Ers Training Menu q3 - 2021

July – Sept
2021
ELECTRIC
ROPE
SHOVEL
TRAINING RESOURCES
E-Learning Courses
Instructor-Led / Instructor Technical Training Packages (ITTP ’s)
Guides / Schedules / Technical Skill Paths
DIG IN!
ABOUT THIS GUIDE
All course materials are developed in partnership
with the engineering product support and technical
stewards. This guide includes all available training
resources available to dealers, customers and em-
ployees regarding the electric rope shovel's compo-
nents and operation. The Technical Training Team is
always updating content and supporting new prod-
uct introductions.
Important Note for Caterpillar Workday Users Only :

Please use actual course name to search for Workday
courses as course numbers will no longer be used to
search for a course.
OPERATOR TRAINING
Important Notice:
All electric rope shovel (ERS) operator training is
coordinated and provided through the Equipment
Training Solutions (ETS) Team.
For all ERS Operator Training / Operator

Assessments, requests and quotations please
contact:
OP E RA T OR TR AI NIN G C OU RS E
OF F ER ING S AN D IN FO R M A TI ON Tony Torres
PAGES 46—48 ETS Coordinator
Email: [email protected]
Electric Rope Shovel Product Support 2

TABLE OF
CONTENTS
4/ M EET TH E TE AM
5 / D E AL ER US AG E O F E RS C OU R SE S
6/ E RS T R AI NI N G P R O D UC T S H OWC A SE
Th is s e ct io n h i gh l i gh ts n ew , up d at e d o r u p-
co mi n g co u rs e s.
8 / ER S O PE R ATI N G G UI D E S TRAINING RESOURCES
Th e s e g ui d e s o ut li n e t h e b e st op e r at i n g
The Electric Rope Shovel Technical
pr ac tic e s fo r en s u ri n g sa f e p r o du ct iv i ty . Training Team has created content to
9 / T EC H NI C I A NS S KI LL S PA THS support current and new products in
the field.
T ech n ic ia n s k il ls p at hs a r e i d e nt i fi ed w it h a
li st i n g of s upp o rt i n g c ou r s es.
This resource contains information
36 / C O U RSE D E SC RI P TI O NS & I N F OR -
regarding the current e-learning,
MA TI ON
instructor-led and recommended
D e sc ri pt i on s of E - le a r ni n g a n d IL T C o u rs e s training paths for technicians sup-
al o n g w it h I TTP ’ s a n d Gu i d es. porting the electric rope shovel.
43 / OP E RA TI ON E -LE A RNI N G C O U RS ES
44 / M EC H ANI C A L I T T P ’ s To request instructor-led Mechanical
45 / E LEC TRI C A L I LT C O U RS ES or Electrical Training please email us
at:
46 / OP E RA T OR I L T C O U RS ES
[email protected]
48 / OP E RA T OR, M G M T/S P RV C O U RSE S
49 / SI EM EN S AD VA N C ED I G BT TR AI NI N G
He r e y o u w i l l fi nd in fo r ma ti o n a bo ut S i e m en s

MEET
THE
MARK M. SMITH
Technical Training Manager
TEAM
Please join us to welcome our new team member
Dipa Das. Dipa is a seasoned Trainer, Course Devel-
Dipa Das
oper, and Professional Consultant who focuses on Senior Technical Training Specialist
providing customer-centric learning solutions.
The Electric Rope Shovel Technical Training Team is

small, but mighty! We are always working hard to
bring the best resources to you. We continuously
look for ways to engage our learners and provide the MESHELL MORTENSEN
Graphic Design/Developer
level of content needed to understand and support
our product.
Please email us feedback or requests for future

courses at [email protected]
MANNY NAVARETTE
Training Specialist/Graphics

ELECTRIC ROPE SHOVEL E-LEARNING
Did you know that there are over 40 electric rope shovel E -learning courses available
on the Dealer Performance Center (DPC)? Is your organization utilizing the available
training to its fullest?
24%
overall percentage increase
from 2019 to 2020 in dealer
usage.
Where does your dealership stand?

Set a goal to utilize all of the available training to improve your organizations ERS knowledge. These courses are here
for you!
If you don’t see a course that you identify as a critical need, let us know! Your feedback is important to us and ensures
that we develop and deliver the right training at the right time.

ERS TRAINING PRODUCT
Showcase
With each new quarter comes progress, the training team is consistently
New Courses
working on developing. This page showcases new and updated training
courses, ITTP’s, guides and Channel 1 videos.
&
Updates!
For updated courses, even though you may have previously taken the course,
it is always recommended to take it again in order to pick up any changes or
updates. Some of these can be significant!
Click on the course to be sent to the Workday learning page.

Web Based Training Courses
Interactive HydraCrowd™ Warm-Up Modes Schematic Diagrams — 30 Minutes (NEW!)
DPC#:56724 Virtual Instructor-Led Training Course
Description: This interactive schematic diagram is designed to provide technicians servicing the
Electric Rope Shovel's HydraCrowd system with a clearer understanding of the system functionali- 7495 Electric Rope Shovel Mechanical Maintenance Course (NEW!)
ty and how to read the schematics related to the various HydraCrowd warm-up modes. DPC#:54268
Description: This 5-day (@ 4-5 hours/day) virtual course is designed to provide participants
Interactive Hose Flushing Modes Schematic Diagrams — 15 Minutes (NEW!) general mechanical maintenance information for the Cat 7495 Electric Rope Shovel. It provides a
DPC#:56715 thorough overview of the front-end equipment, lower works and upper works components.
Description: This interactive schematic diagram is designed to provide technicians servicing the Contact Manny Navarette for additional information [email protected]
Electric Rope Shovel's HydraCrowd system with a clearer understanding of the system functionali-
ty and how to read the schematics related to the various HydraCrowd hose flushing modes.
Interactive Overload Relief Schematic Diagrams — 15 Minutes (NEW!)

DPC#:56712
Description: This interactive schematic diagram is designed to provide technicians servicing the Channel 1 Video
Electric Rope Shovel's HydraCrowd system with a clearer understanding of the system functionali-
ty and how to read the schematics related to the various HydraCrowd overload relief modes. HydraCrowd™ Warm-Up Schematics — 9:28 (NEW!)
Interactive HydraCrowd™ Extend & Retract Schematic Diagrams — 15 Minutes (NEW!) Description: This video provides an interactive schematic diagram for technicians servicing the
DPC#:56716 Electric Rope Shovel's HydraCrowd system. It provides a clearer understanding of the system
Description: This interactive schematic diagram is designed to provide technicians servicing the functionality and a brief overview of the schematics related to the various HydraCrowd warm-up
Electric Rope Shovel's HydraCrowd system with a clearer understanding of the system functionali- modes.
ty and how to read the schematics related to the HydraCrowd extend and retract modes.
Reading HydraCrowd™ Schematics — 15 Minutes (NEW!)

DPC#:56720
Description: This course provides Electric Rope Shovel technicians with a basic understanding of
HydraCrowd schematic symbols and shows how to interrupt the flow of oil through the system
based on valve state.
7495 HydraCrowd™ Service Procedures—Part 1 — Minutes (Updated)
DPC#:41871
Description: This course will provide knowledge on service procedures required for HydraCrowd
system, which is found on Cat Electric Rope Shovels.
7495 HydraCrowd™ Service Procedures—Part 2 — Minutes (Updated)

DPC#:41872
Description: This course will provide knowledge on service procedures required for the Hydra-
Crowd system, which is found on Cat Electric Rope Shovels.Please refer to your service manual for
further specifications.
7495 HydraCrowd™ Inspection and Service Schedule — Part 2 — Minutes (Updated)

DPC#:41873
Description: This is an introductory level course on inspecting the HydraCrowd system found on
Cat 7495 Electric Rope Shovels. This course discusses the Preventative Maintenance Program,
what inspections are needed, how these inspections are done and their importance to the
performance of the HydraCrowd system. Safety considerations in performing inspections are also
discussed

