CAT BUCYRUS 495HD MINING SHOVEL OPERATOR’S MANUAL SN 141254 – PDF DOWNLOAD

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CAT BUCYRUS 495HD MINING SHOVEL OPERATOR’S MANUAL SN 141254 – PDF DOWNLOAD

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CAT BUCYRUS 495HD MINING SHOVEL OPERATOR’S MANUAL SN 141254 – PDF DOWNLOAD

Language : English
Pages : 102
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT BUCYRUS 495HD MINING SHOVEL OPERATOR’S MANUAL SN 141254 – PDF DOWNLOAD

GENERAL INFORMATION

• This manual is designed to assist the owner in the operation 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. When a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.
• Safe operation of the machine minimizes production delays and costly damage to equipment. Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to prevent accidents from occurring and are provided in the interest of all mine personnel. Overall safety depends upon the use of good judgement and the alertness of the entire mining crew.
• Throughout this manual, the use of the terms “LEFT, RIGHT, FRONT, and REAR” refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab. 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 for this purpose.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT BUCYRUS 495HD MINING SHOVEL OPERATOR’S MANUAL SN 141254 – PDF DOWNLOAD

GENERAL INFORMATION 5
SAFETY 6
SAFETY – SWINGING RESTRAINT & BALLAST BOX SUPPORT 7
BALLAST BOX SUPPORT 7
SWINGING RESTRAINT 8
SAFETY PRECAUTIONS 10
FIRE PREVENTION 13
Fire Extinguisher Locations 13
MACHINE PLACARDS 14
Safety & Stored Energy Decals 15
MACHINE OVERVIEW 16
LOWER WORKS 17
Truck Frame and Crawlers 17
CRAWLERS 18
Crawler & Truck Frame Section View 19
TRUCK FRAME 19
SWING RACK 20
Swing Rack and Roller Circle 20
ROLLER CIRCLE 20
Roller Circle Assembly 21
PROPEL MACHINERY 22
COLLECTOR RINGS 23
ROTATING DECK 23
REVOLVING FRAME 24
CENTER PINTLE 24
DECK EXTENSIONS 25
Deck Extensions and Ballast Box – Plan View 25
BALLAST BOX 25
MACHINERY HOUSE 25
IMPORTANT NOTE
This document is protected under applicable copyright laws to the extent available Any
unauthorized and unlawful reproduction, distribution or other use shall be subject to liability
© 2008 Bucyrus International, Inc All Rights Reserved
BI617167
Manual No 10648
495HD Electric Mining Shovel
2 Aug 2008
Bucyrus International, Inc
VERTICAL BOARDING LADDER, LEFT 26
BOARDING STAIRS 28
A-FRAME 29
A- Frame and Front End Support Components 29
HOIST MACHINERY 30
Hoist Machinery – Plan View 30
SWING MACHINERY 31
Swing Machinery Components 31
CROWD MACHINERY 32
Crowd Machinery Components 32
OPERATOR’S CAB 33
COMPRESSED AIR SYSTEM 34
AUTOMATIC LUBRICATION SYSTEM 34
Lubrication Room 35
FRONT END EQUIPMENT 36
SUSPENSION STRANDS 36
BOOM 37
Boom Assembly 37
RUNNING ROPES 38
Ropes – General Arrangement 38
SADDLE BLOCK 39
DIPPER HANDLE 39
DIPPER 40
Dipper Assembly 40
PADLOCK 41
DIPPER TRIP 41
Dipper Trip – General Arrangement 41
OPERATOR’S CONTROLS 42
Location of the Operating Controls 42
Operator’s Cab 43
PRIMARY OPERATING CONTROLS 44
Operator’s Control Consoles in the Cab 44
CONTROLS ON THE LEFT CONSOLE 45
LEFT JOYSTICK 45
DIPPER TRIP 45
SIGNAL HORN 45
RADIO 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
CONTROLS ON THE RIGHT CONSOLE 47
BI617167
Aug 2008
495HD Electric Mining Shovel
3 Manual No 10648
Bucyrus International, Inc
RIGHT JOYSTICK 47
CONTROL STOP PUSHBUTTON 48
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
Language Screen 55
Icon Screen 55
Active Alarm 56
New Alarm 56
Alarms Help 57
Rope Reeving/Pintle Tightening 58
Rope Reeving/Pintle Tightening Help 59
Calibration Limits 59
Limit Calibration Help 60
Fault Counters/Operating Hours 61
PLC Menu Screen 61
Typical Bearing Temperature Screen 62
Operator’s Screen 62
AUXILIARY CONTROLS 63
REMOTE START CONSOLE 63
HOUSE LIGHT CIRCUIT BREAKERS 64
LIGHTING TRANSFER SWITCH 65
LUBRICATION CONTROL PANEL 65
PRE-START CHECKS 66
WALKAROUND GROUND LEVEL INSPECTION 66
ON-BOARD INSPECTION 67
MACHINE START-UP, OPERATION AND SHUTDOWN 69
START-UP 69
Start-Up Control Locations 69
RESTARTING AFTER AN ELECTRICAL FAULT 71
OPERATION 72
MACHINERY MOTIONS 73
HOIST MOTION 73
CROWD MOTION 74
PROPEL MOTION 75
Propel – Straight Forward/Reverse 75
BI617167
Manual No 10648
495HD Electric Mining Shovel
4 Aug 2008
Bucyrus International, Inc
SWING MOTION 76
PROPER SWING MOTION 77
STEERING 78
COUNTER-ROTATION TURNS 80
POSITIONING THE MACHINE 81
BACK-UP METHOD 81
DRIVE-BY METHOD 82
START OF THE DIG CYCLE 83
Force the Dipper Lip into the Bank 83
Variations on Dipper Penetration 84
Dig with the Dipper Beneath the Boom Point 85
ENGAGING THE BANK 85
SLOPE LIMITATIONS 87
Slope vs Degrees 87
Rollover and Operation Limits 88
EXCAVATED MATERIAL 88
OPERATION CHECKS 89
OPERATING HINTS 90
STOPPING THE MACHINE 91
MACHINE SHUTDOWN 91
TYPICAL MACHINE SPECIFICATIONS 92
WEIGHTS 92
GENERAL ESTIMATED COMPONENT WEIGHTS 94

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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