Cat Electric Rope Shovel 495HD Mining Shovel Operator’s Manual - PDF DOWNLOAD

BI617167

SN: 141254 Manual

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Bucyrus International, Inc. 1100 Milwaukee Ave.• P.O.Box 500 • South Milwaukee, Wisconsin 53172-0500 USA

BI617167

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10648

Aug. 2008

BI617167

Bucyrus International, Inc. 495HD Electric Mining Shovel

DANGER: THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/ OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.

DANGER: DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY. The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.

THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between the machine and the ground. The portable trail cable and power lines supplying electric energy to the machine must have a ground wire, ample in capacity, running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult your local electrical supplier for details.

DANGER: DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.

Aug. 2008

Manual No. 10648

BI617167

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10648

Aug. 2008

BI617167

Bucyrus International, Inc. 495HD Electric Mining Shovel

495HD Electric Mining Shovel Operator’s Manual Manual No. 10648 sn: 141254 Lot 102

Always refer to the safety information in this manual before starting any maintenance procedure on this machine.

Table of Contents 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 Aug. 2008

Bucyrus International, Inc. All Rights Reserved.

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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

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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

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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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495HD Electric Mining Shovel Operator’s Manual

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.

Periodic additions or revisions may be made to this manual. 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, USA Telephone (414)-768-4000

53172-0500

It is the policy of Bucyrus International, Inc. to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations 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.

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SAFETY The safety alert symbols displayed here and throughout this manual, are used to call your attention to instructions concerning your 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.

In the event you question your ability 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/or damage to the front-end of the machine.

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

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SAFETY - SWINGING RESTRAINT & BALLAST BOX SUPPORT

BALLAST BOX SUPPORT Before performing any maintenance on the mining shovel, it should be resting on a firm, level surface.

Any mining shovel field work that requires the removal or lowering of the boom must incorporate additional support of the ballast box. The supports may be wooden cribbing or steel structures. Two supports positioned side-by-side on level ground are recommended. These supports are intended to accept vertical loads only. To prevent machine rotation use the swing brakes, cable stays, welded ties, etc. Refer to SWING RESTRAINT in this section of the manual.

When electric-powered, cable-style mining shovels are properly ballasted and operational, the center of gravity for the machine's upper works lies within the roller circle area. This assumes that the boom is attached to the machine and in its elevated, working position. As such, the machine should not be prone to tipping.

Boom removal or lowering will cause the center of gravity to shift toward the ballast box, decreasing machine stability. Stability is further dependent on the orientation of the upper works relative to the undercarriage. The machine may tip more easily over one of the four quadrants of the crawler mounting than it may over others.

Normally the machine is more likely to tip over the rear-most lower-roller than over the side of a crawler. Therefore, with the boom removed and the ballast box sitting over the rear of the crawlers, the machine may be unstable. Because ballast quantities differ from machine to machine and model to model, it is recommended that the ballast box be supported before beginning any procedure to lower and/or remove the boom.

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SWINGING RESTRAINT Before performing any maintenance on the mining shovel, it should be resting on a firm, level surface. A small ground slope is enough to cause the machine to freely rotate if the brakes are not set or other restraints are not used. Once moving, it will keep going.

The following shows the relation between an out-of-level or slope and the resulting difference in elevation over a 14 ft. swing rack:

Slope

%

Difference in Elevation

0.25o

0.4%

0.75”

1.0o

1.7%

2.9”

5.0o

8.7%

14.7”

Where possible, all work on the swing brakes, motors, gearcases, or rack pinions should occur with the dipper attached to the machine and the full weight of the dipper on the ground. If the dipper is not resting firmly on the ground, then an external means of preventing machine upper works rotation is required. Tie the upper works to the lower works using the preferred method mentioned below.

Mining shovels rotate using multiple swing units. Power is transferred from electric motors through individual gearcases, to pinions and into a fixed swing rack. Electric motor control prevents inadvertent machine rotation during operation. Should machine electric power be lost, spring-set brakes on the swing drive motors lock the geartrain to prevent machine rotation.

When working on the brakes, motors, or geartrains, it is an accepted practice to set the dipper on the ground. The weight of the dipper and handle will prevent machine rotation. EVEN IF ALL BRAKES, MOTORS, AND OR SWING GEARCASES ARE REMOVED, the machine should not rotate.

In certain circumstances it may not be possible to rest the full weight of the dipper firmly on the ground. For instance, the dipper, handle or the boom may not be attached to the machine.

To prevent machine rotation, with any of the major structures removed, two swing motor brakes should be set. A single brake in good operational condition is acceptable. However, a minimum of two brakes is recommended due to the possibility that the proper operation of a single brake may be unknown.

Caution:

Manual No. 10648

ON MACHINES USING PLANETARY DUAL-OUTPUT SWING DRIVES, BOTH SWING PINIONS PER DRIVE MUST BE ENGAGED WITH THE SWING RACK IN ORDER FOR THE SWING BRAKE TO BE EFFECTIVE. The internal differential drive in the gearcase allows one pinion to rotate, even if the brake is set, when the other pinion has been removed.

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An external means of preventing machine rotation must be used - if the dipper is not resting firmly on the ground and if any of the following are true: •

Two brakes are not effectively set and coupled to the motors, or

•

The motors and geartrain are not fully coupled to the swing pinions, or

•

The swing pinions are not engaged to the swing rack

The preferred method to prevent machine rotation is to use a pair of one inch diameter steel cables to tie the upper works to the lower works. Other alternatives such as welded plates etc. can also be used.

To use the steel cables, attach one end of each cable to the bottom surface of the revolving frame.

Attach the other end of each cable to the top surface of the truck frame. This arrangement will prevent relative motion between the revolving frame and the truck frame. Installation of these cable restraints should become a part of the lockout procedure if conditions so warrant.

For typical part numbers and locating dimensions, refer to Bucyrus drawing E021447

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SAFETY PRECAUTIONS

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 man 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 is 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 them 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.

• Use extreme caution when working around drilled holes.

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Maintenance Precautions: • Do not wear rings, wristwatches or loose fitting clothing when working on machinery. They could get caught on moving parts causing serious injury.

• Always wear a safety belt or harness when the danger of falling exists.

• Always have a second person to monitor the lifeline when working in confined spaces.

• Do not start an engine indoors unless adequate exhaust ventilators are provided and in operation.

• Never use the machine air or hydraulic systems for support when working on the machine.

Deactivate or isolate the entire system prior to performing maintenance.

• Equipment should be parked on level ground at all times during machine servicing and periods of idleness.

• Cranes and hoists must be of sufficient capacity to lift the heavier components (gearcases, pipe arms, etc.) Always work within the limitations of the equipment being utilized.

• Be sure heavy items are properly rigged and supported from cranes or hoists before removing supporting members from the machine.

• Utilize guide lines or ropes to minimize the swing of suspended heavy components.

• Have sufficient service personnel available when removing or installing large heavy items to maintain control at all times.

• Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load, they could fail.

• When disassembling a machine, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.

• When using an oxy/acetylene torch, always wear welding goggles and gloves. Keep a charged fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart.

• Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Always be sure to wear safety glasses.

• Use extreme caution when using compressed air to dry parts. Use approved air blowguns, do not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding to protect everyone in the work area.

• Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

• Protective eye goggles should be worn at all times when working on the air conditioning system.

Work on the air conditioning system only in a well ventilated area.

• Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.

• Always wear approved rubber gloves and use insulated hooks or tongs when handling trail cable.

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Operating Precautions: • Wear hearing protection when exposed to the following noise levels in excess of the period indicated: 8 hours at 90 dBa 4 hours at 95 dBa 2 hours at 100 dBa 1 hour at 105 dBa 30 minutes at 110 dBa 15 minutes at 115 dBa • When in doubt about the noise level, wear approved hearing protection.

• Do not attempt to get on or off the machine while it is in operation. Notify the operator prior to any attempt to board/exit the machine.

• Do not move or operate the machine without first knowing the location and purpose of all personnel, test or support equipment, on or near the machine.

• Do not allow unauthorized personnel on board the machine while in operation.

• Use audible signals to warn of machine movements. A signal horn button is provided for this purpose.

• Do not propel until the travel route has been cleared of obstructions.

• Do not propel the machine on a slope greater than that specified in SLOPE LIMITATIONS in Section 2 of this manual.

• Prevent trail cable from being dragged on the ground for long distances or at high speeds.

• Limit the amount of cable being pulled by the machine. Pulling too much cable will damage both the cable and the machine.

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FIRE PREVENTION •

Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate.

•

DO NOT smoke while handling flammables or when near batteries.

•

Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque. See Chapter 4 of this manual for the Scheduled Maintenance recommendations and the Daily Inspection procedure.

Fire Extinguisher Locations

•

Repair or replace loose or damaged lines, tubes and hoses as soon as possible.

•

Make certain all clamps, guards and shields are replaced correctly so as to prevent vibration and the chafing of parts during operation.

•

DO NOT carry flammable fluids such as gasoline or solvents on board the machine.

•

DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged lines, tubes, or hoses. Replace them immediately.

•

DO NOT start the machine or move any of the controls if a warning tag is attached to the controls or the start panel.

•

Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.

•

Keep all structural frame compartments, walkways and work areas clean and free of lubricant residue.

•

NEVER weld, burn, or perform service on the machine alone.

•

If a motor or other component is running hot, shut down the machine until it has cooled and the cause is determined and repaired.

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MACHINE PLACARDS The placards depicted below are mounted on your machine as delivered from Bucyrus International, Inc. These hazard warning placards convey information to operators, maintenance personnel, or anyone who will be on or near the machine. The information is designed to help prevent situations that may result in injury to personnel or damage to the machine.

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Safety & Stored Energy Decals

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MACHINE OVERVIEW The 495HD Electric Mining Shovel is designed and constructed to provide efficient service under the most severe conditions. The machine is built to the highest possible standards and will provide trouble free operation if properly maintained. This section of the manual introduces the machine and its functional capabilities/limitations.

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LOWER WORKS The lower works is comprised of the truck frame, right and left crawler frames, crawler belts, propel machinery, swing rack, roller circle and collector ring system.

Truck Frame and Crawlers

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CRAWLERS The machine is provided with a crawler type mounting composed of two belts, one on each side of the truck frame. Each belt consists of links driven by a sprocket type drive tumbler. Individual crawler links are heavy alloy steel castings connected by heat treated pins.

