Operator - Manual 495HR 141311 141313

Bucyrus International, Inc.
495HR Electric Mining Shovel
Safety
The safety alert symbols displayed here and throughout this manual are used to call attention to
instructions concerning 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 that anyone servicing this machine is aware of these SAFETY SYMBOLS and their
definitions. If it is impossible 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/her 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.
May. 2009 s–i Manual No. 10791

SAFETY PRECAUTIONS
DANGER: This manual provides information and data for the maintenance
and/or operation of this machine. All electrical equipment must be
serviced by qualified individuals who have been properly trained to
work with high voltage systems and variable frequency AC 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.
DANGER: 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.
DANGER: HIGH VOLTAGE! 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.
Manual No. 10791 s – ii May. 2009

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
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.
May. 2009 s – iii Manual No. 10791

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 utilize 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.
Manual No. 10791 s – iv May. 2009

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 and 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 - OPERATION.
• 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.
May. 2009 s–v Manual No. 10791

FIRE PREVENTION
Figure s-1: Fire Extinguisher Locations

• 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.
• 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, shutdown the machine until it has cooled and
the cause is determined and repaired.
Manual No. 10791 s – vi May. 2009

WARNING SIGNS AND DECALS

The placards depicted below are mounted on the 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 which may result in injury to personnel or damage to the machine.
May. 2009 s – vii Manual No. 10791

Figure s-2: Stored Energy Decals
Manual No. 10791 s – viii May. 2009


Operator’s Manual
Manual No. 10791
SN: 141311 Lot 115 • SN: 141313 Lot 117
Always refer to the safety section in this manual before starting any maintenance
procedure on this machine.
Table of Contents
SAFETY
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s-ii
GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s-iii
MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s-iv
OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s-v
FIRE PREVENTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s-vi
Figure s-1: Fire Extinguisher Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .s-vi
WARNING SIGNS AND DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s-vii
Figure s-2: Stored Energy Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s-viii
SECTION 1 - INTRODUCTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MACHINE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Figure 1-1: Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
LOWER WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-2: Truck Frame and Crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CRAWLERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1-3: Right Crawler Assembly (Left Opposite) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
TRUCK FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SWING RACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 1-4: Swing Rack and Roller Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
ROLLER CIRCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Figure 1-5: Roller Circle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
PROPEL MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
COLLECTOR RINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
ROTATING DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
REVOLVING FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
CENTER PINTLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
DECK EXTENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
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.
May. 2009 T-I Manual No. 10791

Figure 1-6: Deck Extensions and Ballast Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

BALLAST BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
MACHINERY HOUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
BOARDING STAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
VERTICAL BOARDING LADDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
A-FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Figure 1-7: A-Frame and Front End Support Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
HOIST MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Figure 1-8: Hoist Machinery - Plan View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Figure 1-9: Swing Machinery Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
CROWD MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Figure 1-10: Crowd Machinery Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
COMPRESSED AIR SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
AUTOMATIC LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Figure 1-11: Lubrication Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
LUBE RESERVOIR FILL / OVERFLOW PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Figure 1-12: Lube Reservoir Fill / Overflow Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
FRONT END EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Figure 1-13: Front End Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
SUSPENSION STRANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Figure 1-14: Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
RUNNING ROPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Figure 1-15: Ropes - General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
SADDLE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Figure 1-16: Saddle Block Bushing Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
DIPPER HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
DIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Figure 1-17: Dipper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
PADLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Figure 1-18: Left and Right Padlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
DIPPER TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Figure 1-19: Dipper Trip Motor and Dipper Trip Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
SECTION 2 - OPERATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
OPERATION NEAR ELECTRICAL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
ADJUSTABLE ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-1: Armrest Adjustment Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
ADJUSTABLE FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-2: Footrest Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
PRIMARY OPERATING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
CONTROLS ON THE LEFT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Manual No. 10791 T – II May. 2009

Figure 2-3: Left Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

LEFT JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
DIPPER TRIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
SIGNAL HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
START PUSHBUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
PLC POWER ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
DRIVE CABINET TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
INCOMPLETE SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SYSTEM READY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
PHASE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
AUXILIARY GROUND FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
HOIST BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
CROWD BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SWING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
PROPEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
HVAC UNIT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
HVAC SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
HVAC FAN SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
CABIN LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
CONTROLS ON THE RIGHT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-4: Right Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
RIGHT JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
EMERGENCY STOP PUSHBUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
WINDSHIELD WIPER SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
CONTROL STOP PUSHBUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
CONTROL RESET PUSHBUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
DIG/PROPEL TRANSFER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
MAIN POWER OFF PUSHBUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
EARTH CONTINUITY LOCKOUT PUSHBUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
SEAT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
RADIO/CASSETTE/CD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
OPERATOR’S DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
DISPLAY AREA AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
DISPLAY SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Figure 2-5: Title Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Figure 2-6: Language Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Figure 2-7: Icon Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Figure 2-8: Active Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Figure 2-9: New Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Figure 2-10: Alarms Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Figure 2-11: Rope Reeving/Pintle Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Figure 2-12: Rope Reeving/Pintle Tightening Help. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Figure 2-13: Calibration Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Figure 2-14: Limit Calibration Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Figure 2-15: Fault Counters/Operating Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Figure 2-16: PLC Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
May. 2009 T – III Manual No. 10791

Figure 2-17: Typical Bearing Temperature Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Figure 2-18: Operator’s Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
LUBRICATION CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
FIRE SUPPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
SECTION 3 - MACHINE SPECIFICATIONS