Showcase +
Workday NOMBRE DPC#
Descripción General de la Pala de Cuerda Electrica de Serie 7495 40281
Descripción General de los Components y del Sistema 7495 HydraCrowd 41663
Procedimientos de Servicio de 7495 HydraCrowd: Parte 1 41871

COURSES
Procedimientos de Servicio de 7495 HydraCrowd: Parte 2 41872
AVAILABLE IN Programa de Inspección y Servicio de 7495 HydraCrowd 41873
SPANISH Remoción y Reemplazo de los Components de 7495 HydraCrowd 40935
7495 SIBAS 44353
Módulo de Entrenamiento de Control Mejorado de Movimientos de 7495 44939
Pala Electrica—Repaso General del Sistema de Mando Electrico 56254
Descripción General de la Pala de Cuerda Electrica 40748
“Someday, when I grow up…”

What’s Happening!
The Electric Rope Shovel team is eager to provide instructor-led training every Training
year. This year due to COVID-19 it made delivering training challenging, but
not impossible!
To meet and exceed our dealer and customer needs, we have all had to make
Delivered
some significant changes to our business model due to the pandemic. For
product training, we are currently adapting our offerings so we can now offer
virtual instructor-led training.
Nevertheless, instructor-led training could be delivered to customers based

on if there was an urgent need. Earlier this year, with the help of the Environ-
ment, Health, and Safety team the ERS Training team delivered training safely
at the Tucson Mining Center.
7495 ERS Electrical Systems Level II

DPC#:41733
Even though there were safety precautions that the participants undertook, the training
team and the instructor were able to deliver successful training to Round Mountain Gold.
Participant course survey results showed the course to be highly effective, scoring 4.83 out
of 5 stars for the overall rating of the course.
Job well done by the ERS training team and electrical team!
Participants were handed a Caterpillar® certificate for their participation and attendance .
This is an excellent achievement for the ERS team.

BEST OPERATING PRACTICES GUIDES
Based off of our “Managing ERS and Use of Best Operating Practices” course, this complete reference guide will help
to improve ERS safety and productivity.
ENGLISH
Electric Rope Shovel Best Operating Practices Guide (Media#: PEBJ0109)
EN ESPAÑOL
Pala de Cable Electrica – Guía de Mejores Prácticas de Operación (Media#: PSBJ0109)
EM PORTUGUÊS
Escavadeira a Cabo – Guia das Melhores Práticas Operacionais (Media#: PPBJ0109)
Free Electronic Download or Order copies through catpublications.com

at: https://catpublications.com/
This is a GREAT resource for

Operators, Mining Managers
and Mining Supervisors!
Description: This 100 page full-color guide provides the essential “Best Practices” for proper and efficient electric
rope shovel operations. It focuses on recognizing good or poor operating practices and techniques and how they
affect machine safety, productivity and component life.

TECHNICIAN SKILLS PATHS
DIG IN! PAGE
SKILLS FOR ROPE CROWD & HYDRACROWD TECHNICIANS 12

- Lubrication and Pneumatic Systems Technician 13
- Undercarriage Technician 14
- Bucket Technician 15
- Welding Technician
SKILLS FOR ROPE CROWD TECHNICIANS 17

- Handle and Saddleblock Change Out Technician 18
- Powertrain / Gearbox Technician 19
- Wire Ropes and Suspension Technician
SKILLS FOR HYDRACROWD TECHNICIANS 22

- HydraCrowd Hydraulic Systems Technician 23
- HydraCrowd Handle and Saddleblock Change Out Technician 26
- HydraCrowd Powertrain and Gearbox Technician 27
- Wire Ropes and Suspension Technicians
SKILLS FOR ERS REBUILD TECHNICIANS 30

- HydraCrowd Cylinder Rebuild Technician 31
- ERS Gearbox Rebuild Technician 31
- 7495 ERS Brake Rebuild Technician
SKILLS FOR ELECTRICAL ERS TECHNICIANS 32

- Electrical Systems Technician I — 7495 HydraCrowd or Rope Crowd—Unqualified (< 50V) 33
- Electrical Systems Technician II — 7495 HydraCrowd or Rope Crowd—Qualified (> 50V) 35

TECHNICIAN SKILLS PATHS
Technician Roles are defined by Subject Matter Experts (SME) to fulfill service and maintenance needs per the
equipment. Each role is divided into Task Competencies, Machine Competencies and Fundamental Competen-
cies. The Task Competencies are Specific to Service and Maintenance Tasks and are Instructor Technical Training
Packages (ITTP’s). The Machine Competencies are Specific to Machine Systems and are E-Learning Courses. Funda-
mental Competencies are Common Core Competencies for all Electric Rope Shovel Technician Roles.
Fundamental Competencies are supported by courses that are readily available. These courses will be recommended
for each Role, but are NOT provided by the Electric Rope Shovel Technical Training Team. These can be found on-line
or can be provided by Cat dealers or 3rd parties. Electric Rope Shovel product specific courses are found under the
Machine Competencies or Task Competencies headings.

SKILLS—ROPE CROWD & HYDRACROWD TECHNICIAN

ROPE CROWD & HYDRACROWD TECHNICIAN
Lubrication & Pneumatic Systems Technician
E-LEARNING
 DPC# Duration WORKDAY COURSE NAME PAGE
40748 01:00 Electric Rope Shovel Overview 39
44658 01:00 7495 Electric Rope Shovel Electrical Course for Mechanical Service Techs 43
40236 01:00 7495 Electric Rope Shovel Lubrication (Electrical Support) 44
41230 01:30 7495 Series Electric Rope Shovel Lubrication 39
42639 00:45 7495 Electric Rope Shovel Automatic Lubrication System and Inspection 39
42745 00:45 7495 Electric Rope Shovel Lower Works—Level 1 38
51715 01:00 7495 Electric Rope Shovel Mechanical Systems Upper Works - Level I 38
51803 01:00 7495 Electric Rope Shovel Mechanical Systems Front End—Level 1 38
- - TO BE DEVELOPED—7495 ERS Compressed Air System
INSTRUCTOR TECHNICAL TRAINING PACKAGES (ITTP’s)
 DPC# Duration WORKDAY COURSE NAME PAGE
- - TO BE DEVELOPED—7495 ERS Compressed Air System (Operation Theory, System Trouble-

shooting, Introduction to Compressor & Troubleshooting
- - TO BE DEVELOPED—7495 ERS Single Line Lincoln Lube System (Operational Therapy, Trouble-
shooting, Injector Capacities & Adjustment, Pump Replacement & Repair)
RECOMMENDED CORE TRAINING

 COURSE NAME  COURSE NAME
Electrical Hazards Fasteners

Work Rules & Work Instruction Environmental Protection & Hazards
Crane Operator Hand Signals Workshop Tools
Communication Skills Lockout/Tagout Procedures
Mechanical & Stored Energy Hazards Torque Methods—Manual & Hydraulic Wrench
Measuring Tools Fall Protection
Occupational Health & Safety Site Specific Mine Communications
Understanding Drawings Jacking, Blocking & Lifting
Compressed Gas Cylinder Safety Confined Space Safety

Undercarriage Technician
E-LEARNING
 DPC# DURATION WORKDAY COURSE NAME PAGE
44658 01:00 7495 ERS Electrical Course for Mechanical Service Techs 43
41867 00:30 7495 Series Electric Rope Shovel Couplings Training 39
41807 01:00 7495 Series Electric Rope Shovel Brakes Training 39
- - TO BE DEVELOPED—Maintenance Inspection & Service Schedule
- - TO BE DEVELOPED—Propel & Undercarriage Arrangement Overview (
- - TO BE DEVELOPED—7495 Center Pintle Nut Adjustment Overview
- - TO BE DEVELOPED—7495 ERS Propel Drive Shaft
- TO BE DEVELOPED—ERS Air & Lube. Mech Components

- - TO BE DEVELOPED—Crawler Link & Pin Change, Belt Tightening
- - TO BE DEVELOPED—Air & Lube Component Replacement
- - TO BE DEVELOPED—Center Pintile Nut Adjustment & Ballast Check Procedure
- - TO BE DEVELOPED—Coupling Replacement & Alignment
- - TO BE DEVELOPED—Track Roller Frame Rod Bolt Super Nut Re-Torque
- - TO BE DEVELOPED—Component Replacement Load Roller & Take-Up Idler
- - TO BE DEVELOPED—Component Replacement Propel Motor, Brake, Propel Transmission, Shaft