Innovative drive tumblers made from large diameter steel castings have lugs extending beyond the tumbler rims. They are mounted on forged alloy steel shafts that turn on large anti-friction bearings mounted within the crawler frame. The sprocket type lugs provide a large area of contact against the crawler links, extending the life of both links and tumblers.

Upper and lower rollers rotate on forged steel shafts cantilever mounted from the crawler side frames for ease of maintenance and inspection. Four (4) 55" (1.39m) diameter lower rollers per frame are specially suited to withstand the periodic single point ground reaction caused by uneven pit floors. Teepee style dirt deflectors combined with vee-ring face seals prevent dirt entry into lower roller bushings. Five upper rollers on each frame support the upper crawler belt, reducing propel friction and drag. These side frames are stress relieved weldments comprised of steel castings and cold weather steel plates.

The hook surface on the inner lower edge of the crawler frame engages a rail on the bottom of the truck frame. Both parts are factory machined to ensure solid contact.

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Cast take-up tumblers are mounted on each end of the take-up axle. These tumblers are fitted with manganese-bronze bushings protected by a sealed hubcap. A vee-ring face seal protects the take-up bushing from dirt contamination.

A square take-up axle fits into rectangular slots in the crawler frame which permits the axle to be moved forward and backward for belt adjustment. Shims are inserted fore and aft of the axle in these slots to position, tension and locate the tumbler and crawler belt.

Crawler & Truck Frame Section View

TRUCK FRAME The truck frame is a stress relieved welded cellular box structure which utilizes impact resistant steel in the major load carrying members. The low temperature toughness of the steel assures adequate strength and durability across a wide range of temperatures frequently encountered in machine applications. A fabricated support structure welded integrally into the truck frame supports the center pintle hub area.

The inner diameter of the hub is machined to accept the center pintle bushing. Truck frame surfaces which mate to crawler side frames and swing rack are shop machined to assure proper alignment and solid foundation.

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SWING RACK The swing rack is a large diameter external tooth gear mounted on the top of the truck frame concentric with the center pintle bore. The rack is constructed of a one-piece forged steel rim welded to a cast support core and welded to the truck frame during erection.

Swing Rack and Roller Circle

ROLLER CIRCLE The roller circle is comprised of upper and lower rails, 56 tapered rollers and inner/outer roller frames. Lower rail segments are secured to the top surface of the swing rack forming a continuous rolling path for the rollers. Upper rails attach to the bottom of the revolving frame, fore and aft of the center pintle. Upper rail ends are tapered to provide a smooth approach for the rollers. Rollers are tapered to ensure non-skid contact with rails. The rollers are spaced and aligned with pins and low maintenance polyurethane bushings.

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Roller Circle Assembly

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PROPEL MACHINERY The propel machinery is driven by two AC motors, each horizontally mounted to a shelf, cantilevered off the truck frame. The motors are coupled to twin planetary gearcases high up off the pit floor for protection from water and rock damage. The planetary gearcases bolt to the crawler frames. One low-inertia, spring-set, air-released, disc-type air brake is mounted to each of the two motors. The dual planetary configuration with separate drive motors permits straight ahead or reverse propel as well as counter rotation steering.

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COLLECTOR RINGS High voltage collector rings, on bottom of the revolving frame, transfer electric power from the truck frame to the rotating deck. Electric power enters the truck frame just below the propel motor and is transferred by means of collector ring shoes to the collector rings. The shoes are mounted between the cast center pintle hub and the swing rack.

ROTATING DECK The rotating deck consists of revolving frame, center pintle, right and left deck extensions, operator’s cab and the machinery house. Also included are the electrical system components, operating controls, air system, A-frame, along with the hoist, swing and crowd machinery units.

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REVOLVING FRAME The revolving frame is the main structural member of the rotating deck. It is a welded, stress relieved structure with integral lugs for mounting the Aframe, crowd machinery and boom. Provisions are made for mounting deck extensions, operator’s cab, ballast box and swing gearcases. Machined pads on the deck locate hoist drive motor and machinery frames.

The revolving frame is connected to the truck frame by the center pintle.

CENTER PINTLE

The center pintle is a large diameter, hollow, cylindrical forging and threaded at the bottom. A bronze coated steel core spherical thrust washer between the lower retaining nut with dual lockbars, and the bottom surface of the truck frame provides a wear surface for pintle loads. The top of the center pintle is doweled and bolted to the revolving frame using a split clamping collar.

The hollow pintle provides passage for air and grease lines and electrical cables from the revolving frame to the lower works. This is done by means of a swivel and collector ring assembly.

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DECK EXTENSIONS Right and left side deck extensions are bolted to each side of the revolving frame. They provide a mounting area for the electrical transformers and accessory machinery as well as supporting the machinery house walls.

Deck Extensions and Ballast Box - Plan View

BALLAST BOX The ballast box is an all-welded steel fabrication located at the rear of the main revolving frame. A series of vertical plates in the box form compartments for holding ballast.

MACHINERY HOUSE The machinery house encloses the revolving frame, ballast box and deck extensions. It is constructed of self-supporting steel panels with built-in framing. Removable roof sections are provided over the swing machinery and to the side and rear of the A-frame. The house also provides mounting for the air ventilation and pressurization system. A separate electrical room is located over the ballast box. Platforms and stairs facilitate access to the sides and tops of the house for inspection and maintenance purposes. A right-hand pivoting boarding stair and left-hand side boarding ladder permit easy access onto the machine.

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VERTICAL BOARDING LADDER, LEFT The vertical boarding ladder is one of the means for boarding the machine, located on the left-hand side of the machine, at the rear of the machinery house. Use the pull chord from ground level to lower the ladder. When the boarding ladder is not latched in place, the operator's controls are deactivated.

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The ladder is a movable structure with a bracket and two rollers at four locations on the ladder. The rollers straddle a rail on each side of the ladder frame. Wire ropes (one on each side of the ladder) connect to the top of the ladder, pass up through sheaves and down to a counterweight inside each side of the ladder mounting frame.

The ladder should be in the UP position when at rest, with the weight of the counterweights holding it in place. If not, or if rough action is noted, check for binding in the rail structure, damaged or missing rollers, or binding with the counterweights.

Periodically check for lubricant in the sheaves at the top of the ladder.

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BOARDING STAIRS A set of boarding stairs is attached to the machinery house platform - either on the left side of the machine, the right side or both. When lowered, the stairs allow entrance to the machinery house from ground level. To activate the stairs, a chord attached to a lever arm is reachable from the ground. An additional lever is available at the top of the stairs. These stairs must be in their raised and latched position to enable the operator’s controls.

DANGER:

STORED ENERGY! System may be under hydraulic pressure which can cause severe personal injury or death. Shut down pump and relieve system of all pressure before removing components.

The boarding stairs pivot about a pivot shaft attached to the boarding platform. A set of counterweights offsets the weight of the stairs. A self-contained hydraulic system, with an accumulator and cylinder, operates the stairs.

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A-FRAME An A-frame with seamless tubular alloy steel front legs provides ample space for the retracted dipper handle end. The rear legs are cold weather steel fabricated beams. Both front and rear legs are pin connected to lugs integral with the revolving frame. The A-frame supports the boom via structural strands.

A- Frame and Front End Support Components

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HOIST MACHINERY The hoist machinery consists of a motor coupled to two gear reductions which drive the hoist drum. A spring set, air released plate disc type brake is mounted to the motor. A hoist rotary encoder limits hoist travel. The hoist motor is connected to the motor pinion shaft by a gear tooth coupling.

The first reduction gear set is mounted in an oil lubricated, totally enclosed gearcase. The second reduction gears are drip lubricated with open gear lubricant from the automatic lubrication system.

All shafts run on anti-friction bearings. The hoist bull gear is bolted to a spider on the left hand side of the drum.

The hoist drum is manufactured with machined, flame hardened rope grooves. Drum spider stub shafts turn on anti-friction bearings supported by side frames which are bolted to the rotating deck.

Hoist Machinery - Plan View

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SWING MACHINERY Two planetary swing gearboxes, each driven by a vertically mounted motor, are mounted on either side of the revolving frame. Dual output shafts from each gearbox are splined to pinions which engage the swing rack.

Swing Machinery Components

Bolt-on mounting permits easy field exchange or replacement of either the planetary gearboxes or the splined pinions. Check the magnetic plug in each gearcase at each scheduled maintenance.

The four pinions result in lower shared tooth loads for longer pinion and rack life. A spring set air released plate disc brake is mounted on each of the two swing motors.

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CROWD MACHINERY The crowd machinery, located at the front center of the revolving frame, consists of motor, brake, drum and gearing. A crowd rotary encoder prevents overtravel of the dipper handle. This is done by setting the limits on the panel view screen. Locating the crowd machinery on the revolving frame, instead of the boom, substantially reduces front end weight resulting in lower swing inertia and reduced required swing effort. The entire machinery unit can be removed from the machine should maintenance or overhaul become necessary.

Crowd Machinery Components

The crowd drum drives the crowd and retract rope system. Rope grooves are machined and flame hardened. The crowd and retract ropes are attached to the drum by ferrule-becket anchors which greatly simplifies rope changes.

A spring set, air released plate disc type crowd brake is mounted on the electric drive motor.

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OPERATOR’S CAB The isolated and elevated operator’s cab at the right hand front of the machinery house provides a comfortable, safe and efficient working environment for the operator. Sufficient space is provided for the fully adjustable operator’s seat, the standard operator’s display panel, and two storage lockers.

The cab is sound and heat insulated with interior walls made of a sound deadening steel-plasticsteel composite. A one-piece front window is supplied in a rugged, easy-to-change frame. A forward front window slant with over hanging roof helps keep the window clean. Transparent sun shades are provided in front and side windows.

Visibility through both side and front windows is excellent. The operator has the best view in the industry of the digging face and for truck spotting. This view is enhanced by the streamlined sides and top surfaces of the boom, unencumbered by crowd machinery or dipper handles on the outside of the boom.

The air conditioner and pressurizing unit utilizes environmentally friendly 134a refrigerant in the cooling system. Interior ducting distributes the airflow to best suit the comfort of the operator.