TYPICAL MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table 3-1: Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table 3-2: Front End Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table 3-3: Rope Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table 3-4: Typical Dimensions and Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
GENERAL ESTIMATED COMPONENT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
LOWER WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
UPPER WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
FRONT END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SECTION 4 - MACHINE OPERATION

PRE-START CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
WALK-AROUND GROUND LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
ON-BOARD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
START-UP, OPERATION AND SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
MACHINE START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
RESTARTING AFTER AN ELECTRICAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
MACHINERY MOTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
HOIST MOTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
CROWD MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
PROPEL MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-1: Propel - Straight Forward/Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
SWING MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
PROPER SWING MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
COUNTER-ROTATION TURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
POSITIONING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
BACK-UP METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
DRIVE-BY METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
START OF THE DIG CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Figure 4-2: Force the Dipper Lip into the Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Figure 4-3: Variations on Dipper Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Figure 4-4: Dig with the Dipper Beneath the Boom Point . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
ENGAGING THE BANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Figure 4-5: Engage the Bank Under the Boom Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Figure 4-6: Hoist Force Opposes Crowd Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Figure 4-7: Make Effective Use of the Hoist Effort. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
SLOPE LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Figure 4-8: Slope vs. Degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Figure 4-9: Rollover and Operation Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Manual No. 10791 T – IV May. 2009

EXCAVATED MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
OPERATING HINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
STOPPING THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
May. 2009 T–V Manual No. 10791

Manual No. 10791 T – VI May. 2009

Section 1
Introduction
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 judgment and the alertness of the entire
mining crew.
Throughout this section, and the remainder of the 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.
May. 2009 1–1 Manual No. 10791

MACHINE OVERVIEW
This 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 and limitations.
Figure 1-1: Nomenclature
Manual No. 10791 1–2 May. 2009

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.
Figure 1-2: Truck Frame and Crawlers
May. 2009 1–3 Manual No. 10791

CRAWLERS
This machine is provided with a crawler system composed of 2 independently-driven crawler
frame assemblies, one on each side of the truck frame. Each crawler has its own belt 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 which 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.
Lower rollers rotate on forged steel shafts mounted within the crawler side frames. Eight smaller
rollers and 1 large roller per frame are specially suited to withstand the periodic single point
ground reaction caused by uneven pit floors. Slide bars on top of 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 crawler assemblies are bolted to the truck frame with large diameter rods and torque nuts.
Each crawler belt can be independently adjusted for tension.
Figure 1-3: Right Crawler Assembly (Left Opposite)
Manual No. 10791 1–4 May. 2009

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.
May. 2009 1–5 Manual No. 10791

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 a 4-piece gear bolted to the truck frame.
Figure 1-4: Swing Rack and Roller Circle
Manual No. 10791 1–6 May. 2009

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.
Figure 1-5: Roller Circle Assembly
May. 2009 1–7 Manual No. 10791

PROPEL MACHINERY
The propel machinery is driven by two AC motors, each horizontally mounted to the crawler
frames. Each motor is coupled to a right-angled planetary gearcase high up off the pit floor for
protection from water and rock damage. One spring-set, air-released, disc 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. 10791 1–8 May. 2009

COLLECTOR RINGS
There are three sets of collector rings on the machine - low voltage, propel and high voltage. The
low voltage collector rings transfer power from the revolving frame back to the propel motors.
The propel collector rings provide control to the propel motors and power for the propel blower
motor.
High voltage collector rings, on the bottom of the revolving frame, transfer electric power from the
truck frame to the revolving deck. Electric power enters the truck frame just below the propel
motors 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.
May. 2009 1–9 Manual No. 10791

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.
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 the hoist drive motor and machinery frames.
Refer to a view of the revolving frame assembly with deck extensions and ballast box in this
section.
The revolving frame is connected to the truck frame by the center pintle.
CENTER PINTLE
DANGER: HIGH VOLTAGE! EXTREME CARE MUST BE EXERCISED AT ALL

TIMES WHEN PERFORMING MAINTENANCE IN THE CENTER
PINTLE AREA. High voltage can cause serious or fatal injury.
Installation, operation and servicing of components should be
performed only by qualified personnel. ALWAYS DISCONNECT the
electrical power BEFORE accessing the center pintle area.
The center pintle is a large diameter, hollow cylindrical forging with a flange at the top. It is
threaded at the bottom with a lower nut used to hold it in place. A bronze coated steel core
spherical thrust washer between the lower adjusting nut and the bottom surface of the truck
frame provides a wear surface for pintle loads. The upper clamping collar at the top of the center
pintle is doweled and bolted to the revolving frame to keep the center pintle from rotating.
The hollow pintle provides passage for air and grease lines and electrical cables from the
revolving frame to the lower works using a swivel and collector ring assembly.
Manual No. 10791 1 – 10 May. 2009

May. 2009 1 – 11 Manual No. 10791

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.
Figure 1-6: Deck Extensions and Ballast Box

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. Boarding stairs permit easy access onto the
machine.
Manual No. 10791 1 – 12 May. 2009

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.
May. 2009 1 – 13 Manual No. 10791

VERTICAL BOARDING LADDER
The vertical boarding ladder is one of the means for boarding the machine, located on the left
side of the machine, at the rear of the machinery house. Use the pull chord from ground level to
lower the ladder. This ladder must be in the raised and latched position to enable the operator’s
controls.
Manual No. 10791 1 – 14 May. 2009

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.
Figure 1-7: A-Frame and Front End Support Components
May. 2009 1 – 15 Manual No. 10791