Group – Axle & Drive Sprocket


Bucket Technician
E-LEARNING
44415 01:00 7495 Electric Rope Shovel Dipper Basics 42
42035 01:00 Caterpillar Series LatchFree Dipper 42
41763 00:30 LatchFree Dipper - Link Assembly Removal and Replacement 43
52494 00:30 7495 Electric Rope Shovel Wet Disc Snubber 43
41802 01:30 ERS Rope Change Out 42
42233 01:00 Wire Rope Inspection and Maintenance 42
- - TO BE DEVELOPED—Bucket Change Out
- - TO BE DEVELOPED—Maintenance Insp & Service Schedule

AEXQ2341 0030 LatchFree Dipper—Link Assembly Removal and Replacement 45
- - TO BE DEVELOPED—Pitch Brace Length Adjustment
- - TO BE DEVELOPED—Bucket Basics – GET, Latch Bar, Snubber, Pitch Brace
- - TO BE DEVELOPED—Tilted Latch Bucket – Latch Lever Shimming
- - TO BE DEVELOPED—Snubber Adjustment & Repair
- - TO BE DEVELOPED—Bucket Change Out for Rope Crowd
- - TO BE DEVELOPED—Bucket Change out for HydraCrowd


Welding Technician
E-LEARNING
- - TO BE DEVELOPED—Weld/No Weld Zones on ERS
- - TO BE DEVELOPED—Importance of Preheat & Theory of Post Weld Enhancements
- - TO BE DEVELOPED—7495 ERS Preheat, Filler Metal & Post Heat Requirements for Major Struc-
tures, Buckets & Alloy Casting Materials
- - TO BE DEVELOPED—Region Specific Training Available Consumables etc.

TBD - TO BE DEVELOPED—7495 ERS In-Depth Review of Steels Used for Major Structure & Alloy Steel
Types for Castings, Bucket Handle, etc. Proper Selection of Filler Wire & Proper Preheat for
Welding (demonstrate proficiency).

Mechanical & Stored Energy Hazards Fall Protection
Measuring Tools Site Specific Mine Communications
Occupational Health & Safety Jacking, Blocking & Lifting
Understanding Drawings Confined Space Safety
Compressed Gas Cylinder Safety

SKILLS—ROPE CROWD TECHNICIAN

ROPE CROWD TECHNICIAN
Handle and Saddle Block Change-Out Technician
E-LEARNING

 DPC# WORKDAY COURSE NAME PAGE
TBD TO BE DEVELOPED—Trip Change Out for Rope Crowd
TBD TO BE DEVELOPED—Bucket Handle Change Out for Rope Crowd
TBD TO BE DEVELOPED—Saddle Block Change Out for Rope Crowd

Mechanical & Stored Energy Hazards Fall Protection
Measuring Tools Site Specific Mine Communications
Occupational Health & Safety Jacking, Blocking & Lifting
Understanding Drawings Confined Space Safety
Compressed Gas Cylinder Safety

Powertrain / Gearbox Technician
E-LEARNING
40242 00:45 7495 Series Electric Rope Shovel Air Filtration Training 39
44735 01:00 7495 Electric Rope Shovel and CAT OGL 42
- - 7495 Electric Rope Shovel Air and Lube Mechanical Components
- - Rope Crowd System and Component Overview
- - Swing System & Component Overview Including Slew Ring
- - 7495 Electric Rope Shovel Compressed Air System
- - Hoist System & Component Overview
- - Maintenance Insp & Service

- - TO BE DEVELOPED— Hoist Drum Groove Cracks Inspection & Ultrasonic Testing
- - TO BE DEVELOPED—Slew Ring
- - TO BE DEVELOPED—Swing Gearbox Changeout
- - TO BE DEVELOPED—Air & Lube Compressor & Replacement
- - TO BE DEVELOPED—Hoist Output Shaft Change Out
- - TO BE DEVELOPED—Swing Output Shaft Change Out
- - TO BE DEVELOPED—Coupling Replacement & Alignment
- - TO BE DEVELOPED—Swing SuperBolt Re-Torque
- - TO BE DEVELOPED—Crowd Gearbox Change Out
- - TO BE DEVELOPED—Hoist Drum Change Out
- - TO BE DEVELOPED—Hoist Gearbox Change Out

Powertrain / Gearbox Technician continued:


Wire Ropes and Suspension Technician
E-LEARNING
- - TO BE DEVELOPED—Hoist System & Trip Group Component Overview
- - TO BE DEVELOPED—Rope Crowd System & Component Overview
- - TO BE DEVELOPED—Suspension Strand Introduction
- - TO BE DEVELOPED—Maintenance Inspection & Service

TO BE DEVELOPED—Trip Rope Change Out
TO BE DEVELOPED—Crowd/Retract Rope Change Out
TO BE DEVELOPED—Hoist Rope Change Out
TO BE DEVELOPED—Suspension Strand Change Out


SKILLS—HYDRACROWD TECHNICIAN

HYDRACROWD TECHNICIAN
HydraCrowd Hydraulic Systems Technician
E-LEARNING
42201 01:00 7495 Electric Rope Shovel Electrical WinDaq 43
(For Cat Dealer and Caterpillar Personnel Only)
41640 01:30 7495 Electric Rope Shovel WinDaq Level 2 HydraCrowd 43

41663 01:00 7495 HydraCrowd System and Component Overview 39

56713 01:30 7495 HydraCrowd System Troubleshooting Guide 41
41871 01:00 7495 HydraCrowd Service Procedures Course—Part 1 (Updated) 41
41872 01:00 7495 HydraCrowd Service Procedures Course—Part 2 (Updated) 41
45496 00:45 7495 HydraCrowd Updates Part 1 – Cylinder Manifold 42
52342 01:00 7495 HydraCrowd Updates Part 2 – Machinery House 42

41873 00:30 7495 HydraCrowd Inspection and Service Schedule Course (Updated) 41
40935 01:00 7495 HydraCrowd Component Removal and Replacement 41
54963 00:30 7495 HydraCrowd Adaptive Control System Upgrade Overview 41
55628 00:30 HydraCrowd Full ACS — Basics of Hydraulics 39
56020 00:30 Reading HydraCrowd Schematics 39
56716 00:15 Interactive HydraCrowd Extend & Retract Schematic Diagrams (New) 40
56712 00:15 Interactive HydraCrowd Overload Relief Schematic Diagrams (New) 40
56715 00:15 Interactive HydraCrowd Hose Flushing Modes Schematic Diagrams (New) 40
56724 00:30 Interactive HydraCrowd Warm-Up Modes Schematic Diagrams (New) 40
- - TO BE DEVELOPED—HydraCrowd Electrical Overview
- - TO BE DEVELOPED—HydraCrowd Cylinder Change Out Overview
- - TO BE DEVELOPED—HydraCrowd Guide Shoe Change Out

- - TO BE DEVELOPED—HydraCrowd System Hazard Mitigation & Pressure Relief/Verify Before Service
- - TO BE DEVELOPED—HydraCrowd Cylinder Change Out Procedure
- - TO BE DEVELOPED—HydraCrowd Pump Replacement & Timing
- - TO BE DEVELOPED—HC Component & System Cleaning Procedures
- - TO BE DEVELOPED—Hydraulic Fluid Cleanliness Standards, HC Comp Cleanliness Req. Sys Start-up

& Operational Req., Oil Sampling, Oil Analysis Reports
- - TO BE DEVELOPED—HydraCrowd System Start-Up and Air Purge Requirements & Procedures
- - TO BE DEVELOPED—HydraCrowd Accumulator Hands-on Charging Repair and Replacement

HydraCrowd Hydraulic Systems Technician continued:
ITTP’s continued:
- - - TO BE DEVELOPED—HydraCrowd Components Hands-on Repair & Replacement
- - - TO BE DEVELOPED—HydraCrowd System Cold Start Sequence and Logic
- - - TO BE DEVELOPED—HydraCrowd Power Module Maintenance and Repair


