CAT Electric Rope Shovel 7295 Electric Rope Shovel Service Manual – PDF DOWNLOAD

Description

CAT Electric Rope Shovel 7295 Electric Rope Shovel Service Manual – PDF DOWNLOAD

DESCRIPTION:

CAT Electric Rope Shovel 7295 Electric Rope Shovel Service Manual – PDF DOWNLOAD

Safety Symbols

• Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used are safe and correct.
• Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit and free from the influence of alcohol, drugs, or any medications that might impair his/her eyesight, hearing or reactions. The safety alert symbols displayed here and throughout this manual are used to call attention to instructions concerning personal safety.
• Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine. Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions. If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional service representative or the manufacturer.
• The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.

TABLE OF CONTENTS:

CAT Electric Rope Shovel 7295 Electric Rope Shovel Service Manual – PDF DOWNLOAD

1: SM…………………………………………………………. 1
BI010591-EN-DISCLAIMER.pdf………………………………………. 0
1: SM – EN…………………………………………………. 0
2: OM – EN…………………………………………………. 0
3: ESM – EN Page 1………………………………………….. 0
4: ESM – EN Page 2………………………………………….. 0
5: VM – EN Page 1…………………………………………… 0
6: VM – EN Page 2…………………………………………… 0
SM141403-EN_S.pdf………………………………………………. 0
Safety Symbols …………………………………………….. 7
Safety Precautions …………………………………………. 9
General Precautions: ……………………………………….. 10
Maintenance Precautions: ……………………………………. 11
Operating Precautions: ……………………………………… 12
Fire Prevention ……………………………………………. 13
Fire Extinguisher Locations …………………………………. 14
Common Safety Features ……………………………………… 15
Emergency Lighting …………………………………………. 15
Emergency Lighting Locations ………………………………… 15
Mine Signal ……………………………………………….. 16
Mine Signal Switch …………………………………………. 16
Mine Signal Horn Location …………………………………… 16
Dual Mirrors ………………………………………………. 17
Right Side Mirror ………………………………………….. 17
Propel Back-up Alarm ……………………………………….. 18
Propel Back-up Horn Location ………………………………… 18
Emergency Stop Pushbutton …………………………………… 19
Emergency Stop Pushbutton Location …………………………… 19
Vertical Boarding Ladder ……………………………………. 19
Cameras …………………………………………………… 19
Warning Signs and Decals ……………………………………. 20
SM141403-EN_1.pdf………………………………………………. 0
About This Manual ………………………………………….. 0
Purpose …………………………………………………… 0
Organization ………………………………………………. 0
Revisions …………………………………………………. 0
Precautions and Disclaimers …………………………………. 0
Terminology ……………………………………………….. 0
Contact …………………………………………………… 0
Safety – Swinging Restraint & Ballast Box Support ……………… 0
Ballast Box Support ………………………………………… 0
Swinging Restraint …………………………………………. 0
Machine Overview …………………………………………… 0
Nomenclature ………………………………………………. 0
Lower Works ……………………………………………….. 0
Truck Frame and Crawlers ……………………………………. 0
Crawlers ………………………………………………….. 0
Crawler Assembly …………………………………………… 0
Truck Frame ……………………………………………….. 0
Truck Frame ……………………………………………….. 0
Swing Rack ………………………………………………… 0
Swing Rack and Roller Circle ………………………………… 0
Roller Circle ……………………………………………… 0
Roller Circle Assembly ……………………………………… 0
Propel Machinery …………………………………………… 0
Propel Machinery …………………………………………… 0
Collector Rings ……………………………………………. 0
Rotating Deck ……………………………………………… 0
Revolving Frame ……………………………………………. 0
Center Pintle ……………………………………………… 0
Deck Extensions ……………………………………………. 0
Deck Extensions and Ballast Box ……………………………… 0
Ballast Box ……………………………………………….. 0
Machinery House ……………………………………………. 0
Boarding Stairs ……………………………………………. 0
RH Boarding Stairs …………………………………………. 0
Retractable Boarding Ladder …………………………………. 0
A-Frame …………………………………………………… 0
A- Frame and Front End Support Components …………………….. 0
Hoist Machinery ……………………………………………. 0
Hoist Machinery – Plan View …………………………………. 0
Swing Machinery ……………………………………………. 0
Swing Machinery Components ………………………………….. 0
Crowd Machinery ……………………………………………. 0
Crowd Machinery Components ………………………………….. 0
Operator’s Cab …………………………………………….. 0
Compressed Air System ………………………………………. 0
Automatic Lubrication System ………………………………… 0
Lubrication Room …………………………………………… 0
Lube Reservoir fill / Overflow Plumbing ………………………. 0
Lube Reservoir Fill / Overflow Plumbing ……………………… 0
Front End Equipment ………………………………………… 0
Suspension Strands …………………………………………. 0
Boom ……………………………………………………… 0
Boom Assembly ……………………………………………… 0
