CAT BUCYRUS 495HD Mining Shovel Operator’s Manual BI012100 – PDF DOWNLOAD

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CAT BUCYRUS 495HD Mining Shovel Operator’s Manual BI012100 – PDF DOWNLOAD

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CAT BUCYRUS 495HD Mining Shovel Operator’s Manual BI012100 – PDF DOWNLOAD

Language : English
Pages :128
Downloadable : Yes
File Type : PDF

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CAT BUCYRUS 495HD Mining Shovel Operator’s Manual BI012100 – PDF DOWNLOAD

Safety Symbols

• Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used are safe and correct.
• Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit and free from the influence of alcohol, drugs, or any medications that might impair his/her eyesight, hearing or reactions.
• The safety alert symbols displayed here and throughout this manual are used to call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine.
• Be certain that anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions. If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional service representative or the factory.
• The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.

S.2.1 General Precautions
• The employment of qualified maintenance personnel, through a scheduled
maintenance program, is the best way to minimize machine downtime and maximize
productivity of equipment.
• Keep hands, feet and clothing away from rotating parts.
• Wear a hard hat, safety shoes and protective lenses at all times.
• Replace any and all safety and warning placards if they are defaced or removed from
the machine.
• Think before you act. Carelessness is one luxury the service person cannot afford.
• Excessive or repeated skin contact with sealants or solvents may cause skin irritation.
In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material
and the suggested method of cleanup.
• Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load
could slip off of the hook if they are not functioning properly.
• If a heavy item begins to fall, let it fall, don’t try to catch it.
• Keep your work area organized and clean. Wipe up oil or spills of any kind
immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall,
slipping or tripping.
• Floors, walkways and stairways must be clean and dry. After fluid draining operations
be sure all spillage is cleaned up.
• Electrical cords and wet metal floors make a dangerous combination.
• Regularly inspect for any loose bolts or locking devices and properly secure them.
• Use extreme caution while working near any electrical lines or equipment whether it be
high or low voltage. Never attempt electrical repairs unless you are qualified.
• Check limit switches for proper operation.
• After servicing, be sure all tools, parts or servicing equipment are removed from the
machine and secured in an appropriate storage area.
• Mechanical Brakes are designed for use as static holding brakes only. Use as a motion
(dynamic) brake in emergency situations only.
• Use proper interior and exterior lighting.
• Install and maintain proper grounding and ground fault protection systems.
• Allow electrical inspection and maintenance to be performed only by a qualified
electrician.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT BUCYRUS 495HD Mining Shovel Operator’s Manual BI012100 – PDF DOWNLOAD