HydraCrowd Handle & Saddle Block Change Out Technician
E-LEARNING
41873 00:30 7495 HydraCrowd Inspection and Service Schedule Course 41
41871 01:00 7495 HydraCrowd Service Procedures Course—Part 1 41
TO BE DEVELOPED—Bucket Change Out for Rope/HydraCrowd
- - TO BE DEVELOPED—Handle and Saddleblock Change Out for HydraCrowd
- - TO BE DEVELOPED—HydraCrowd Cylinder Change Out Overview
- - TO BE DEVELOPED—HydraCrowd Guide Shoe Change Out

- - TO BE DEVELOPED–Trip Rope Change Out for HydraCrowd
- - TO BE DEVELOPED—HydraCrowd Cylinder Change Out Procedure
- - TO BE DEVELOPED—Handle Change Out for HydraCrowd
- - TO BE DEVELOPED—Saddle Block Change Out for HydraCrowd



HydraCrowd Powertrain/Gearbox Technician
E-LEARNING
41663 01:00 7495 HydraCrowd System and Component Overview 39
44735 01:00 7495 Electric Rope Shovel and Cat OGL 42
40242 00:45 7495 Series Electric Rope Shovel Air Filtration Training 39
41873 00:30 7495 HydraCrowd Inspection and Service Schedule Course 41
45496 00:45 7495 HydraCrowd Updates Part 1 - Cylinder Manifold 42
52342 01:00 7495 HydraCrowd Updates Part 2 - Machinery House 42
Hoist System and Component Overview
ERS Air and Lube Mechanical Components
HydraCrowd Cylinder Change Out Overview
7495 Electric Rope Shovel Compressed Air System
Maintenance Inspection and Service Schedule
Swing System and Component Overview Including Slew Ring

HydraCrowd Powertrain/Gearbox Technician continued:
- - TO BE DEVELOPED—Hoist Drum Groove Cracks Inspection & Ultrasonic Testing
- - TO BE DEVELOPED—Air & Lube Comp & Replacement
- - TO BE DEVELOPED—Slew Ring
- - TO BE DEVELOPED—HC Cylinder Change-Out Procedure
TO BE DEVELOPED—Hoist Drum Change-Out
TO BE DEVELOPED—Hoist Output Shaft Change-Out
TO BE DEVELOPED—Swing Output Shaft Change-Out
TO BE DEVELOPED—Hoist Gearbox Change-Out
TO BE DEVELOPED—Coupling Replacement & Alignment
TO BE DEVELOPED—Swing Gearbox Change–Out
TO BE DEVELOPED—Swing SuperBolt Re-Torque
TO BE DEVELOPED—HC Pump Replacement & Timing



Wire Ropes and Suspension Technician
E-LEARNING
- - TO BE DEVELOPED—Hoist System & Trip Group Component Overview
- - TO BE DEVELOPED—Suspension Strand Introduction
- - TO BE DEVELOPED—Maintenance Inspection & Service

TO BE DEVELOPED—Trip Rope Change Out
TO BE DEVELOPED—Hoist Rope Change Out
TO BE DEVELOPED—Suspension Strand Change Out


SKILLS—REBUILD TECHNICIAN

REBUILD TECHNICIAN
E-LEARNING
44663 01:00 7495 HydraCrowd Single Piston Cylinder Rebuild Overview 41
- - TO BE DEVELOPED—7495 ERS Gearbox Rebuild Overview

AEXQ2108 7495 Electric Rope Shovel HydraCrowd Single Piston Cylinder Rebuild Procedure 45
- TO BE DEVELOPED—7495 ERS Gearbox Rebuild Overview
TO BE DEVELOPED—7495 Electric Rope Shovel Hoist Brake Rebuild Procedure
TO BE DEVELOPED—7495 ERS Gearbox Rebuild Procedure


SKILLS—ELECTRICAL TECHNICIAN

ELECTRICAL TECHNICIAN
Electrical Technician I—7495 HydraCrowd or Rope Crowd
E-LEARNING
44353 01:00 7495 Electric Rope Shovel SIBAS 44
42661 01:00 7495 Electric Rope Shovel Power Distribution 44
43468 01:00 7495 Electric Rope Shovel Power Conversion and Control 44
42201 01:00 7495 Electric Rope Shovel Electrical Windaq 43
41640 01:30 7495 Electric Rope Shovel Windaq Level 2 HydraCrowd 43

42808 01:00 7495 Electric Rope Shovel Windaq Level 2 Electrical 43

- - TO BE DEVELOPED—Product Solutions & Understanding
- - TO BE DEVELOPED—7495 Electric Rope Shovel Siemens IGBT Overview
- - TO BE DEVELOPED—Air Systems Electrical Basics
- - TO BE DEVELOPED—Auto Lubrication Electrical Basics
- - TO BE DEVELOPED—7495 Electrical Systems Overview
- - TO BE DEVELOPED—Trail Cable
- - TO BE DEVELOPED—Drive Power Transformers 1
- - TO BE DEVELOPED—Drive Power Transformers 2
- - TO BE DEVELOPED—Maintenance Station Procedure
- - TO BE DEVELOPED—Machine Control and Communications
- - TO BE DEVELOPED—Auxiliary Power Transformers
- - TO BE DEVELOPED—Mine Sub-Station
- - TO BE DEVELOPED—Operator Station Procedures

Electrical Technician I—7495 HC or Rope Crowd continued:
- TO BE DEVELOPED—DEALER SYSTEMS—Applied Failure Analysis
- TO BE DEVELOPED—DEALER SYSTEMS—Cultivating and Handling Customer Relations
- TO BE DEVELOPED—MACHINE SYSTEMS—Machine Drawings and Schematics
- TO BE DEVELOPED—MACHINE SYSTEMS—Machine Documents and Manuals
- TO BE DEVELOPED—High Voltage Collector
- TO BE DEVELOPED—High Voltage Cabinet
- TO BE DEVELOPED—Motor Control Center
- TO BE DEVELOPED—Auto Lubrication Electrical—Advanced
- TO BE DEVELOPED—Air Systems Electrical—Advanced
- TO BE DEVELOPED—Auxiliary Power Transformers
- TO BE DEVELOPED—Mine Sub-Station
- TO BE DEVELOPED—Auxiliary Propel Collector

PPE National Electrical Code
ESD The Caterpillar 7 Step Diagnostic Process
Programmable Logic Controller (PLC) Engineering Drawing and Documentation
Caterpillar Literature Communication
NFPA 70 E MSHA New Miner & Annual Refresher Training
Environmental Protection Measures Tools
Confined Space Safety Emergency Procedures
First Aid and CPR Pneumatic Systems
Jacking, Blocking and Lifting Fasteners
Lockout/Tagout Mine Operations
Instrumentation Electrical Safety
Job Hazard Analysis Customer Relations
Fuels and Lubricants Fire Safety
Electrical and Electronic Fundamentals Workshop Tools
Computers and Programming Mechanical Principals
Occupational Health and Safety Hydraulic Fundamentals
Bearing, Seals and Gaskets

Electrical Technician II—7495 HydraCrowd or Rope Crowd
E-LEARNING
44353 01:00 7495 Electric Rope Shovel SIBAS 44
42661 01:00 7495 Electric Rope Shovel Power Distribution 44
43468 01:00 7495 Electric Rope Shovel Power Conversion and Control 44
42201 01:00 7495 Electric Rope Shovel Electrical Windaq 43
41640 01:30 7495 Electric Rope Shovel Windaq Level 2 HydraCrowd 43

