Manual Operación Pala Eléctrica 495hd

BI010672
495HD
MINING SHOVEL
OPERATOR’S MANUAL
SN: 141317
SN: 141319
Manual No. 10758
495HD
141317mc.cdr Pg. 2
141317cl
Bucyrus International, Inc.

1100 Milwaukee Ave. • P.O.Box 500 • South Milwaukee, Wisconsin 53172-0500 USA
BI010672
495HD Electric Mining Shovel
Manual No. 10758 Apr. 2009

BI010672
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.
Apr. 2009 Manual No. 10758

BI010672
Manual No. 10758 Apr. 2009

BI010672

Operator’s Manual
Manual No. 10758
sn: 141317 Lot 118
sn: 141319 Lot 123
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
VERTICAL BOARDING LADDER, LEFT ............................................................................... 26
BOARDING STAIRS .............................................................................................................. 28
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.
© 2009 Bucyrus International, Inc. All Rights Reserved.
Apr. 2009 1 Manual No. 10758

BI010672
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
RIGHT JOYSTICK ..................................................................................................... 47
CONTROL STOP PUSHBUTTON ............................................................................ 48
CONTROL RESET PUSHBUTTON .......................................................................... 48
Right Control Console ....................................................................................................... 48
Manual No. 10758 2 Apr. 2009

BI010672
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
SWING MOTION ............................................................................................................. 76
PROPER SWING MOTION ............................................................................................. 77
STEERING ...................................................................................................................... 78
COUNTER-ROTATION TURNS ...................................................................................... 80
Apr. 2009 3 Manual No. 10758

BI010672
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
Manual No. 10758 4 Apr. 2009

BI010672

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:

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.
Apr. 2009 5 Manual No. 10758

BI010672
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.
Manual No. 10758 6 Apr. 2009

BI010672
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.
Apr. 2009 7 Manual No. 10758

BI010672
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 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: 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.
Manual No. 10758 8 Apr. 2009

BI010672
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
Apr. 2009 9 Manual No. 10758

BI010672
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.
Manual No. 10758 10 Apr. 2009

BI010672
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,
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.
Apr. 2009 11 Manual No. 10758

BI010672
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.
Manual No. 10758 12 Apr. 2009

BI010672
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.
Apr. 2009 13 Manual No. 10758

BI010672
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.
Manual No. 10758 14 Apr. 2009

BI010672
Safety & Stored Energy Decals
Apr. 2009 15 Manual No. 10758

BI010672
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.
Crowd Half
Sheave
Machinery House Suspension Strands
Filters
Electrical Boom
Control Equalizers Point
A-Frame Sheaves
Room
Filter
Operator’s Air Conditioner
Cab
Electrical Shipper Boom
Machinery Shaft
Control House
Room
Saddle Block
Dipper Handle
Retract Rope
Retract Rope
Take-Up
Mechanism
495HD Dipper Trip
Machinery
Pitch Hoist
Snubbers Brace Ropes
Boom
Crowd
Bumper
Machinery Padlocks
Crawler Swing Rack Dipper
Assembly Trip Dipper
Rope
Boarding Dipper
Stair Door
141317_nm
Manual No. 10758 16 Apr. 2009

BI010672
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
Apr. 2009 17 Manual No. 10758

BI010672
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.
Manual No. 10758 18 Apr. 2009

BI010672
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.
Apr. 2009 19 Manual No. 10758

BI010672
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.
Manual No. 10758 20 Apr. 2009

BI010672
Roller Circle Assembly
Apr. 2009 21 Manual No. 10758

BI010672
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.
Manual No. 10758 22 Apr. 2009

BI010672
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.
Apr. 2009 23 Manual No. 10758

BI010672
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 A-
frame, 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.
Manual No. 10758 24 Apr. 2009

BI010672
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.
Apr. 2009 25 Manual No. 10758

BI010672
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.
Manual No. 10758 26 Apr. 2009

BI010672
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.
Apr. 2009 27 Manual No. 10758

BI010672
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.
Manual No. 10758 28 Apr. 2009

BI010672
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
Apr. 2009 29 Manual No. 10758

BI010672
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
Manual No. 10758 30 Apr. 2009

BI010672
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.
Apr. 2009 31 Manual No. 10758

BI010672
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.
Manual No. 10758 32 Apr. 2009

BI010672
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-plastic-
steel 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.
Apr. 2009 33 Manual No. 10758

BI010672
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.
Manual No. 10758 34 Apr. 2009

BI010672
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.
Apr. 2009 35 Manual No. 10758

BI010672
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.
Manual No. 10758 36 Apr. 2009

BI010672
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.
Apr. 2009 37 Manual No. 10758

BI010672
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.
Manual No. 10758 38 Apr. 2009

BI010672
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.
Apr. 2009 39 Manual No. 10758

BI010672
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
Manual No. 10758 40 Apr. 2009

BI010672
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
Apr. 2009 41 Manual No. 10758

BI010672
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.
Manual No. 10758 42 Apr. 2009

BI010672
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.
Apr. 2009 43 Manual No. 10758