Running Ropes ……………………………………………… 0
Ropes – General Arrangement …………………………………. 0
Saddle Block ………………………………………………. 0
Dipper Handle ……………………………………………… 0
Dipper ……………………………………………………. 0
Dipper Assembly ……………………………………………. 0
Padlocks ………………………………………………….. 0
Left and Right Padlocks …………………………………….. 0
Dipper Trip ……………………………………………….. 0
Dipper Trip Motor and Dipper Trip Sheave …………………….. 0
General Estimated Component Weights ………………………….. 0
SM141403-EN_2.pdf………………………………………………. 0
Lubrication Principles ……………………………………… 0
Greasing Main A.C. Drive Motors ……………………………… 0
1. Type of grease ………………………………………….. 0
2. Initial commissioning ……………………………………. 0
3. Maintenance …………………………………………….. 0
4. Regreasing intervals …………………………………….. 0
Lubricant Selection ………………………………………… 0
Gearcase Lubricant Replacement/Sampling ………………………. 0
Lubricant Change Cycle ……………………………………… 0
Automatic Lubrication System ………………………………… 0
Lube Room …………………………………………………. 0
Lubrication Room Details ……………………………………. 0
Lube Reservoir fill / Overflow Plumbing ………………………. 0
Lube Reservoir Fill / Overflow Plumbing ……………………… 0
Auto Lube Control Panel …………………………………….. 0
Lower Works Lubrication …………………………………….. 0
Revolving Frame Lubrication …………………………………. 0
Front End Lubrication ………………………………………. 0
Lubricant Injectors ………………………………………… 0
Lincoln Type SL-1 Lubricant Injectors ………………………… 0
SL-1 Lubricant Injector Operation ……………………………. 0
Lincoln Type SL-V Lubricant Injectors ………………………… 0
Lubricant Injector (SL-V) …………………………………… 0
Adjusting Injectors ………………………………………… 0
SL-V Lubricant Injector Operation ……………………………. 0
Injector Advantages ………………………………………… 0
Propel Machinery Lubrication ………………………………… 0
Hoist Machinery Lubrication …………………………………. 0
Filter Element Cleaning …………………………………….. 0
Swing Machinery Lubrication …………………………………. 0
Swing Machinery MPG & OGL Lubrication Lines …………………… 0
Crowd Machinery Lubrication …………………………………. 0
Oil Pump ………………………………………………….. 0
Air Compressor Lubrication ………………………………….. 0
ACSL – Air Compressor (Screw-type) Lubricant ………………….. 0
Lubricant Specifications ……………………………………. 0
MPO – Multi-Purpose Oil …………………………………….. 0
AM11093-EN.pdf…………………………………………………. 0
1: SM………………………………………………………105
AM11093 ERS Manual Disclaimer Page_EN.pdf……………………… 0
1: SM – EN………………………………………………106
ERS Manual Back Cover.pdf……………………………………. 0
1: English………………………………………………121
BlankPage.pdf…………………………………………… 0
Page 1……………………………………………… 0
SM141403-EN_3.pdf………………………………………………. 0
Introduction ……………………………………………….124
Preventive Maintenance Program ……………………………….124
Elements Of An Effective Maintenance Program ………………….125
Scheduled Preventive Maintenance Program ……………………..126
General Safety Considerations ………………………………..126
Maintenance During Machine Operation ………………………….127
Maintenance Precautions ……………………………………..127
Preventive Maintenance For Lubrication ………………………..129
Lubricant Cleanliness ……………………………………….130
Frequency Of Inspection And Maintenance ………………………131
Maintenance Schedules ……………………………………….131
Maintenance Inspection Check Points …………………………..131
Daily ……………………………………………………..132
Every 100 Hours, Or Weekly ………………………………….136
Every 500 Hours, Or Monthly …………………………………138
Every 1250 Hours, Or Quarterly ……………………………….142
Every 2500 Hours, Or Semi-annually ……………………………146
5000 Hours, Or Annually …………………………………….149
Major Component Locations ……………………………………152
Machine Nomenclature ………………………………………..152
Lower Works and Crawlers …………………………………….153
Crawler Assembly ……………………………………………154
Crawler Link Assembly ……………………………………….155
Propel Machinery ……………………………………………156
Roller Circle Section View …………………………………..157
Roller Frame Assembly ……………………………………….158
Collector Rings …………………………………………….159
Center Pintle Assembly ………………………………………161
Revolving Frame Deck Extensions ………………………………162
Hoist Machinery …………………………………………….163
Swing Machinery …………………………………………….164
Crowd Machinery …………………………………………….165
Lubrication Reservoirs ………………………………………166
Operators Cab ………………………………………………167
Boarding Stairway …………………………………………..168
Machinery House Walkways and Platforms ………………………..169
Front End Equipment …………………………………………170
Boom Support Ropes ………………………………………….171
Boom Bumpers ……………………………………………….172
Dipper Assembly …………………………………………….173
SM141403-EN_4.pdf………………………………………………. 0
Lower Works ……………………………………………….. 0
Truck Frame Assembly ……………………………………….. 0
Truck Frame and Crawlers Assembly ……………………………. 0
Swing Rack Assembly ………………………………………… 0