42808 01:00 7495 Electric Rope Shovel Windaq Level 2 Electrical 43

56254 00:30 Electric Rope Shovel - Electric Drive System Overview 44
- - TO BE DEVELOPED—Production Solutions and Understanding
- - TO BE DEVELOPED—7495 Electric Rope Shovel Siemens IGBT Overview
- - TO BE DEVELOPED—Air Systems Electrical Basics
- - TO BE DEVELOPED—Auto Lubrication Electrical Basics
- - TO BE DEVELOPED—7495 Electrical Systems Overview
- - TO BE DEVELOPED—Operator Station Procedures
- - TO BE DEVELOPED—Safety Procedures
- - TO BE DEVELOPED—Applied Failure Analysis
- - TO BE DEVELOPED—Maintenance Station Procedure
- - TO BE DEVELOPED—Cultivating and Handling Customer Relations

Electrical Technician II—7495 Hc or Rope Crowd continued:
- TO BE DEVELOPED—Electrical System Technician—Unqualified (< 50V)
- TO BE DEVELOPED—Electrical System Technician—Qualified (> 50V)

PPE National Electrical Code
ESD The Caterpillar 7 Step Diagnostic Process
Programmable Logic Controller (PLC) Engineering Drawing and Documentation
Caterpillar Literature Communication
NFPA 70 E MSHA New Miner & Annual Refresher Training
Environmental Protection Measures Tools
Confined Space Safety Emergency Procedures
First Aid and CPR Pneumatic Systems
Jacking, Blocking and Lifting Fasteners
Lockout/Tagout Mine Operations
Instrumentation Electrical Safety
Job Hazard Analysis Customer Relations
Fuels and Lubricants Fire Safety
Electrical and Electronic Fundamentals Workshop Tools
Computers and Programming Mechanical Principals
Occupational Health and Safety Hydraulic Fundamentals
Bearing, Seals and Gaskets

COURSE DESCRIPTIONS
& INFORMATION

E-LEARNING TRAINING COURSE DESCRIPTIONS
Mechanical
Course Number Available in Spanish
Workday Course Name
DPC
7495 Mechanical Systems Lower Works – Level I (Part 1 of 3) 42745 No
Description: This course is a pre-requisite for ERS mechanical systems instructor-led training. The purpose of this course is to familiarize you with
the mechanical components on the lower works of the Cat® Electric Rope Shovel and the basic function of each component.
Focus will be on component identification and general introduction to component purpose.
This course includes the following:
· 7495 Cat Electric Rope Shovel Models
· Identification of deck arrangements, shovel motions and electrical systems
· Lower Works component identification and function of the following:
- Track Roller Frame Group
- Propel Machinery
- Slew Ring

Workday Course Name
DPC
7495 Mechanical Systems Upper Works – Level I (Part 2 of 3) 51715 No
Description: This course is a pre-requisite for ERS mechanical systems instructor led training. The purpose of this course is to familiarize you with
the mechanical components on the upper works of the Cat Electric Rope Shovel and the basic function of each component.
Focus will be on component identification and general introduction to component purpose.

· 7495 Cat Electric Rope Shovel Models identification
· Upper Works component identification and function of the following:
- Chassis
- Center Pintle
- Electrical - Collector Rings
- Hoist, Crowd and Swing Machinery
- Compressed Air System
- Automatic Lubrication System
- Machinery House and Major Components

Workday Course Name
DPC
7495 Mechanical Systems Front-End Equipment – Level I (Part 3 of 3) 51803 No
Description: This course is a pre-requisite for ERS mechanical systems instructor led training. The purpose of this course is to familiarize you with
the mechanical components on the front end of the Cat Electric Rope Shovel and the basic function of each component.
Focus is on component identification and general introduction to component purpose.

· 7495 Cat Electric Rope Shovel Models identification
· Front End component identification and function of the following:
- Boom
- Handle Assembly
- HydraCrowd™ Handle Assembly
- A-Frame
- Running Ropes
- Buckets

Workday Course Name
DPC
7495 Electric Rope Shovel Brakes Training 41807 No
Description: This course is intended for Cat dealer’s sales professionals, field representatives and anyone interested in learning more about this
product.

Workday Course Name
DPC
7495 Electric Rope Shovel Couplings 41867 No
Description: This course is intended for Cat dealer’s sales professionals, field representatives and anyone interested in learning more about this
product. After taking the course, you should be able to explain the different procedures for grid and gear couplings, summarize the maintenance
procedures for couplings and describe the safety considerations for coupling maintenance.

Workday Course Name
DPC
7495 Series Electric Rope Shovel Air Filtration Training 40242 No
Description: This course is intended for anyone interested in learning more about this product such as Cat dealer sales professionals or field
representatives.

Workday Course Name
DPC
7495 Electric Rope Shovel Overview 40787 Yes
Description: This course will cover: History, Theory of Operation, Product Line Features and Benefits: - Mechanical - Electrical - Operator's Cab -
Safety - Serviceability, Mining Technology and Competitive Information.

Workday Course Name
DPC
7495 Electric Rope Shovel Lubrication 41230 No
Description: This course will provide basic knowledge about the lubrication process for the 7495 Series Electric Rope Shovel systems.

Workday Course Name
DPC
7495 Electric Rope Shovel Automatic Lubrication & Inspection 42639 No
Description: This course will provide basic knowledge about the automatic lube system for the 7495 Series Electric Rope Shovel.

Workday Course Name
DPC
7495 HydraCrowd™ System and Component Overview 41663 Yes
Descripión General de los Components y del Sistema 7495 HydraCrowd
Description: This course is intended for field representatives and anyone interested in learning more about 7495 HydraCrowd System and Com-
ponents.

Workday Course Name
DPC
HydraCrowd Full ACS — Basics of Hydraulics 55628 No
Description: This course is designed to provide HydraCrowd technicians, maintenance personnel, managers and supervisors with a working
knowledge of basic hydraulic principles.
Workday Course Name
DPC
Reading HydraCrowd Schematics 56020 No
Description: This course provides Electric Rope Shovel technicians with a basic understanding of HydraCrowd schematic symbols and shows how
to interrupt the flow of oil through the system based on valve state.

Workday Course Name
DPC
Interactive HydraCrowd Extend & Retract Schematic Diagrams (New) 56716 No
Description: This interactive schematic diagram is designed to provide technicians servicing the Electric Rope Shovel’s HydraCrowd system with a
clearer understanding of the system functionality and how to read the schematics related to the HydraCrowd extend and retract modes.
Workday Course Name Course Number Available in Spanish

DPC
Interactive HydraCrowd Overload Relief Schematic Diagrams (New) 56712 No
clearer understanding of the system functionality and how to read the schematics related to the HydraCrowd overload relief modes.

Workday Course Name
DPC
Interactive HydraCrowd Hose Flushing Modes Schematic Diagrams (New) 56715 No
clearer understanding of the system functionality and how to read the schematics related to the various HydraCrowd hose flushing modes.

Workday Course Name
DPC
Interactive HydraCrowd Warm-Up Modes Schematic Diagrams (New) 56724 No
clearer understanding of the system functionality and how to read the schematics related to the various HydraCrowd warm-up modes.


Workday Course Name
DPC
7495 HydraCrowd™ Service Procedures – Part 1 (Updated) 41871 Yes
Procedimientos de Servicio de 7495 HydraCrowd: Parte 1 SPANISH
Description: This course will provide knowledge on service procedures required for the HydraCrowd system, which is found on Cat Electric Rope
Shovels.

Workday Course Name
DPC
7495 HydraCrowd™ Service Procedures – Part 2 (Updated) 41872 Yes
Procedimientos de Servicio de 7495 HydraCrowd: Parte 2
Description: This course will provide knowledge on service procedures required for the HydraCrowd system, which is found on Cat Electric Rope
Shovels Please refer to your service manual for further specifications.

Workday Course Name
DPC
7495 HydraCrowd™ Inspection and Service Schedule (Updated) 41873 Yes
Programa de Inspección y Servicio de 7495 HydraCrowd
Description: This is an introductory level course on inspecting the HydraCrowd system found on Cat 7495 Electric Rope Shovels. This course dis-
cusses the Preventative Maintenance Program, what inspections are needed, how these inspections are done and their importance to the perfor-
mance of the HydraCrowd system. Safety considerations in performing inspections are also discussed.
Workday Course Name
DPC
7495 HydraCrowd™ System Troubleshooting Guide 56713 No
Description: This guide will provide information on how to troubleshoot the 7495 Electric Rope Shovel HydraCrowd System. This is a study on how
to recognize symptoms in the HydraCrowd System and understand the steps required to investigate the action needed for a resolution.

