

inertia and cycle times
• Bridge-strand suspension ropes

(rather than wire) extend life
• Wide-spread boom point

sheaves stabilizes dipper in bank
• Boom limit switch with soft

setdown prevents boom jacking
shock loads

Front End – Boom
• Fully stress relieved impact

resistant steel
• Enhanced structural configuration
reduces weld related stress
concentration and extends life
• 100% penetration and UT quality
welds secure all main splice
joints
• Open manholes and ladders
allow structural inspection without
lowering the boom
• 20.4 m (67 ft) length and 43º

angle optimize dumping height
and facilitate truck positioning

Front End – Handle & Saddle Block
• Reduced handle stress associated with One-piece, forged, seamless tube

86.4 cm (34") dia. with 7.62 cm (3") wall.
torsional loads
• Saddle block has manganese bronze

bushings to eliminate galling
• Saddle block has one-piece liner to

reduce handle contact stress

Front End – Handle Fabrication
• Handle is fabricated from single

billet for reduced stresses and
extended life

Front End – Handle Fabrication
Heated
Pierced
ID Descaled
Ingots
23.6 tonnes (26 tons)
each Drawing Process

Dipper
• Dippers engineered & enhanced by

SolidWorks® modeling & computer
aided design
• FEA (finite element analysis)
performed on structures as needed

Dipper
• Dipper Features:
– Structural parts made from
sturdy, high-strength structural
steel
– Dipper bowl, back & door
weldments are stress relieved
– Door pins inserted into forged
manganese bushings
– Padlock pin rotates in a centri-
fugally cast explosion hardened
bushing
– Adjustable pitch brace facilitates
changing the rake angle of dipper
– Easy access to fulcrum and shim
adjustment
– Box beams provide torsional
rigidity

Dipper – Lip Styles
FastFil™ Straight-Sided
(Trapezoidal)
• Lip style options: Whistler 12 Spade Lip
– Whistler 12 Spade (standard)

• Easier penetration OPTIONAL
• Lower bank resistance
• Reduced corner loading
• Eliminates bulldozing STANDARD
• Less drag
– Whistler 12 Flat Bottom (optional)
• For iron ore applications
Dipper – Body Styles
FastFil (Trapezoidal) Straight-Sided

Small to medium size payloads Small to larger size payloads
(up to 49.7 m³ / 65 yd³)

Fastfil™ Dipper
• Unique trapezoidal design eliminates voids

• Fantastic fill factor
– 110% typical
• Easy bank penetration & reduced drag
• Built-in adapter base

Dipper – Tooth Options
Shroud
Whistler
Tooth
Dipper Lip
Whistler WH-12

Cat® 7495 HD: Sustainability & Safety

What is sustainable development?
Sustainable Development is defined as “development that meets

the needs of the present without compromising the ability of future
generations to meet their own needs.”
– World Commission on Environment and Development, 1987
A Sustainable Company is one that “creates profit for its owners

and shareholders while protecting the environment and improving
the lives of those with whom it interacts.”
– The Triple Bottom Line, Andrew Savitz, 2006

What is sustainable development?
Sustainable Development for Caterpillar

means leveraging technology and innovation
to increase efficiency and productivity with
less impact on the environment and helping
our customers do the same – enabling their
businesses to become more productive by
providing products, services and solutions
that use resources more efficiently.
Of course, it starts with our own

operations, with our customers in mind.