Roller Circle ……………………………………………… 0
Roller Frame Assembly ………………………………………. 0
Roller Circle Repair ……………………………………….. 0
Roller Circle ~Section View …………………………………. 0
Roller Circle and Rails …………………………………….. 0
Roller Circle ~Exploded View ………………………………… 0
Crawler Belts ……………………………………………… 0
Crawler Belt Maintenance ……………………………………. 0
Crawler Belt Tension Adjustment ……………………………… 0
Crawler Belt Tension Adjustment ……………………………… 0
Correct Belt Tension ……………………………………….. 0
Crawler Shoe Replacement ……………………………………. 0
Crawler Belt Replacement ……………………………………. 0
Crawler Belt and Shoe Replacement ……………………………. 0
Crawler Side Frame Assembly …………………………………. 0
Crawler Side Frame Maintenance ………………………………. 0
Crawler Assembly – Right Shown, Left Opposite …………………. 0
Slide Bar Rebuild ………………………………………….. 0
Crawler Mounted Slide Bars ………………………………….. 0
Crawler Front Idler Assembly ………………………………… 0
(Left Shown, Right Opposite) ………………………………… 0
Crawler Front Idler Roller Assembly ………………………….. 0
Front Idler Assembly – Section View ………………………….. 0
Load And Idler Rollers ……………………………………… 0
Roller Removal Or Replacement ……………………………….. 0
Load Roller Removal ………………………………………… 0
Propel Assembly ……………………………………………. 0
Propel Drive Shaft Assembly – Exploded View …………………… 0
Propel Drive Shaft Assembly – Section View ……………………. 0
Installation Notes …………………………………………. 0
Main Propel Drive Shaft Removal ……………………………… 0
Fixtures for the Main Propel Shaft …………………………… 0
Propel Shaft Pilot Rod ……………………………………… 0
Propel Shaft End Support ……………………………………. 0
Details for the Main Propel Shaft Fixtures ……………………. 0
Main Propel Shaft – Disassembly ……………………………… 0
Main Propel Shaft – Section View …………………………….. 0
Tumbler Rebuild Procedure …………………………………… 0
Crawler Tumbler Rebuild …………………………………….. 0
Crawler Drive Tumbler Rebuild Template ……………………….. 0
Propel Machinery …………………………………………… 0
Propel Planetary Gearcase …………………………………… 0
Propel Gearcase Removal …………………………………….. 0
Propel Gearcase Installation ………………………………… 0
Propel Motors ……………………………………………… 0
Propel Motor Removal ……………………………………….. 0
Propel Motor and Motor Support ………………………………. 0
Propel Motor Installation …………………………………… 0
Center Pintle ……………………………………………… 0
Center Pintle – Section Views ……………………………….. 0
Center Pintle Adjustment ……………………………………. 0
Center Pintle Sleeve Removal ………………………………… 0
Collector Rings ……………………………………………. 0
Collector Rings – Propel and Low Voltage ……………………… 0
(Rear Section View) ………………………………………… 0
Collector Ring Inspection …………………………………… 0
Collector Ring Repair ………………………………………. 0
Rotating Deck ……………………………………………… 0
Swing Machinery ……………………………………………. 0
Inspection ………………………………………………… 0
Swing Gearcase …………………………………………….. 0
Swing Motor Removal ………………………………………… 0
Gearcase Cover Removal ……………………………………… 0
View G ……………………………………………………. 0
Intermediate Shaft And Gear Assembly Removal ………………….. 0
Intermediate Shaft And Gear Assembly Re-assembly ………………. 0
Vertical Swing Shaft And Pinion Removal ………………………. 0
Vertical Swing Shaft And Pinion Re-assembly …………………… 0
Detail A ………………………………………………….. 0
Detail B ………………………………………………….. 0
Detail C ………………………………………………….. 0
Hoist Machinery ……………………………………………. 0
Hoist Machinery Assembly ……………………………………. 0
Hoist Motor Removal ………………………………………… 0
Hoist Gearcase, Coupling and Motor Assembly …………………… 0
Hoist Motor Mounting – Side View …………………………….. 0
Hoist Gearcase Assembly …………………………………….. 0
Hoist Gearcase Assembly …………………………………….. 0
Hoist Gearcase Section View …………………………………. 0
Hoist Gearcase Cover Removal ………………………………… 0
Propel Gearcase Cover Mounting Flanges ……………………….. 0
Hoist Motor Pinion Shaft Removal …………………………….. 0
Hoist Motor Pinion Shaft Section View ………………………… 0
Hoist Motor Pinion Bearing Installation ………………………. 0
View C ……………………………………………………. 0
Hoist Intermediate Shaft Removal …………………………….. 0
Hoist Intermediate Shaft Bearing Installation …………………. 0
View C ……………………………………………………. 0
Hoist Drum Assembly ………………………………………… 0
Inspection ………………………………………………… 0
Hoist Drum Removal …………………………………………. 0
Hoist Drum Gear Replacement …………………………………. 0
Hoist Drum Bearing Removal ………………………………….. 0
View A – Right Side Shown …………………………………… 0
View B – Right Side Shown …………………………………… 0
Hoist Drum Bearing Installation ……………………………… 0
View C ……………………………………………………. 0
Hoist Mounting Bolts ……………………………………….. 0
Hoist Limit Switch …………………………………………. 0
Crowd Machinery ……………………………………………. 0
Gearcase Cover Removal ……………………………………… 0
