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

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

FILE DETAILS:

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

Language : English
Pages :100
Downloadable : Yes
File Type : PDF

DESCRIPTION:

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

SN: 141157
SN: 141162

• Introduction
  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, the 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 OPERATOR’S MANUAL – 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
WARNING SIGNS AND DECALS 14
Stored Energy Decals 15
MACHINE OVERVIEW 16
LOWER WORKS 17
Truck Frame and Crawlers 17
CRAWLERS 18
Right Crawler Assembly (Left Opposite) 18
TRUCK FRAME 19
SWING RACK 20
Swing Rack and Roller Circle 20
ROLLER CIRCLE 21
Roller Circle Assembly 21
PROPEL MACHINERY 22
COLLECTOR RINGS 23
ROTATING DECK 24
Deck Plan 24
REVOLVING FRAME 25
CENTER PINTLE 25
DECK EXTENSIONS 26
Deck Extensions and Ballast Box 26
BALLAST BOX 26
MACHINERY HOUSE 26
BOARDING STAIRS – RIGHT 27
OWER STEP 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
OPERATION 42
OPERATION NEAR ELECTRICAL LINES 42
OPERATOR’S CONTROLS 44
PRIMARY OPERATING CONTROLS 44
CONTROLS ON THE LEFT CONSOLE 45
LEFT MASTER SWITCH 45
DIPPER TRIP 45
SIGNAL HORN 45
Left Control Console 46
START PUSHBUTTON 47
PLC POWER ON 47
DRIVE CABINET TEMPERATURE 47
INCOMPLETE SEQUENCE 47
SYSTEM READY 47
PHASE SEQUENCE 47
AUXILIARY GROUND FAULT 47
HOIST BRAKE 47
CROWD BRAKE 47
SWING BRAKE 47
BI616921
495HD Electric Mining Shovel
Bucyrus International, Inc
Nov 2004 3 Manual No 10288
PROPEL BRAKE 48
HVAC UNIT SELECTOR 48
TEMPERATURE 48
HVAC SYSTEM CONTROL 48
HVAC FAN SPEED 48
AUXILIARY HEATER 48
CONTROLS ON THE RIGHT CONSOLE 49
RIGHT MASTER SWITCH 49
Right Control Console 50
EMERGENCY STOP PUSHBUTTON 51
WINDSHIELD WIPER SWITCHES 51
CONTROL STOP PUSHBUTTON 51
CONTROL RESET PUSHBUTTON 51
AIR COMPRESSOR 52
DIG/PROPEL TRANSFER SWITCH 52
HEATED MIRRORS 52
MAIN POWER OFF PUSHBUTTON 52
MAN ON GROUND 53
EARTH CONTINUITY LOCKOUT PUSHBUTTON 53
SEAT POSITION 53
RADIO/CASSETTE/CD 53
OPERATOR’S DISPLAY 54
DISPLAY AREA AND INDICATORS 54
DISPLAY SCREENS 55
Title Screen 55
Main Menu 56
Main Menu – Info 56
Active Alarm 57
New Alarm 57
Alarms Help 58
Rope Reeving/Pintle Tightening 59
Rope Reeving/Pintle Tightening Help 60
Calibration Help 61
Fault Counters/Operating Hours 62
PLC Menu Screen 62
Typical Bearing Temperature Screen 63
Operator’s Screen 63
BRAKE INDICATORS 64
TIME/DATE WINDOW 64
CONTROL STATUS INDICATORS 65
LIMIT SLOWDOWN INDICATORS 65
DIG/PROPEL INDICATOR 65
INFORMATIONAL ICONS 66
DELAYED SHUTDOWN INDICATOR 66
ACTIVE ALARMS INDICATOR 66
BI616921
495HD Electric Mining Shovel
Bucyrus International, Inc
Manual No 10288 4 Nov 2004
AIR PRESSURE 66
LUBRICATION CONTROL PANEL 67
FIRE SUPPRESSION SYSTEM 67
PRE-START CHECKS 68
WALK-AROUND GROUND LEVEL INSPECTION 68
ON-BOARD INSPECTION 70
START-UP, OPERATION AND SHUTDOWN 71
MACHINE START-UP 71
RESTARTING AFTER AN ELECTRICAL FAULT 72
MACHINE OPERATION 73
MACHINERY MOTIONS 74
HOIST MOTION 74
CROWD MOTION 75
PROPEL MOTION 76
Propel – Straight Forward/Reverse 76
SWING MOTION 77
PROPER SWING MOTION 78
STEERING 79
COUNTER-ROTATION TURNS 81
POSITIONING THE MACHINE 82
BACK-UP METHOD 82
DRIVE-BY METHOD 83
START OF THE DIG CYCLE 84
Force the Dipper Lip into the Bank 84
Variations on Dipper Penetration 85
Dig with the Dipper Beneath the Boom Point 86
ENGAGING THE BANK 86
SLOPE LIMITATIONS 88
Slope vs Degrees 88
Rollover and Operation Limits 89
EXCAVATED MATERIAL 89
OPERATION CHECKS 90
OPERATING HINTS 91
STOPPING THE MACHINE 92
SHUTDOWN 92
TYPICAL MACHINE SPECIFICATIONS 93
COMPONENT WEIGHTS 95

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