Caterpillar 7295 Electric Rope Shovel Service Manual BI010935
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Caterpillar 7295 Electric Rope Shovel Service Manual BI010935 - Image 5

Caterpillar 7295 Electric Rope Shovel Service Manual BI010935

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: BI010935
  • Number of Pages: 501
  • Size: 10.6MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 7295 Electric Rope Shovel
  • 1. BI010591-EN-DISCLAIMER.pdf
  • 1.1. SM – EN
  • 1.2. OM – EN
  • 1.3. ESM – EN Page 1
  • 1.4. ESM – EN Page 2
  • 1.5. VM – EN Page 1
  • 1.6. VM – EN Page 2
  • 2. SM141403-EN_S.pdf
  • 2.1. Safety Symbols
  • 2.2. Safety Precautions
  • 2.3. General Precautions
  • 2.4. Maintenance Precautions
  • 2.5. Operating Precautions
  • 2.6. Fire Prevention
  • 2.7. Fire Extinguisher Locations
  • 2.8. Common Safety Features
  • 2.9. Emergency Lighting
  • 2.10. Emergency Lighting Locations
  • 2.11. Mine Signal
  • 2.12. Mine Signal Switch
  • 2.13. Mine Signal Horn Location
  • 2.14. Dual Mirrors
  • 2.15. Right Side Mirror
  • 2.16. Propel Back-up Alarm
  • 2.17. Propel Back-up Horn Location
  • 2.18. Emergency Stop Pushbutton
  • 2.19. Emergency Stop Pushbutton Location
  • 2.20. Vertical Boarding Ladder
  • 2.21. Cameras
  • 2.22. Warning Signs and Decals
  • 3. SM141403-EN_1.pdf
  • 3.1. About This Manual
  • 3.2. Purpose
  • 3.3. Organization
  • 3.4. Revisions
  • 3.5. Precautions and Disclaimers
  • 3.6. Terminology
  • 3.7. Contact
  • 3.8. Safety – Swinging Restraint Ballast Box Support
  • 3.9. Ballast Box Support
  • 3.10. Swinging Restraint
  • 3.11. Machine Overview
  • 3.12. Nomenclature
  • 3.13. Lower Works
  • 3.14. Truck Frame and Crawlers
  • 3.15. Crawlers
  • 3.16. Crawler Assembly
  • 3.17. Truck Frame
  • 3.18. Truck Frame
  • 3.19. Swing Rack
  • 3.20. Swing Rack and Roller Circle
  • 3.21. Roller Circle
  • 3.22. Roller Circle Assembly
  • 3.23. Propel Machinery
  • 3.24. Propel Machinery
  • 3.25. Collector Rings
  • 3.26. Rotating Deck
  • 3.27. Revolving Frame
  • 3.28. Center Pintle
  • 3.29. Deck Extensions
  • 3.30. Deck Extensions and Ballast Box
  • 3.31. Ballast Box
  • 3.32. Machinery House
  • 3.33. Boarding Stairs
  • 3.34. RH Boarding Stairs
  • 3.35. Retractable Boarding Ladder
  • 3.36. A-Frame
  • 3.37. A- Frame and Front End Support Components
  • 3.38. Hoist Machinery
  • 3.39. Hoist Machinery – Plan View
  • 3.40. Swing Machinery
  • 3.41. Swing Machinery Components
  • 3.42. Crowd Machinery
  • 3.43. Crowd Machinery Components
  • 3.44. Operators Cab
  • 3.45. Compressed Air System
  • 3.46. Automatic Lubrication System
  • 3.47. Lubrication Room
  • 3.48. Lube Reservoir fill / Overflow Plumbing
  • 3.49. Lube Reservoir Fill / Overflow Plumbing
  • 3.50. Front End Equipment
  • 3.51. Suspension Strands
  • 3.52. Boom Assembly
  • 3.53. Running Ropes
  • 3.54. Ropes – General Arrangement
  • 3.55. Saddle Block
  • 3.56. Dipper Handle
  • 3.57. Dipper
  • 3.58. Dipper Assembly
  • 3.59. Padlocks
  • 3.60. Left and Right Padlocks
  • 3.61. Dipper Trip
  • 3.62. Dipper Trip Motor and Dipper Trip Sheave
  • 3.63. General Estimated Component Weights
  • 4. SM141403-EN_2.pdf
  • 4.1. Lubrication Principles
  • 4.2. Greasing Main A.C. Drive Motors
  • 4.3. Type of grease
  • 4.4. Initial commissioning
  • 4.5. Maintenance
  • 4.6. Regreasing intervals