Sustainability and Customer Value
Sustainability Improvement Customer Value

Fuel efficiency O & O costs (operational efficiency)
Extended service intervals License to operate (compliance)
Waste reduction Improved access to bid process
Noise/sound Risk reduction/mitigation
Safety
Competitiveness and market position
Air quality emissions

Employee recruitment and retention
Greenhouse gas emissions

Reputation (brand)
Fuel flexibility (alternative fuels)

Measurable Sustainability Performance
• Economic
– Life Cycle Cost
• Environmental
– Fuel/Energy Efficiency
– Air quality Emissions
– Greenhouse Gas Emissions
– Materials Efficiency
– Manufacturing Impacts
– Supply Chain Impacts
• Social
– Safety
– Sound
SD attributes being integrated into NPI…items in blue available for machines

2020 Goals for Operations
2020 Goals for Products, Services & Solutions

Caterpillar Global Support

Superior Rope Shovel Safety
Designed and constructed with an attentiveness to safety
• Features Lube room hoist Non-skid material
– Non-skid material on roof
surfaces prevent falls
– Grip strut stairs, platforms &
walkways facilitate safe
movement around the
machine
– Stored energy warning signs
installed at appropriate
locations reduce injuries
– 907 kg (2000 lbs) monorail
mounted electric chain hoist in
lube room provides easy safe
lifting of supplies from ground
to lube room Stored Energy Warning Sign
– Shaft guards installed on
Shaft Guards
Lincoln lube pumps prevent
injuries

• Stored Energy Warning Signs

– Machine was analyzed by engineers for stored energy
– Stored energy locations are clearly marked with signs warning
personnel of danger and advising them to use the proper procedures to
access the area

Designed and constructed with an attentiveness to safety
• Features
– Excellent visibility for
maximum operator situational
awareness
– Forty-five degree rear facing
boarding stairs provide fast &
convenient egress to/from the
machine
Line of sight diagram

Cat® 7495 HD: Equipping your electric rope shovel

Optional Equipment
• Technology Package • Boarding

– AccessDirect – Left-hand boarding stair
– MIDAS – Left-hand stair from platform to roof
– AccuLoad
– Bearing Temperature Monitoring • Cable Handling
– Stinger
• Safety
– Cable Reel
– Remote Hoist/Crowd Drum Control
– Safety Lighting • Training
• Front-End/Dippers – VAST
– LatchFree™ Dipper System – Online CBT (Computer Based Training)
• Climate – Additional electrical, mechanical, or
operator training
– Cold Weather Package
– Extreme Cold Weather Package • Other
– Hot Weather Package – Test power equipment package
• Filtration – Welding outlets
– Auto-reversing house filtration fans – Tow lug package
– PureMax filtration system

Technology Package
• Information is key in cutting cost

per tonne in mining operations
• Caterpillar offers a technology
package that collects, transmits,
stores and analyzes key shovel
data helping you:
– Increase productivity
– Decrease downtime
– Minimize delay in machine repair
– Improve planning accuracy
• Technology package includes:
– AccessDirect™
– MIDAS™
– AccuLoad™
– Bearing temperature monitoring

Technology Options – AccessDirect™
Any PC with Internet connection
can access the shovel
Main Tower
Access Point
AccessDirect™
Server
MIDAS™
Server
Internet
Mobile Repeater
 For direct LOS, if required
 Can be moved around
 Can be solar powered
Firewall
Any PC on the mine network

can access the shovel
Technology Options – AccessDirect™
• Electrical interface system that facilitates remote access to

machine’s on board computer via internet
– Permits monitoring, adjustment, resetting, and modification of electrical parameters
– Arrives with software for PLC, software for drives resident, and one server per fleet
• Features
– High speed data transfer
– Expandable to include Accuload and Midas
– Adaptable to third party communication systems (Modular Mining)
• Benefits
– Enables factory experts to join the local maintenance team
– Prepares maintenance personnel to arrive on site ready to fix rather than analyze
the problem
– Reduces MTTR
– Reduces daily maintenance efforts
– Enhances diagnostic capabilities

Technology Options – MIDAS™ (Condition Monitoring System)
• A diagnostic system that helps optimize

machine performance by providing,
logging, and analyzing data on a variety of
machine variables
• Package comes with software, hardware,
and a server
• Benefits
– Provides remote real-time monitoring of
machine performance
– Records system vitals and makes historical
data available in an all inclusive “flight
recorder” functionality
– Generates trends, reports, and analysis
– Gives depth and scope to diagnostic tools
– Allows for advanced search and query
– Broadens understanding of machine
performance
– Delivers insight into how to best utilize
machines in mine operations

