SURFACE
MINING
EXTRACTION
EQUIPMENT
PART C
Caterpillar
Performance
Handbook
®
Edition 44
800.437.4228
www.hawthornecat.com
© 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.
ELECTRIC ROPE SHOVELS
CONTENTS
ELECTRIC ROPE SHOVELS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digging Envelopes. . . . . . . . . . . . . . . . . . . . . . . .
General Dimensions . . . . . . . . . . . . . . . . . . . . . .
Ground Bearing Pressure . . . . . . . . . . . . . . . . . .
Dipper Selection . . . . . . . . . . . . . . . . . . . . . . . . .
Truck Match . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES
16-29
16-29
16-32
16-35
16-42
16-49
16-50
16-51
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.
●
Superior availability: AC IGBT electric rope shovels
have routinely demonstrated electrical availabilities
of greater than 98%.
●
Greater reliability: Fewer components including interchangeable 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 mining conditions.
INTRODUCTION
Electric rope shovels are one of the largest loading
tools on the market. They run in a truck-shovel operation with mining trucks in order to move large quantities 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 mining applications all over the world.
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Electric
Rope Shovels
Features
Robust Front End Design
The 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 handle design allows the Cat handle to rotate under torsional stress, transferring stress into the ropes rather
than into the boom.
●
Improved line of sight: Cat machines provide operators 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 stabilize the dipper as it engages the bank for easier and
more efficient digging.
Cat Cab
Caterpillar’s state-of-the-art operator’s cab is the product of a multi-year collaboration between Caterpillar,
mining companies and shovel operators. 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 a fully pneumatic suspension system, low-effort
joysticks and dual display screens optimized for operator comfort.
Power Demand Management System
Caterpillar’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 generators 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.
16-30
HydraCrowd™
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. HydraCrowd 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™
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 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 Design
The unique FastFil dipper provides customers with
faster and fuller dipper loads where the application permits. 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 dipper body cuts load and dump time. Combined, FastFil
features optimize fill factor.
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Features
AccessDirect™
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 issues — 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.
MIDAS
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 operation and
provides users with a 3D model to watch the shovel in
motion.
AccuLoad
AccuLoad is a data analysis system that provides
real-time feedback on dipper 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.
Electric
Rope Shovels
Major Structures
Cat major structures are designed for extended performance 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 stressrelieve entire weldments for reduced susceptibility to
cracking. Interiors of finished structures are painted
white to facilitate field inspection.
Safety
Safety 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 commitment 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 programs to help keep your operators and maintenance personnel out of harm’s way. Additionally, the electric rope
shovel product line has incorporated additional safety
product enhancements as part of Caterpillar’s engagement and dedication to the Earth Moving Equipment
Safety Round Table or EMESRT.
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Electric
Rope Shovels
Specifications
MODEL
Payload
Operating Weight
Dipper Range
Drive
Distribution System Requirements (separate system)
Distribution System Requirements (large system)
Average 15 Minute Demand
Peak Power
Crowd Type
Hoist Ropes
Number
Diameter
Type
Construction
Crowd/Retract Ropes
Number
Diameter
Type
Construction
16-32
7295
7395
45 tonnes
50 tons
789 251 kg
1,740,000 lb
19.1-38.3 m³
25-50 yd³
AC IGBT
2000 kVA
1320 kVA
538-753 kW
2152 kW
Tubular handle rope crowd
64 tonnes
70 tons
1 288 656 kg
2,841,000 lb
20.7-55.8 m³
27-73 yd³
AC IGBT
3500 kVA
2000 kVA
777-1087 kW
3106 kW
Tubular handle rope crowd
2
57 mm
2.25"
Twin dual
6×41
2
70 mm
2.8"
Twin dual
8×37
1 crowd, 1 retract
60 mm
2.4"
Single dual
8×37
1 crowd, 1 retract
64 mm
2.5"
Single dual
8×37
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Specifications
MODEL
Payload
Operating Weight
Dipper Range
Drive
Distribution System Requirements
(separate system)
Distribution System Requirements
(large system)
Average 15 Minute Demand
Peak Power
Crowd Type
Hoist Ropes
Number
Diameter
Type
Construction
Crowd/Retract Ropes
Number
Diameter
Type
Construction
Electric
Rope Shovels
7495 HD
7495
7495 HydraCrowd
82 tonnes
90 tons
1 306 346 kg 2,880,000 lb
27.5-60.4 m³
36-79 yd³
AC IGBT
109 tonnes
120 tons
1 369 246 kg
3,018,670 lb
30.6-62.7 m³
40-82 yd³
AC IGBT
109 tonnes
120 tons
1 382 400 kg
3,047,670 lb
30.6-62.7 m³
40-82 yd³
AC IGBT
3500 kVA
4000 kVA
4000 kVA
2000 kVA
832-1165 kW
3330 kW
Tubular handle rope crowd
—
926-1297 kW
3706 kW
Tubular handle rope crowd
—
945-1322 kW
3778 kW
Tubular handle HydraCrowd
2
70 mm
2.8"
Twin dual
8×37
2
70 mm
2.8"
Twin dual
8×37
1 crowd, 1 retract
64 mm
2.5"
Single dual
8×37
1 crowd, 1 retract
64 mm
2.5"
Single dual
8×37
2
70 mm
2.8"
Twin dual
8×37
N/A
N/A
N/A
N/A
N/A = Not Available.