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COMPRESSED AIR SYSTEM The compressed air system consists of a rotary screw type air compressor, air receiver, controls and center pintle air swivel. Hydraulic high pressure hose is used throughout. The air system is used to operate all brakes and lubrication components and to perform various other functions.

AUTOMATIC LUBRICATION SYSTEM The lube system is located in an insulated, double wall, lube room which can be heated for cold weather operation. A one ton (907 kg) monorail-mounted electric chain hoist is provided to be used to raise supplies from the ground onto the left house platform and into the lube room. Lube points on the electric motors, suspension rope pins and some dipper pins are manually accessed. All other lube points are fed from the automatic system or by oil bath.

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A single line type automatic lubrication system applies open gear lubricant (OGL) and grease via a programmable logic controller (PLC). The system has six lube pumps (four for OGL and two for grease), each feeding individual PLC controlled circuits. Lincoln Powermaster Four (75) to (1) air powered pumps are mounted on two reservoirs; one 100 gallon and one 200 gallon. High pressure hoses with reusable fittings are utilized.

Lubrication Room

The six separately controlled lube circuits provide selective distribution frequency and quantity resulting in reduced lubricant usage and cost.

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FRONT END EQUIPMENT The front end equipment consists of the boom, boom point sheaves, padlock, saddle block, dipper handle, dipper, dipper trip mechanisms, running ropes and boom suspension strands.

SUSPENSION STRANDS The suspension strands are designed to maintain the proper 43 degree boom angle. These are fixed-length strands that support the entire weight of the boom and the load.

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BOOM The boom is a welded steel structure consisting of twin box girders integrally connected at the boom point and in the lower section between the shipper shaft and boom feet. Impact resistant steel is utilized, coupled with 100% penetration and UT quality welds on all main splice joints.

Design optimization has resulted in heavier outside skin plates, minimizing the need for internal diaphragms. This reduction in weld related stress concentrations further enhances structural life.

Open manholes have been incorporated in the boom as a standard feature permitting periodic structural inspection. Integral “ladders” within the upper boom sections permit internal access without lowering the boom.

Boom Assembly

The boom is supported by four pre-stressed suspension (structural) strands attached to equalizer links on the A-frame. These inherent long life structural strands carry the working loads of the front end equipment. When structural fatigue finally does begin, it can start in the outside layer of wires which will be easily detected by visual inspection. Internal cracks in the suspension strands must be checked by x-ray. A boom limit switch with soft setdown prevents boom jacking shock loads.

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RUNNING ROPES Hoist, crowd, retract and dipper trip ropes are all plastic impregnated for increased life and for sheave and drum grooving life enhancement. The double twin hoist ropes are attached to the center of the hoist drum using ferrule-becket anchoring for faster rope change out. Each rope passes over a boom point sheave through the padlock and back over the boom point sheave to the hoist drum. The dual twin hoist rope configuration stabilizes the dipper while digging by attachment to the outer edges of the dipper body.

Ropes - General Arrangement

Crowd and retract ropes are attached to the crowd drum and work as an integral system. As the crowd rope is wound on to the drum, the retract rope is reeled off.

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SADDLE BLOCK The saddle block, positioned between the boom side girders and pivoting on manganese-bronze bushings about the shipper shaft, acts as a guide for the longitudinal movement of the dipper handle. The free floating design of the handle in the saddle block eliminates handle torsion.

DIPPER HANDLE One end of the 34" (0.86m) diameter handle connects to the dipper. The crowd rope half sheave attaches to the other end. A hydraulic adjustable take-up mechanism at the dipper end is used to remove slack from the crowd/retract rope system. The dipper handle moves in and out within the saddle block.

An electrical rate reduction circuit, along with the crowd ropes, absorb digging shock loads encountered when the dipper is crowded into the bank.

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DIPPER A general purpose dipper is usually constructed as a casting and plate weldment. The dipper lip and lower front are alloy heat treated castings. The dipper body, back, upper sides and door are made of steel plate. Removable Whistler type tooth adapters and replaceable tooth points are attached to the lip casting to penetrate the bank material.

The door is hinged and latched to the dipper body. A dipper trip mechanism controls the release of the latch bar, allowing the door to swing open. The latch bar holds the door shut during digging.

Spring loaded snubbers dampen the door’s swinging action.

Dipper Assembly

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PADLOCK Padlocks connect the hoist ropes to the outer edges of the dipper while still permitting fore and aft and sideways movement.

DIPPER TRIP The dipper trip is a wire rope activated dipper door trip mechanism driven by an electric motor through gear reduction mounted on the boom near the boom foot.

Dipper Trip - General Arrangement

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OPERATOR’S CONTROLS

Location of the Operating Controls

The operator must become familiar with the machine and its operating controls. The preceding figure depicts the general location of controls on the machine.

The operating controls will be grouped as primary and secondary controls, depending upon their location. The primary controls are the controls located in the operator’s cab and the secondary controls are the controls located in the machinery house.

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Operator’s Cab

The descriptions listed should familiarize the operator with each control’s location and functional use. The terms left, right, forward and reverse indicate directions with the operator seated in the cab, facing forward, with the boom extending over the take-up axle of the crawlers.

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PRIMARY OPERATING CONTROLS

Operator’s Control Consoles in the Cab

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CONTROLS ON THE LEFT CONSOLE LEFT JOYSTICK The Left Joystick controls the crowd/horn/dipper trip and propel. It is the vertical handle mounted on the left console of the operator’s seat. This joystick will spring return to neutral when released.

During normal operation, pushing the joystick forward will extend the dipper handle and dipper into the bank. Pulling the joystick rearward will retract the dipper handle and dipper toward the machine. The neutral position between the crowd and retract functions is defined by a detent that is easily felt. The rate of motion is controlled by varying the distance the joystick is moved from the neutral (center) position. Full forward or full rearward position provides maximum speed to the handle. Moving the joystick to neutral will cause a braking action slowing the crowding or retracting handle. Reversing the joystick will cause the motion to stop and if the joystick is held in this position, it will change the direction of the motion.

With the propel transfer switch in the PROPEL position, pushing the joystick forward will cause the left crawler to move forward. Pulling the joystick to the rear will cause the left crawler to move in the reverse direction. The crowd/retract motion is locked out electrically when the machine is in the propel mode.

Refer to JOYSTICK CONFIGURATION in this section of the manual to view the standard and alternate configurations for the Right and Left Joysticks.

DIPPER TRIP The dipper trip is part of the left joystick function in the standard configuration. Moving the joystick to the right will activate the dipper trip mechanism which releases the dipper door latch. The dipper trip is operational throughout the entire range of the crowd motion.

SIGNAL HORN Moving the Left Joystick (in the standard configuration) to the left will activate the signal horn. The signal horn is operational throughout the entire movement range of the crowd motion.

RADIO The radio supplied with your machine is an AM/FM Stereo radio with the capability to play cassette tapes in the player incorporated. This is a quality piece of sound equipment and will provide long term operation.

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HOIST BRAKE A selector switch used to set or release the Hoist Brake.

CROWD BRAKE A selector switch used to set or release the Crowd Brake.

SWING BRAKE A selector switch used to set or release the Swing Brake.

PROPEL BRAKE A selector switch used to set or release the Propel Brake.

Left Control Console

CLIMATE CONTROL PANEL The Climate Control Panel contains a rheostat controller on the top portion of the panel which is used to tailor the temperature of the air delivered to the operator’s cab within the selected mode of operation.

The Mode switch is provided to set the basic mode of operation for the roof mounted air conditioning/ heater unit.

The Blower Speed switch controls the volume of air being moved by the unit.

WINDSHIELD WIPER SWITCH The windshield wiper switch is located on the Operator Display monitor console at the left of the left operator’s console. It controls the speed of the wipers, as well as the starting and stopping of the wipers.

WINDSHIELD WASHER SWITCH The windshield washer switch is located with the windshield wiper switch on the Operator Display monitor console. It controls the supply to the washer reservoir which powers the washers.

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CONTROLS ON THE RIGHT CONSOLE

RIGHT JOYSTICK The Right Joystick controls the hoist/swing and propel. It is a joystick mounted on the right console of the operator’s seat. The joystick is used to control the hoist, swing and right crawler motions of the machine. The position of the propel transfer switch will determine whether this joystick controls the hoist motion or the crawler motion.

With the propel transfer switch in the dig position, and during normal operation, pushing the joystick forward will lower the dipper. Pulling the joystick to the rear will hoist the dipper. The neutral position between the hoist and lower functions is defined by a detent that is easily felt.

The speed of moving the dipper is controlled by varying the distance the joystick is moved from the neutral (center) position. The full forward or full rearward position provides maximum speed to the dipper. Moving the joystick to neutral will cause a braking action slowing the hoisting or lowering motion. Reversing the joystick will cause the motion to stop and if the joystick is held in this position, it will change the direction of the motion.

NOTE: When the right joystick is used in the hoist/lower mode it is a spring returned switch.

That is, it will return to the neutral position when it is released.

Moving the joystick to the left from the neutral position will cause the machine to swing to the left.

Moving the joystick to the right will cause the machine to rotate to the right. The swing motion is operational throughout the entire movement range of hoisting or lowering the dipper. The swing rate of acceleration is controlled by varying the distance the joystick is moved from the neutral position. Moving the joystick to the neutral position will not stop the swing motion but will allow the machine to coast. To stop or change direction the control joystick is moved past the neutral point in the opposite direction. The rate of deceleration is controlled by varying the distance the joystick is moved from the neutral position in the opposite direction.

Refer to JOYSTICK CONFIGURATION in this section of the manual to view the alternate configurations for the Right and Left Joysticks.

With the propel transfer switch in the propel position, pushing the joystick forward will cause the right crawler to move forward. Pulling the joystick to the rear will cause the right crawler to move in the reverse direction. The hoist motion is locked out electrically when the machine is in the propel mode.

NOTE: When the JOYSTICK is used in the swing mode the switch is a spring returned switch.

That is, it will return to the neutral position when it is released.

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CONTROL STOP PUSHBUTTON The control stop pushbutton is a pushbutton located on the right operator’s console. Normally it is used to de-energize controls after the machine has been safely stopped by placing motion controls in neutral.

