SAFETY PRECAUTIONS

CROWD MACHINERY..........................................................................................................29 Crowd Machinery Components ...................................................................................................29 OPERATOR’S CAB..............................................................................................................30 COMPRESSED AIR SYSTEM..............................................................................................31 AUTOMATIC LUBRICATION SYSTEM ..................................................................................31 Lubrication Room .......................................................................................................................32 FRONT END EQUIPMENT.........................................................................................................33 SUSPENSION STRANDS.....................................................................................................33 BOOM...................................................................................................................................34 Boom Assembly ........................................................................................................................34 RUNNING ROPES ................................................................................................................35 Ropes - General Arrangement ....................................................................................................35 SADDLE BLOCK..................................................................................................................36 DIPPER HANDLE.................................................................................................................36 DIPPER.................................................................................................................................37 Dipper Assembly ........................................................................................................................37 PADLOCKS ..........................................................................................................................38 Left and Right Padlocks .............................................................................................................38 DIPPER TRIP........................................................................................................................38 Dipper Trip - General Arrangement .............................................................................................38 TYPICAL MACHINE SPECIFICATIONS .......................................................................................39 GENERAL ESTIMATED COMPONENT WEIGHTS....................................................................41

495HF COLOR DECK PLAN .........................................................................................( foldout )

Section 1 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.

Periodic additions or revisions may be made to this manual. These can be ordered and will be mailed direct to you from the factory. Should you require additional information or factory service assistance contact your regional service representative or:

Bucyrus International, Inc. 1100 Milwaukee Avenue P.O. Box 500 South Milwaukee, Wisconsin 53172-0500, USA Telephone (414)-768-4000 Fax: (414) 768-4210

It is Bucyrus International’s policy to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to it’s machines at any time. This will be without incurred obligation to install such changes on machines sold previously.

Due to this ongoing program of product research and development, some procedures, specifications and parts may be altered in a constant effort to improve our machines.

SAFETY

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 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 Bucyrus service representative or the factory.

The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.

NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken.

CAUTION: This signal word serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to.

DANGER: This signal word denotes an imminently dangerous hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

DANGER: This signal word denotes an imminently dangerous electrical hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

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 eyesight, hearing or reactions.

CAUTION: STORED ENERGY! Components on machine are heavy and removal of pins without proper preparation and precaution can cause serious bodily injury and/ordamage to the front-end of the machine.

Safety must always be paramount!

Consult your supervisor when safety is in doubt.