L.H. Gearcase Cover Mounting Flanges …………………………. 0
R.H. Gearcase Cover Mounting Flanges …………………………. 0
Crowd 1st Intermediate Reduction Gears ……………………….. 0
1st Intermediate Shaft ……………………………………… 0
1st Intermediate Shaft Bearing Installation …………………… 0
View C ……………………………………………………. 0
Crowd 2nd Intermediate Reduction Gears ……………………….. 0
2nd Intermediate Shaft ……………………………………… 0
2nd Intermediate Shaft Bearing Installation …………………… 0
View C ……………………………………………………. 0
Crowd Motor Removal ………………………………………… 0
Top View of Crowd Motor, Motor Coupling and Brake ……………… 0
Crowd Motor Installation ……………………………………. 0
Crowd Brake Removal ………………………………………… 0
Crowd Brake and Brake Guard …………………………………. 0
Motor Pinion Shaft Removal ………………………………….. 0
Section View A – A (Top View) ……………………………….. 0
Section View B-B (Top View) …………………………………. 0
Section View C-C (Top View) …………………………………. 0
Crowd Gear And Drum ………………………………………… 0
Crowd Frame & Drum – Right Side View …………………………. 0
Crowd Drum Removal …………………………………………. 0
Section View A …………………………………………….. 0
Machinery House ……………………………………………. 0
Walkways, Stairways and Handrails ……………………………. 0
Boarding Stairs ……………………………………………. 0
Retractable Boarding Ladder …………………………………. 0
Front End Equipment ……………………………………….. 0
Front End Equipment ………………………………………… 0
Boom Assembly ……………………………………………… 0
Boom Repair ……………………………………………….. 0
Boom Limit Switch Installation ………………………………. 0
Section A – A Boom Inductive Proximity Switch …………………. 0
Boom Point Sheaves …………………………………………. 0
Boom Point Sheave Assembly (2 Places) ………………………… 0
Boom Point Sheave Removal And Disassembly …………………….. 0
Boom Point Sheave Reassembly And Installation …………………. 0
Boom Bumper ……………………………………………….. 0
Saddle Block ………………………………………………. 0
Saddle Block ………………………………………………. 0
Saddle Block Repair ………………………………………… 0
Saddle Block Removal ……………………………………….. 0
Saddle Block Sheave ………………………………………… 0
Dipper Handle ……………………………………………… 0
Handle Removal …………………………………………….. 0
Retract Take-Up Mechanism ………………………………….. 0
Front Stop & Spreader ………………………………………. 0
Spreader Repair …………………………………………… 0
Dipper Assembly ……………………………………………. 0
Dipper Door Latch Bar and Lever ……………………………… 0
Section D …………………………………………………. 0
Latch Bar Adjusting Procedure ……………………………….. 0
Dipper Removal & Installation ……………………………….. 0
View A …………………………………………………… 0
View B …………………………………………………… 0
View C ……………………………………………………. 0
View D ……………………………………………………. 0
Dipper Door Snubbers ……………………………………….. 0
Snubber Adjustment …………………………………………. 0
View A ……………………………………………………. 0
Dipper Pitch Brace …………………………………………. 0
Fixed Length Pitch Brace Assembly ……………………………. 0
Dipper Padlock …………………………………………….. 0
Dipper Trip Assembly ……………………………………….. 0
A-Frame …………………………………………………… 0
Auxiliary Winch …………………………………………… 0
Auxiliary Winch Assembly ……………………………………. 0
Boom Suspension Ropes ………………………………………. 0
Wire Ropes ………………………………………………… 0
Wire Rope Inspection ……………………………………….. 0
Hoist Rope Reeving & Replacement …………………………….. 0
Shim for Hoist Rope Socket …………………………………. 0
Crowd Rope Reeving & Replacement …………………………….. 0
Crowd Rope Reeving …………………………………………. 0
Crowd Rope Drum Reeving …………………………………….. 0
Retract Rope Reeving & Replacement …………………………… 0
Retract Rope Reeving ……………………………………….. 0
Retract Rope Take-Up Mechanism ………………………………. 0
Retract Rope Tightening …………………………………….. 0
Dipper Trip Rope Reeving & Replacement ……………………….. 0
Hoist and Crowd Limit Systems ……………………………….. 0
Setting Rope Limits In The Hoist & Crowd System ……………….. 0
View A – Calibration Limits Screen …………………………. 0
Crowd Slowdown/Stop Limit …………………………………… 0
Retract Slowdown/Stop Limits ………………………………… 0
Lower Slowdown/Stop Limits ………………………………….. 0
Hoist Slowdown/Stop Limits ………………………………….. 0
SM141403-EN_5.pdf………………………………………………. 0
Brakes …………………………………………………….374
Machine Motion Brakes ……………………………………….374
Disc Brake Operation ………………………………………..375
Maintenance ………………………………………………..375
Brake Adjustment Specifications ………………………………375
Brake Adjustment Chart ………………………………………375
Hoist Brake ………………………………………………..376
Hoist Brake and Motor Location ……………………………….376
Hoist Brake Adjustment ………………………………………378
Hoist Brake Installation …………………………………….380
Crowd Brake ………………………………………………..381
Crowd Brake Location ………………………………………..381
Section View B-B ……………………………………………382
Crowd Brake Installation …………………………………….384
Propel Brake ………………………………………………385
Propel Brake and Motor ………………………………………385
Section View C-C ……………………………………………386