Technology Options – Accuload™
• Data analysis system

– Provides real-time feedback on dipper
load
• Outstanding accuracy
– +/- 4% error on >90% of loads
• No mechanical sensors
• Adaptable to mine conditions
• With MIDAS, Accuload data can be
logged & analyzed
• Benefits:
– Monitors material moved
– Prevents overloading of trucks
– Allows operator to monitor load & shift
performance
– Improves operator performance

Technology Options – Bearing Temperature Monitoring
• Description:
– Monitors hoist, swing & crowd
bearing temperatures
– Alerts user of temperature problems
• Benefits:
– Helps predict maintenance through
bearing temperature trending
– Reduces downtime
– Reduces risk of major failure

Safety Options
• Caterpillar is committed to
providing safe products
• Designs are continuously
evaluated to identify & alleviate
safety hazards
• Standard machine includes many
safety enhancements
• Additional options offered to bring
the machine into compliance with
the strictest codes and regulations
including:
– Remote Hoist/Drum Control
– Safety Lighting Packages
– Immobilization Cables

Safety Options – Remote Hoist/Crowd Drum Control
• Description:
– A remote control that allows
maintenance personnel to operate the
hoist (or crowd) from the machinery
house
– Control contains a motion start/stop
control, emergency stop, joystick, and
status indicators
• Benefits:
– Reduces time spent changing ropes
– Improves safety by giving maintenance
personnel full control of the rope reeving
process
– Allows only one reeving mode at a time
for safe control of the machine motion
– Facilitates rope positioning on the drum

Safety Options – Safety Lighting Package
• 20 V, 60 Hz base unit with 12 V output and 360 W capacity

• 11 weather proof adjustable double Halogen fixtures mounted
strategically around the machinery house
• Two self-luminous exit lights
• Four propel warning lights

Safety Options – Immobilization Cables
• Description:
– Easy to use, one-inch steel
cables, and anchor points, to
connect revolving frame to truck
frame
Immobilization Cable
• Benefits:
– Improves safety for maintenance
personnel, especially when
working on swing components
– Holds upper works in place,
even if brakes are not set
properly

Dipper Option – LatchFree™ Dipper System
• Description:
– Strong steel link, located at top of dipper
body, replaces latch assembly
– Design extensively evaluated by peer
review, FEA & strain gauge analysis
• Benefits:
– Improves safety by removing the need to
maintain the latch bar, latch keeper,
shims & inserts
– Eliminates the number one reason for
unplanned shovel downtime – the latch
assembly
– Increases efficiency by improving uptime
& reducing lost loads
– Reduces maintenance cost due to
repositioning of components away from
the harsh conditions of the lower dipper
body

Climate Options
• Cat machines operate on six

continents in a variety of
environments – from the Atacama
Desert to the Siberian Coal Fields
• To ensure efficient operation, under
all conditions, Caterpillar offers a
variety of additional climate
packages
• Standard machines operate:
– Up to 3,048 m (10,000 ft)
– From 1°C to 41°C (33°F to 105°F)
• With climate packages, machines
operate:
– Up to 5,200 m (17,000 ft)
– From -40°C to 50°C (-40°F to 122°F)

Climate Options – Cold Weather Package
• Allows operation to -20°C/-4°F

• Includes:
– Two 25kW house heaters
– Air compressor air dryer
– Eight 750W hoist heaters
– Four 820W swing heaters

Climate Options – Extreme Cold Weather Package
• Allows operation to -40°C/-40°F

• Includes:
– Four 25kW house heaters
– 10kW cab heater
– Air compressor air dryer
– Heated mirrors
– Eight 750W hoist heaters
– Four 820W swing heaters
– FHT2 Fan Shut off
– Insulated machinery house