HOIST MACHINERY
The hoist machinery consists of a motor coupled to two gear reductions which drive the hoist
drum. A spring-set, air-released disc 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 multiple coupling shaft
assembly.
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.
Figure 1-8: Hoist Machinery - Plan View
Manual No. 10791 1 – 16 May. 2009

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. Bolt-on mounting permits easy field exchange or replacement of
either the planetary gearboxes or the splined pinions. The four pinions result in lower shared
tooth loads for longer pinion and rack life. A spring-set, air-released, disc brake is mounted on
each of the two swing motors.
Figure 1-9: Swing Machinery Components
May. 2009 1 – 17 Manual No. 10791

CROWD MACHINERY
The crowd machinery is located at the front, center of the revolving frame. It consists of a motor,
spring-set, air-released disc brake, drum and gearing. A crowd rotary encoder prevents
overtravel of the dipper handle. With the crowd machinery on the revolving frame instead of the
boom, front end weight is substantially reduced - 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.
The crowd drum drives the crowd and retract rope system. Rope grooves are machined into the
drum 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 disc type brake is mounted on the electric drive motor.
Figure 1-10: Crowd Machinery Components
Manual No. 10791 1 – 18 May. 2009

OPERATOR’S CAB
The isolated and elevated operator’s cab at the right, 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, a helper’s seat and the standard operator’s display panel.
The cab is sound and heat insulated with interior walls made of a sound deadening steel-plastic-
steel composite. Electric powered windshield wipers are provided for quiet, dependable
operation. 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.
An 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.
May. 2009 1 – 19 Manual No. 10791

COMPRESSED AIR SYSTEM

The compressed air system consists of a rotary screw type air compressor, air receiver, air
brakes, controls and center pintle air swivel. Hydraulic high pressure hose is used throughout.
The air system is used to operate all machinery motion brakes and lubrication components and
to perform various other functions.
Manual No. 10791 1 – 20 May. 2009

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.
A single-line 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 75:1 air
powered pumps are mounted on two reservoirs. High pressure hoses with reusable fittings are
utilized.
The six separately controlled lube circuits provide selective distribution frequency and quantity
resulting in reduced lubricant usage and cost.
Figure 1-11: Lubrication Room
May. 2009 1 – 21 Manual No. 10791

LUBE RESERVOIR FILL / OVERFLOW PLUMBING

The lube reservoir fill/overflow plumbing is located in the support structure directly below the lube
room at the front, left side of the machine. Lubricants can be added at this location. The overflow
connections are also located here. DO NOT plug the overflow connections.
Figure 1-12: Lube Reservoir Fill / Overflow Plumbing
Manual No. 10791 1 – 22 May. 2009

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.
Figure 1-13: Front End Equipment

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.
May. 2009 1 – 23 Manual No. 10791

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.
Figure 1-14: Boom Assembly
Manual No. 10791 1 – 24 May. 2009

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.
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.
Figure 1-15: Ropes - General Arrangement
May. 2009 1 – 25 Manual No. 10791

SADDLE BLOCK
The saddle block is positioned between the boom side girders in the mid-section of the boom. It
pivots on manganese-bronze bushings about the shipper shaft. It 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.
Figure 1-16: Saddle Block Bushing Arrangement
Manual No. 10791 1 – 26 May. 2009

DIPPER HANDLE
The dipper handle assembly is a weldment consisting of a large diameter tube and a handle end
where the machine’s dipper is attached.
The handle has a take-up mechanism that removes slack from the retract rope during operation.
At the rear of the assembly is crowd take-up mechanism that removes slack from the crowd rope.
The dipper tube moves in and out within the saddle block during operation.
May. 2009 1 – 27 Manual No. 10791

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 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.
Figure 1-17: Dipper Assembly
Manual No. 10791 1 – 28 May. 2009

PADLOCKS
Padlocks connect the hoist ropes to the outer edges of the dipper while still permitting fore and
aft and sideways movement.
Figure 1-18: Left and Right Padlocks
May. 2009 1 – 29 Manual No. 10791

DIPPER TRIP
The dipper trip is a wire rope activated dipper door trip mechanism driven by 2 electric motors
through gear reduction mounted on the boom near the boom foot.
Figure 1-19: Dipper Trip Motor and Dipper Trip Sheave
Manual No. 10791 1 – 30 May. 2009

Section 2
Operation
GENERAL INFORMATION
This section of the manual will assist in the operation of this machine. It provides the operator
with the location and explanation of the controls, instructions for machine operation and certain
maneuvering techniques. Throughout this section and the remainder of the 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.
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 judgment and the alertness of the entire
mining crew. Refer to Section 1 in this manual for specific safety precautions.
OPERATION NEAR ELECTRICAL LINES
DANGER: HIGH VOLTAGE! The following precautions shall be complied

with whenever operating around or near electrical distribution and
transmission lines.
Working in the vicinity of electrical power lines presents a very serious hazard and special
precautions must be taken. For purposes of this manual we are considering the entire machine
or its load, in any position, that can reach to within the minimum distance specified by local, state
and federal regulations.
Safe operating practices require that you maintain the maximum possible distance from the lines
and never violate the minimum clearances.
Before working in the vicinity of power lines, always take the following precautions:
• Always contact the owners of the power lines or the nearest electric utility before
beginning work.
• You and the electrical utility representative must jointly determine what specific
precautions must be taken to ensure safety.
• It is the responsibility of the user and the electric utility to see that necessary precautions
are taken.
• Consider all lines to be power lines and treat all power lines as energized even though it
is known that the power is shut off and the line is visibly grounded.
• Slow down the operating cycle. Reaction time may be too slow and distances may be
misjudged.
• Caution all ground personnel to stand clear of the machine at all times.
• Use a signal person to guide the machine into close quarters. The sole responsibility of
the signal person is to observe the approach of the machine to the power line. The signal
person must be in direct communication with the operator and the operator must pay
close attention to the signals.
May. 2009 2–1 Manual No. 10790