Actuation of this pushbutton when motions are running will cause all motions to automatically electrically brake to a stop and, when the motion speed has reached less than 5% speed, set all mechanical brakes. If the motions are already stopped, the brakes will be set and power is removed immediately. A similar switch is located on the front panel of the PLC control cabinet that can be used during testing of the machine.

DANGER:

THE OPERATOR SHOULD NEVER LEAVE THE OPERATOR’S SEAT BEFORE PRESSING THE CONTROL STOP PUSHBUTTON. Setting only the mechanical brakes with individual switches is not a sufficient safeguard to prevent machine damage and/or personnel hazards.

CONTROL RESET PUSHBUTTON CAUTION:

This is not an automatic reset system. All controls must be returned to neutral before the control reset button is pushed.

Right Control Console

The control reset pushbutton is a pushbutton located on the right operator’s console. The reset pushbutton restores control to all motions if no additional faults exist. This pushbutton is inoperative until the main power start control has been actuated.

If a control fault occurs that shuts down a motion, all motions will automatically be shut down together. At this time the operator should set all brakes. If the fault clears, the motion may be reset by pressing this pushbutton. If the fault does not clear, the unfaulted motions can be restarted by pressing this pushbutton to enable these motions to re-position themselves.

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DIG/PROPEL TRANSFER SWITCH The Dig/Propel Transfer Switch is used to switch between the two primary operating modes of the machine. The current mode of operation will be indicated on the Operator’s screen on the Operator’s Display.

IMPORTANT: • WHILE IN THE DIG MODE, THE PROPEL CONTROLS ARE DISABLED. • WHILE IN THE PROPEL MODE, THE DIG CONTROLS ARE DISABLED. The recommended procedure to transfer from dig to propel is to bring all motions to a controlled stop by the operator. Turn the hoist brake switch to the SET position and then press the control stop pushbutton. Turn the transfer switch from DIG to PROPEL. When the indicator on the Operator Display screen indicates that the transfer has been completed, turn the propel brake switch to release.

EMERGENCY STOP PUSHBUTTON The machine stop/emergency stop pushbutton is located on the right operator’s console. It is used to remove power from the machine motions after the motions have been stopped in the normal manner. A second purpose of the pushbutton is to stop the machine under operational emergency conditions. Pushing this button will provide electrical and immediate mechanical braking simultaneously. Therefore, this button should only be used if the operator intends the harshest braking of all motions. If the machine is in motion, power will remain on the motions in order to provide electrical braking for a few seconds. If the machine is in motion or stopped, this button will power the DC bus to approximately zero voltage quickly after the time delay.

CAUTION:

PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY RESULT IN COMPONENT DAMAGE.

A second pushbutton that also provides the functions as described above is located in the remote start console and is labeled “machine stop.”

MAIN POWER OFF PUSHBUTTON The main power off pushbutton is located on the right operator’s console. It is used only to immediately remove power from the drives in case of an electrical emergency involving component failure or fire.

CAUTION:

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PUSHING THE “POWER OFF” PUSHBUTTON WHILE IN MOTION WILL IMMEDIATELY SET THE MECHANICAL BRAKES AND REMOVE INCOMING HIGH VOLTAGE FROM THE DRIVES. THIS ACTION MAY RESULT IN COMPONENT DAMAGE. It will also result in the inability to power the DC bus voltage down to a low value. This voltage will decay slowly, taking several minutes.

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EARTH CONTINUITY LOCKOUT PUSHBUTTON The earth continuity lockout pushbutton is used to trip the breaker that supplies power to the machine.

When the machine is operating, this pushbutton should be used to shutdown the machine only when removal of power to the machine is required.

TELEPHONE A telephone is located at the rear of the right control console. This telephone is connected to other phone stations throughout the machine.

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OPERATOR’S SEAT

Operator’s Seat - Front View

The operator’s seat has been selected to provide a maximum of operator comfort along with easy control access for increased productivity. The seat has numerous adjustments allowing it to be tailored to meet the individual needs of each operator.

Weight Adjustment The seat should be adjusted for the operator’s weight by pulling the actuator lever of the automatic weight and height adjuster while the operator is sitting in the seat and the machine is stationary.

Height Adjustment The seat height is adjusted pneumatically by pulling or pressing the adjustment lever as required to obtain the position required. DO NOT operate the compressor unit for more that 1 minute continuously.

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Seat Cushion Angle Adjustment The angle of the seat cushion can be adjusted individually from the back. Lift the handle and exert pressure in the desired direction while seated. Release handle once the required position is achieved.

Seat Depth Adjustment The depth of the seat pan can be individually adjusted. Lift the handle and slide the seat pan forward or backwards to position. Release the handle when the desired position is obtained.

Armrest Adjustment The armrests can be adjusted to fit the individual needs of each operator or folded up and placed out of the way.

To adjust the armrest height loosen the manual friction knobs on the outboard side of the armrest allowing the armrests to pivot. Move the armrest to any desired position within its range and retighten when desired.

To raise the arm rests; lift at front and stow vertically.

Headrest Adjustment The headrest can easily be adjusted by lifting, or tilting, headrest to the desired position.

Lumbar Support The curvature of the backrest can be adjusted pneumatically by pressing the switches on the lower left rear of the backrest.

Backrest Adjustment The backrest is adjusted by lifting the lever and then releasing once the desired position is obtained.

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OPERATOR’S DISPLAY A PC based Operator’s Display is used to provide the operator with an interface to the machine and its functional areas. From this informational display the operator can make inputs that affect machine operation, monitor systems and make system adjustments. Through this display terminal the operator will receive pertinent fault data to identify potential problems and prevent machine damage.

Operator’s Display Panel

The display panel is mounted on an arm assembly protruding from a pedestal on the right side of the operator. The arm allows individual operators to locate the screen in any desired position. The monitor screen can be rotated along the horizontal and vertical axes.

DISPLAY AREA AND INDICATORS The display area of the monitor screen is the large area in the center of the screen. This area is “touch sensitive.” All information will be displayed on this area in either a text format or in the form of visual icons. The buttons and icons that appear on the screen will respond to touching the screen in the appropriate area of the icon.

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These icons and buttons will react by activating the screen, switch activation or display information relevant to the icon.

All the machine controls can be found on the Operator’s Display Panel touch sensitive screen or the left and right Control Consoles of the operator’s seat.

DISPLAY SCREENS The Title Screen display appears when the machine is initially started.

Title Screen

The information provided in the central area of the screen is machine specific.

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Language Screen

This screen allows the language used on the screens to be reset.

Icon Screen

This screen displays the icons used throughout all the screens in the system.

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Active Alarm

The Active Alarm screen will provide a list of all active alarms and faults that have been initiated on the machine and have not been RESET. Once an alarm or fault has been sensed, these messages will remain visible and WILL NOT be removed from this screen until it is RESET.

New Alarm

When a new alarm occurs, it shows up in a separate window on the top of any screen. It is cleared when there are no active alarms, the user goes to one of the other alarm screens, or the user presses the X next to the line.

NOTE: It is important to remember that messages will appear in this screen that are no longer active alarm messages. All messages will appear since the time of the last reset.

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Alarms Help

The Alarms Help screen can be reached from any of the alarm message screens at any time. This screen will provide clarifying information related to the alarm system on your machine.

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Rope Reeving/Pintle Tightening

The Rope Reeving/Pintle tightening screen is selected in order to make adjustments to the center pintle or change any of the main machine wire ropes. This screen will become active in the pintle tightening mode. If rope reeving is the desired intent, a selection must be made at the buttons in the lower left of the display area.

NOTE: Before switching between different modes of operation the Disable Selected Mode button should be pressed.

Switches for the activation/release of the hoist, crowd and swing brakes are provided, along with condition indicators displayed below the brake switches. This screen assists in the correct wrapping of the ropes on drums and allows full control of drum movements.

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Rope Reeving/Pintle Tightening Help

This screen will provide clarifying information on the reeving of ropes and pintle tightening.

Calibration Limits

The Calibration screen is used to set the various limits required to control the movements of the machine.

On this screen can be found switches for the hoist, crowd and swing brakes along with status indicators for each.

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Limit Calibration Help

This screen will provide clarifying information on the calibration process.

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Fault Counters/Operating Hours

The Fault Counter/Operating Hours screen provides the operator with information on the number of faults that have occurred since last RESET. It also provides the total operating hours.

PLC Menu Screen

This screen will activate further screens which are used to monitor various racks within the PLC cabinets.

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Typical Bearing Temperature Screen

Operator’s Screen

The Operator’s Screen is the primary operational information tool to be visible to the machine operator during daily use of this machine. The controls available on this screen will provide the operator with the information needed to view “at a glance” the status of items required for digging and make changes in control settings.

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AUXILIARY CONTROLS

REMOTE START CONSOLE The remote start panel is located on the right side of the machine just inside the machinery house door. The panel contains the following switches and indicator lights used to initially start the machine: Phase Sequence Light This green indicator light, when lit, indicates that incoming power sequence is correct. If the light is OFF, have electrical maintenance change the trail cable phase sequence.

Drive Cabinets Temperature Light This green indicator light, when lit, indicates that the drive electronic cabinets are at the correct operating temperature. Too low or too high cabinet temperatures will not allow the machine to start.

PLC Power On Light This green indicator light, when lit, indicates that PLC and drive control power is on. This light should be lit about 20 seconds after the UPS mg set is started.

System Ready Light This green indicator light, when lit, indicates the system is ready to start. When the system run pushbutton is pressed and the system successfully started, this light will go out.

Auxiliary Ground Fault Light This green indicator light, when lit, indicates that no auxiliary power ground fault exists. If the light is OFF, alert an electrician as soon as possible.

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Incomplete Sequence Light This red indicator light, when lit, indicates the automatic start-up sequence did not complete in a preset time period. Have an electrician troubleshoot the sequence. If this indicator does not light up, the start-up sequence is progressing properly and machine start-up can continue.

System Run Pushbutton This pushbutton will energize the drive system when pressed if the system ready light is on.

Air Compressor Start/Stop Pushbuttons The air compressor start and stop pushbuttons are used to control the auxiliary air compressor.

The stop pushbutton is only used for complete machine shutdown or when maintenance is being performed on the air compressor.

HOUSE LIGHT CIRCUIT BREAKERS The house light circuit breakers are located on the right side wall of the machinery house next to the remote start console. A main light circuit breaker is located on the auxiliary control cabinet. The breakers protect the lights from over-current loads.