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Electric
Rope Shovels
Specifications
MODEL
Payload
Operating Weight
Dipper Range
Drive
Distribution System Requirements (separate system)
Average 15 Minute Demand
Peak Power
Crowd Type
Hoist Ropes
Number
Diameter
Type
Construction
Crowd/Retract Ropes
Number
Diameter
Type
Construction
7495 HF
7495 HF HydraCrowd
109 tonnes
120 tons
1 429 120 kg
3,150,670 lb
30.6-62.7 m³
40-82 yd³
AC IGBT
4000 kVA
926-1297 kW
3706 kW
Tubular handle rope crowd
109 tonnes
120 tons
1 442 274 kg
3,179,670 lb
30.6-62.7 m³
40-82 yd³
AC IGBT
4000 kVA
945-1322 kW
3778 kW
Tubular handle HydraCrowd
2
70 mm
2.8"
Twin dual
8×37
1 crowd, 1 retract
64 mm
2.5"
Single dual
8×37
2
70 mm
2.8"
Twin dual
8×37
N/A
N/A
N/A
N/A
N/A = Not Available.
16-34
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Digging Envelopes
● 7295
Electric
Rope Shovels
m
ft
m
ft
MODEL
Dumping Height
Dumping Height at Maximum Crowd Limit
Dumping Radius
Cutting Height
Cutting Radius
Effective Length of Dipper Handle
7295
9.22 m
7.00 m
18.69 m
15.56 m
21.78 m
9.45 m
30'3"
23'0"
61'4"
51'1"
71'5"
31'0"
16
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Electric
Rope Shovels
Digging Envelopes
● 7395
m
ft
m
ft
MODEL
Dumping Height
Dumping Height at Maximum Crowd Limit
Dumping Radius
Cutting Height
Cutting Radius
Effective Length of Dipper Handle
16-36
7395
10.00 m
7.91 m
20.50 m
16.70 m
23.30 m
14.30 m
32'11"
25'11"
67'2"
54'11"
76'5"
47'0"
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Digging Envelopes
● 7495 HD
Electric
Rope Shovels
m
ft
m
ft
MODEL
Dumping Height
Dumping Height at Maximum Crowd Limit
Dumping Radius
Cutting Height
Cutting Radius
Effective Length of Dipper Handle
7495 HD
10.60 m
8.45 m
21.00 m
17.30 m
23.97 m
14.30 m
34'10"
27'9"
69'0"
56'10"
78'8"
47'0"
16
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Electric
Rope Shovels
Digging Envelopes
● 7495
m
ft
m
ft
MODEL
Dumping Height
Dumping Height at Maximum Crowd Limit
Dumping Radius
Cutting Height
Cutting Radius
Effective Length of Dipper Handle
16-38
7495
10.06 m
8.61 m
21.64 m
17.80 m
25.20 m
14.30 m
33'0"
28'3"
71'0"
58'5"
82'8"
47'0"
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Digging Envelopes
7495 HydraCrowd
●
Electric
Rope Shovels
m
ft
m
ft
MODEL
Dumping Height
Dumping Height at Maximum Crowd Limit
Dumping Radius
Cutting Height
Cutting Radius
Effective Length of Dipper Handle
7495 HydraCrowd
10.06 m
8.61 m
21.64 m
17.80 m
25.20 m
14.30 m
33'0"
28'3"
71'0"
58'5"
82'8"
47'0"
16
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Electric
Rope Shovels
Digging Envelopes
● 7495 HF
m
ft
m
ft
MODEL
Dumping Height
Dumping Height at Maximum Crowd Limit
Dumping Radius
Cutting Height
Cutting Radius
Effective Length of Dipper Handle
16-40
7495 HF
10.06 m
8.61 m
21.64 m
17.80 m
25.20 m
14.30 m
33'0"
28'3"
71'0"
58'5"
82'8"
47'0"
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●
Digging Envelopes
7495 HF HydraCrowd
Electric
Rope Shovels
m
ft
m
ft
MODEL
Dumping Height
Dumping Height at Maximum Crowd Limit
Dumping Radius
Cutting Height
Cutting Radius
Effective Length of Dipper Handle
7495 HF HydraCrowd
10.06 m
8.61 m
21.64 m
17.80 m
25.20 m
14.30 m
33'0"
28'3"
71'0"
58'5"
82'8"
47'0"
16
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General Dimensions
● 7295
CL ROTATION
CL ROTATION
Electric