DANGER: HIGH VOLTAGE! Death or injury could result should any part of
the machine approach the minimum distance of an energized
power line specified by local, state and federal regulations.
Manual No. 10790 2–2 May. 2009

OPERATOR’S SEAT
ADJUSTABLE ARMREST
Figure 2-1: Armrest Adjustment Locations
May. 2009 2–3 Manual No. 10790

ADJUSTABLE FOOTREST
Figure 2-2: Footrest Components

The pitch of the footrest can be adjusted from horizontal to 20 degrees in five degree increments.
The pitch of the footrest is positioned using a push-button quick release pin.
To adjust the pitch, stand to the left of the operator seat. Lift up on the footrest bars to take the
weight off the pitch locking pin. Remove the pin by deprssing the button on the pin, then sliding it
out. Lift or lower the footrest pad to the desired pitch. Use the yellow notches and arrows to
determine which holes are aligned for the locking pin. The holes and aligned when an arrow is
centered over a yellow notch. Adjust the pitch to align one of the five holes, then insert the pin.
Lower the footrest pad until it rests on the locking pin.
The footrest height can be adjusted while sitting in the seat. There are four height adjustments.
Before adjusting the footrest height, ensure the pitch locking pin is fully in place.
To raise the footrest height, raise the lift tab. When the footrest has reached the desired height,
lower the lift tab until the latch hook engages the height adjustment latch.
To lower the footrest height, raise the lift tab. Press on the front portion of the height adjustment
latch. Slowly lower the lift tab to the desired height. Release the height adjustment latch, then
lower the lift tab until the latch hook engages the height adjustment latch.
Manual No. 10790 2–4 May. 2009

CONTROLS
The operator must become familiar with the machine and its operating controls before operating
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.
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 and facing forward, and with the boom extending over the front of the crawlers.
PRIMARY OPERATING CONTROLS
May. 2009 2–5 Manual No. 10790

CONTROLS ON THE LEFT CONSOLE
Figure 2-3: Left Control Console
Manual No. 10790 2–6 May. 2009

LEFT JOYSTICK
The left joystick controls the crowd/horn/dipper trip and propel. It is the vertical handle mounted
on the left armrest of the operator’s seat. The switch 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.
DIPPER TRIP
The dipper trip is part of the left joystick function. Moving the left 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 to the left will activate the signal horn. The signal horn is operational
throughout the entire movement range of the crowd motion.
START PUSHBUTTON
When pressed, will power up the drive system. The system ready light will go out.
May. 2009 2–7 Manual No. 10790

PLC POWER ON
A green light that indicates the status of the PLC.
DRIVE CABINET TEMPERATURE
A green light that indicates temperature in the drive cabinet is neither too low nor too high.
INCOMPLETE SEQUENCE
A red light that indicates an incomplete sequence of startup events.
SYSTEM READY
A green light that indicates that the drive system is ready to start, but not yet started.
PHASE SEQUENCE
A green light that indicates that the phase sequence is okay in the incoming power.
AUXILIARY GROUND FAULT
A green light that when lit, indicates that no auxiliary power ground fault exists. If the light is off,
alert an electrician as soon as possible.
HOIST BRAKE
A selector switch used to set or release the hoist brake.
CROWD BRAKE
A selector switch used to set or release the crowd brake.
SWING BRAKE
A selector switch used to set or release the swing brake.
PROPEL BRAKE
A selector switch used to set or release the propel brake.
HVAC UNIT SELECTOR
A 3-position switch used to select air conditioner unit No.1, units No.1 and No. 2, or unit No. 2.
TEMPERATURE
A rheostat used to control the temperature in the operator’s cab relative to the selected mode of
operation.
HVAC SYSTEM CONTROL
A 4-position selector switch used to select the HVAC system mode of operation.
HVAC FAN SPEED
A 3-position selector switch used to control the volume of air moved by the system.
CABIN LIGHTS
A dimmer switch used to control the brightness of the cabin lights inside the operator’s cab.
Manual No. 10790 2–8 May. 2009
CONTROLS ON THE RIGHT CONSOLE
Figure 2-4: Right Control Console
May. 2009 2–9 Manual No. 10790

RIGHT JOYSTICK
The right joystick controls the hoist/swing and propel. It is a joystick mounted on the right armrest
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 switch controls
the hoist motion or the crawler motion.
With the propel transfer switch in the dig position, 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 the switch is a spring returned
switch. That is, it will return to the neutral position when it is released.
Moving the right 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.
With the propel transfer switch in the propel position, pushing the lever forward will cause the
right crawler to move forward. Pulling the lever 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 right 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.
Manual No. 10790 2 – 10 May. 2009

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.
WINDSHIELD WIPER SWITCHES

The windshield wiper switches control the starting and stopping as well as the speed of the
windshield wipers.
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.
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 reposition themselves.
May. 2009 2 – 11 Manual No. 10790

AIR COMPRESSOR
A 3-position selector switch to RUN, START or turn OFF the compressor.
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 hoist 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.
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.
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.
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.
SEAT POSITION
A selector switch is used to move the operator’s seat and consoles forward or back. The seat will
continue to move as long as the switch is held, or until the end of the seat’s travel is reached.
Manual No. 10790 2 – 12 May. 2009