Climate Options – Hot Weather Package
• Allows operation to 50°C/122°F

• Includes:
– Dual IGBT skid air conditioners to
replace heat exchangers
IGBT Skid Air Conditioner

Filtration Options – Auto-Reversing Filtration Fans
• Description:
– Three auto-reversing fans
– Fans start-up in reverse, spin 30
seconds, spin to zero speed, and
restart in the forward direction
• Benefits:
– Prevents debris from blocking air
inlets
– Maximizes the effectiveness of the
Dynavane filtration/pressurization
system
– Reduces maintenance time
– Helps keep filter elements clean
– Extends life of filters
– Lessens drag on the fan

Filtration Options – PureMax Filter System
• Hi-tech filtration system

ideal for dry, dusty
conditions
• Nanofiber cartridge filters
provide cleaner air, higher
efficiency, and longer filter
life
• Dual short screw
conveyor dust removal
system keeps roof clear of
dust build up
• Clean-side filter access
facilitates filter changing
• Pulse cleaning technology
self cleans filters

Filtration Options – PureMax Filter System
Filtered Air • Eliminates dust in the

electrical room
• Extends the life of
electrical components
Unfiltered • Purifies air 25% better

Air In than similar sized
systems
• Improves efficiency
• Simplifies filter changing
• Eliminates dust build up
on roof
Filtered Air
Dirt & Dust
removed by
screw conveyor

Boarding Options
• 45° left-hand boarding stair

– Rear facing electro-hydraulic
powered
– Stairs and handrails made to
code and safety standards
• Left or right power step

– Self-contained electro-
hydraulic power unit
– Failsafe hydraulics for
enhanced safety

Cable Handling Options
• Stinger
– Structural steel stinger with wire
supports and hinged support
connection to allow vertical
movement
– Increases overall safety
– Improves control for easier propel
– Minimizes trail cable damage
• Cable Reel
– Structural steel cable reel with
self-contained automatic
adjustable electric-hydraulic take-
up/tensioning drive
– Capacity of approx. 457 m (1500
ft)
– Improves overall safety
– Extends cable life

Training Options
• Well-trained personnel maximize

machine performance and mine
productivity
• Caterpillar offers a variety of

training options to bring your
employees up to speed on our
equipment
• Training offerings include:

– VAST™ shovel simulator
– CBT (computer based training)
modules
– Additional onsite training days
and/or courses
– Training courses in South
Milwaukee

Training Options – VAST™ Simulator
• Description:
– Cat electric mining shovel simulator
– Replicates Cat machine controls and
responses and typical scenarios found in
mining applications
– Includes two joysticks, table mounts,
VAST software, simulation manager
software, and a detailed instruction and
installation guide
• Benefits:
– Provides a safe and controlled learning
environment
– Minimizes interruption in mine productivity
due to operator training
– Decreases overall training costs
– Reduces shovel damage and repair costs
– Tracks and evaluates user progress
– Easy to transport
Requires high end gaming computer (not included)
Monitor pictured above not included

Training Options – CBT (Computer Based Training)
• Description:
– Highly visual and interactive training
on technical subjects via online short
courses
– Courses offered on a variety of
topics from safety & operation to
mechanical & electrical repairs
• Benefits:
– Improves safety and machine
performance
– Provides a cost-effective way to train new
employees on Cat equipment
– Provides additional and/or refresher
training for current employees
– Offers convenient, 24/7 accessibility from
anywhere with an internet connection

Test Power Equipment Package
• Megohmmeter
• Loop calibrator
• Rogowski current transducer
• 8 channel data acquisition device
• Temperature probe
• Test leads