  • 4.7. Lubricant Selection
  • 4.8. Gearcase Lubricant Replacement/Sampling
  • 4.9. Lubricant Change Cycle
  • 4.10. Automatic Lubrication System
  • 4.11. Lube Room
  • 4.12. Lubrication Room Details
  • 4.13. Lube Reservoir fill / Overflow Plumbing
  • 4.14. Lube Reservoir Fill / Overflow Plumbing
  • 4.15. Auto Lube Control Panel
  • 4.16. Lower Works Lubrication
  • 4.17. Revolving Frame Lubrication
  • 4.18. Front End Lubrication
  • 4.19. Lubricant Injectors
  • 4.20. Lincoln Type SL-1 Lubricant Injectors
  • 4.21. SL-1 Lubricant Injector Operation
  • 4.22. Lincoln Type SL-V Lubricant Injectors
  • 4.23. Lubricant Injector (SL-V)
  • 4.24. Adjusting Injectors
  • 4.25. SL-V Lubricant Injector Operation
  • 4.26. Injector Advantages
  • 4.27. Propel Machinery Lubrication
  • 4.28. Hoist Machinery Lubrication
  • 4.29. Filter Element Cleaning
  • 4.30. Swing Machinery Lubrication
  • 4.31. Swing Machinery MPG OGL Lubrication Lines
  • 4.32. Crowd Machinery Lubrication
  • 4.33. Oil Pump
  • 4.34. Air Compressor Lubrication
  • 4.35. ACSL – Air Compressor (Screw-type) Lubricant
  • 4.36. Lubricant Specifications
  • 4.37. MPO – Multi-Purpose Oil
  • 5. AM11093-EN.pdf
  • 5.1. AM11093 ERS Manual Disclaimer Page_EN.pdf
  • 5.2. ERS Manual Back Cover.pdf
  • 6. SM141403-EN_3.pdf
  • 6.1. Introduction
  • 6.2. Preventive Maintenance Program
  • 6.3. Elements Of An Effective Maintenance Program
  • 6.4. Scheduled Preventive Maintenance Program
  • 6.5. General Safety Considerations
  • 6.6. Maintenance During Machine Operation
  • 6.7. Maintenance Precautions
  • 6.8. Preventive Maintenance For Lubrication
  • 6.9. Lubricant Cleanliness
  • 6.10. Frequency Of Inspection And Maintenance
  • 6.11. Maintenance Schedules
  • 6.12. Maintenance Inspection Check Points
  • 6.13. Every 100 Hours, Or Weekly
  • 6.14. Every 500 Hours, Or Monthly
  • 6.15. Every 1250 Hours, Or Quarterly
  • 6.16. Every 2500 Hours, Or Semi-annually
  • 6.17. Hours, Or Annually
  • 6.18. Major Component Locations
  • 6.19. Machine Nomenclature
  • 6.20. Lower Works and Crawlers
  • 6.21. Crawler Assembly
  • 6.22. Crawler Link Assembly
  • 6.23. Propel Machinery
  • 6.24. Roller Circle Section View
  • 6.25. Roller Frame Assembly
  • 6.26. Collector Rings
  • 6.27. Center Pintle Assembly
  • 6.28. Revolving Frame Deck Extensions
  • 6.29. Hoist Machinery
  • 6.30. Swing Machinery
  • 6.31. Crowd Machinery
  • 6.32. Lubrication Reservoirs
  • 6.33. Operators Cab
  • 6.34. Boarding Stairway
  • 6.35. Machinery House Walkways and Platforms
  • 6.36. Front End Equipment
  • 6.37. Boom Support Ropes
  • 6.38. Boom Bumpers
  • 6.39. Dipper Assembly
  • 7. SM141403-EN_4.pdf
  • 7.1. Lower Works
  • 7.2. Truck Frame Assembly
  • 7.3. Truck Frame and Crawlers Assembly
  • 7.4. Swing Rack Assembly
  • 7.5. Roller Circle
  • 7.6. Roller Frame Assembly
  • 7.7. Roller Circle Repair
  • 7.8. Roller Circle Section View
  • 7.9. Roller Circle and Rails
  • 7.10. Roller Circle Exploded View
  • 7.11. Crawler Belts
  • 7.12. Crawler Belt Maintenance
  • 7.13. Crawler Belt Tension Adjustment
  • 7.14. Crawler Belt Tension Adjustment
  • 7.15. Correct Belt Tension
  • 7.16. Crawler Shoe Replacement
  • 7.17. Crawler Belt Replacement
  • 7.18. Crawler Belt and Shoe Replacement
  • 7.19. Crawler Side Frame Assembly
  • 7.20. Crawler Side Frame Maintenance