RADIO/CASSETTE/CD
A quality AM/FM radio with cassette and CD player is installed for the operator’s use and
connected to speakers in the operator’s cab.
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.
May. 2009 2 – 13 Manual No. 10790

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.
These icons and buttons will react by activating the screen, switch activation or display
information relevant to the icon. The switches and buttons will be covered in the following pages
under the screen topic in which they appear.
The indicators on the lower portion of the screen area are indicators and sensors which indicate
the functionality of the operator display and it’s interface with the machine’s PLC controller. They
have no effect on machine operational use.
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.
Figure 2-5: Title Screen

The information provided in the central area of the screen is machine specific.
Manual No. 10790 2 – 14 May. 2009

Figure 2-6: Language Screen

This screen allows the language used on the screens to be reset.
Figure 2-7: Icon Screen

This screen displays the icons used throughout all the screens in the system.
May. 2009 2 – 15 Manual No. 10790

Figure 2-8: 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.
Figure 2-9: 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. 10790 2 – 16 May. 2009

Figure 2-10: 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.
Figure 2-11: Rope Reeving/Pintle Tightening
May. 2009 2 – 17 Manual No. 10790

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.
Figure 2-12: Rope Reeving/Pintle Tightening Help

This screen will provide clarifying information on the reeving of ropes and pintle tightening.
Manual No. 10790 2 – 18 May. 2009

Figure 2-13: 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.
Figure 2-14: Limit Calibration Help

This screen will provide clarifying information on the calibration process.
May. 2009 2 – 19 Manual No. 10790
Figure 2-15: 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.
Figure 2-16: PLC Menu Screen

This screen will active further screens which are used to monitor various racks within the PLC
cabinets.
Manual No. 10790 2 – 20 May. 2009

Figure 2-17: Typical Bearing Temperature Screen
Figure 2-18: 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 to make changes in control settings. The pressure gauge is located on the right portion of the
Operator Display. It indicates the regulated air pressure available in the air system.
May. 2009 2 – 21 Manual No. 10790

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.
FIRE SUPPRESSION SYSTEM

Fires on surface mining equipment typically involve faults in electrical equipment, or the
combustion of flammable fluids. The time between the onset of the fire and its detection is critical.
Early detection and suppression of a fire minimizes hazards to personnel, equipment damage,
downtime and loss of production. The optional fire suppression system on this machine is
supplied and installed by an outside source. Please refer to the system’s manufacturer for
maintenance and parts information.
Manual No. 10790 2 – 22 May. 2009

Section 3
Machine Specifications
TYPICAL MACHINE SPECIFICATIONS
This specification describes the principal mechanical features of a standard Bucyrus
International, Inc. 495HR IGBT Acutrol controlled machine. The machine is fully revolving,
crawler mounted and equipped to operate from an alternating current power source.
NOTE: These are typical machine specifications.
Table 3-1: Weights
(pounds) (kilograms)
Working Weight (w/dipper) 3,011,000 1,365,728
Dipper (73 yd3, 56 m3) 170,000 77,110
Ballast 667,000 302,546
Net weight, minus ballast and dipper 2,174,000 986,109
Table 3-2: 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 3” (nominal) 7.62 cm
Table 3-3: Rope Data

# Ropes Diameter Type Construction
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 3/4” 19.1mm single 6X37
Boom Suspension 4 3 1/4” 82.6mm equalized structural strand
May. 2009 3–1 Manual No. 10790

Table 3-4: Typical Dimensions and Working Ranges

US Metric
Dipper payload (tons nominal) 110 100 tonnes
Dipper capacities (range) 40-80 yd3
30.6-61.2 m3
Length of boom 67' 20.4 m
Boom angle 43° 43°
Effective length of dipper handle 35’-10” 10.9 m
Overall length of dipper handle 47’-0” 14.3 m
A: Dumping height 33’-0” 10.0 m
A1: Dumping height at maximum radius 28’-3” 8.6 m
B: Dumping radius - maximum 71’-0” 21.6 m
C: Cutting height - maximum 60’-3” 18.0 m
D: Cutting radius - maximum 82’-0” 25.0 m
E: Radius of level floor 52’-11” 16.1 m
G: Clearance height @ boom point sheaves 68’-0” 20.7 m
H: Clearance radius @ boom point sheaves 64’-9” 19.7 m
I: Clearance radius @ revolving frame 29’-11” 9.1 m
J: Clearance - revolving frame to ground 11’-11” 3.6 m
K: Height of A-frame 45’-7” 13.9 m
N: Operator’s Cab Eye Level 30’-0” 9.1 m
D
H
G
C
K 495HR
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mdim495HR
I E
B
Manual No. 10790 3–2 May. 2009

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.
LOWER WORKS
Quantity Weight Each

(U.S. Pounds)
Truck frame 1 191,430
Pintle bushing 1 280
Lower rail 9 570
Thrust rail 9 170
Propel brake adapter 2 370
Propel brake 2 650
Propel brake hub 2 60
Propel motor 2 4,500
Propel motor blower 2 210
Propel motor duct assembly 2 185
Propel brake guard 2 60
Coupling 2 130
Crawler belt (2 per machine) 2 244,000
Crawler link, 102 In. (47 per belt) 47 2,500
Crawler assembly~shipping 2 128,500
Crawler structure 2 74,750
Propel gearcase 2 15,840
Front iIdler 2 5,800
Front idler shaft 2 1,150
Adjusting block 4 370
Load roller 8 2,020
Load roller shaft 8 550
Rear idler 2 3,800
Rear idler shaft 1 700
Drive tumbler 1 7,120
Drive shaft assembly 1 4,330
Drive shaft 1 3,370
Center pintle sleeve 1 9,100
Center pintle upper collar 1 380
Center pintle thrust washer 1 400
Center pintle lock nut assembly 1 1,470
May. 2009 3–3 Manual No. 10790