Workday Course Name
DPC
7495 HydraCrowd™ Component Removal and Replacement Course 40935 Yes
Remoción y Reemplazo de los Components de 7495 HydraCrowd
Description: This course will provide knowledge on component removal and replacement required for the HydraCrowd system, which is found on
Cat Electric Rope Shovels.

Workday Course Name
DPC
7495 HydraCrowd Single Piston Cylinder Rebuild Overview 44663 No
Description: This course is an introduction to the Single Piston Cylinder Rebuild procedure. The focus of this course is on component identification
and procedure overview to familiarize the learner with the rebuild process. The cylinder seal and cylinder manifold tests are also discussed. The
course concludes with salvage and reuse guidelines.

Workday Course Name
DPC
7495 HydraCrowd Adaptive Control Systems Upgrade Overview 54963 No
Description: This course defines the main components of the new HydraCrowd system and their functions. It describes the updates made to the
system and how these benefit our customers including any changes to maintenance and serviceability.


Workday Course Name
DPC
7495 HydraCrowd™ Update Part 1 – Cylinder Manifold 45496 No
Description: This course provides an overview of the ACS Cylinder Manifold, Sleeve Hydraulic & Electrical Installation and the Boom Hydraulic &
Electrical Installation upgrades found on the Cat® Electric Rope Shovels. The purpose of this course is to familiarize you with the components and
processes involved with these HydraCrowd updates. Focus will be on component identification and general introduction.
· ACS Cylinder Manifold, Sleeve Hydraulic and Boom Hydraulic component identification.
· Overview of the ACS Cylinder Manifold, Sleeve Hydraulic and Boom Hydraulic functions.
· Electrical installation of the Sleeve and Boom Hydraulics.
· Introduction to the Pilot System.

Workday Course Name
DPC
7495 HydraCrowd™ Update Part 2 – Machinery House 52342 No
Description: This course is part 2 of the 7495 HydraCrowd Updates found on Cat Electric Rope Shovels. The purpose of this course is to familiarize
you with the HydraCrowd updates for the pump control manifold assembly, circulation manifold and return/PDT filters. The new pilot system is
also covered. Focus will be on component identification and general introduction to affected processed.

Workday Course Name
DPC
7495 Wire Rope Inspection and Maintenance 42233 No
Description: This course will provide information about wire rope. This is an overview of the characteristics of wire rope and of how to prepare
and handle the rope prior to installation.

Workday Course Name
DPC
ERS Rope Change Out 41802 No
Description: This course will provide information about the Rope Care and the Rope Change Out process for the 7295, 7395 and the 7495 Series
Cat Electric Rope Shovels. This is an overview of the running ropes and safety considerations for rope change out. Detailed steps will be provided
for change out of the hoist, crowd, retract and dipper trip ropes. Also covered is the rope tightening procedure and setting limits. Refer to the
service manual for further specifications.

Workday Course Name
DPC
7495 Electric Rope Shovel and Cat OGL 44735 No
Description: This course will cover how Cat OGL affects the performance of machinery and how it is superior to grease based products. The sec-
ond part of this course will illustrate the importance of inspection and what to look for while inspecting.

Workday Course Name
DPC
7495 Electric Rope Shovel Dipper Basics 44415 No
Description: This course will cover information on the 7495 Electric Rope Shovel Dipper.

Workday Course Name
DPC
Caterpillar Series LatchFree™ Dipper 42035 No
Description: This is an intermediate level course. To complete the course successfully, you may need to refresh your basic knowledge of this
product and safety. For foundational level knowledge, please refer to the Electric Rope Shovel Overview course. This course will help you become
more knowledgeable on the LatchFree Dipper System. You will be better prepared to perform routine maintenance on the dipper.

Workday Course Name
DPC
LatchFree Dipper Link Assembly Removal and Replacement 41763 No
Description: This course covers information on how to remove and install the link assembly on the LatchFree Dipper.
Workday Course Name
DPC
7495 Electric Rope Shovel Wet Disc Snubber 52494 No
Description: This course will cover information on the 7495 Electric Rope Shovel Wet Disc Snubber - NPI. This course is intended for Dealer Service
Techs to learn more about the Wet Disc Snubber. In this course you will learn the difference between the standard snubber and the Wet Disc
Snubber. Also included in this course is Support Information and the detailed components in the Wet Disc Snubber.
After successfully completing this course you will:

• Understand the difference between the standard snubber and the Wet Disc Snubber.
• Be familiar with the support of the Wet Disc Snubber.

Workday Course Name
DPC
7495 Electric Rope Shovel Electrical Course for Mechanical Technicians 44658 No
Description: This course is specifically designed for mechanical technicians to have an understanding of the basic electrical systems on the 7495
Electric Rope Shovel.
Electric
Workday Course Name
DPC
7495 Electric Rope Shovel Electrical WinDaq 42201 No
Description: The purpose of this course is to explain the software, hardware, and equipment needed when working with the Windaq tool. This
course also includes comparisons on the equipment, in order make the best choice in determining which to use.
Workday Course Name DPC
7495 Electric Rope Shovel WinDaq Level 2 HydraCrowd 41640 No

Description: The purpose of this course is to explain the Windaq data collection and analysis for HydraCrowd. It describes tests and test proce-
dures for HydraCrowd commissioning, new cylinder start-up and troubleshooting. If you are not familiar with the WinDaq Tool it is recommended
that you take 7495 Electric Rope Shovel WinDaq (DPC # 42201, WD # 37190) prior to beginning this course.
Workday Course Name DPC
7495 Electric Rope Shovel WinDaq Level 2 Electrical 42808 No

Description: The purpose of this course is to explain the Windaq data collection and analysis. It describes tests and test procedures for the 7495
Electric Rope Shovel. If you are not familiar with the WinDaq Tool it is recommended that you take 7495 Electric Rope Shovel WinDaq (DPC #
42201, WD37190) prior to beginning this course.
At the end of this course, you will be able to:
• Understand how to record and the options available.

• Perform display changes.
• Look at a Windaq recording and determine if it is normal and if the motion control system is working properly.
• Understand what to look for on the Windaq recordings to determine problem.


Workday Course Name
DPC
7495 Electric Rope Shovel Power Distribution 42661 No
Description: This course is designed to prepare the participant to identify and describe the main components and circuits of the 7495 Electric
Rope Shovel Power Distribution System. In addition, this course describes in general terms the capabilities and main features of the system.

Workday Course Name
DPC
7495 Electric Rope Shovel Power Conversion and Control 43468 No
Description: This course is designed to ensure technicians are able to identify, locate and describe the main circuits and components of the 7495
Power Conversion and Motion Control System. It is important that the technicians are able to identify and describe the components to ensure a
quick, accurate resolution of machine problems.

Workday Course Name
DPC
7495 ERS SIBAS 44353 Yes
7495 ERS SIBAS SPANISH
Description: This 7495 Electric Rope Shovel SiBAS 32 Controller module is designed to provide the course participants with the competencies
needed to identify, describe and use the software for 7495 Electric Rope Shovel SiBAS 32 Controller.

Workday Course Name
DPC
7495 Electric Rope Shovel Lubrication (Electrical Support) 40236 No
Description: This course will provide basic electrical knowledge to support the lubrication process for the 7495 Series Electric Rope Shovel sys-
tems.