Rope Shovels
MODEL
Boom Length
A
B
C
D
E
F
G
H
I
16-42
Height
7295
18.00 m
59'0"
18.15 m
59'7"
A-Frame Height
11.94 m
39'2"
Overall Width
12.39 m
40'8"
Tail Swing Radius
7.98 m
26'2"
Clearance Radius
17.48 m
57'4"
Radius of Level Floor
15.58 m
51'1"
Minimum Ground Clearance
0.78 m
2'6"
Track Length
10.26 m
33'8"
Operator Eye Level
8.20 m
26'11"
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General Dimensions
● 7395
MODEL
Boom Length
A
B
C
D
E
F
G
H
I
Electric
Rope Shovels
7395
19.51 m
64'0"
Height
19.50 m
63'11"
A-Frame Height
13.30 m
43'8"
Overall Width
13.01 m
42'8"
Tail Swing Radius
8.67 m
28'5"
Clearance Radius
19.05 m
62'6"
Radius of Level Floor
15.40 m
50'6"
Minimum Ground Clearance
0.86 m
2'10"
Track Length
10.41 m
34'2"
Operator Eye Level
8.64 m
28'4"
16
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Electric
Rope Shovels
General Dimensions
● 7495 HD
MODEL
Boom Length
A
B
C
D
E
F
G
H
I
16-44
7495 HD
20.40 m
67'0"
Height
20.10 m
65'10"
A-Frame Height
13.30 m
43'8"
Overall Width
13.01 m
42'8"
Tail Swing Radius
8.67 m
28'5"
Clearance Radius
19.74 m
64'9"
Radius of Level Floor
16.92 m
55'6"
Minimum Ground Clearance
0.86 m
2'10"
Track Length
10.41 m
34'2"
Operator Eye Level
8.64 m
28'4"
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General Dimensions
● 7495
MODEL
Boom Length
A
B
C
D
E
F
G
H
I
Electric
Rope Shovels
7495
20.40 m
67'0"
Height
20.87 m
68'6"
A-Frame Height
14.00 m
46'0"
Overall Width
13.11 m
43'0"
Tail Swing Radius
9.34 m
30'8"
Clearance Radius
19.65 m
64'5"
Radius of Level Floor
17.47 m
57'4"
Minimum Ground Clearance
0.90 m
3'0"
Track Length
11.43 m
37'6"
Operator Eye Level
10.61 m
34'10"
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Electric
Rope Shovels
General Dimensions
● 7495 HydraCrowd
MODEL
Boom Length
A
B
C
D
E
F
G
H
I
16-46
7495 HydraCrowd
20.40 m
67'0"
Height
20.87 m
68'6"
A-Frame Height
14.00 m
46'0"
Overall Width
13.11 m
43'0"
Tail Swing Radius
9.34 m
30'8"
Clearance Radius
19.65 m
64'5"
Radius of Level Floor
17.47 m
57'4"
Minimum Ground Clearance
0.90 m
3'0"
Track Length
11.43 m
37'6"
Operator Eye Level
10.61 m
34'10"
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General Dimensions
● 7495 HF
MODEL
Boom Length
A
B
C
D
E
F
G
H
I
Electric
Rope Shovels
7495 HF
20.40 m
67'0"
20.87 m
68'6"
A-Frame Height
14.00 m
46'0"
Overall Width
13.96 m
46'1"
Tail Swing Radius
9.34 m
30'8"
Clearance Radius
19.65 m
64'5"
Radius of Level Floor
17.47 m
57'4"
Minimum Ground Clearance
0.90 m
3'0"
Track Length
11.43 m
37'6"
Operator Eye Level
10.61 m
34'10"
Height
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Electric
Rope Shovels
General Dimensions
● 7495 HF HydraCrowd
MODEL
Boom Length
A
B
C
D
E
F
G
H
I
16-48
7495 HF HydraCrowd
20.40 m
67'0"
20.87 m
68'6"
A-Frame Height
14.00 m
46'0"
Overall Width
13.96 m
46'1"
Tail Swing Radius
9.34 m
30'8"
Clearance Radius
19.65 m
64'5"
Radius of Level Floor
17.47 m
57'4"
Minimum Ground Clearance
0.90 m
3'0"
Track Length
11.43 m
37'6"
Operator Eye Level
10.61 m
34'10"
Height
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Ground Bearing Pressure
GROUND BEARING PRESSURE
conditions. Selecting links that require higher ground bearing pressure than what exists at site will make propelling
the machine difficult. A link too narrow for the application
may even cause the crawlers to sink into the ground.