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LIGHTING TRANSFER SWITCH

The lighting transfer switch is located on the right side wall of the machinery house near the lighting control center. This switch is used to transfer power for lighting from on machine source to off machine source.

LUBRICATION CONTROL PANEL The top row on this panel consists of a group of indicating lights. A red light indicating that the system has a fault and a green light indicating that power for the system is provided for each independent lubricating system (A, B & C). Isolating switches are used to provide power to each system and a means of isolating each system from electrical power. They are also used to reset lubrication faults. These switches are normally on. Manual lube buttons are also provided.

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PRE-START CHECKS Before starting, inspect the machine to ensure it is ready to be put into operation. Failure to make such a routine check could result in unnecessary downtime. For example: an undetected oil leak could result in a dry gearcase, eventually leading to excessive gear wear or destruction, seized bearings or other mechanical problems. Broken strands in the hoist ropes, crowd rope, retract rope or structural strands could, if undetected, result in serious injury or damage to the machine or haulage unit. A few minutes spent inspecting the machine often results in considerable savings in time and machine efficiency. Section 4 of this manual contains reproducible checklists to assist in record keeping and ensure that adequate inspection standards are met.

WALKAROUND GROUND LEVEL INSPECTION Check the following areas daily during a general walkaround inspection: 1.

Check the areas under and around the crawlers for signs of oil leaks. If single droplets are noticed, leakage is minimal. Determine the point of leakage and make a note of it on the log sheet. If pooling of oil is noticed, determine the source and take corrective action immediately.

Determine if loose hardware, a defective gasket, a combination of both, or a similar problem is responsible. Tighten hardware or replace defective gaskets.

2.

Inspect the crawler belts for missing links or lock pins, excessive belt sag, cracked shoes or other deterioration. Check the oil level in the propel planetary gearcase. Add oil as required.

3.

Check the swing rack and pinion guards for rocks, dirt and other debris that will interfere with the operation of the machine. Inspect the swing rack gear and rollers for the proper lubricant film.

DANGER:

HIGH VOLTAGE! THE MACHINE TRAIL CABLE CARRIES A LETHAL VOLTAGE. Handle the cable in an approved manner with appropriate rubber gloves and insulated hooks or tongs.

4.

Visually inspect the trail cable for cuts, abrasions and other damage.

5.

Visually inspect exterior of machinery house for damage or evidence of internal leakage.

6.

Inspect the dipper trip mechanism, rope, latch bar and associated hardware for damage, adjustment and wear.

7.

Inspect the dipper door, hardware and bumpers for damage and excessive wear.

8.

Inspect fulcrum attachment points, take up cylinders and spacers, and dipper handle for damage, excessive wear and evidence of adequate lubrication.

9.

Inspect boom bumper for security and damage.

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10.

Inspect the dipper and tooth adapters for tightness and excessive wear.

11.

Inspect padlocks for damage, wear and evidence of adequate lubrication.

12.

Check both the running ropes and the boom structural strands for broken strands and loose sockets.

ON-BOARD INSPECTION Check the following areas daily on board the machine: 1.

Visually inspect the swing, crowd and hoist gearcases for oil levels and leaks. Repair or service as required.

2.

Visually inspect all machinery for loose bolts, nuts, clamps or unusual deterioration. Repair as required.

3.

Visually inspect the open gears of the swing, crowd and hoist machinery for proper lubricant film and evidence of adequate lubrication from the automatic lubricant dispensing system.

4.

Visually inspect hoist and crowd ropes for wear, lubrication and evidence of birdcaging near the drum attachment beckets.

5.

Check the oil level in the air compressor. Add oil if required.

6.

Check lubricant supply level in the air system lubricator and lube system lubricators.

7.

Inspect the automatic lubrication central pumping stations for any signs of malfunctioning.

Check the lubricant supply and refill tanks if required.

8.

Visually inspect swing, crowd and hoist brake assemblies for damage, wear and evidence of an overheated condition.

9.

Check the operator’s cab for cleanliness and visual condition of controls and location of special equipment that may be required by the mine site. Check all operating controls for freedom of movement. Controls should move freely without binding.

10.

Clean windows of operator’s cab.

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11.

Inspect all walkways and stairways to ensure there are no obstructions or fluids creating a safety hazard.

12.

Ensure ladder(s), steps and/or man basket are raised and properly stowed.

13.

Perform the following manual lubrication points: Crowd Cushion Sheave .............. OGL - 1 Fitting Padlock Pins ............................... OGL - 6 Fittings Dipper Pins ................................. OGL - 2 Fittings Dipper Trip Rope Guide Roller .... OGL - 1 Fitting Latch Lever Sleeve ..................... OGL - 1 Fitting Structural Strand Pins ................. OGL - 4 Fittings Hoist Rope Roller Bushings ....... MPG - 4 Fittings

NOTE: Detailed information on the proper servicing of these components can be found in Sections 3 and 4 of this manual.

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MACHINE START-UP, OPERATION AND SHUTDOWN START-UP Whether starting the machine for the first time, or starting after the machine has been in service for some time, the procedures are essentially the same.

1.

Perform all pre-start checks listed in PRE-START CHECKS in this section of the manual.

2.

Raise the boarding stair, making sure it is secured in the raised position. The limit switch at the top of the stair will not close and the controls will not energize if the stair is not in the fullyraised position.

Start-Up Control Locations

3.

In the operator’s cab check that all brake switches are in the SET position and that the joysticks are in the neutral position. Then go to the electrical room at the rear of the machinery house.

4.

At the AC control cabinet verify that the uninterruptable breaker is in the ON position. At the motor control cabinet, verify that all breakers are in the ON position.

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5.

At the remote starting console in the machinery house, use the following sequence to start the machine: a.

Verify that the green AUXILIARY GROUND FAULT light is lit.

CAUTION:

b.

IF THE AUXILIARY GROUND FAULT LIGHT IS OFF, ALERT AN ELECTRICIAN AS SOON AS POSSIBLE. The machine may be operated with one fault but a second fault could cause damage to the machine and/or become a safety hazard. The fault should be cleared as soon as possible.

Verify that the green PHASE SEQUENCE light is lit. This indicates that the incoming power sequence is correct. If not, the light will be out and the machine will not start.

Electrical maintenance personnel must correct the problem.

NOTE: This PHASE SEQUENCE light also indicates auxiliary power phase unbalance, phase loss or under-voltage. Any of these faults occurring while the machine is running will produce an alarm. In the event of such an alarm an electrician should be notified, however the machine may be operated.

6.

c.

Verify that the PLC and drive cabinets’ green temperature lights are lit. If the cabinet temperature is too low or too high, the machine cannot be started.

d.

Press the UNINTERRUPTABLE POWER SUPPLY on pushbutton. A second start pushbutton is located on the UPS control cabinet.

e.

Verify that the green PLC POWER ON light is lit. This light should be on about 20 seconds after the UPS motor is started.

f.

Turn the AIR COMPRESSOR RUN switch to the run position or press the start pushbutton.

g.

Verify that the green SYSTEM READY light is lit.

h.

Press the SYSTEM RUN pushbutton. When this button is pressed, the system ready light will go out and the drive system will automatically power up.

i.

Verify that the red INCOMPLETE SEQUENCE light is out. If lit, call the electrician to troubleshoot the sequence.

In the operator’s cab, verify that the air pressure displayed on the operator’s display is correct.

The machine cannot be operated until the air pressure is at the specified rating.

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7.

Verify that the brake switches are in the set position, the joysticks are in the neutral position and the air pressure is at the correct pressure. Sound the signal horn and be sure all personnel are clear of machine.

8.

Turn the propel transfer switch to the DIG position. When the Operator Display lights indicate that the process is complete, press the control reset pushbutton to activate the controls.

9.

Turn the hoist, crowd, swing and propel brake switches to their RELEASED position.

10.

Briefly actuate swing, crowd, hoist and propel controls to make sure each motion is operational.

RESTARTING AFTER AN ELECTRICAL FAULT To restart the machine after the electrical control system has gone into a fault condition, proceed as follows: NOTE: Before any or all motions can be reset, the following conditions must be met: a.

No operator’s monitor special screens should be activated.

b.

For hoist/propel motion the hoist/propel transfer switch is in the position called for by the operator’s mode selector switch.

c.

The joystick for the motion being reset must be in the neutral position.

d.

The motion mechanical brake selector switch must be in the released position.

1.

For hoist or crowd travel limit faults, the motion will first slow down and then will stop, but the controls will remain active. Reversing the joystick will remove the fault and allow continued operation.

2.

For a boom jacking fault, the motion will stop but the controls will remain active. Reversing the left joystick will remove the fault and allow continued operation.

3.

If the boarding ladder is pulled down while the machine is in operation, an alarm message will be sent to the operator and swing and propel motions will be shut down. The hoist and crowd motions will remain active.

Once the ladder is back in position, the motions may be restarted by pressing the control reset pushbutton.

4.

For most other faults, the machine will be shut down and the brakes set. In these situations, the controls cannot be reset until the fault has been corrected by an electrician.

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OPERATION Efficient operation is essentially the result of understanding and applying the basic techniques related to each machine motion, to achieve fast, smooth and safe load cycles. The interrelated coordination of the hoist, swing and crowd motions results in efficient machine operation.

Each motion is described in the following paragraphs. The operator should thoroughly learn each motion, its purpose and how this knowledge can be applied in becoming a better operator.

When learning to handle the operator controls, be sure that all personnel are clear of the machine and that there is ample clearance with no danger spots around the machine, such as culverts, ditches, embankments and that the machine is not too close to the digging face or overhanging ledge and large rocks.

Use the Operator Display panel, in the operator’s cab, to assist in the operation of the machine.

The monitor allows a large number of messages to be sent to the operator from all portions of the control system. These messages fit into four basic categories: 1.

Normal routine operational messages.

2.

Alarm only.

3.

Delayed shutdown messages.

4.

Immediate faults and shutdowns.

This monitor also allows the setting of certain operating parameters for the machine. Refer to OPERATOR’S DISPLAY in this section of the manual for detailed descriptions of the Operator Display monitor screens and how they relate to the proper operation of the machine.