Swing Brake ………………………………………………..387
Location of Swing Brakes and Motors …………………………..387
Section View D-D (Swing Brake) ……………………………….388
View D (Swing Brake) ………………………………………..388
Swing Brake Installation …………………………………….389
View G …………………………………………………….389
Swing Brake Burnishing ……………………………………..391
Spring Replacement – All Brakes ………………………………392
Friction Disc Replacement – All Brakes ………………………..394
O-ring Replacement – All Brakes ………………………………396
Couplings ………………………………………………….398
Grid Couplings ……………………………………………..398
Lubrication ………………………………………………..399
Coupling Disassembly And Grid Removal …………………………399
Grid Coupling Installation …………………………………..400
Seal Replacement Without Hub Removal ………………………….403
Grid Coupling Alignment ……………………………………..405
Grid Coupling Data ………………………………………….405
Gear Couplings ……………………………………………..406
Installation ……………………………………………….406
Gear Coupling Alignment ……………………………………..409
Gear Coupling Data ………………………………………….409
SM141403-EN_6.pdf………………………………………………. 0
Air Compressor – Dual ……………………………………….412
Air Compressor Location ……………………………………..412
Air Compressor Assembly ……………………………………..413
Compressor Start-up Procedure ………………………………..414
Compressor Shutdown Procedure ………………………………..415
Compressor Fluid Level Check …………………………………416
Recommended Lubrication Guide ………………………………..417
General Compressor Maintenance ……………………………….418
Fluid & Fluid Filter Change Procedure …………………………418
Air Filter Maintenance ………………………………………420
Air / Fluid Separator Element Change ………………………….421
Lockout Valves ……………………………………………..422
Lockout Valve Locations ……………………………………..422
Lube Room Lockout Valve ……………………………………..423
Safety Warnings …………………………………………….424
SM141403-EN_7.pdf………………………………………………. 0
House Filter Fans …………………………………………..428
Lubrication ………………………………………………..429
Dynavane Air Cleaner ………………………………………..429
Filter Components Overview …………………………………..430
Air Conditioner …………………………………………….431
Specifications ……………………………………………..432
Air Conditioner – Block Diagram ………………………………432
SM141403-EN_8.pdf………………………………………………. 0
Capscrew (Bolt) Grade ……………………………………….436
Bolt Tightening …………………………………………….437
Torque Wrench Method ………………………………………..437
Table 1 – Lubricated or Plated Threads or with Hardened Washers ….437
Table 2 – Dry Threads ……………………………………….438
Turn-of-nut Method ………………………………………….439
Table of Snug Tight Torque Values …………………………….439
Split Flange Assembly Procedure ………………………………441
Torque Table For Split Flange Assembly ………………………..443
Wire Locking Capscrews ………………………………………444
Patterns for Wirelocking Capscrews ……………………………444
Procedure For Use Of Mechanical Tensioner On Crawler Rods ……….445
Connecting Rods – Crawlers to Truck Frame ……………………..446
Torque Nut Removal Procedure …………………………………447
Thread Lubrication ………………………………………….447
Torque Nut Helpful Hints …………………………………….448
Locking Assemblies ………………………………………….449
Locking Assembly Removal …………………………………….451
Pinion And Hub Installation ………………………………….452
Removal From A Shaft ………………………………………..452
Mounting A Pinion Or Hub On A Shaft …………………………..452
Hub Adapter Pre-heat Advance Requirements ……………………..455
Motor Coupling Pre-heat Advance Requirements …………………..456
Maintenance Welding …………………………………………457
Welding Electrodes ………………………………………….458
Repair Welding Of Cracks …………………………………….459
Joint Preparation for Repair of Cracks ………………………..459
Preheat ……………………………………………………460
Welding Technique …………………………………………..461
Repair Welding Of Broken Parts ……………………………….462
Repair Welding Swing Rack Teeth ………………………………463
Preparation ………………………………………………..464
Swing Rack Welding Electrodes ………………………………..465
Preheat ……………………………………………………465
Welding Procedure …………………………………………..466
Welding And Cutting Equipment ………………………………..468
Stress Relieving & Temperature Measuring Equipment ……………..469
Wire Rope Care And Maintenance ……………………………….471
Storage …………………………………………………..471
Checking Diameter ………………………………………….471
Correct Method for Checking Wire Rope Diameter …………………471
Handling Wire Rope …………………………………………472
Improper Methods for Uncoiling Wire Rope ………………………473
Seizing Wire Rope ………………………………………….474
End Preparations/Terminations ………………………………..476
Wire Rope Clips …………………………………………….477
Wire Rope Clip Application ………………………………….478
Wedge Sockets ……………………………………………..480
Inspection of Sheaves and Drums ……………………………..481
Examples of Sheave Groove Conditions ………………………….481
Groove Gauge for New or Re-Worked Sheaves ……………………..482
Inspecting for Worn Sheave …………………………………..483