Ground 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
MODEL
Standard Link Length
Ground Bearing Pressure
Optional Link Length
Ground Bearing Pressure
The chart below lists the link length options for each
electric rope shovel model as well as the corresponding
minimum ground bearing pressures.
7295
140 cm
372 kPa
183 cm
284 kPa
7395
55"
53.9 psi
72"
41.2 psi
Electric
Rope Shovels
213 cm
395 kPa
274 cm
308 kPa
MODEL
7495 HydraCrowd
Standard Link Length
Ground Bearing Pressure
Optional Link Length
Ground Bearing Pressure
200 cm
374 kPa
259 cm
289 kPa
79"
54.2 psi
102"
50 psi
7495 HD
84"
57.4 psi
108"
44.6 psi
213 cm
401 kPa
274 cm
311 kPa
7495 HF
318 cm
245 kPa
356 cm
219 kPa
125"
35.6 psi
140"
31.8 psi
7495
84"
58.1 psi
108"
45.2 psi
200 cm
372 kPa
259 cm
288 kPa
79"
53.9 psi
102"
41.8 psi
7495 HF HydraCrowd
318 cm
248 kPa
356 cm
221 kPa
125"
35.9 psi
140"
32.1 psi
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Electric
Rope Shovels
Dipper Selection
DIPPER SELECTION
density, divide insitu (undisturbed material density) by
1 + swell factor.
Selecting the correct dipper size plays an integral role
in maximizing productivity from a truck shovel operation. Optimal dipper size is a function of truck size,
material loose density, and fill factor.
Material loose density =
Insitu
(1 + swell factor)
The first step in calculating dipper size is to determine 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.
Once material loose density is calculated, use the
equation below to find the optimal dipper size.
For example, consider a mine operating a 7495 shovel
(maximum payload = 120 tons) and 797 trucks (payload = 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.
For example: For a mine with the following conditions:
Optimal machine
payload
Optimal dipper size =
× Fill factor
Material loose
density
Insitu: 2.276 ton/yd³
Swell factor: 35%
Fill factor: 95%
Optimal machine payload: 100 tons
Optimal dipper size =
Once optimal machine payload is determined, material loose density and fill factor are used to calculate
the optimum dipper size. To calculate material loose
MODEL
Dipper Range
MODEL
Dipper Range
16-50
7295
19.138.3 m³
7395
2550 yd³
20.755.8 m³
7495 HydraCrowd
30.6-62.7 m³
40-82 yd³
100 tons
× .95 = 62.5 yd³
2.276 ÷
(1 + 0.35)
7495 HD
2773 yd³
27.560.4 m³
7495 HF
30.6-62.7 m³
40-82 yd³
7495
3679 yd³
30.662.7 m³
4082 yd³
7495 HF HydraCrowd
30.6-62.7 m³
40-82 yd³
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Truck Match
Electric
Rope Shovels
TRUCK MATCH
Truck 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.
MODEL
772G
773G
775G
777G
MT3300 AC
785D
789D
MT3700 AC
MT4400 AC
793F
795F AC
MT5500 AC
MT6300 AC
797F
Payload
7295
7395
7495 HD
7495
7495 HF
tonne (ton)
45 (50)
64 (70)
82 (90)
109 (120)
109 (120)
45 (50)
57 (63)
65 (72)
97 (107)
2
136 (150)
3
2
2
136 (150)
3
2
2
2
181 (200)
4
3
186 (205)
4
3
2
221 (244)
5
4
3
2
2
227 (250)
5
2
4
3
2
313 (345)
5
4
3
3
326 (360)
5
4
3
3
363 (400)
4
4
4
363 (400)
4
4
4
16
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Notes —
16-52
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