  • 7.21. Crawler Assembly – Right Shown, Left Opposite
  • 7.22. Slide Bar Rebuild
  • 7.23. Crawler Mounted Slide Bars
  • 7.24. Crawler Front Idler Assembly
  • 7.25. (Left Shown, Right Opposite)
  • 7.26. Crawler Front Idler Roller Assembly
  • 7.27. Front Idler Assembly – Section View
  • 7.28. Load And Idler Rollers
  • 7.29. Roller Removal Or Replacement
  • 7.30. Load Roller Removal
  • 7.31. Propel Assembly
  • 7.32. Propel Drive Shaft Assembly – Exploded View
  • 7.33. Propel Drive Shaft Assembly – Section View
  • 7.34. Installation Notes
  • 7.35. Main Propel Drive Shaft Removal
  • 7.36. Fixtures for the Main Propel Shaft
  • 7.37. Propel Shaft Pilot Rod
  • 7.38. Propel Shaft End Support
  • 7.39. Details for the Main Propel Shaft Fixtures
  • 7.40. Main Propel Shaft – Disassembly
  • 7.41. Main Propel Shaft – Section View
  • 7.42. Tumbler Rebuild Procedure
  • 7.43. Crawler Tumbler Rebuild
  • 7.44. Crawler Drive Tumbler Rebuild Template
  • 7.45. Propel Machinery
  • 7.46. Propel Planetary Gearcase
  • 7.47. Propel Gearcase Removal
  • 7.48. Propel Gearcase Installation
  • 7.49. Propel Motors
  • 7.50. Propel Motor Removal
  • 7.51. Propel Motor and Motor Support
  • 7.52. Propel Motor Installation
  • 7.53. Center Pintle
  • 7.54. Center Pintle – Section Views
  • 7.55. Center Pintle Adjustment
  • 7.56. Center Pintle Sleeve Removal
  • 7.57. Collector Rings
  • 7.58. Collector Rings – Propel and Low Voltage
  • 7.59. (Rear Section View)
  • 7.60. Collector Ring Inspection
  • 7.61. Collector Ring Repair
  • 7.62. Rotating Deck
  • 7.63. Swing Machinery
  • 7.64. Inspection
  • 7.65. Swing Gearcase
  • 7.66. Swing Motor Removal
  • 7.67. Gearcase Cover Removal
  • 7.68. View G
  • 7.69. Intermediate Shaft And Gear Assembly Removal
  • 7.70. Intermediate Shaft And Gear Assembly Re-assembly
  • 7.71. Vertical Swing Shaft And Pinion Removal
  • 7.72. Vertical Swing Shaft And Pinion Re-assembly
  • 7.73. Detail A
  • 7.74. Detail B
  • 7.75. Detail C
  • 7.76. Hoist Machinery
  • 7.77. Hoist Machinery Assembly
  • 7.78. Hoist Motor Removal
  • 7.79. Hoist Gearcase, Coupling and Motor Assembly
  • 7.80. Hoist Motor Mounting – Side View
  • 7.81. Hoist Gearcase Assembly
  • 7.82. Hoist Gearcase Assembly
  • 7.83. Hoist Gearcase Section View
  • 7.84. Hoist Gearcase Cover Removal
  • 7.85. Propel Gearcase Cover Mounting Flanges
  • 7.86. Hoist Motor Pinion Shaft Removal
  • 7.87. Hoist Motor Pinion Shaft Section View
  • 7.88. Hoist Motor Pinion Bearing Installation
  • 7.89. View C
  • 7.90. Hoist Intermediate Shaft Removal
  • 7.91. Hoist Intermediate Shaft Bearing Installation
  • 7.92. View C
  • 7.93. Hoist Drum Assembly
  • 7.94. Inspection
  • 7.95. Hoist Drum Removal
  • 7.96. Hoist Drum Gear Replacement
  • 7.97. Hoist Drum Bearing Removal
  • 7.98. View A – Right Side Shown
  • 7.99. View B – Right Side Shown
  • 7.100. Hoist Drum Bearing Installation
  • 7.101. View C
  • 7.102. Hoist Mounting Bolts
  • 7.103. Hoist Limit Switch
  • 7.104. Crowd Machinery
  • 7.105. Gearcase Cover Removal
  • 7.106. Gearcase Cover Mounting Flanges
  • 7.107. Gearcase Cover Mounting Flanges
  • 7.108. Crowd 1st Intermediate Reduction Gears
  • 7.109. t Intermediate Shaft
  • 7.110. t Intermediate Shaft Bearing Installation
  • 7.111. View C
  • 7.112. Crowd 2nd Intermediate Reduction Gears
  • 7.113. d Intermediate Shaft