Breaking In A New Wire Rope …………………………………483
Inspection Data …………………………………………….483
Guideline to Inspections and Reports …………………………484
Wire Rope Stretch vs. Rope Life ………………………………488
Examples of Broken Wires …………………………………….491
Seals ……………………………………………………..492
Seal Installation …………………………………………..492
Split Seal Installation ……………………………………..493
Gearcase Sealing ……………………………………………494
141403_n.pdf…………………………………………………… 0
Page 1……………………………………………………..496
141403_d.pdf…………………………………………………… 0
Page 1……………………………………………………..497
BI010948-EN.pdf………………………………………………… 0
Page 1…………………………………………………….. 0
BI010949-EN.pdf………………………………………………… 0
Page 1…………………………………………………….. 0
BI010948-EN.pdf………………………………………………… 0
Page 1……………………………………………………..498
BI010949-EN.pdf………………………………………………… 0
Page 1……………………………………………………..499
BI010950-EN.pdf………………………………………………… 0
Page 1…………………………………………………….. 0
141403 Manual Back Cover.pdf…………………………………….. 0
1: English…………………………………………………. 0
BI010598-EN.pdf………………………………………………… 0
1: English………………………………………………….501
2: Spanish…………………………………………………. 0
3: Portuguese………………………………………………. 0
SM141403-EN_2.pdf………………………………………………. 0
Lubrication Principles ……………………………………… 0
Greasing Main A.C. Drive Motors ……………………………… 0
1. Type of grease ………………………………………….. 0
2. Initial commissioning ……………………………………. 0
3. Maintenance …………………………………………….. 0
4. Regreasing intervals …………………………………….. 0
Lubricant Selection ………………………………………… 0
Gearcase Lubricant Replacement/Sampling ………………………. 0
Lubricant Change Cycle ……………………………………… 0
Automatic Lubrication System ………………………………… 0
Lube Room …………………………………………………. 0
Lubrication Room Details ……………………………………. 0
Lube Reservoir fill / Overflow Plumbing ………………………. 0
Lube Reservoir Fill / Overflow Plumbing ……………………… 0
Auto Lube Control Panel …………………………………….. 0
Lower Works Lubrication …………………………………….. 0
Revolving Frame Lubrication …………………………………. 0
Front End Lubrication ………………………………………. 0
Lubricant Injectors ………………………………………… 0
Lincoln Type SL-1 Lubricant Injectors ………………………… 0
SL-1 Lubricant Injector Operation ……………………………. 0
Lincoln Type SL-V Lubricant Injectors ………………………… 0
Lubricant Injector (SL-V) …………………………………… 0
Adjusting Injectors ………………………………………… 0
SL-V Lubricant Injector Operation ……………………………. 0
Injector Advantages ………………………………………… 0
Propel Machinery Lubrication ………………………………… 0
Hoist Machinery Lubrication …………………………………. 0
Filter Element Cleaning …………………………………….. 0
Swing Machinery Lubrication …………………………………. 0
Swing Machinery MPG & OGL Lubrication Lines …………………… 0
Crowd Machinery Lubrication …………………………………. 0
Oil Pump ………………………………………………….. 0
Air Compressor Lubrication ………………………………….. 0
ACSL – Air Compressor (Screw-type) Lubricant ………………….. 0
Lubricant Specifications ……………………………………. 0
MPO – Multi-Purpose Oil …………………………………….. 0
SM141403-EN_4.pdf………………………………………………. 0
Lower Works ………………………………………………..180
Truck Frame Assembly ………………………………………..180
Truck Frame and Crawlers Assembly …………………………….180
Swing Rack Assembly …………………………………………181
Roller Circle ………………………………………………182
Roller Frame Assembly ……………………………………….183
Roller Circle Repair ………………………………………..184
Roller Circle ~Section View ………………………………….185
Roller Circle and Rails ……………………………………..186
Roller Circle ~Exploded View …………………………………187
Crawler Belts ………………………………………………188
Crawler Belt Maintenance …………………………………….188
Crawler Belt Tension Adjustment ………………………………189
Crawler Belt Tension Adjustment ………………………………190
Correct Belt Tension ………………………………………..191
Crawler Shoe Replacement …………………………………….191
Crawler Belt Replacement …………………………………….192
Crawler Belt and Shoe Replacement …………………………….192
Crawler Side Frame Assembly ………………………………….193
Crawler Side Frame Maintenance ……………………………….193
Crawler Assembly – Right Shown, Left Opposite ………………….194
Slide Bar Rebuild …………………………………………..195
Crawler Mounted Slide Bars …………………………………..195
Crawler Front Idler Assembly …………………………………196
(Left Shown, Right Opposite) …………………………………196
Crawler Front Idler Roller Assembly …………………………..197
Front Idler Assembly – Section View …………………………..197
Load And Idler Rollers ………………………………………199
Roller Removal Or Replacement ………………………………..201
Load Roller Removal …………………………………………201
Propel Assembly …………………………………………….203
Propel Drive Shaft Assembly – Exploded View ……………………203
Propel Drive Shaft Assembly – Section View …………………….204
Installation Notes ………………………………………….205
Main Propel Drive Shaft Removal ………………………………206