Workday Course Name
DPC
Electric Rope Shovel—Electric Drive System Overview 56254 Yes
Pala Electrica—Repaso General del Sistema de Mando Electrico SPANISH
Description: The purpose of this course is to provide an overview of the upcoming upgrades and improvements made to the electric drive
system of the 7495 and 7495 HF electric rope shovel. These features will be available beginning in late 2020 and early 2021.
Operation
Workday Course Name
DPC
Best Operating Practices for Electric Rope Shovels - Managing ERS 44495 No
Description: This course is specifically designed for mining managers, supervisors, dealers and site personnel working around electric rope shovels.
It discusses general management of electric rope shovels and the importance of applying best operational practices to safely achieve lower cost-
per-ton and improved machine availability. This web-based course is Section 1 of instructor-led course DPC#41964 / WD#08E57525 entitled
“Managing ERS and Use of Best Operating Practices”.
Course Number DPC Available in Available in
Workday Course Name Spanish Portuguese
Enhanced Motion Control: Operator Assist 1 (E-learning) 56290 No No
Description: Description: This course was designed to make operators aware of the changes implemented for Enhanced Motion Control. After
successfully completing this course, the operator will be aware of the following changes made by Enhanced Motion Control (EMC) and how shov-
el operation will be affected. Anti-Swing in Bank Hoist Stall Prevention Rope Crowd Impact Prevention Rope Crowd Overspeed Prevention Hoist
Rope Slack Prevention / Boom Jack Minimization.
44
Electric Rope Shovel Product Support
ITTP / ILT / VILT TRAINING COURSE DESCRIPTIONS
For purchase and scheduling of all Mechanical or Electrical ILT and Virtual Instructor-Led Training (VILT) courses, please contact:
• Manny Navarette at [email protected] or
• Mark M. Smith at [email protected]
All enrollments must be received no less than 30 days prior to start of class. “No shows” upon start of class will be billed at 100%
Mechanical ITTP’s & VILT

Course Name ITTP Number
on DPC
7495 HydraCrowd Single Piston Cylinder Rebuild Procedure (ITTP) AEXQ2108
For Cat Instructors Only - Instructor Technical Training Package (ITTP)
Description: The focus of this course is to cover the steps associated with rebuilding a used Single Piston (SP) HydraCrowd™ cylinder.
This includes cylinder manifold removal and installation, and cylinder disassembly and assembly procedures. Also covered are safety,
facility and tool requirements, components identification, cylinder seal tests, cylinder manifold test, and salvage and reuse guidelines.
Course Name ITTP Number

on DPC
LatchFree™ Link Removal-Install Procedure (ITTP) AEXQ2341
For Cat Instructors Only - Instructor Technical Training Package (ITTP)
Description: This course is designed to prepare participants to Remove and Install the LatchFree Link on the Cat Electric Rope Shovel by
performing the correct steps to remove the link and camshaft, then disassemble, assemble and re-install the link and camshaft. Trou-
bleshooting, assessing for salvage and reuse, and performing a follow-up check is also required to ensure a properly serviced bucket
link. Participants must demonstrate their knowledge of and ability to perform the processes to pass this course.
At the completion of this course, participants will be able to locate and identify link and camshaft components. Participants will
demonstrate how to troubleshoot the link, properly prepare for the link work procedures, remove and install the link and camshaft,
disassemble and assemble the link and camshaft, perform a follow-up check after installation.
Participants will demonstrate knowledge of these procedures by performing hands-on tasks following a checklist and using reference
material.
Course Name VILT Number

on DPC
7495 Mechanical Maintenance (VILT) (Delivered Virtually via MS Teams) (NEW!) 54268
VIRTUAL
Description: This 5-day (@ 4-5 hours/day) virtual course is designed to provide participants general mechanical maintenance infor-
mation for the Cat 7495 Electric Rope Shovel. It provides a thorough overview of the front-end equipment, lower works and upper

INSTRUCTOR-LED (ILT) TRAINING COURSE DESCRIPTIONS
Electrical ILT Courses

Course Name Course Number
DPC
7495 Electric Rope Shovel Siemens IGBT Overview Training 42355
Description: This training course is designed to introduce electrical service personnel to the CAT 7495 Electric Rope Shovel. It is especially suited
to service technicians who are unfamiliar with the particular electrical and control systems of the 7495. Course is taught at Siemens facility located
in Alpharetta, Georgia, USA.
See Siemens Training Schedule on pages 50-51 for Additional Information
Training is Held at Siemens Training Facility in Alpharetta, GA USA
Duration: 5 days
Course Name
7495 Electrical Systems Level I (available with machine purchase)
Description: The Caterpillar 7495 Electrical Level I Course is provided as part of a machine purchase. Class duration is 5 days on site after comple-
tion of the machine commissioning. Taught at the Tucson Mining Center or at the Customer mine site.
Duration: 5 days
Minimum: 6 Enrollees
Maximum: 10 Enrollees
Course Name Course Number

DPC
7495 Electrical Systems Level II 41733
NOTE: Prerequisite Requirement - 7495 Electrical Systems Level I

Description: The Caterpillar 7495 Electric Rope Shovel Level II Electrical Systems Course was developed to introduce CAT electrical service person-
nel with the procedures needed to safely identify, service and troubleshoot electrical faults common to the Caterpillar 7495 Electric Rope Shovel.
The module includes familiarization and hands-on practice on the prescribed procedures needed to identify electrical faults and return the
machine to operational condition. Training will include in classroom with hands-on lab. Taught at the Tucson Mining Center or at Customer mine
site. If at mine site, REQUIRES the availability of a 7495 ERS for classroom lab work.
Duration: 3 1/2 days

Minimum: 4 Enrollees
Maximum: 8 Enrollees

ILT TRAINING COURSE DESCRIPTIONS
Operator ILT Courses

Course Number
Course Name
DPC
Level I Electric Rope Shovel — Competent Operator Training Course 42488
Description: This course is designed for entry level operators with less than 3 years of operating experience. Includes classroom training covering:
Safety, walkaround inspections, operator’s compartment, start-up/shut down procedures, basic operating procedures based on industry require-
ments and basic earthmoving fundamentals so an individual can develop skills to operate equipment safely and proficiently.
Attendees receive a Certificate of Completion.
Program Duration
Typical classes are 2 days (classroom). Complex machines and applications can take additional time.
Cancellation Fee
Up to thirty calendar days prior to start of the class, cancellation fee is 25% of total program cost. Within fifteen days, cancellation fee is 50% of
total program cost.
Minimum: 4 Enrollees / Maximum: 6 Enrollees
Course Name
Level II Professional ERS Operator Training Course
Included with machine purchase or can be Purchased Separately

Note: If taught in conjunction with a machine purchase, a total of 10 days of training is provided (2 days classroom and 8 days in-the-iron).
This course is designed for experienced Electric Rope Shovel operators with 3 or more years of experience. Participants benefit by refining oper-
ating techniques and learning application tips and knowledge. Training includes classroom and in-the-iron activities covering: Safety, walkaround
inspections, operator’s compartment, start-up/shutdown procedures, basic operating procedures based on industry requirements and basic
earthmoving fundamentals so an individual can develop skills to operate equipment safely and proficiently. Attendees receive a Certificate of
Completion.
Program Duration
Typical program is 10 days in length. This includes 2 days of classroom and 8 days of in-the-iron activities. Complex machines and applications can
take additional time.
Cancellation Fee
total program cost.

ILT TRAINING COURSE DESCRIPTIONS
Course Name
Level III Professional ERS Operator Certification
This course is designed as an evaluation of the experienced electric rope shovel operator skill set. Certification is earned through demonstration
of skills by completing established operational tasks to Caterpillar standards. Program ensures operation and application efficiency by machine
family in a number of applications.
Successful completion of a Level II class is a prerequisite.
Participants need to demonstrate the ability to conduct a thorough walkaround inspection, pass a safety quiz with a score of 100% and a written
knowledge assessment with a minimum score of 80%. They must also complete the required competencies (in-the-iron) established for safe and
efficient electric rope shovel operation.
Participants that meet these requirements earn a Certificate of Registry. (Participants that do NOT meet these requirements will receive a
certificate of participation.)
Program Duration
Typically 1 to 2 days per machine family, up to a maximum of 4 days for complex applications. Includes testing and in-the-iron activities.
Cancellation Fee
total program cost.