  • 7.114. d Intermediate Shaft Bearing Installation
  • 7.115. View C
  • 7.116. Crowd Motor Removal
  • 7.117. Top View of Crowd Motor, Motor Coupling and Brake
  • 7.118. Crowd Motor Installation
  • 7.119. Crowd Brake Removal
  • 7.120. Crowd Brake and Brake Guard
  • 7.121. Motor Pinion Shaft Removal
  • 7.122. Section View A – A (Top View)
  • 7.123. Section View B-B (Top View)
  • 7.124. Section View C-C (Top View)
  • 7.125. Crowd Gear And Drum
  • 7.126. Crowd Frame Drum – Right Side View
  • 7.127. Crowd Drum Removal
  • 7.128. Section View A
  • 7.129. Machinery House
  • 7.130. Walkways, Stairways and Handrails
  • 7.131. Boarding Stairs
  • 7.132. Retractable Boarding Ladder
  • 7.133. Front End Equipment
  • 7.134. Front End Equipment
  • 7.135. Boom Assembly
  • 7.136. Boom Repair
  • 7.137. Boom Limit Switch Installation
  • 7.138. Section A – A Boom Inductive Proximity Switch
  • 7.139. Boom Point Sheaves
  • 7.140. Boom Point Sheave Assembly (2 Places)
  • 7.141. Boom Point Sheave Removal And Disassembly
  • 7.142. Boom Point Sheave Reassembly And Installation
  • 7.143. Boom Bumper
  • 7.144. Saddle Block
  • 7.145. Saddle Block
  • 7.146. Saddle Block Repair
  • 7.147. Saddle Block Removal
  • 7.148. Saddle Block Sheave
  • 7.149. Dipper Handle
  • 7.150. Handle Removal
  • 7.151. Retract Take-Up Mechanism
  • 7.152. Front Stop Spreader
  • 7.153. Spreader Repair
  • 7.154. Dipper Assembly
  • 7.155. Dipper Door Latch Bar and Lever
  • 7.156. Section D
  • 7.157. Latch Bar Adjusting Procedure
  • 7.158. Dipper Removal Installation
  • 7.159. View A
  • 7.160. View B
  • 7.161. View C
  • 7.162. View D
  • 7.163. Dipper Door Snubbers
  • 7.164. Snubber Adjustment
  • 7.165. View A
  • 7.166. Dipper Pitch Brace
  • 7.167. Fixed Length Pitch Brace Assembly
  • 7.168. Dipper Padlock
  • 7.169. Dipper Trip Assembly
  • 7.170. A-Frame
  • 7.171. Auxiliary Winch
  • 7.172. Auxiliary Winch Assembly
  • 7.173. Boom Suspension Ropes
  • 7.174. Wire Ropes
  • 7.175. Wire Rope Inspection
  • 7.176. Hoist Rope Reeving Replacement
  • 7.177. Shim for Hoist Rope Socket
  • 7.178. Crowd Rope Reeving Replacement
  • 7.179. Crowd Rope Reeving
  • 7.180. Crowd Rope Drum Reeving
  • 7.181. Retract Rope Reeving Replacement
  • 7.182. Retract Rope Reeving
  • 7.183. Retract Rope Take-Up Mechanism
  • 7.184. Retract Rope Tightening
  • 7.185. Dipper Trip Rope Reeving Replacement
  • 7.186. Hoist and Crowd Limit Systems
  • 7.187. Setting Rope Limits In The Hoist Crowd System
  • 7.188. View A – Calibration Limits Screen
  • 7.189. Crowd Slowdown/Stop Limit
  • 7.190. Retract Slowdown/Stop Limits
  • 7.191. Lower Slowdown/Stop Limits
  • 7.192. Hoist Slowdown/Stop Limits
  • 8. SM141403-EN_5.pdf
  • 8.1. Brakes
  • 8.2. Machine Motion Brakes
  • 8.3. Disc Brake Operation
  • 8.4. Maintenance
  • 8.5. Brake Adjustment Specifications
  • 8.6. Brake Adjustment Chart
  • 8.7. Hoist Brake
  • 8.8. Hoist Brake and Motor Location
  • 8.9. Hoist Brake Adjustment
  • 8.10. Hoist Brake Installation
  • 8.11. Crowd Brake
  • 8.12. Crowd Brake Location
  • 8.13. Section View B-B
  • 8.14. Crowd Brake Installation
  • 8.15. Propel Brake
  • 8.16. Propel Brake and Motor
  • 8.17. Section View C-C
  • 8.18. Swing Brake
  • 8.19. Location of Swing Brakes and Motors
  • 8.20. Section View D-D (Swing Brake)
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