Fixtures for the Main Propel Shaft ……………………………207
Propel Shaft Pilot Rod ………………………………………208
Propel Shaft End Support …………………………………….208
Details for the Main Propel Shaft Fixtures …………………….208
Main Propel Shaft – Disassembly ………………………………210
Main Propel Shaft – Section View ……………………………..212
Tumbler Rebuild Procedure ……………………………………213
Crawler Tumbler Rebuild ……………………………………..213
Crawler Drive Tumbler Rebuild Template ………………………..214
Propel Machinery ……………………………………………215
Propel Planetary Gearcase ……………………………………217
Propel Gearcase Removal ……………………………………..217
Propel Gearcase Installation …………………………………219
Propel Motors ………………………………………………220
Propel Motor Removal ………………………………………..221
Propel Motor and Motor Support ……………………………….222
Propel Motor Installation ……………………………………223
Center Pintle ………………………………………………225
Center Pintle – Section Views ………………………………..228
Center Pintle Adjustment …………………………………….229
Center Pintle Sleeve Removal …………………………………230
Collector Rings …………………………………………….231
Collector Rings – Propel and Low Voltage ………………………231
(Rear Section View) …………………………………………231
Collector Ring Inspection ……………………………………233
Collector Ring Repair ……………………………………….234
Rotating Deck ………………………………………………235
Swing Machinery …………………………………………….235
Inspection …………………………………………………236
Swing Gearcase ……………………………………………..237
Swing Motor Removal …………………………………………238
Gearcase Cover Removal ………………………………………240
View G …………………………………………………….240
Intermediate Shaft And Gear Assembly Removal …………………..242
Intermediate Shaft And Gear Assembly Re-assembly ……………….243
Vertical Swing Shaft And Pinion Removal ……………………….246
Vertical Swing Shaft And Pinion Re-assembly ……………………249
Detail A …………………………………………………..249
Detail B …………………………………………………..250
Detail C …………………………………………………..250
Hoist Machinery …………………………………………….252
Hoist Machinery Assembly …………………………………….252
Hoist Motor Removal …………………………………………253
Hoist Gearcase, Coupling and Motor Assembly ……………………253
Hoist Motor Mounting – Side View ……………………………..254
Hoist Gearcase Assembly ……………………………………..255
Hoist Gearcase Assembly ……………………………………..255
Hoist Gearcase Section View ………………………………….256
Hoist Gearcase Cover Removal …………………………………257
Propel Gearcase Cover Mounting Flanges ………………………..258
Hoist Motor Pinion Shaft Removal ……………………………..258
Hoist Motor Pinion Shaft Section View …………………………260
Hoist Motor Pinion Bearing Installation ……………………….261
View C …………………………………………………….261
Hoist Intermediate Shaft Removal ……………………………..262
Hoist Intermediate Shaft Bearing Installation ………………….264
View C …………………………………………………….264
Hoist Drum Assembly …………………………………………265
Inspection …………………………………………………266
Hoist Drum Removal ………………………………………….266
Hoist Drum Gear Replacement ………………………………….268
Hoist Drum Bearing Removal …………………………………..271
View A – Right Side Shown ……………………………………271
View B – Right Side Shown ……………………………………272
Hoist Drum Bearing Installation ………………………………273
View C …………………………………………………….273
Hoist Mounting Bolts ………………………………………..274
Hoist Limit Switch ………………………………………….275
Crowd Machinery …………………………………………….276
Gearcase Cover Removal ………………………………………278
L.H. Gearcase Cover Mounting Flanges ………………………….278
R.H. Gearcase Cover Mounting Flanges ………………………….280
Crowd 1st Intermediate Reduction Gears ………………………..281
1st Intermediate Shaft ………………………………………282
1st Intermediate Shaft Bearing Installation ……………………285
View C …………………………………………………….285
Crowd 2nd Intermediate Reduction Gears ………………………..286
2nd Intermediate Shaft ………………………………………287
2nd Intermediate Shaft Bearing Installation ……………………290
View C …………………………………………………….290
Crowd Motor Removal …………………………………………291
Top View of Crowd Motor, Motor Coupling and Brake ………………292
Crowd Motor Installation …………………………………….293
Crowd Brake Removal …………………………………………294
Crowd Brake and Brake Guard ………………………………….294
Motor Pinion Shaft Removal …………………………………..295
Section View A – A (Top View) ………………………………..297
Section View B-B (Top View) ………………………………….297
Section View C-C (Top View) ………………………………….298
Crowd Gear and Drum …………………………………………299
Crowd Frame & Drum – Right Side View ………………………….299
Crowd Drum Removal ………………………………………….300
Section View A ……………………………………………..301
Machinery House …………………………………………….303
Walkways, Stairways and Handrails …………………………….304
Boarding Stairs …………………………………………….305
Retractable Boarding Ladder ………………………………….307
Front End Equipment ………………………………………..308
Front End Equipment …………………………………………308
Boom Assembly ………………………………………………309
