PDF Operator’s Manual CAT BUCYRUS 495HD Mining Shovel - 1 MB
This operator's manual is the essential guide for anyone operating the CAT Bucyrus 495HD mining shovel.
It provides comprehensive information on safety procedures, machine controls, and daily inspection routines.
Adhering to the instructions in this manual is vital for ensuring the safety of the crew and the longevity of this massive and expensive piece of equipment.
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BI624100
495HD
Mining Shovel
Operator’s Manual
Manual No. OM141432-EN
PRELIMINARY SAMPLE 03-25-2011
Bucyrus International, Inc.
1100 Milwaukee Ave. Phone: 1-414-768-4000
South Milwaukee, WI Web: www.bucyrus.com
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BI624100
Safety
Safety Precautions
S.2.1 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 person 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
PRELIMINARY SAMPLE 03-25-2011
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 be
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 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.
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BI624100
Introduction
About This Manual
1.1.4 Revisions
This manual may be revised without notice. The most recent electronic version is available
online.
1.1.5 Precautions and Disclaimers
• Carefully study and follow all procedures in this manual. Safe operation of the machine
minimizes production delays and costly damage to equipment.
• Safety guidelines are intended to prevent accidents and are provided in the interest of all
mine personnel. Overall safety depends on the use of good judgment and the alertness of the
entire mining crew.
• It is the owner/mine's responsibility to perform the necessary risk assessment to outline
proper safety precautions. A minimum of unplanned machine downtime and more reliable
machine operation should result when a systematic and thorough maintenance/service
procedure is adhered to for this machine.
PRELIMINARY SAMPLE 03-25-2011
• 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.
1.1.6 Contact
For more information or factory service assistance, contact your regional service representative
or:
Caterpillar Global Mining LLC
6744 S. Howell Ave.
Oak Creek, WI, USA 53154
Tel. (+1) 414.768.4000
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BI624100
Introduction
Lower Works
1.3.4 Roller Circle
The roller circle is composed of the upper rails, lower rails, thrust rails, 50 tapered rollers and
inner/outer roller cages. The lower rail segments are secured to the top surface of the swing rack
forming a continuous rolling path for the rollers. The upper rails are attached 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.
PRELIMINARY SAMPLE 03-25-2011
Figure 1-5 Roller Circle Assembly
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BI624100
Introduction
Rotating Deck
1.4.7 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.
PRELIMINARY SAMPLE 03-25-2011
Figure 1-7 A-Frame and Front End Support Components
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BI624100
Introduction
Front End Equipment
1.5.2 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.
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. A boom limit switch with soft setdown prevents boom jacking shock loads.
PRELIMINARY SAMPLE 03-25-2011
Figure 1-13 Boom Assembly
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BI624100
Operation
Controls
2.2.1 Primary Operating Controls
PRELIMINARY SAMPLE 03-25-2011
Figure 2-2 Operator’s Control Consoles in Cab
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BI624100
Operation
Operator’s Display
2.4 Operator’s Display
A PC based Operator’s Display is used to provide the operator with an interface to the machine
and it’s functional areas. From this informational display the operator can make inputs that effect
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.
The display panel is mounted on an articulated arm assembly protruding from the seat base on
the left side of the operator. The articulated arm allows individual operators to locate the screen
in any desired position. The monitor screen can be rotated along the horizontal and vertical axis.
PRELIMINARY SAMPLE 03-25-2011
Figure 2-6 Operator’s Display Panel
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BI624100
Operation
Operator’s Display
PRELIMINARY SAMPLE 03-25-2011
Figure 2-19 Typical Bearing Temperature Screen
Figure 2-20 Operator’s Screen
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B I 6 2 4 1
Machine Specifications
General Estimated Component Weights
LOWER WORKS (Continued)
Quantity Weight Each
(U.S. Pounds)
Roller, Upper 8 620
Shaft, Upper Roller 8 400
Washer, Thrust,Lower Roller 8 50
Collar, Lower Roller 8 210
Center Pintle Sleeve Assy 1 7,900
Center Pintle Lower Nut 1 1,450
Collar, Center Pintle, Upper 1 380
Washer, Thrust, Center Pintle 1 400
PRELIMINARY SAMPLE 03-25-2011
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BI624100
Machine Operation
Start-up, Operation And Shutdown
PRELIMINARY SAMPLE 03-25-2011
4.2.4.2 Crowd Motion
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.
This joystick also controls the signal horn and dipper trip.
NOTE: The following represents the standard configuration.
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BI624100
Machine Operation
Start-up, Operation And Shutdown
4.2.4.7 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.
PRELIMINARY SAMPLE 03-25-2011
Figure 4-2 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.
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