UPPER WORKS

(U.S. Pounds)
A-frame front leg 1 23,000
A-frame rear leg 2 6,650
Motor, gear 2 610
Auxiliary winch assembly 1 3,575
Boom foot pin 2 600
Upper rail 2 500
Swing planetary gearcase 1 10,600
Swing pinion shaft assembly 2 1,980
Swing pinion shaft 4 1,460
Swing bearing carrier 4 230
Swing shaft bearing 4 100
Swing brake adapter 2 270
Swing brake 2 490
Swing motor (w/o tach) 1 3,600
Swing motor (w/tach) 1 3,600
Crowd drive pinion, bearings & hrdwr 1 170
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 1 280
Crowd gearcase cover 1 2,700
Crowd upper gear guard 1 170
Crowd gear guard - lower 1 340
Crowd drum 1 12,800
Crowd drum spur gear 1 4,970
Crowd 1st intermediate pinion shaft 1 130
Crowd 1st intermediate gear 1 1,080
Crowd brake 1 500
Crowd brake adapter 1 270
Crowd motor 1 4,000
Reservoir, 300 gal. lube 1 780
Air swivel 1 150
Manual No. 10790 3–4 May. 2009

UPPER WORKS (Continued)

(U.S. Pounds)
Collector ring assembly 1 230
Front housing 1 140
Rear housing 1 140
Hoist planetary gearcase 1 35,500
Hoist pinion (shaft pinion) 2 1,650
Hoist pinion bearing carrier 2 460
Hoist gear guard - bottom 1 2,000
Hoist gear guard - rear 1 940
Hoist gear guard - front 1 1,300
Hoist gear guard w/cover 1 200
Hoist bearing housing 2 3,200
Hoist drum 1 27,000
Hoist spider 1 16,000
Hoist drum gear 1 11,000
Hoist pedestal - R. H. 1 8,320
Hoist pedestal - L. H. 1 8,700
Hoist oil cooler 1 2,650
Hoist motor 1 15,000
Hoist brake 1 1,350
Hoist brake adapter 1 500
Hoist brake hub 1 210
Flexible gear coupling 1 1,270
Blower 1 700
Hoist blower adapter plate 1 260
Hoist coupling guard, assembly & weld 1 300
RH boarding stairs 1 5,250
LH boarding ladder 1 2,950
Machinery house filter assembly 2 1,330
Revolving frame ship assembly 1 161,600
May. 2009 3–5 Manual No. 10790

FRONT END

(U.S. Pounds)
Boom (bare) 1 148,450
Boom bumper assembly 1 6,630
Boom point sheave assembly 1 16,500
Boom point shaft 2 1,040
Boom point sheave 2 5,050
Saddle block & liner assembly 1 25,010
Saddle block liner bushing 2 1,290
Saddle block/shipper shaft bushing 2 100
Shipper shaft collar 2 110
Shipper shaft 1 4,880
Shipper shaft assembly 1 5,110
Ropes, Foreign Supplied 1 14,600
Suspension rope (pendant) 4 2,750
Pendant equalizer - R.H. 1 2,400
Pendant equalizer - L.H. 1 2,400
Handle weldment 1 48,620
Crowd take-up shop assy 1 11,210
Crowd take-up guide 1 2,160
Crowd take-up worm gear 1 610
Crowd take-up gear housing 1 490
Crowd take-up screw rod 1 4,520
Crowd half-sheave 1 1,920
Retract take-up cylinder 2 150
Retract take-up guide 1 500
Retract spreader and stop 1 2,100
Crowd sheave 2 2,600
Padlock (RH) 1 5,230
Padlock (LH) 1 5,230
Padlock pin & collar assy (kit) 2 530
Padlock sheave pin 1 370
Padlock sheave 1 730
Manual No. 10790 3–6 May. 2009

FRONT END (Continued)

(U.S. Pounds)
Dipper, 60YD, field assy 1 142,000
Includes:
Body, 60YD w/liners 1 108,000
Latch bar assy 1 1,180
Latch lever 1 500
Snubber (RH) 1 1,750
Snubber (LH) 1 1,750
Pitch brace w/bushings 2 3,170
Dipper door and tilt latch assembly 1 28,000
Dipper door & liners, assembly 1 25,750
Dipper door, welded 1 23,450
Tooth, Dipper 9 210
Adapter, Tooth 9 830
May. 2009 3–7 Manual No. 10790

Manual No. 10790 3–8 May. 2009

Section 4
Machine Operation
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.
May. 2009 4–1 Manual No. 10791

WALK-AROUND GROUND LEVEL INSPECTION

Check the following areas daily during a general walk-around 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.
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.
Manual No. 10791 4–2 May. 2009

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.
11. Inspect all walkways and stairways to ensure there are no obstructions or fluids creating a
safety hazard.
12. Ensure all external stairways and/or ladder(s) and optional 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
NOTE: Detailed information on the proper servicing of these components can be found in
Sections 3 and 4 of this manual.
May. 2009 4–3 Manual No. 10791