BI010672
PRIMARY OPERATING CONTROLS
Operator’s Control Consoles in the Cab
Manual No. 10758 44 Apr. 2009

BI010672
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.
Apr. 2009 45 Manual No. 10758

BI010672
HOIST BRAKE
A selector switch used to set or release

the Hoist Brake.
CROWD BRAKE

the Crowd Brake.
SWING BRAKE

the Swing Brake.
PROPEL BRAKE

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 controls the speed of the wipers, as well as the starting and stopping of
the wipers.
WINDSHIELD WASHER SWITCH
The windshield washer switch controls the supply to the washer reservoir which powers the washers.
Manual No. 10758 46 Apr. 2009

BI010672
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.
Apr. 2009 47 Manual No. 10758

BI010672
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.
Manual No. 10758 48 Apr. 2009

BI010672
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: 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.
Apr. 2009 49 Manual No. 10758

BI010672
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.
Manual No. 10758 50 Apr. 2009

BI010672
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.
Apr. 2009 51 Manual No. 10758

BI010672
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 re-
tighten 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.
Manual No. 10758 52 Apr. 2009

BI010672
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.
Apr. 2009 53 Manual No. 10758

BI010672
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.
Manual No. 10758 54 Apr. 2009

BI010672
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.
Apr. 2009 55 Manual No. 10758

BI010672
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.
Manual No. 10758 56 Apr. 2009

BI010672
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.
Apr. 2009 57 Manual No. 10758

BI010672
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.
Manual No. 10758 58 Apr. 2009

BI010672
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.
Apr. 2009 59 Manual No. 10758

BI010672
Limit Calibration Help
This screen will provide clarifying information on the calibration process.
Manual No. 10758 60 Apr. 2009

BI010672
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.
Apr. 2009 61 Manual No. 10758

BI010672
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.
Manual No. 10758 62 Apr. 2009

BI010672
AUXILIARY CONTROLS
REMOTE START CONSOLE
The remote start panel is located on the right

side of the machine. 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.
Apr. 2009 63 Manual No. 10758

BI010672
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.
Manual No. 10758 64 Apr. 2009

BI010672
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.
Apr. 2009 65 Manual No. 10758

BI010672
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.
Manual No. 10758 66 Apr. 2009

BI010672
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.
Apr. 2009 67 Manual No. 10758

BI010672
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.
Manual No. 10758 68 Apr. 2009

BI010672
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 fully-
raised 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.
Apr. 2009 69 Manual No. 10758

BI010672
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: 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.
b. 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.
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.
6. 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.
Manual No. 10758 70 Apr. 2009

BI010672
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.
Apr. 2009 71 Manual No. 10758

BI010672
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.
Manual No. 10758 72 Apr. 2009

BI010672
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: This joystick also controls the swing motion through left and right
motions.
NOTE: The following represents the standard configuration.
Apr. 2009 73 Manual No. 10758

BI010672
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: This joystick also controls the signal horn and dipper trip.
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.
Manual No. 10758 74 Apr. 2009

BI010672
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
Apr. 2009 75 Manual No. 10758

BI010672
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.
Manual No. 10758 76 Apr. 2009

BI010672
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: 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.
Apr. 2009 77 Manual No. 10758

BI010672
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.
Manual No. 10758 78 Apr. 2009

BI010672
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.
Apr. 2009 79 Manual No. 10758

BI010672
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 bog-
down.
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.
Manual No. 10758 80 Apr. 2009

BI010672
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.
Apr. 2009 81 Manual No. 10758

BI010672
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.
Manual No. 10758 82 Apr. 2009

BI010672
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.
Apr. 2009 83 Manual No. 10758

BI010672
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
Manual No. 10758 84 Apr. 2009

BI010672
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.
Apr. 2009 85 Manual No. 10758

BI010672
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.
Manual No. 10758 86 Apr. 2009

BI010672
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
Apr. 2009 87 Manual No. 10758

BI010672
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.
Manual No. 10758 88 Apr. 2009

BI010672
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.
Apr. 2009 89 Manual No. 10758

BI010672
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.
Manual No. 10758 90 Apr. 2009

BI010672
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.
Apr. 2009 91 Manual No. 10758

BI010672
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
(pounds) (kilograms)
Working Weight (w/Dipper) 2,695,000 1,222,431
Dipper (40 yd3, 30 m3) 132,700 60,200
Ballast 607,500 275,557
Shipping Weight 2,087,000 946,647
Front End Equipment

Boom Welded, Impact Resistant Steel
Boom Point Sheaves Twin Grooved, Flame Hardened
Boom Point Sheave Diameter 96" 243.84cm
Shipper Shaft Sheaves Twin Grooved, Flame Hardened
Shipper Shaft Sheave Diameter 72" 182.88cm
Dipper Handle Diameter 34" 86.36cm
Dipper Handle Wall Thickness 2.5" (nominal) 6.35 cm
Rope Data
# Ropes Diameter Type Constr.
Hoist 2 2 3/4" 69.88mm Twin Dual 6X37
Crowd 1 2 1/2" 63.5mm Single Dual 6X37
Retract 1 2 1/2" 63.5mm Single Dual 6X37
Dipper Trip 1 5/8" 15.9mm Single 6X37
Boom Suspension 4 3 1/4" 82.6mm Equalized Structural
Manual No. 10758 92 Apr. 2009

