PDF Operator's Manual Cat Electric Rope Shovel 295HR Mining Shovel - 1 MB
This operator's manual is the official guide for the Cat 295HR Electric Rope Shovel.
It contains vital information on safety, machine controls, and daily operational procedures.
Proper understanding and application of the contents in this manual are critical for maximizing the productivity and safety of this massive mining machine.
It is a fundamental resource for all crew members.
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BI619836
BUCYRUS R
295HR
MINING SHOVEL
OPERATOR’S MANUAL
SN:141346
SN:141347
SN:141350
SN:141351
Manual No. 10710
BUCYRUS
295HR
HIGH PERFORMANCE
141346mc.cdr Pg. 2
Bucyrus International, Inc.
1100 Milwaukee Ave. • P.O.Box 500 • South Milwaukee, Wisconsin 53172-0500 USA
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BI619836
Bucyrus International, Inc.
295HR Electric Mining Shovel
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”.
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.
July 2009 7 Manual No. 10710
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BI619836
Bucyrus International, Inc.
295HR Electric Mining Shovel
LOWER WORKS
The lower works is comprised of the truck frame, right and left crawler frames, crawler belts,
propel machinery, swing rack and roller circle.
Truck Frame and Crawlers
July 2009 17 Manual No. 10710
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BI619836
Bucyrus International, Inc.
295HR Electric Mining Shovel
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. Boarding stairs permit easy access onto the machine.
BOARDING STAIRS
A set of boarding stairs is attached to the machinery house platform on the right side of the machine.
When lowered, the stairs allow entrance to the machinery house from ground level. To lower the
stairs, a chord attached to the stairway is reachable from the ground. The stairs must be in the
raised position to enable the operator’s controls.
RH Boarding Stairs
July 2009 27 Manual No. 10710
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BI619836
Bucyrus International, Inc.
295HR Electric Mining Shovel
FRONT END EQUIPMENT
The front end equipment consists of the boom, the 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 boom angle. These are fixed-length
strands that support the entire weight of the boom and the load.
July 2009 37 Manual No. 10710
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BI619836
Bucyrus International, Inc.
295HR Electric Mining Shovel
CONTROLS ON THE LEFT CONSOLE
LEFT JOYSTICK
omsL1346
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 cassette player.
July 2009 47 Manual No. 10710
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BI619836
Bucyrus International, Inc.
295HR Electric Mining Shovel
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.
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.
July 2009 57 Manual No. 10710
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BI619836
Bucyrus International, Inc.
295HR Electric Mining Shovel
WINDSHIELD WIPERS
There are two electrically operated windshield wipers on the front window of the cab: one for the
lower portion of the window and one for the upper portion of the window.
Check the wiper blades to make sure they swing freely across the window without contacting the
window frame. Reposition the pantograph arm on the wiper motor shaft if necessary to prevent
contact with the window frame.
Frequently check the condition of the wiper blades and replace if damaged.
WINDSHIELD WASHER
An optional electric operated windshield washer unit supplies a cleaning agent to the windshield
through spray nozzles when activated. When operating in warm climates, water may be used as
the agent. In areas where freezing temperatures are encountered, a suitable commercial windshield
washer solvent with anti-freezing characteristics is recommended.
July 2009 67 Manual No. 10710
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BI619836
Bucyrus International, Inc.
295HR Electric Mining Shovel
SWING MOTION
In standard configuration, Swing motion is controlled by the operator’s right joystick. To swing in
either direction, move the joystick lever in the direction of swing. Practice swinging in each direction
until a “feel” is developed for start-up and stopping.
NOTE: The joy stick also controls the hoisting and lowering of the dipper through forward and
backward motions.
DANGER: Each motion - hoist or swing - is fully operational throughout the
complete movement of the other motion.
NOTE: When this joystick is used for propelling the machine, the hoist and swing motions are
electrically locked out.
NOTE: The following represents the standard configuration.
July 2009 77 Manual No. 10710
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BI619836
Bucyrus International, Inc.
295HR Electric Mining Shovel
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.
July 2009 87 Manual No. 10710