START-UP, OPERATION AND SHUTDOWN

MACHINE 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 earlier in this section of the manual.
2. Ensure that all boarding stairs and/or ladders are in their raised and latched position.
3. At the AC control cabinet (part of the MCC) verify that the uninterruptable breaker is in the ON
position. At the motor control cabinet, verify that all breakers are in the ON position.
4. In the operator’s cab check that all brake switches are in the set position and that the control
joysticks are in the neutral position. Then go to the electrical room at the rear of the machinery
house.
5. In the operator’s cab and use the following sequence to start the machine.
a. Verify that the auxiliary ground fault light, which is a green light, is lit.
CAUTION: If the light is off, alert an electrician as soon as possible. The

machine may be operated with one such 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 phase sequence light, which is a green light, is lit. This indicates that the
incoming power sequence is correct. If it is not correct, the light will be out and the
machine will not start. The electrical maintenance personnel must correct the sequence.
NOTE: This light also indicates auxiliary power phase unbalance, phase loss or under voltage.
If any of these faults occurs, when the machine is running, an alarm will also sound. In
event of such an alarm, the electrician should be notified but machine may be operated.
c. Verify that the PLC and drive cabinet’s temperature lights, which are green lights, are lit. If
the cabinet temperature is too low or too high, the machine cannot be started.
d. Verify that the PLC power on light, which is a green light, is lit.
e. Turn the air compressor switch to the run position, if so equipped, or select one of multiple
compressors. (For machines with pushbuttons instead of a switch to control the air
compressor, press the start pushbutton)
f. Verify that the system ready light, which is a green light, is lit.
g. Press the system START pushbutton. When this button is pressed, the system ready light
will go out and the drive system will automatically power up.
h. Verify that the incomplete sequence light, which is a red light, is out. If the light is lit, call
the electrician to troubleshoot the sequence.
6. Check the air pressure gauge for correct air pressure. The machine cannot be operated until the
air pressure is at the specified rating.
7. Again 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 display lights indicate that the
process is complete, press the control reset pushbutton to activate the controls.
9. Turn the hoist, crowd and swing brake switches to the released position.
10. Briefly actuate the swing, crowd and hoist controls to make sure each motion is operational.
Manual No. 10791 4–4 May. 2009

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 are 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 master switch for the motion being reset must be in the NEUTRAL position.
d. The motion mechanical brake selector switch must be in the SET 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 master switch will remove the fault and allow
continued operation.
2. For a boom jacking fault, ALL motions will stop but the controls will remain active. Reversing the
crowd master switch will remove the fault and allow continued operation.
3. If the boarding ladder and/or stairs are 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.
a. Once the ladder and/or stairs are 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 brakes set. In these situations, the
controls cannot be reset until the fault has been corrected by an electrician.
MACHINE 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 controls, be sure that all personnel are clear of the machine. Be
sure 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’s display 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:
• Normal routine operational messages
• Alarm only
• Delayed shutdown messages
• Immediate faults and shutdowns
This display also allows the setting of certain operating parameters for the machine. Refer to
OPERATOR’S DISPLAY in this section, as the proper use of the monitor messages is essential
for the operation of the machine.
May. 2009 4–5 Manual No. 10791

MACHINERY MOTIONS
HOIST MOTION
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 the 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.
Manual No. 10791 4–6 May. 2009

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.
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 is achieved.
May. 2009 4–7 Manual No. 10791

PROPEL MOTION
Propel motion is controlled by placing the propel transfer switch in the propel mode and actuating
the hoist master switch control and/or crowd master switch control. To propel in a straight forward
direction, push forward on both the hoist and crowd master switches 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.
Figure 4-1: Propel - Straight Forward/Reverse
Manual No. 10791 4–8 May. 2009

SWING MOTION
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 joystick 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.
May. 2009 4–9 Manual No. 10791

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 swung 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 swung 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 it’s best to have the door open
on an empty dipper and the dipper lowered to a point that permits
moving without striking the ground.
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.
Manual No. 10791 4 – 10 May. 2009

Haulage units should be positioned so their centerline 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 this tactic. A bulldozer or loader
should be used to help the machine operator maintain a clean pit
floor in conjunction with the machine.
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.
May. 2009 4 – 11 Manual No. 10791

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° might be used to minimize material build up on the crawler belt roller path.
A single sharp turn should be avoided to minimize material build up on the crawler belt roller path
and subsequent high loading of crawler belt and associated propel components.
Manual No. 10791 4 – 12 May. 2009

COUNTER-ROTATION TURNS
• 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.
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.
CAUTION: When using the counter-rotation method for turning, use a helper
to 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
the neutral position. The propel brakes are set when both joysticks
are returned to the neutral position.
When moving the machine in a straight line, always propel forward (in the direction of the take-up
axle) to reduce strain and wear on the crawler belts and propel mechanism. This is especially
important in long propels or in deadheading back to the beginning of a cut.
May. 2009 4 – 13 Manual No. 10791

When not possible to propel forward, and propelling to the rear is required, make sure the trail
cable is clear of the machine and follow the signals given by the helper. For increased safety the
machine’s upper works should be rotated in a position that allows 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 loading of haul units.
POSITIONING THE MACHINE

There are two basic methods for positioning an excavator at a bank working face. The first
method is the “back-up method”. The second method is the “drive-by method”. Both methods are
acceptable and effective when set up correctly.
BACK-UP METHOD
When using the back-up method, the excavator is placed in the bank with the front of the
machine turned directly toward the digging face. The haulage units are spotted on both sides of
the machine. The bank is worked until a 180° semicircle has been excavated. When the point is
reached where a 90° swing to either side is required to load haulage units, the excavator is
moved to a new cut.
Move the machine right to left along the bank. The operator should set the left brake first. In
increments, back the machine until the crawlers are at a 45° angle to the original digging path.
Then, back the machine straight until the right crawler crosses the corner of the excavated
semicircle.
Manual No. 10791 4 – 14 May. 2009

