295HR - Operator's Manual PDF

BUCYRUS
295HR
MINING SHOVEL
OPERATORS MANUAL
PRELIMINARY
FOR REVIEW ONLY
SN:141346
SN:141347
SN:141350
SN:141351
Manual No. 10710
BUCYRUS
295HR
141346mc.cdr Pg. 2
HIGH PERFORMANCE
141346_cl
Bucyrus International, Inc.

1100 Milwaukee Ave. P.O.Box 500 South Milwaukee, Wisconsin 53172-0500 USA
BUCYRUS INTERNATIONAL, Inc.
Preliminary - For Review Only

295HR Electric Mining Shovel
Manual No. 10710
Dec 2008

DANGER:
THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND
OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE
SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO
WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/
OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN
PERSONAL INJURY OR DEATH.
DANGER:
DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE
WITHOUT A FULL UNDERSTANDING OF EACH COMPONENTS OPERATION AND
FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE,
HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR
OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY.
The FEEDER CABLE must contain a provision for a ground connection, especially whenever
2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on
ground circuits) to a suitable permanent ground. At the machine, the power line must securely
terminate through a bolted connection to the machine frame. This provides a constant ground for
the machine and its electrical equipment. Failure to provide this adequate ground endangers
employees and equipment.
THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE
CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between
the machine and the ground. The portable trail cable and power lines supplying electric energy to
the machine must have a ground wire, ample in capacity, running parallel to the main wires over
the entire distance from the transformer to the machine. A suitable grounding system must be
used at the transformer. Consult your local electrical supplier for details.
DANGER:
DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE
ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT
INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING
RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY
CHECK SYSTEM IS ALSO RECOMMENDED.
Dec 2008
Manual No. 10710

Manual No. 10710
Dec 2008

295HR Mining Shovel

Operators Manual
Manual No. 10710
sn: 141346 Lot 68
sn: 141347 Lot 69
sn: 141350 Lot 70
sn:141351 Lot 71
Always refer to the safety information in this manual before starting any
maintenance procedure on this machine.
Table of Contents
GENERAL INFORMATION ............................................................................................................ 5
SAFETY .................................................................................................................................. 6
SAFETY PRECAUTIONS ........................................................................................................ 7
FIRE PREVENTION .............................................................................................................. 10
WARNING SIGNS AND DECALS .......................................................................................... 11
Stored Energy Decals ................................................................................................................ 12
MACHINE OVERVIEW ................................................................................................................ 13

Nomenclature ............................................................................................................................. 13
LOWER WORKS ....................................................................................................................... 14

Truck Frame and Crawlers ......................................................................................................... 14
CRAWLERS .......................................................................................................................... 15
Crawler Assembly ...................................................................................................................... 15
TRUCK FRAME .................................................................................................................... 16

SWING RACK ....................................................................................................................... 17
Swing Rack and Roller Circle ..................................................................................................... 17
ROLLER CIRCLE ................................................................................................................. 18

Roller Circle Assembly ............................................................................................................... 18
PROPEL MACHINERY .......................................................................................................... 19

COLLECTOR RINGS ............................................................................................................ 20
ROTATING DECK ....................................................................................................................... 20
REVOLVING FRAME ............................................................................................................. 21
CENTER PINTLE .................................................................................................................. 21
DECK EXTENSIONS ............................................................................................................ 22
Deck Extensions and Ballast Box .............................................................................................. 22
BALLAST BOX ...................................................................................................................... 22

MACHINERY HOUSE ............................................................................................................ 22
BOARDING STAIRS .............................................................................................................. 23
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.
2008
Dec 2008
Bucyrus International, Inc. All Rights Reserved.
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Manual No. 10710

A-FRAME............................................................................................................................... 23
A- Frame and Front End Support Components ........................................................................... 23
HOIST MACHINERY .............................................................................................................. 24

Hoist Machinery - Plan View ....................................................................................................... 24
SWING MACHINERY ............................................................................................................. 25

Swing Machinery Components .................................................................................................... 25
CROWD MACHINERY .......................................................................................................... 26

Crowd Machinery Components ................................................................................................... 26
OPERATORS CAB .............................................................................................................. 27

COMPRESSED AIR SYSTEM .............................................................................................. 28
AUTOMATIC LUBRICATION SYSTEM .................................................................................. 28
Lubrication Room ....................................................................................................................... 29
LUBE RESERVOIR FILL / OVERFLOW PLUMBING ............................................................ 30

Lube Reservoir Fill / Overflow Plumbing ..................................................................................... 30
FRONT END EQUIPMENT ......................................................................................................... 31

SUSPENSION STRANDS ..................................................................................................... 31
BOOM ................................................................................................................................... 32
Boom Assembly ........................................................................................................................ 32
RUNNING ROPES ................................................................................................................ 33

Ropes - General Arrangement .................................................................................................... 33
SADDLE BLOCK .................................................................................................................. 34