BI010672
Typical Dimensions and Working Ranges

US Metric
Dipper Capacity (nominal) ............................................. 54 yd3 41.2 m3
Dipper Capacities (range) ......................................... 40-80 yd3 30.6-61.2 m3
Length of Boom ................................................................... 67' 20.4m
Boom Angle ......................................................................... 43o
Effective Length of Dipper Handle ................................... 35’10" 10.92 m
Overall Length of Dipper Handle ........................................... 47' 14.32 m
A: Dumping Height .......................................................... 34’4" 10.46 m
B: Dumping Height at Maximum Radius ......................... 28’3" 8.61 m
C: Radius of Level Floor ................................................. 50"6 15.39 m
D: Maximum Dumping Radius ........................................ 66’9" 20.34 m
E: Maximum Cutting Height ............................................ 58’3" 17.76 m
F: Maximum Cutting Radius ........................................... 78’2" 23.82 m
G: Maximum Depth below Ground Level .......................... 10’6" 3.20 m
H: Clearance Height @ Boom Point Sheaves .................. 67’0" 20.42 m
I: Clearance Radius @ Revolving Frame ........................ 29’7" 9.01 m
J: Clearance Radius (Rev. Frame to Ground) .................. 11’4" 3.45 m
K: Height of A-Frame ...................................................... 44’4" 13.51 m
L: Overall Machine Width ............................................... 42’8" 13.00 m
M: Ground Clearance (Lowest point of Truck Frame) .......... 22" 0.56 m
N: Operator’s Cab Eye Level ........................................... 29’0" 8.84 m
D
H
BUCYRUS
G
C
495HD
K acutrol
N A
A1
mdim495HD
I E
B
Apr. 2009 93 Manual No. 10758

BI010672
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
Manual No. 10758 94 Apr. 2009

BI010672

(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
Apr. 2009 95 Manual No. 10758

BI010672

(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
Manual No. 10758 96 Apr. 2009

BI010672

(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
Apr. 2009 97 Manual No. 10758

BI010672
Manual No. 10758 98 Apr. 2009

Manual Operación Pala Eléctrica 495hd

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Manual Operación Pala Eléctrica 495hd

Încărcat de

Drepturi de autor:

Formate disponibile

BI010672

Bucyrus International, Inc.

Bucyrus International, Inc.

495HD Electric Mining Shovel

Manual No. 10758 Apr. 2009

Bucyrus International, Inc.

495HD Electric Mining Shovel

DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE

DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE

Apr. 2009 Manual No. 10758

Bucyrus International, Inc.

495HD Electric Mining Shovel

Manual No. 10758 Apr. 2009

Bucyrus International, Inc.

495HD Electric Mining Shovel

495HD Electric Mining Shovel

GENERAL INFORMATION ............................................................................................................ 5

Apr. 2009 1 Manual No. 10758

Bucyrus International, Inc.

495HD Electric Mining Shovel

Manual No. 10758 2 Apr. 2009

Bucyrus International, Inc.

495HD Electric Mining Shovel

DIG/PROPEL TRANSFER SWITCH ............................................................................... 49

Apr. 2009 3 Manual No. 10758

Bucyrus International, Inc.

495HD Electric Mining Shovel

POSITIONING THE MACHINE .................................................................................................... 81

Manual No. 10758 4 Apr. 2009

Bucyrus International, Inc.

495HD Electric Mining Shovel

495HD Electric Mining Shovel

Bucyrus International, Inc.

Apr. 2009 5 Manual No. 10758

Bucyrus International, Inc.

495HD Electric Mining Shovel

CAUTION: This signal word serves as a reminder of safety practices, or directs

DANGER: This signal word denotes an imminently dangerous electrical hazard

CAUTION: STORED ENERGY! Components on machine are heavy and removal

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

Manual No. 10758 6 Apr. 2009

Bucyrus International, Inc.

495HD Electric Mining Shovel

SAFETY - SWINGING RESTRAINT & BALLAST BOX SUPPORT

BALLAST BOX SUPPORT

Apr. 2009 7 Manual No. 10758

Bucyrus International, Inc.

495HD Electric Mining Shovel

0.25o 0.4% 0.75”

Caution: ON MACHINES USING PLANETARY DUAL-OUTPUT SWING DRIVES,

Manual No. 10758 8 Apr. 2009

Bucyrus International, Inc.

495HD Electric Mining Shovel

Apr. 2009 9 Manual No. 10758

Bucyrus International, Inc.

495HD Electric Mining Shovel

Manual No. 10758 10 Apr. 2009

Bucyrus International, Inc.

495HD Electric Mining Shovel

Apr. 2009 11 Manual No. 10758

Bucyrus International, Inc.

495HD Electric Mining Shovel

Manual No. 10758 12 Apr. 2009