Table of Contents............................................  3
Safety.......................................................  9
S.1 Safety Symbols...........................................  9
S.2 Safety Precautions....................................... 11
	S.2.1 General Precautions................................ 12
	S.2.2 Maintenance Precautions............................ 13
	S.2.3 Operating Precautions.............................. 15
	S.2.4 Fire Prevention.................................... 16
	S.2.5 Common Safety Features............................. 17
		S.2.5.1 Mine Signal.................................. 17
		S.2.5.2 Propel Warning Lights........................ 18
		S.2.5.3 Propel Back-up Alarm......................... 19
		S.2.5.4 Emergency Stop Pushbutton.................... 20
		S.2.5.5 Boarding Stairs.............................. 21
		S.2.5.6 Vertical Boarding Ladder..................... 21
S.3 Warning Signs And Decals................................. 22
Introduction................................................. 25
1.1 About This Manual........................................ 25
	1.1.1 Purpose............................................ 25
	1.1.2 Organization....................................... 25
	1.1.3 Terminology........................................ 25
	1.1.4 Revisions.......................................... 26
	1.1.5 Precautions and Disclaimers........................ 26
	1.1.6 Contact............................................ 26
	1.1.7 Swinging Restraint & Ballast Box Support........... 27
		1.1.7.1 Ballast Box Support.......................... 27
	1.1.8 Swinging Restraint................................. 28
1.2 Machine Overview......................................... 30
1.3 Lower Works.............................................. 31
	1.3.1 Crawlers........................................... 32
	1.3.2 Truck Frame........................................ 33
	1.3.3 Swing Rack......................................... 35
	1.3.4 Roller Circle...................................... 36
	1.3.5 Propel Machinery................................... 37
	1.3.6 Collector Rings.................................... 38
1.4 Rotating Deck............................................ 40
	1.4.1 Revolving Frame.................................... 40
	1.4.2 Center Pintle...................................... 40
	1.4.3 Deck Extensions.................................... 42
	1.4.4 Ballast Box........................................ 43
	1.4.5 Machinery House.................................... 43
		1.4.5.1 Vertical Boarding Ladder, Left............... 44
		1.4.5.2 Boarding Stairs.............................. 46
	1.4.6 A-Frame............................................ 47
	1.4.7 Hoist Machinery.................................... 48
	1.4.8 Swing Machinery.................................... 49
	1.4.9 Crowd Machinery.................................... 50
	1.4.10 Operator’s Cab.................................... 51
	1.4.11 Compressed Air System............................. 52
	1.4.12 Automatic Lubrication System...................... 53
1.5 Front End Equipment...................................... 55
	1.5.1 Suspension Strands................................. 55
	1.5.2 Boom............................................... 56
	1.5.3 Running Ropes...................................... 57
	1.5.4 Saddle Block....................................... 58
	1.5.5 Dipper Handle...................................... 59
	1.5.6 Dipper............................................. 60
	1.5.7 Padlocks........................................... 61
	1.5.8 Dipper Trip........................................ 62
Operation.................................................... 63
2.1 General Information...................................... 63
	2.1.1 Operation Near Electrical Lines.................... 63
2.2 Controls................................................. 65
	2.2.1 Primary Operating Controls......................... 66
		2.2.1.1 Controls On The Left Console................. 67
			2.2.1.1.1 Left Joystick.......................... 68
			2.2.1.1.2 Dipper Trip............................ 68
			2.2.1.1.3 Signal Horn............................ 68
			2.2.1.1.4 Radio.................................. 68
			2.2.1.1.5 Hoist Brake............................ 69
			2.2.1.1.6 Crowd Brake............................ 69
			2.2.1.1.7 Swing Brake............................ 69
			2.2.1.1.8 Propel Brake........................... 69
			2.2.1.1.9 Climate Control Panel.................. 69
			2.2.1.1.10 Windshield Wiper Switch............... 69
			2.2.1.1.11 Windshield Washer Switch.............. 69
		2.2.1.2 Controls On The Right Console................ 70
			2.2.1.2.1 Right Joystick......................... 71
			2.2.1.2.2 Control Stop Pushbutton................ 72
			2.2.1.2.3 Control Reset Pushbutton............... 72
			2.2.1.2.4 Dig/propel Transfer Switch............. 72
			2.2.1.2.5 Emergency Stop Pushbutton.............. 73
			2.2.1.2.6 Main Power Off Pushbutton.............. 73
			2.2.1.2.7 Earth Continuity Lockout Pushbutton.... 73
			2.2.1.2.8 Telephone.............................. 73
2.3 Operator’s Seat.......................................... 74
2.4 Operator’s Display....................................... 76
	2.4.1 Display Area and Indicators........................ 77
	2.4.2 Display Screens.................................... 78
2.5 Auxiliary Controls....................................... 87
	2.5.1 Remote Start Panel................................. 87
		2.5.1.1 Phase Sequence Light......................... 87
		2.5.1.2 Drive Cabinets Temperature Light............. 88
		2.5.1.3 PLC Power On Light........................... 88
		2.5.1.4 System Ready Light........................... 88
		2.5.1.5 Auxiliary Ground Fault Light................. 88
		2.5.1.6 Incomplete Sequence Light.................... 88
		2.5.1.7 System Run Pushbutton........................ 88
		2.5.1.8 Air Compressor Start/Stop Pushbuttons........ 88
		2.5.1.9 House Light Circuit Breakers................. 88
		2.5.1.10 Lighting Transfer Switch.................... 89
	2.5.2 Lubrication Control Panel.......................... 90
	2.5.3 Windshield Wipers.................................. 91
	2.5.4 Windshield Washer.................................. 91
Machine Specifications....................................... 93
3.1 Typical Machine Specifications........................... 93
3.2 General Estimated Component Weights...................... 95
	3.2.1 Lower Works........................................ 95
	3.2.2 Upper Works........................................ 97
	3.2.3 Front End.......................................... 99
Machine Operation............................................101
4.1 Pre-start Checks.........................................101
	4.1.1 Walk-around Ground Level Inspection................101
	4.1.2 On-board Inspection................................102
4.2 Start-up, Operation And Shutdown.........................103
	4.2.1 Machine Start-up...................................103
	4.2.2 Restarting After An Electrical Fault...............104
	4.2.3 Machine Operation..................................105
	4.2.4 Machinery Motions..................................105
		4.2.4.1 Hoist Motion.................................105
		4.2.4.2 Crowd Motion.................................107
		4.2.4.3 Propel Motion................................108
		4.2.4.4..............................................109
		4.2.4.5 Swing Motion.................................109
			4.2.4.5.1 Proper Swing Motion....................110
		4.2.4.6 Steering.....................................112
			4.2.4.6.1 Counter-rotation Turns.................113
		4.2.4.7 Positioning the Machine......................115
			4.2.4.7.1 Back-up Method.........................115
			4.2.4.7.2 Drive-by Method........................116
		4.2.4.8 Start Of The Dig Cycle.......................117
		4.2.4.9 Engaging The Bank............................121
		4.2.4.10 Slope Limitations...........................123
	4.2.5 Excavated Material.................................125
	4.2.6 Operation Checks...................................125
	4.2.7 Operating Hints....................................126
	4.2.8 Stopping the Machine...............................127
	4.2.9 Shutdown...........................................127

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