OPERATOR & MANAGEMENT/SUPERVISOR
COURSE DESCRIPTIONS
Course Number Available in Available in
Course Name DPC Spanish Portuguese
7495 Electric Rope Shovel - Managing ERS and Use of Best Operating Practices (2- 41964 Yes Yes
Day Course)
Course Number Available in Available in
Course Name DPC Spanish Portuguese
7495 Electric Rope Shovel - Managing ERS and Use of Best Operating Practices – 45348 Not Not
Oil Sands Edition (2-Day Course) Applicable Applicable
This version of the “Managing ERS and Use of Best Operating Practices” course
has been adjusted for the oil sands mining district. Information and references
pertaining to drilling and blasting processes and the fragmentation of material
have been omitted. All other topics and information remain the same.
Description: This course provides the basics of proper and efficient electric rope shovel operations. It focuses on recognizing good or
poor operating practices and techniques, how to correct them and their effect on machine safety and productivity. Beneficial for
Mining Personnel – Mining managers, supervisors, operators and service or support personnel. Also, Caterpillar and Cat Dealer
Personnel. This knowledge is helpful to mining managers and supervisors for making better and more informed operating decisions
for their ERS fleet, improving productivity while lowering their operating costs. Includes 200+page Student Workbook (hard copy
provided at Tinaja Hills classes / Electronic copy provided at mine site for printing. Attendees receive a Certificate of Completion.
Program Duration: 2 days (16 hours)

Cancellation Fee: Up to fifteen calendar days prior to start of the class, cancellation fee is 25% of total program cost. Within fifteen days, can-
cellation fee is 50% of total program cost.
Course Number DPC Available in Available in
Course Name Spanish Portuguese
7495 Electric Rope Shovel—Managing ERS and Use of Best Operating Practic- 520065 Yes No
es—For Experienced Operators (1-Day Course)
Program Duration: 1 day (8 hours)

Cancellation Fee: Up to fifteen calendar days prior to start of the class, cancellation fee is 25% of total program cost. Within fifteen days, can-
cellation fee is 50% of total program cost.
Guide Name
English Spanish Portuguese
Media # Media # Media #
Electric Rope Shovel Best Operating Practices Guide PEBJ0109 PSBJ0109 PPBJ0109
Description: This 100 page full-color guide provides the essential “Best Practices” for proper and efficient electric rope shovel operations. It
focuses on recognizing good or poor operating practices and techniques and how they affect machine safety, productivity and component life.
This is a great resource for operators, mining managers and mining supervisors.

SIEMENS ADVANCED IGBT ELECTRICAL TRAINING
NOTICE: All Siemens Courses are currently on hold due to the current situation with COVID-19.
For Siemen’s IGBT Course enrollment: contact Manny Navarette at email: [email protected] or Mark M. Smith at
email: [email protected]

SIEMENS ADVANCED IGBT ELECTRICAL TRAINING
NOTICE: All Siemens Courses are currently on HOLD due to the current situation with COVID-19.
SIEMENS IGBT ADVANCED ELECTRICAL TRAINING (for Air Cooled MRC)
Scope of Class: This 7495 IGBT Electrical Training Course is offered to IGBT Standard Shovel customers. It is assumed that the people in the
class will be familiar with electrical shovels and basic electrical fundamentals. This class introduces the student to the technology as applied on
the standard IGBT shovels
IMPORTANT NOTICE: This Training is included in each machine purchase and includes slots for four (4) students. A minimum of 4 students
must be enrolled for a class to be held. If the mining customer opts to split the 4 students between multiple trainings, there is no guarantee
that the class can be held at the requested time. Other participants will be sought to fill the remaining open training slots, but If the minimum
of 4 cannot be reached, the class must be postponed until such time as the minimum number of participants can be met.
ATTENDEES MUST BE EMPLOYEE OF MINE SITE, NO CONTRACTORS OR CONSULTANTS
Location: Siemens Alpharetta, 100 Technology Drive, Alpharetta GA, USA
Class Length: 5 days Monday – Friday Class Size: Max 10, Min 4
Languages: English or Spanish
Classes in a language other than English require a minimum of two months notice to Siemens to ensure instructor availability
Registration: Registration is on a first come, first served basis
NO ONSITE TRAINING ALLOWED. All training will take place at Siemens’ Alpharetta site
IMPORTANT INFORMATION:
* Registration: Registration is on a first come, first served basis
* DO NOT just show up for class as there is minimum enrollment requirement. If not met, the class will be cancelled.
* Purchase order is due within 14 days of registration, or with registration if registering within 14 days
* Purchase order should be made out to Caterpillar Global Mining in South Milwaukee WI
* All courses and materials are in English or Spanish. Translator responsibility of purchaser.
* 4 student MINIMUM, 10 maximum
* Cut off for registration is 21 days prior
* Cancellation Fee paid attendance – up to 21 days 0%, 21 days or less incl. no show 100%
* Cancellation if against machine – up to 21 days prior 0%, less than 21 days seat marked as utilized
For additional information or to request a quote, please contact:
- Manny Navarette at email: [email protected] or
- Mark M. Smith at email: [email protected]

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July – Sept

Important Note for Caterpillar Workday Users Only :

For all ERS Operator Training / Operator

Electric Rope Shovel Product Support 2

Electric Rope Shovel Product Support 3

providing customer-centric learning solutions.

The Electric Rope Shovel Technical Training Team is

Please email us feedback or requests for future

Electric Rope Shovel Product Support 4

Where does your dealership stand?

Electric Rope Shovel Product Support 5

Click on the course to be sent to the Workday learning page.

Interactive Overload Relief Schematic Diagrams — 15 Minutes (NEW!)

Reading HydraCrowd™ Schematics — 15 Minutes (NEW!)

7495 HydraCrowd™ Service Procedures—Part 2 — Minutes (Updated)

7495 HydraCrowd™ Inspection and Service Schedule — Part 2 — Minutes (Updated)

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Descripción General de los Components y del Sistema 7495 HydraCrowd 41663

Procedimientos de Servicio de 7495 HydraCrowd: Parte 1 41871

SPANISH Remoción y Reemplazo de los Components de 7495 HydraCrowd 40935

7495 SIBAS 44353

Módulo de Entrenamiento de Control Mejorado de Movimientos de 7495 44939

Pala Electrica—Repaso General del Sistema de Mando Electrico 56254

Descripción General de la Pala de Cuerda Electrica 40748

“Someday, when I grow up…”

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Nevertheless, instructor-led training could be delivered to customers based

7495 ERS Electrical Systems Level II

This is an excellent achievement for the ERS team.

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Free Electronic Download or Order copies through catpublications.com

This is a GREAT resource for

Electric Rope Shovel Product Support 9

DIG IN! PAGE

SKILLS FOR ROPE CROWD & HYDRACROWD TECHNICIANS 12

SKILLS FOR ROPE CROWD TECHNICIANS 17

SKILLS FOR HYDRACROWD TECHNICIANS 22

SKILLS FOR ERS REBUILD TECHNICIANS 30

SKILLS FOR ELECTRICAL ERS TECHNICIANS 32

Electric Rope Shovel Product Support 10

Electric Rope Shovel Product Support 11

Electric Rope Shovel Product Support 12

 DPC# Duration WORKDAY COURSE NAME PAGE

40748 01:00 Electric Rope Shovel Overview 39

40236 01:00 7495 Electric Rope Shovel Lubrication (Electrical Support) 44

41230 01:30 7495 Series Electric Rope Shovel Lubrication 39

42745 00:45 7495 Electric Rope Shovel Lower Works—Level 1 38

- - TO BE DEVELOPED—7495 ERS Compressed Air System

INSTRUCTOR TECHNICAL TRAINING PACKAGES (ITTP’s)

 DPC# Duration WORKDAY COURSE NAME PAGE

- - TO BE DEVELOPED—7495 ERS Compressed Air System (Operation Theory, System Trouble-

RECOMMENDED CORE TRAINING

Electrical Hazards Fasteners

Crane Operator Hand Signals Workshop Tools

Communication Skills Lockout/Tagout Procedures

Electric Rope Shovel Product Support 13

41867 00:30 7495 Series Electric Rope Shovel Couplings Training 39

41807 01:00 7495 Series Electric Rope Shovel Brakes Training 39

42745 00:45 7495 Electric Rope Shovel Lower Works—Level 1 38