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MACHINERY MOTIONS HOIST MOTION In standard configuration, Hoist motion is controlled by the operator’s right joystick. Set the propel transfer switch in the DIG mode. The crawlers should be positioned so that the digging is done over the front of the crawlers. Move the joystick between hoist and lower until a “feel” is developed for the height, depth range and speed at which the dipper moves. Practice the hoist function until movement can be stopped smoothly.

CAUTION:

NOTE:

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This joystick also controls the swing motion through left and right motions.

The following represents the standard configuration.

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CROWD MOTION In standard configuration, Crowd motion is controlled by the operator’s left joystick. Move the joystick to crowd and retract the dipper handle until a “feel” is developed for the limits and speed of the motion.

CAUTION: NOTE:

This joystick also controls the signal horn and dipper trip.

The following represents the standard configuration.

Practice the crowd and retract functions until the movement can be stopped smoothly. Combine the crowd and hoist functions and practice until smooth coordinated motions and subsequent machine effectiveness are achieved.

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PROPEL MOTION Propel motion is controlled by placing the propel transfer switch in the propel mode and actuating the left or right joystick. To propel in a straight forward direction, push forward on both the left and right joysticks at the same time. The speed is increased as the levers are displaced farther from neutral. To propel straight in reverse, pull equally both joysticks to the rear.

NOTE: The control stop pushbutton must be pressed before the propel transfer switch can be activated.

DANGER:

THE HOIST BRAKE MUST BE SET WHENEVER IN THE PROPEL MODE.

Propel - Straight Forward/Reverse

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SWING MOTION In standard configuration, Swing motion is controlled by the operator’s right joystick. To swing in either direction, move the joystick lever in the direction of swing. Practice swinging in each direction until a “feel” is developed for start-up and stopping.

NOTE: The joy stick also controls the hoisting and lowering of the dipper through forward and backward motions.

DANGER:

Each motion - hoist or swing - is fully operational throughout the complete movement of the other motion.

NOTE: When this joystick is used for propelling the machine, the hoist and swing motions are electrically locked out.

NOTE: The following represents the standard configuration.

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PROPER SWING MOTION Proper swing motion means smooth control and an efficient swing cycle. The swing motion is begun toward the haulage unit when the dipper is filled and is clear of the bank.

DANGER:

EXTENSIVE DAMAGE TO THE DIPPER HANDLE AND DIPPER CAN OCCUR IF THE MACHINE IS ROTATED BEFORE THE DIPPER CLEARS THE BANK.

The swing motion begins with acceleration to an optimum point at which the excavator is brought to a stop over the haulage unit. Maximum efficiency and minimum swing machinery wear are direct results of mastering the swing motion.

NOTE: Improper swing motion results in erratic control and an inefficient swing cycle.

DANGER:

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THE DIPPER SHOULD NEVER BE POSITIONED OVER PERSONNEL, TRAIL CABLES, RELATED ELECTRICAL EQUIPMENT OR OTHER EQUIPMENT. When the dipper is loaded, accidental tripping of the dipper door could result in death or serious injury to personnel and extensive damage to equipment. Empty dippers may contain small fragments of material that can be extremely dangerous when dropped from a considerable height. On long moves open the door on an empty dipper and lower the dipper to a point that permits moving without striking the ground.

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Time is required to accelerate any motion from zero to working speed and also to decelerate from working speed back to zero. THE TIME EXPENDED FOR ACCELERATING AND DECELERATING THE SWING REPRESENTS THE MAJOR PART OF THE ENTIRE DIG CYCLE. Therefore, the swing arcs must be kept to a minimum to obtain maximum operating efficiency. As an example: assuming that a 90° swing results in 100 percent of the maximum output, increasing the swing arc to 180° reduces output to 70 percent, while decreasing the swing arc to 45° increased the output to 126 percent. Therefore, a swing arc of 90° or less should usually be used.

Haul units should be positioned so their center line is approximately under or not more than slightly outside the swing path of the boom point. This substantially reduces the amount of dipper maneuvering required of the operator when positioning the dipper for dumping. Positioning of the haulage unit inside or outside the boom point makes it necessary to retract or crowd the dipper handle and dipper, which breaks the operator’s natural rhythm.

A clean, level pit floor must be maintained. A good operator will always clean the floor before moving into the bank. A clean and level floor grade is a requisite to safe and stable machine operation and reduces damage to crawler links and related components.

DANGER:

“SWEEPING” SHOULD NEVER BE ATTEMPTED WITH THE MACHINE. Sweeping consists of lowering the dipper to the ground and using the swing motion of the machine to move the dipper from side-to-side and “sweep” the pit floor. THE DIPPER, DIPPER HANDLE AND BOOM STRUCTURES CAN BE DAMAGED BY SWEEPING. A bulldozer or loader should be used to help the machine operator maintain a clean pit floor in conjunction with the shovel.

STEERING

To make a gradual forward right turn, move the LEFT joystick (crowd) forward and leave the right joystick (hoist) in neutral.

To make a gradual forward left turn, move the RIGHT joystick (hoist) forward and leave the left joystick (crowd) in neutral.

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Whenever possible, gradual turns should be made in short increments of 15° to 20° maximum.

Propel straight for a short distance (usually 1/2 the length of the crawler belts) to clear the crawler belts of stone and other debris; then make another 15° to 20° turn. Continue until the turn is completed.

NOTE: When steering in soft material such as sand, clay, etc., increments of less than 15° to 20° should be used to minimize material build up on the crawler belt roller path.

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COUNTER-ROTATION TURNS Although possible, a single sharp turn should be avoided to minimize material build up on the crawler belt roller path. This results in high loading of the crawler belt and associated propel components.

To make a sharp right turn, move the LEFT joystick forward and pull the RIGHT joystick to the rear.

To make a sharp left turn, move the RIGHT joystick forward and pull the LEFT joystick to the rear.

CAUTION:

When using the counter-rotation method for turning, have a helper ensure that the trail cable does not get fouled and/or torn from the machine.

NOTE: The ability of the machine to turn sharply is dependent on the surface on which the machine is setting. A soft surface will cause the crawlers to dig-in and machine to bogdown.

CAUTION:

The propel brakes are released when either joystick is moved from neutral. The propel brakes are set when both joysticks are returned to neutral.

When moving the machine in a straight line, propel forward, which is in the direction of the take-up axle to reduce strain on the crawler belts and propel mechanism. When not possible and propelling to the rear, make sure the trail cable is clear of the machine and follow the signals given by the helper. The machine should be rotated in a position to allow the operator to face the direction of travel.

NOTE: Turning when propelling to the rear requires that the master control be positioned in a direction opposite the actual direction in which the turn takes place.

The machine should be moved close to the bank in short and frequent moves to maintain digging efficiency. Movement should occur between the loadings of haul units.

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POSITIONING THE MACHINE There are two basic methods for positioning the machine at the working face of the bank: the “back-up method” and the “drive-by method”. Both methods are acceptable and effective.

BACK-UP METHOD When using the back-up method, position the machine at the bank with the front of the machine facing the digging face. The haul units are spotted on both sides of the machine. The bank can be excavated until a 180° circular area of material has been removed from the bank. Once the material is removed, a 90° or greater swing will be required in order to load the haul units, requiring the machine to be moved.

To reposition the machine, propel to the rear, away from the bank, at an approximate 45° angle to the bank. When the machine is centered in-line with the untouched edge of the previous excavation, propel straight toward the bank and position the machine for further digging.

The back-up method will minimize the swing arc and reduce moving time, produce less bank toe area clean up and simplify handling of the trail cable, cable standard and trail cable boat.

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DRIVE-BY METHOD NOTE: If mine conditions or equipment prevent the use of the following procedures, use the “Back-up Method” instead.

Position the machine crawlers parallel to the bank with the outer set of crawler tracks directly in line with the bank toe.

The haul units must approach the machine from the front, making a turn away from the machine as the unit’s front wheel approaches the outside crawler. Haul units then stop in a position to allow backing toward the point of the bank for loading.

During the load cycle, swing arc is to one side only and should not exceed 90°. The cycle time from one full haul unit to the next empty unit should not exceed the cycle time between successive dipper loads to each unit.

During the load cycle, the swing arc should not exceed 90°. The time between finishing one truck to the first digging cycle of the next should not exceed that of any cycle during a load.

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START OF THE DIG CYCLE

The crowd motion forces the dipper lip into the bank at the start of the digging cycle. It is the crowd thrust which enables the dipper lip and front opening to get into a column of material of sufficient cross section to fill the dipper rapidly.

Force the Dipper Lip into the Bank

There is a direct relationship between crowd depth of bank penetration and the distance the dipper must rise in the bank to fill the dipper. The deeper the “bite” the quicker the dipper will be filled, providing the hoist force is sufficient to cut the column of material. Do not attempt to lift the entire bank with each pass. As soon as the dipper is full, retract it from the bank and swing the machine to fill the truck.

Crowd penetration should be rapid just at the arc of entry and rise as the dipper enters the bank.

This will permit as much digging as possible near the base of the bank. This is of particular advantage when digging loose or blasted material. The greater the hoist force and crowd thrust, the faster the dipper filling time of the dig cycle. The crowd thrust should be maintained to hold the dipper in the bank while it is being hoisted. An added benefit of proper crowd thrust and hoist force is that the opposing vertical resistance of the bank material tends to have a “ramming” effect in the dipper front opening, minimizing voids and producing larger dipper loads.

It is important that the full cutting surface of the dipper contact the bank on each pass. A full face cut combined with deep bank penetration will result in a full dipper for the least amount of hoist. A partial cut, even with deep bank penetration, requires a greater rise and tends to leave voids in the dipper, requiring additional passes to fill the haulage unit.

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Shallow bank penetration of the arc of entry and rise is ineffective and inefficient. A shaving cut dribbles material into the dipper resulting in voids and making additional passes necessary while accelerating dipper lip wear.

NOTE: A Deeper Bite = Quicker Fill Times

Digging should take place under the boom point for maximum shovel effectiveness. If necessary, the machine should be moved closer to the bank face, rather than extending the dipper handle.

Reaching for material results in a partially filled dipper and excessive crowd and retract time. Use caution not to damage the boom point sheaves when operating close to the high wall.

Variations on Dipper Penetration

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Overcrowding with the dipper lowered can result in lifting the boom. This jacking action can result in damaged components.

