Aug. 2008

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

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 53172-0500 Telephone (414)-768-4000

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.

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.

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.

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:

Difference in Slope % Elevation

0.25o

1.0o

5.0o 0.4% 0.75” 1.7% 2.9” 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: 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.

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

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.

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.

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.