Additional Miscellaneous Options
• Welding outlets
• Welding machine
• Tow lugs

Cat® 7495 HD: Productivity

Exceptional Availability
• 96% Electrical
– AC IGBT Technology is extremely reliable - MTBF is in the thousands of hours
– Little regular maintenance is required
• No regular maintenance on IGBT power control module/SiBAS control module
• Motor maintenance reduced to grease and bearing replacement every 30,000 hours
– Repairs are fast – MTTR averages less than 1 hour
• Many IGBT drive components are interchangeable between motions and machines
• 90% Overall
– Use of heavy-duty, mine grade materials extends MTBF
• Stress relieved, high strength, cold weather steel
• Manganese-bronze lined bushing in saddle block
– Innovative designs reduce planned maintenance
• Placement of dual swing machinery eliminates need to rotate the swing rack
– Innovative designs reduce MTTR
• Planetary gearcases for faster change out
• Most maintenance on house load rollers do not require jacking up the upper works
• Continued Improvement
– LatchFree Dipper System

High Productivity
• Payload
– Up to 81 tonne (90 ton)
• Machine Clearance
– Front-end easily handles
today’s largest mining
trucks
• Loading
– Three-pass loads 218
tonne (240 ton) mining
trucks 7495 HD Loading a Cat 793C Truck
– Four-pass loads 328 tonne
(360 ton) mining trucks

7495 HD - Loading Profile
777F 785D 789C 793D 795F 797F

100 ton 150 ton 195 ton 240 ton 345 ton 400 ton
91 tonne 136 177 218 313 363
tonne tonne tonne tonne tonne
7295
33 yd³
28 m³ 2 3 4
7395 HR
53 yd³
44 m³ 3 4
7495 HD
65 yd³
50 m³ 3 4 5
7495/7495
HF
82 yd³ 2 3 4
62 m³

Cat® 7495 HD: Serviceability

Reduced Maintenance
• Planetary gear cases accelerate gear

change outs
• AC Motors reduce motor maintenance
• Automated electro/hydraulic crowd
rope take-up system simplifies
crowd/retract rope tightening
• White painted interiors facilitate crack
monitoring
• Air and oil filter design and placement
speed up routine filter changes
• Thermal stress relief extends major
structure life
• One piece tubular handle crowd
system greatly decreases
maintenance compared to rack and
pinion system

Cat® 7495 HD: Product Support

Outstanding Service
• Local customized support – over 100 locations across the globe
• Projects staffed by experienced, knowledgeable Caterpillar service
engineers
• Services
– Machine moves and field
assembly
– Turnkey machine upgrades
• LatchFree Dipper System
– Component rebuilds
– Machine maintenance and
operation
– Turnkey Repair
• Shovel roller, rail, and rack replacements
• Provide all necessary skilled technicians, equipment, supplies and tooling
– Technical Services

Outstanding Service – Technical Service
• Non destructive UT testing

– Caterpillar technicians locate and monitor fatigue indications in
critical components and welds
• Conditional Analysis
– Complete, comprehensive analysis of machine components
• Suspension Pendant Inspections
– Radiographic inspection of bridge strand suspension cables to
detect interior broken strands
• Alignment audits
• OEM supported technical
consulting & troubleshooting

Outstanding Service – MARCs
• Maintenance and repair contracts

– 30+ years of experience
– Contracts tailor to each customer
– Services
• Parts planning
• Machine maintenance
• Maximize Value
– Optimize machine performance
– Reduce operating costs
– Enhance mine safety
• Minimize Risk
– Pre-defined costs make overall operation planning and budgeting easier
and more efficient

Outstanding Service – MARCs
• 24/7 On-site maintenance and repair service

• Pre-defined costs
• Professional, technical, and engineering support
• Hiring and training of skilled labor personnel
• Superior mine safety
• Maximized machine availability, productivity, and efficiency
• Maintenance planning coordinated with mine production
• Inventory management support
• Parts forecasting
• Lower administrative costs
• High degrees of customization and flexibility

