Media Media Number: BI643277

Publication Date: 18 May 2015

Special Instruction
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Heavy Duty Hoist Brake Friction Disc Inspection

Electric Rope Shovel

7495 (S/N: ER601176, ER601322, ER601425, ER601440, ER601449,
ER601450, ER601473, ER601474, ER601486, ER601487, ER601488,
ER601519, ER601524)
7495HD (S/N: ER701246)
7495HF (S/N: ER801522)

Introduction

The 7495 Electric Rope Shovel Service Manual, preventive maintenance section, documents the
required hoist brake assembly daily and 500 hour/ monthly checks. This special instruction adds
the requirement for a 3000 service hour maintenance check for the heavy duty hoist brake
assembly to inspect for friction disc spline wear.

Important Safety Information

Do not attempt mechanical or electrical maintenance on this machine without a full

understanding of each component’s operation and function. Components utilizing
electrical power, air pressure, hydraulic pressure and compression or tension springs for
operation must be deactivated and isolated prior to disassembly.

Never service a brake supporting a load. Make sure the Hoist drum will remain in a
secured position. Failure to do so could result in serious injury or death.
 Media Number: BI643277

Friction Disc Inspection Procedure

1. Park the machine on a firm, level work surface.

2. Lower the dipper so it rests flat on the ground. Allow padlocks to rest in the down position
as shown in Illustration 1.

Illustration 1 - Dipper on ground

3. Shut down the machine. Lock out and tag out the operator controls in compliance with
local regulations.

4. Remove the hoist brake guard.

5. Locate the hoist motor brake relay valve. Refer to Illustration 2 – red arrow
for the typical location.

Brake Relay Valve

Illustration 2 - Hoist Motor Brake Relay Valve

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6. Depress and hold the T-shaped pin located on the valve rear to release the brake, as
shown in Illustration 3.

Pin

Illustration 3 - Bypass Pin on Hoist Relay Valve

7. Place a dial indicator at the top dead center (TDC) of the steel core of the friction plate
furthest from the motor (reference Illustration 4). Set the dial indicator reading to zero.

Illustration 4 - Hoist Brake TDC and Front Plate

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8. With a long screwdriver, or a pry bar, lift the friction plate furthest from the hoist motor
(reference Illustration 5) and record the displacement recorded on the dial indicator.

Lift Access Point

Illustration 5 - Friction Disc Orientation

9. If the displacement measurement exceeds .035 inches, replace the friction disc pack in
accordance with Special Instruction BI637610 (Friction Disc Replacement section).

10. If the measurement does not exceed .035 inches, remove the dial indicator and reinstall
the hoist brake guard.

11. Repeat subsequent friction disc assembly inspections at 1000 service hour intervals.

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