Boom Repair ………………………………………………..310
Boom Limit Switch Installation ……………………………….311
Section A – A Boom Inductive Proximity Switch ………………….312
Boom Point Sheaves ………………………………………….313
Boom Point Sheave Assembly (2 Places) …………………………313
Boom Point Sheave Removal And Disassembly ……………………..314
Boom Point Sheave Reassembly And Installation ………………….316
Boom Bumper ………………………………………………..318
Saddle Block ……………………………………………….319
Saddle Block ……………………………………………….319
Saddle Block Repair …………………………………………320
Saddle Block Removal ………………………………………..321
Saddle Block Sheave …………………………………………322
Dipper Handle ………………………………………………323
Handle Removal ……………………………………………..324
Retract Take-Up Mechanism …………………………………..325
Front Stop & Spreader ……………………………………….327
Spreader Repair ……………………………………………328
Dipper Assembly …………………………………………….329
Dipper Door Latch Bar and Lever ………………………………330
Section D ………………………………………………….331
Latch Bar Adjusting Procedure ………………………………..331
Dipper Removal & Installation ………………………………..332
View A ……………………………………………………333
View B ……………………………………………………334
View C …………………………………………………….335
View D …………………………………………………….336
Dipper Door Snubbers ………………………………………..337
Snubber Adjustment ………………………………………….338
View A …………………………………………………….338
Dipper Pitch Brace ………………………………………….339
Fixed Length Pitch Brace Assembly …………………………….339
Dipper Padlock ……………………………………………..340
Dipper Trip Assembly ………………………………………..342
A-Frame ……………………………………………………343
Auxiliary Winch ……………………………………………345
Auxiliary Winch Assembly …………………………………….345
Boom Suspension Ropes ……………………………………….346
Wire Ropes …………………………………………………348
Wire Rope Inspection ………………………………………..349
Hoist Rope Reeving & Replacement ……………………………..349
Shim for Hoist Rope Socket ………………………………….353
Crowd Rope Reeving & Replacement ……………………………..354
Crowd Rope Reeving ………………………………………….355
Crowd Rope Drum Reeving ……………………………………..356
Retract Rope Reeving & Replacement ……………………………358
Retract Rope Reeving ………………………………………..359
Retract Rope Take-Up Mechanism ……………………………….361
Retract Rope Tightening ……………………………………..362
Dipper Trip Rope Reeving & Replacement ………………………..363
Hoist and Crowd Limit Systems ………………………………..364
Setting Rope Limits In The Hoist & Crowd System ………………..365
View A – Calibration Limits Screen ………………………….366
Crowd Slowdown/Stop Limit ……………………………………367
Retract Slowdown/Stop Limits …………………………………368
Lower Slowdown/Stop Limits …………………………………..369
Hoist Slowdown/Stop Limits …………………………………..370
SM141403-EN_2.pdf………………………………………………. 0
Lubrication Principles ……………………………………… 73
Greasing Main A.C. Drive Motors ……………………………… 74
1. Type of grease ………………………………………….. 74
2. Initial commissioning ……………………………………. 74
3. Maintenance …………………………………………….. 74
4. Regreasing intervals …………………………………….. 75
Lubricant Selection ………………………………………… 76
Gearcase Lubricant Replacement/Sampling ………………………. 77
Lubricant Change Cycle ……………………………………… 77
Automatic Lubrication System ………………………………… 78
Lube Room …………………………………………………. 79
Lubrication Room Details ……………………………………. 79
Lube Reservoir fill / Overflow Plumbing ………………………. 80
Lube Reservoir Fill / Overflow Plumbing ……………………… 80
Auto Lube Control Panel …………………………………….. 81
Lower Works Lubrication …………………………………….. 82
Revolving Frame Lubrication …………………………………. 83
Front End Lubrication ………………………………………. 84
Lubricant Injectors ………………………………………… 85
Lincoln Type SL-1 Lubricant Injectors ………………………… 85
SL-1 Lubricant Injector Operation ……………………………. 87
Lincoln Type SL-V Lubricant Injectors ………………………… 89
Lubricant Injector (SL-V) …………………………………… 90
Adjusting Injectors ………………………………………… 91
SL-V Lubricant Injector Operation ……………………………. 92
Injector Advantages ………………………………………… 94
Propel Machinery Lubrication ………………………………… 95
Hoist Machinery Lubrication …………………………………. 96
Filter Element Cleaning …………………………………….. 97
Swing Machinery Lubrication …………………………………. 98
Swing Machinery MPG & OGL Lubrication Lines …………………… 98
Crowd Machinery Lubrication …………………………………. 99
Oil Pump …………………………………………………..101
Air Compressor Lubrication …………………………………..102
ACSL – Air Compressor (Screw-type) Lubricant …………………..103
BI010950-EN.pdf………………………………………………… 0
Page 1……………………………………………………..500
141402 ERS Manual Disclaimer Page_EN.pdf………………………….. 0
1: SM – EN…………………………………………………. 2

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CAT ELECTRIC ROPE SHOVEL 7295 ELECTRIC ROPE SHOVEL SERVICE MANUAL – PDF DOWNLOAD:

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