Outstanding Service – Application Engineering
• Theoretical Production Estimates

– Analysis of potential long-term cost benefits
and productivity improvements from
upgrades or new machines
– Strong support to justify capital expenditure
• Equipment Advice
– Analysis of mine and output requirements
– Recommendation of best machine mix to
achieve your goals
• New Technology Adoption
– Investigation on the benefits of implementing
a new or different technology
– Support planning and implementing the
technology
• Tests and Surveys
– Analysis of machine operation
– Recommendation of ways to improve
machine’s productivity

Outstanding Service – Application Engineering
• Randy Govier
– 15 years of mine engineering
experience in surface mines
– 20 years of application engineering
experience with Caterpillar (formerly
Bucyrus)
– BS in mining engineering from UW-
Platteville
• Bob Shevling
– 25 years of mine engineering
experience in surface mines
– Operational experience in a wide
variety of mining conditions and
configurations
– BS in mining engineering and
geological engineering from South
Dakota School of Mining
Technology

First-Rate Operator Training
• Standard with new machine purchase

– 5 days mechanical maintenance training
• Covers basic mechanical machine repairs
and maintenance
– 5 days electrical maintenance training
• Covers basic electrical repairs and maintenance
– 10 days hands-on operator training
• Improves operator efficiency and safety
– 5 days advanced electrical training
• Covers the IGBT drive
• Taught by Siemens at its Alpharetta, Georgia, USA location
• Training provided on-site by experienced Caterpillar trainer
• Courses provided in English; translation services provided for
additional cost
• Additional training days, simulation training, and computer base
training are also offered for additional cost

Trainers
• Tony Provencio (Rope Shovels)

– 34 years in mining industry (26 as operator,
8 on shovels)
– 10 years safety training experience
– MSHA certified and able to certify others
• Kerry Klein (Draglines)

– 31 years of mining experience (24 years as
lead dragline operator on various draglines)
– Responsibilities included training work
crews in all aspects of dragline operation
and sequencing
– MSHA certified
• Kurt DeHart (Drills)

– 40 years of mining experience (20 as drill
trainer)
– MSHA certified and can certify others

Our mission
Be accountable for delivering the

best solutions for mining customers.
Facts updated: December 2008


7495 HD Rope Shovels TechSalesPres 032212

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Cat® 7495 HD

Electric Rope Shovels

1 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Emergency Contacts Emergency Information

Fire Alarm Description

2 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

3 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

4 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

5 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

1880 Bucyrus Foundry and Manufacturing Company is established

1935 Rope Crowd is introduced

Bucyrus Machine digging

6 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

7 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

45.4 t (50 tons) 63.5 t (70 tons)

7495 HD 7495 / 7495 HF

8 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

9 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Model 785 789 793 795 797

3-4 pass 3-4 pass 3-4 pass 3-4 pass

Model 7295 7395 7495 HD 7495/7495 HF

10 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Total active machines = 227

11 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

7295 7395 7495 HD 7495 HF 7495

2300XPC 2800XPC 4100C 4100C BOSS 4100XPC

WK-20 WK-27 WK-35 WK-55

EKG-18 EKG-32 EKG-50

6040 6050 6060 6090

EX3600 EX5500 EX8000

9350 R9400 R995 R996 R9800

12 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

13 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

• 85 years of experience building electric rope shovels

14 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

15 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

• Eliminates residual stress in complex weld structures

16 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

• Full penetration, profiled and ground welds used in select

17 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

• All welds are visually inspected by

18 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

19 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

20 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

21 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

22 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

• AC IGBT Electrics • Swing Machinery

23 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

24 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

• Less vulnerable to input voltage variation

25 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

• Fuseless regenerative IGBT AC drives

26 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

27 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

• Provides to easy to troubleshoot screens

28 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

29 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

30 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

31 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Bolted and welded front edge joint transmits

Key type hook joint at crawler/truck frame edge assures

32 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Cantilever roller design

33 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING