CAT BUCYRUS 495HD MINING SHOVEL MAINTENANCE & OPERATION MANUAL – PDF DOWNLOAD

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CAT BUCYRUS 495HD MINING SHOVEL MAINTENANCE & OPERATION MANUAL – PDF DOWNLOAD

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CAT BUCYRUS 495HD MINING SHOVEL MAINTENANCE & OPERATION MANUAL – PDF DOWNLOAD

Language : English
Pages :106
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT BUCYRUS 495HD MINING SHOVEL MAINTENANCE & OPERATION MANUAL – PDF DOWNLOAD

SN 141167

Operator’s Manual
GENERAL INFORMATION

• This manual is designed to assist the owner in the operation and preventive maintenance of this machine. By following easy to understand step-by-step procedures the operators and maintenance personnel can perform all tasks in a safe manner. It is important to remember that when a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.
• THIS MANUAL IS NOT THE PARTS BOOK and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by group and/or product code numbers with the associated item/part numbers for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed. RIGHT and LEFT refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.
• Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments. Records on each machine are filed by serial number and when given this number, your machine’s specific design and original equipment is accessed quickly by the Bucyrus International parts representative.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT BUCYRUS 495HD MINING SHOVEL MAINTENANCE & OPERATION MANUAL – PDF DOWNLOAD

ENERAL INFORMATION 5
SAFETY 6
SAFETY – SWINGING RESTRAINT & BALLAST BOX SUPPORT 7
BALLAST BOX SUPPORT 7
SWINGING RESTRAINT 8
SAFETY PRECAUTIONS 10
FIRE PREVENTION 13
MACHINE PLACARDS 14
Safety & Stored Energy Decals 15
OPERATION NEAR ELECTRICAL LINES 16
MACHINE OVERVIEW 17
LOWER WORKS 18
Truck Frame and Crawlers 18
CRAWLERS 19
Crawler & Truck Frame Section View 20
TRUCK FRAME 20
SWING RACK 21
Swing Rack and Roller Circle 21
ROLLER CIRCLE 21
Roller Circle Assembly 22
PROPEL MACHINERY 23
COLLECTOR RINGS 24
ROTATING DECK 25
495HD Deck Plan 25
REVOLVING FRAME 26
CENTER PINTLE 26
DECK EXTENSIONS 27
Deck Extensions and Ballast Box – Plan View 27
BALLAST BOX 27
MACHINERY HOUSE 27
VERTICAL BOARDING LADDER 28
BOARDING STAIRS – LEFT 29
A-FRAME 30
A- Frame and Front End Support Components 30
HOIST MACHINERY 31
Hoist Machinery – Plan View 31
SWING MACHINERY 32
Swing Machinery Components 32
CROWD MACHINERY 33
Crowd Machinery Components 33
OPERATOR’S CAB 34
COMPRESSED AIR SYSTEM 35
AUTOMATIC LUBRICATION SYSTEM 35
Lubrication Room 36
FRONT END EQUIPMENT 37
SUSPENSION STRANDS 37
BOOM 38
Boom Assembly 38
RUNNING ROPES 39
Ropes – General Arrangement 39
SADDLE BLOCK 40
DIPPER HANDLE 40
DIPPER 41
Dipper Assembly 41
PADLOCK 42
DIPPER TRIP 42
Dipper Trip – General Arrangement 42
OPERATOR’S CONTROLS 43
Location of the Operating Controls 43
Operator’s Cab 43
PRIMARY OPERATING CONTROLS 44
Operator’s Control Consoles in the Cab 44
CONTROLS ON THE LEFT CONSOLE 45
LEFT MASTER SWITCH 45
DIPPER TRIP 45
SIGNAL HORN 45
HOIST BRAKE 46
CROWD BRAKE 46
SWING BRAKE 46
PROPEL BRAKE 46
Left Control Console 46
CLIMATE CONTROL PANEL 46
WINDSHIELD WIPER SWITCH 46
WINDSHIELD WASHER SWITCH 46
RADIO 46
CONTROLS ON THE RIGHT CONSOLE 47
RIGHT MASTER SWITCH 47
CONTROL STOP PUSHBUTTON 47
CONTROL RESET PUSHBUTTON 48
Right Control Console 48
DIG/PROPEL TRANSFER SWITCH 49
EMERGENCY STOP PUSHBUTTON 49
MAIN POWER OFF PUSHBUTTON 49
EARTH CONTINUITY LOCKOUT PUSHBUTTON 50
TELEPHONE 50
OPERATOR’S SEAT 51
Operator’s Seat – Front View 51
OPERATOR’S DISPLAY 53
Operator’s Display Panel 53
DISPLAY AREA AND INDICATORS 53
DISPLAY SCREENS 54
Title Screen 54
Main Menu 55
Main Menu – Info 55
Active Alarm 56
New Alarm 56
Alarms Help 57
Rope Reeving/Pintle Tightening 58
Rope Reeving/Pintle Tightening Help 59
Calibration Help 60
Fault Counters/Operating Hours 61
PLC Menu Screen 61
Typical Bearing Temperature Screen 62
Operator’s Screen 62
BRAKE INDICATORS 63
TIME/DATE WINDOW 63
CONTROL STATUS INDICATORS 64
LIMIT SLOWDOWN INDICATORS 64
DIG/PROPEL INDICATOR 64
INFORMATIONAL ICONS 65
DELAYED SHUTDOWN INDICATOR 65
ACTIVE ALARMS INDICATOR 65
AIR PRESSURE 65
AUXILIARY CONTROLS 66
REMOTE START CONSOLE 66
HOUSE LIGHT CIRCUIT BREAKERS 67
LIGHTING TRANSFER SWITCH 68
LUBRICATION CONTROL PANEL 68
PRE-START CHECKS 69
WALKAROUND GROUND LEVEL INSPECTION 69
Daily Inspection Points 70
ON-BOARD INSPECTION 71
On Board Inspection Points 71
MACHINE START-UP, OPERATION AND SHUTDOWN 73
START-UP 73
Start-Up Control Locations 73
RESTARTING AFTER AN ELECTRICAL FAULT 75
OPERATION 76
MACHINERY MOTIONS 77
HOIST MOTION 77
CROWD MOTION 78
SWING MOTION 79
PROPEL MOTION 80
Propel – Straight Forward/Reverse 80
PROPER SWING MOTION 81
STEERING 83
SLOPE LIMITATIONS 84
Slope vs Degrees 84
Rollover and Operation Limits 85
COUNTER-ROTATION TURNS 86
POSITIONING THE MACHINE 87
BACK-UP METHOD 87
DRIVE-BY METHOD 88
THE DIG CYCLE 88
Variations on Dipper Penetration 91
EXCAVATED MATERIAL 93
OPERATION CHECKS 94
OPERATING HINTS 95
STOPPING THE MACHINE 96
MACHINE SHUTDOWN 96
TYPICAL MACHINE SPECIFICATIONS 97
GENERAL ESTIMATED COMPONENT WEIGHTS 99

Questions? Email us: [email protected]

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M