Overcrowding the dipper in the bank slows up the dipper loading process, thereby reducing machine efficiency.

Dig with the Dipper Beneath the Boom Point

ENGAGING THE BANK

To make maximum use of the hoist rope pull, the dipper rise should be as close to vertical as possible.

The dipper should enter the bank approximately under and behind the boom point. The actual cut should start a few degrees behind an imaginary vertical line from the front of the boom point sheaves. Proper bank engagement results in maximum hoisting force in line with the cut. When the dipper is too far forward, bank penetration will be minimal and the hoist and crowd forces will oppose each other rather than working together.

Make Effective Use of the Hoist Effort

Dipper capacity rating is the struck measure cubic yard capacity. When digging, a load greater or less than the rated capacity may be obtained, depending on the type of material. An efficient operation can be measured by the number of dipper loads required to load a haulage unit. When the dipper capacity is efficiently sized to the truck capacity, not less than three or more than five dippers full should be required to load a unit. Other factors such as improper sizing of haulage units to dipper, improper material fragmentation, etc., also must be considered.

Hoist Force Opposes Crowd Force

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In all types of digging the skilled operator must carefully control the desired depth of cut and control the hoist power requirements. Often, digging situations are encountered which require hoist and crowd motions to maneuver around oversize or lodged obstructions in the bank, rather than attempting to lift the entire bank.

DANGER:

MAINTAIN A DIGGING FACE WHICH AVOIDS ANY MAJOR SLIDES WHICH COULD CAUSE AN ACCIDENT. Examine the digging face for large boulders, large rocks, or frozen material which could slide and cause an accident. Avoid overhanging material.

Do not repeatedly stall the dipper in the bank, nor maintain a stall condition. The life expectancy of the hoist machinery and hoist ropes is directly related to the operator’s skill in avoiding stalling. Whenever stall conditions are encountered, back off on the hoist motion, retract the dipper, or do both. Avoid stall conditions at all times.

DANGER:

DO NOT SUSPEND A LOADED OR EMPTY DIPPER IN THE AIR WITH THE BRAKES SET FOR LONG TIME PERIODS. Lower the dipper to the ground if the machine is to be idle or unattended for any length of time. Failure to comply can result in personal injury or death of anyone beneath the dipper.

For most efficient production, the dipper should be loaded from the most remote point while waiting for a truck. When the truck is positioned, excavating should begin close to the haulage unit, progressively working away from the unit.

This technique saves time by allowing smooth, short dig cycles and eliminates excessive swing, crowd and retract motions.

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SLOPE LIMITATIONS While it is strongly recommended that the machine dig on level ground for the greatest possible productivity and the longest component life, limited operation on slopes up to 8% is, however; acceptable with only minimal adverse effects.

NOTE: It is important to remember the difference between Slope Percent and Degrees!

Slope vs. Degrees

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Rollover and Operation Limits

EXCAVATED MATERIAL It is important that the operator not only know the controls but recognize other aspects of the mining operation. Chief among these is the type of material to be excavated. It plays a great part in the overall efficiency of the machine.

Materials can be roughly divided into four categories.

1.

EASY DIGGING - This category includes all loose, free-flowing materials, such as sand and gravel deposits, stock pile materials such as finely crushed stone, ore fines, coal fines and any other similar materials. The dipper will usually obtain a heaped load.

2.

MEDIUM DIGGING - This category includes only materials which can be excavated from their natural beds without blasting and which break up in bulk with some voids. Such material includes clay, dry earth, clay-gravel mixtures, gravel with some boulders, certain types of ores and coal. The dipper will usually obtain a full load, with filling augmented by the material’s natural tendency to break apart when it encounters the dipper lip and teeth.

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3.

HARD DIGGING - Included in this category are materials that require blasting, resulting in good fragmentation, but leaving large chunks which develop voids. Limestone, gypsum shale, cemented gravel, wet earth, clay and certain types of ore and overburden all fall within this category. The dipper will average less than a full load because of the resistance of the material against flow and voids due to blocky material

4.

VERY HARD DIGGING - This category includes all materials that require heavy blasting and give irregular fragmentation. Taconite, granite, laminar shale, certain types of limestone and conglomerate overburden fall into this category. The dipper will average considerably less than a full load, because of the large chunks and interlocking action of the material which block fill.

OPERATION CHECKS During machine operation there are several things to consider relative to safe, efficient machine operation.

1.

Check the motors for unusual noise, loss of power or failure to respond to controls.

2.

Check hoist, crowd, swing and propel machinery for unusual sounds and overheating of bearings.

3.

Avoid slack hoist ropes which could allow the ropes to become crossed on the drum, or skip a groove.

4.

Check the air gauge frequently and investigate immediately if there is a drop in air pressure.

Correct all air leaks.

5.

When propelling, check the engagement of the drive tumblers on the crawler belt links and adjust the belts to correct any improper alignment.

6.

When operating auxiliary functions, such as steering, note any tendency of the controls to jam or hang up. Check and correct any problems at the earliest opportunity.

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OPERATING HINTS The following hints are reminders of the do’s and don’ts related to excavator operation: • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Engage the bank properly.

Load with the successive pass technique.

Maintain a clean pit floor.

Use proper hoist control.

Make effective use of the hoist pull.

Use proper crowd control.

Force the dipper lip into the bank at the arc of entry.

Crowd the dipper into the bank for deep penetration.

Make full face cuts for faster loading cycles.

Dig under the boom point.

Make smooth, safe swing cycles.

Keep swing arcs within 90°.

“Spot” the haulage units properly.

Keep the working faces free of projections.

Propel forward whenever possible rather than backward.

Move up to the bank frequently.

Dig over the take-up axle end of the crawlers whenever possible.

Make gradual turns when propelling.

Do not suspend a loaded dipper for an extended time.

Do not operate too close to material.

Do not operate with missing dipper teeth.

Do not stall hoist or crowd motions.

Do not reach for material.

Do not reach for haulage units.

Do not overcrowd and jack the boom or machine.

Do not make partial face cuts.

Do not make shallow bank penetration.

Do not make erratic swings.

Do not swing until dipper is clear of the bank.

Do not swing loaded or unloaded dippers over personnel or equipment.

Do not “sweep” pit floor.

Do not make sharp turns when propelling.

Do not make long inefficient moves.

Do not exceed swing arc of 90°.

Do not spot haulage units inside or outside the boom point swing arc.

Maintain adequate clearance between digging face and point sheaves.

Do not allow the dipper to contact the crawler belts.

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STOPPING THE MACHINE 1.

Return left and right joysticks to their center positions and set all brake switches.

2.

After all motions are stopped and brakes are set, press the CONTROL STOP pushbutton.

This action will remove power to the control units and set the brakes. The controls will become inoperative.

3.

To stop the machine completely and remove power from the drives, press the MACHINE STOP Pushbutton on the right operator’s console.

MACHINE SHUTDOWN When shutting down the machine at the end of a shift proceed as follows: 1.

Park the machine on firm ground in a position where it cannot be damaged by a slide, falling rocks or flooding. In cold climates, be sure the crawler belts will not freeze into the ground.

2.

Place the dipper firmly on the ground.

3.

Make sure left and right joysticks are in their center positions.

4.

Make sure all brake switches are in their SET positions.

5.

Press the CONTROL STOP pushbutton. All primary controls should be de-energized.

6.

To de-energize the DC bus, press the MACHINE STOP pushbutton on the remote start console or the MACHINE STOP/EMERGENCY STOP pushbutton on the operator’s console.

7.

Place the air compressor switch on the remote start console in the STOP position.

8.

Close all windows in the cab and lock all cab doors.

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TYPICAL MACHINE SPECIFICATIONS This specification describes the principal mechanical features of a standard Bucyrus International, Inc. 495HD Acutrol controlled machine. The machine is fully revolving, crawler mounted, and equipped to operate from an alternating current power source.

WEIGHTS

Working Weight (w/Dipper) Dipper (40 yd3, 30 m3) Ballast Shipping Weight

(pounds)

(kilograms)

2,695,000 132,700 607,500 2,087,000

1,222,431 60,200 275,557 946,647

Front End Equipment Boom Boom Point Sheaves Boom Point Sheave Diameter Shipper Shaft Sheaves Shipper Shaft Sheave Diameter Dipper Handle Diameter Dipper Handle Wall Thickness

Welded, Impact Resistant Steel Twin Grooved, Flame Hardened 96" 243.84cm Twin Grooved, Flame Hardened 72" 182.88cm 34" 86.36cm 2.5" (nominal) 6.35 cm

Rope Data Hoist Crowd Retract Dipper Trip Boom Suspension

Manual No. 10648

# Ropes

Diameter

Type

2 1 1 1 4

2 3/4" 2 1/2" 2 1/2" 5/8" 3 1/4"

Twin Dual 6X37 Single Dual 6X37 Single Dual 6X37 Single 6X37 Equalized Structural

92

69.88mm 63.5mm 63.5mm 15.9mm 82.6mm

Constr.

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Typical Dimensions and Working Ranges US

Dipper Capacity (nominal) ............................................. 53 yd3 Dipper Capacities (range) ......................................... 40-80 yd3 Length of Boom ................................................................... 67' Boom Angle ......................................................................... 43o Effective Length of Dipper Handle ................................... 35’10" Overall Length of Dipper Handle ........................................... 47' A: Dumping Height .......................................................... 34’4" B: Dumping Height at Maximum Radius ......................... 28’3" C: Radius of Level Floor ................................................. 50"6 D: Maximum Dumping Radius ........................................ 66’9" E: Maximum Cutting Height ............................................ 58’3" F: Maximum Cutting Radius ........................................... 78’2" G: Maximum Depth below Ground Level .......................... 10’6" H: Clearance Height @ Boom Point Sheaves .................. 67’0" I: Clearance Radius @ Revolving Frame ........................ 29’7" J: Clearance Radius (Rev. Frame to Ground) .................. 11’4" K: Height of A-Frame ...................................................... 44’4" L: Overall Machine Width ............................................... 42’8" M: Ground Clearance (Lowest point of Truck Frame) .......... 22" N: Operator’s Cab Eye Level ........................................... 29’0"

Metric

48 m3 30.6-61.2 m3 20.4m 10.92 m 14.32 m 10.46 m 8.61 m 15.39 m 20.34 m 17.76 m 23.82 m 3.20 m 20.42 m 9.01 m 3.45 m 13.51 m 13.00 m 0.56 m 8.84 m

D H

BUCYRUS

G C 495HD

K

acutrol

N

A1

A

J I

mdim495HD

E B

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GENERAL ESTIMATED COMPONENT WEIGHTS CAUTION:

These are estimated weights only. Contact your Bucyrus International service representative for the exact weight of components on your specific machine before rigging and lifting.