Lock the left track, propel forward turning the crawler in increments. When the right crawler is in
line with the corner of the semicircle, move forward and proceed to load the haulage units.
The back-up method will minimize the swing arc and reduce moving time. Other advantages are
less bank toe area clean up and simplified handling of the trail cable, cable standard and trail
cable boat.
DRIVE-BY METHOD
NOTE: If the machine and haulage units cannot be set up as described below, the drive-by
method should be avoided.
Position the machine crawlers parallel to the bank with the inside edge of the outer set of crawler
tracks directly in line with the bank toe.
The trucks must approach the machine from the front making a turn away from the machine as
the front wheel approaches the outside crawler. The truck should stop in a position to allow
backing toward the point of the bank for loading.
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.
May. 2009 4 – 15 Manual No. 10791

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.
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.
Manual No. 10791 4 – 16 May. 2009

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. This could necessitate additional passes to fill the haulage unit.
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
May. 2009 4 – 17 Manual No. 10791

Figure 4-3: Variations on Dipper Penetration

Digging should take place under the boom point for maximum machine 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.
Manual No. 10791 4 – 18 May. 2009

Figure 4-4: Dig with the Dipper Beneath the Boom Point
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.
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.
Figure 4-5: Engage the Bank Under the Boom Point

An excavator 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.
May. 2009 4 – 19 Manual No. 10791

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.
Figure 4-6: Hoist Force Opposes Crowd Force
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.
The experienced operator does 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.
Figure 4-7: Make Effective Use of the Hoist Effort
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.
Manual No. 10791 4 – 20 May. 2009

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.
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 acceptable
with only minimal adverse effects.
NOTE: It is important to remember the difference between slope percent and degrees!
Figure 4-8: Slope vs. Degrees
May. 2009 4 – 21 Manual No. 10791

Figure 4-9: Rollover and Operation Limits
Manual No. 10791 4 – 22 May. 2009

EXCAVATED MATERIAL
It is important that the operator not only know the controls, but also 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.
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.
May. 2009 4 – 23 Manual No. 10791

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. 10791 4 – 24 May. 2009

STOPPING THE MACHINE

1. Return hoist control joystick and crowd control joystick to their center positions and set all
brake switches.
2. After all motions are stopped, and brakes set, depress 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 POWER OFF
pushbutton on the right operator’s console.
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 hoist and crowd 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 POWER OFF pushbutton on the operator’s console.
7. Place the air compressor switch OFF position.
May. 2009 4 – 25 Manual No. 10791

Manual No. 10791 4 – 26 May. 2009

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Bucyrus International, Inc.

495HR Electric Mining Shovel

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

DANGER: This signal word denotes an imminently dangerous hazard which

DANGER: This signal word denotes an imminently dangerous electrical

CAUTION: STORED ENERGY! Components on machine are heavy and

Safety must always be paramount!

May. 2009 s–i Manual No. 10791

495HR Electric Mining Shovel

DANGER: Do not attempt mechanical or electrical maintenance on this

DANGER: The FEEDER CABLE must contain a provision for a ground

DANGER: Due to the inherent dangers in the operation of high voltage

Manual No. 10791 s – ii May. 2009

495HR Electric Mining Shovel

May. 2009 s – iii Manual No. 10791

495HR Electric Mining Shovel

Manual No. 10791 s – iv May. 2009

495HR Electric Mining Shovel

May. 2009 s–v Manual No. 10791

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Figure s-1: Fire Extinguisher Locations

Manual No. 10791 s – vi May. 2009

495HR Electric Mining Shovel

WARNING SIGNS AND DECALS

May. 2009 s – vii Manual No. 10791

495HR Electric Mining Shovel

Figure s-2: Stored Energy Decals

Manual No. 10791 s – viii May. 2009

495HR Electric Mining Shovel

495HR Electric Mining Shovel

© 2009 Bucyrus International, Inc. All Rights Reserved.

May. 2009 T-I Manual No. 10791

495HR Electric Mining Shovel

Figure 1-6: Deck Extensions and Ballast Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Manual No. 10791 T – II May. 2009

495HR Electric Mining Shovel

Figure 2-3: Left Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

May. 2009 T – III Manual No. 10791

495HR Electric Mining Shovel

Figure 2-17: Typical Bearing Temperature Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

SECTION 3 - MACHINE SPECIFICATIONS

SECTION 4 - MACHINE OPERATION

Manual No. 10791 T – IV May. 2009

495HR Electric Mining Shovel

EXCAVATED MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

May. 2009 T–V Manual No. 10791

495HR Electric Mining Shovel

Manual No. 10791 T – VI May. 2009

495HR Electric Mining Shovel

Bucyrus International, Inc.

May. 2009 1–1 Manual No. 10791

495HR Electric Mining Shovel

Figure 1-1: Nomenclature

Manual No. 10791 1–2 May. 2009

495HR Electric Mining Shovel

Figure 1-2: Truck Frame and Crawlers

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495HR Electric Mining Shovel

Figure 1-3: Right Crawler Assembly (Left Opposite)

Manual No. 10791 1–4 May. 2009

495HR Electric Mining Shovel

May. 2009 1–5 Manual No. 10791

495HR Electric Mining Shovel