Quantity

Weight Each (U.S. Pounds)

Lower Works Truck Frame ..................................................... 1 ............... 127,300 Pintle Bushing ................................................... 1 ...................... 300 Lower Rail ....................................................... 12 ..................... 220 Propel Brake Adapter ........................................ 2 ...................... 400 Propel Brake, Tach Drive .................................. 2 ................... 1,230 Propel Brake Hub ............................................. 2 ........................ 60 Propel Motor ..................................................... 2 ................... 4,500 Propel Motor Blower ......................................... 2 ...................... 210 Propel Brake Guard, Welded ............................ 2 ........................ 60 Collector Ring Assembly (Propel) ..................... 1 ...................... 230 Crawler Belt (84 in.) .......................................... 2 ............... 240,000 Crawler Link (84 in.) ........................................ 74 .................. 3,100 Crawler Frame Assembly, LH ........................... 1 ................. 67,700 Crawler Frame Assembly, RH .......................... 1 ................. 67,700 Gearcase, Planetary Propel ............................. 2 ................. 18,100 Drive Tumbler ................................................... 2 ................... 6,930 Drive Tumbler Shaft .......................................... 2 ................... 5,800 Drive Tumbler Bearing ...................................... 2 ................... 1,400 Take-up Tumbler ............................................... 2 ................... 6,400 Take-up Shaft .................................................... 1 ................. 22,650 Take-up Cylinder ............................................... 1 ...................... 100 Take-up Tumbler Hub Cap ................................ 2 ...................... 200 Collar, Take-Up Axle .......................................... 2 ...................... 140 Collar, Roller, Lower ......................................... 8 ...................... 210 Roller Hub Cap, Lower ..................................... 8 ...................... 300 Roller Shaft, Lower ........................................... 8 ................... 4,200 Roller Bushing, Lower ...................................... 8 ...................... 240 Roller, Upper Front ........................................... 2 ...................... 740 Roller Shaft, Upper Front .................................. 2 ...................... 460 Roller, Upper ..................................................... 8 ...................... 620 Shaft, Upper Roller ........................................... 8 ...................... 400 Center Pintle Assembly .................................... 1 ................... 9,900 Center Pintle Sleeve ......................................... 1 ................... 7,900 Thrust Washer, Center Pintle ........................... 1 ...................... 400 Center Pintle Lower Nut .................................... 1 ................... 1,475 Collar, Center Pintle, Upper .............................. 1 ...................... 380 Washer, Thrust, Center Pintle .......................... 1 ...................... 400

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Quantity

Weight Each (U.S. Pounds)

Upper Works Revolving Frame, Weldment ............................ 1 ............... 151,000 A-Frame Front Leg ........................................... 1 ................. 23,000 A-Frame Rear Leg ............................................ 2 ................... 6,700 Dual Winch Assembly, Solid Leg ...................... 1 ................... 3,600 Boom Foot Pin .................................................. 2 ...................... 600 Upper-Center Rail ............................................. 6 ...................... 210 Upper End Rail ................................................. 2 ...................... 140 Planetary Swing Gearcase ............................... 2 ................. 10,600 Swing Brake Adapter ........................................ 2 ...................... 270 Swing Brake ..................................................... 2 ...................... 500 Swing Motor (with or without tach) .................... 1 ................... 3,600 Swing Motor Blower .......................................... 1 ...................... 250 Crowd 2nd Intermediate Shaft .......................... 1 ................... 2,000 Crowd 2nd Intermediate Gear .......................... 1 ................... 2,640 Crowd Motor Shaft Coupling ............................. 1 ...................... 150 Crowd Frame ................................................... 1 ................. 11,500 Crowd Pinion Guard ......................................... 1 ...................... 300 Crowd Gearcase Cover .................................... 1 ................... 2,700 Crowd Gear Guard - Upper .............................. 1 ...................... 170 Crowd Gear Guard - Lower .............................. 1 ...................... 340 Crowd Drum ..................................................... 1 ................. 12,800 Crowd Drum Spur Gear .................................... 1 ................... 5,000 Crowd Pinion, 1st Reduction Shaft ................... 1 ...................... 130 Crowd 1st Intermediate Gear ........................... 1 ................... 1,100 Crowd Brake ..................................................... 1 ...................... 500 Crowd Brake Adapter........................................ 1 ...................... 270 Crowd Motor ..................................................... 1 ................... 4,000 Air Swivel .......................................................... 1 ...................... 150 Swivel Housing ................................................. 1 ...................... 640 Swivel Collector Ring Assembly ....................... 1 ...................... 720 Hoist Planetary Gearcase ................................. 1 ................. 35,500 Hoist Pinion ....................................................... 2 ................... 2,600 Shaft, Pinion ..................................................... 2 ................... 1,640 Roller Bearing ................................................... 2 ...................... 240 Bearing Carrier ................................................. 2 ...................... 500 Bearing Retainer ............................................... 2 ...................... 130 Hoist Gear Guard .............................................. 1 ................... 4,700 Hoist Bearing Housing ...................................... 2 ................... 3,000 Hoist Drum ....................................................... 1 ................. 54,700 Spider, Hoist Drum ........................................... 1 ................. 15,450 Hoist Drum Gear .............................................. 1 ................. 11,000 Hoist Frame - R. H. .......................................... 1 ................... 8,900

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Quantity

Weight Each (U.S. Pounds)

Oil Cooler, Air-Cooled ....................................... 2 ................... 1,750 Hoist Motor........................................................ 1 ................. 15,000 Hoist Brake ....................................................... 1 ................... 1,750 Hoist Brake Adapter .......................................... 1 ...................... 500 Hoist Brake Hub ................................................ 1 ...................... 210 Coupling Gear, Float Shaft ................................ 1 ................... 1,275 Hydraulic Crowd Motor Coupling Assembly ...... 1 ...................... 150 Hoist Motor Coupling Guard .............................. 1 ...................... 300 Hoist Motor Blower ........................................... 1 ...................... 700 Boarding Stairway ............................................. 2 ................... 1,520 Retractable Ladder ........................................... 1 ................... 1,750 Machinery House Filter Assembly ..................... 2 ................... 1,350 Control Room Filter Assembly .......................... 1 ................... 1,350 Front End Boom (Bare) ..................................................... 1 ............... 148,500 Boom Bumper .................................................. 4 ........................ 30 Boom Point Shaft ............................................. 2 ................... 1,040 Boom Point Sheave .......................................... 2 ................... 4,750 Boom Bumper Assembly .................................. 1 ................... 6,630 Dipper Trip Motor .............................................. 1 ...................... 690 Boom Point Sheave Assembly ......................... 2 ................... 6,880 Saddle Block Assembly (W/O Shaft) ................ 1 ................. 15,600 Liner Saddle Block Assembly ........................... 2 ................... 1,300 Shipper Shaft Assembly ................................... 1 ................... 5,110 Collar, Shipper Shaft ......................................... 2 ...................... 120 Crowd / Retract Rope ....................................... 2 ................... 2,100 Hoist Rope .................................................... 1 pair ............... 9,000 Suspension Rope ............................................. 4 ................... 2,800 Pendant Equalizer - R.H & L.H.. ....................... 2 ................... 2,400 Crowd Sheave .................................................. 2 ................... 2,600 Dipper Handle ................................................... 1 ................. 49,300 Handle Weldment ............................................. 1 ................. 16,900 Handle End ....................................................... 1 ................... 4,900 Machined Tube ................................................. 1 ................. 25,750 Retract Rope Take-Up Support ......................... 1 ................... 1,600 Crowd Take-Up Guide ....................................... 1 ................... 2,200 Crowd Take-up Worm Gear Wheel .................. 1 ...................... 610 Crowd Take-up Worm Gear Wheel Housing .... 1 ...................... 450 Crowd Take-Up Screw Rod .............................. 1 ................... 4,520 Crowd Take-Up Sheave .................................... 1 ................... 1,920 Sheave Crowd Cushion Pin ............................. 1 ...................... 250 Take-up Cylinder ............................................... 2 ...................... 150 Take Up Guide .................................................. 1 ...................... 500 Retract Spreader and Front Stop ...................... 1 ................... 2,100

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Quantity

Weight Each (U.S. Pounds)

Dipper Assembly (40yd) ............................................ 1 ............... 132,700 Includes: Dipper Body (w/o Liners) .................................. 1 ................. 81,300 Dipper Body (w/Liners) ..................................... 1 ................. 85,000 Dipper Tooth ..................................................... 9 ...................... 210 Tooth Adapter .................................................... 9 ...................... 830 Tooth Wear Cap ............................................... 9 ........................ 50 Tooth C-Clamp ................................................. 9 ........................ 60 Tooth Wedge .................................................... 9 ........................ 40 Center Shroud .................................................. 8 ...................... 490 Center Shroud Wedge ...................................... 8 ........................ 10 Center Shroud C-Clamp ................................... 8 ........................ 10 Corner Shroud .................................................. 4 ................... 1,240 Pitch Brace Assembly, Fixed ............................ 2 ...................... 900 Snubber Assembly ........................................... 2 ................... 1,800 Pin, Handle ....................................................... 2 ...................... 440 Pin, Pitch Brace ................................................ 4 ...................... 300 Pin, Door .......................................................... 2 ...................... 400 Thrust Washer .................................................. 4 ........................ 40 Dipper Door ...................................................... 1 ................. 20,375 Dipper Door Bumper ........................................ 4 ........................ 10 Latch Lever Pin ................................................. 1 ........................ 40 Latch Bar .......................................................... 1 ................... 1,200 Latch Lever ....................................................... 1 ...................... 490 Padlock, Manganese Bushings, No Lube ......... 2 ................... 5,000 Padlock Pin ....................................................... 2 ...................... 370 Padlock Sheave ................................................ 2 ...................... 620

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