DIPPER HANDLE ................................................................................................................. 34
DIPPER ................................................................................................................................. 35
Dipper Assembly ........................................................................................................................ 35
PADLOCKS .......................................................................................................................... 36
Left and Right Padlocks ............................................................................................................. 36
DIPPER TRIP ........................................................................................................................ 37

Dipper Trip Motor and Dipper Trip Sheave .................................................................................. 37
PRIMARY OPERATING CONTROLS ................................................................................... 38

Operators Control Consoles in the Cab ...................................................................................... 38
CONTROLS ON THE LEFT CONSOLE ......................................................................... 39

LEFT JOYSTICK ....................................................................................................... 39
DIPPER TRIP ............................................................................................................ 39
SIGNAL HORN ........................................................................................................... 39
RADIO ....................................................................................................................... 39
HOIST BRAKE .......................................................................................................... 40
CROWD BRAKE ...................................................................................................... 40
SWING BRAKE ......................................................................................................... 40
PROPEL BRAKE ...................................................................................................... 40
Left Control Console .................................................................................................................. 40
CLIMATE CONTROL PANEL ..................................................................................... 40

WINDSHIELD WIPER SWITCH ................................................................................ 40
WINDSHIELD WASHER SWITCH ............................................................................ 40
CONTROLS ON THE RIGHT CONSOLE ....................................................................... 41
RIGHT JOYSTICK ..................................................................................................... 41
CONTROL STOP PUSHBUTTON ............................................................................ 42
Right Control Console ................................................................................................................ 42
CONTROL RESET PUSHBUTTON .......................................................................... 42
Manual No. 10710
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Dec 2008

DIG/PROPEL TRANSFER SWITCH ............................................................................... 43

EMERGENCY STOP PUSHBUTTON ....................................................................... 43
MAIN POWER OFF PUSHBUTTON ......................................................................... 43
CONTROL STOP PUSHBUTTON ............................................................................ 44
Right Control Console ................................................................................................................ 44
CONTROL RESET PUSHBUTTON .......................................................................... 44

DIG/PROPEL TRANSFER SWITCH ............................................................................... 45
EMERGENCY STOP PUSHBUTTON ....................................................................... 45
MAIN POWER OFF PUSHBUTTON ......................................................................... 45
EARTH CONTINUITY LOCKOUT PUSHBUTTON .................................................... 46
TELEPHONE ............................................................................................................. 46
OPERATORS SEAT .................................................................................................................. 46
Operators Seat - Front View ...................................................................................................... 46
OPERATORS DISPLAY ............................................................................................................. 48

Operators Display Panel ............................................................................................................ 48
DISPLAY AREA AND INDICATORS ....................................................................................... 49

AUXILIARY CONTROLS ............................................................................................................. 50
REMOTE START CONSOLE ............................................................................................... 50
HOUSE LIGHT CIRCUIT BREAKERS .................................................................................. 51
LIGHTING TRANSFER SWITCH ........................................................................................... 52
LUBRICATION CONTROL PANEL ........................................................................................ 52
WINDSHIELD WIPERS ........................................................................................................ 53
WINDSHIELD WASHER ....................................................................................................... 53
PRE-START CHECKS ................................................................................................................ 54
WALKAROUND GROUND LEVEL INSPECTION ................................................................. 54
ON-BOARD INSPECTION .................................................................................................... 55
MACHINE START-UP, OPERATION AND SHUTDOWN ............................................................. 57
START-UP ............................................................................................................................. 57
Start-Up Control Locations ......................................................................................................... 57
RESTARTING AFTER AN ELECTRICAL FAULT ................................................................... 59

RESTARTING AFTER AN ELECTRICAL FAULT ................................................................... 61
OPERATION ......................................................................................................................... 62
MACHINERY MOTIONS ........................................................................................................ 63
HOIST MOTION ............................................................................................................... 63
CROWD MOTION ........................................................................................................... 64
PROPEL MOTION ........................................................................................................... 65
Propel - Straight Forward/Reverse .............................................................................................. 65
SWING MOTION ............................................................................................................. 66

PROPER SWING MOTION ............................................................................................. 67
STEERING ...................................................................................................................... 68
COUNTER-ROTATION TURNS ...................................................................................... 70
Dec 2008
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Manual No. 10710

POSITIONING THE MACHINE .................................................................................................... 71

BACK-UP METHOD .............................................................................................................. 71
DRIVE-BY METHOD ............................................................................................................. 72
START OF THE DIG CYCLE .......................................................................................... 73
Force the Dipper Lip into the Bank ............................................................................................. 73
Variations on Dipper Penetration ................................................................................................ 74
Dig with the Dipper Beneath the Boom Point .............................................................................. 75
ENGAGING THE BANK ................................................................................................... 75

EXCAVATED MATERIAL ........................................................................................................ 77
OPERATION CHECKS ......................................................................................................... 78
OPERATING HINTS .............................................................................................................. 79
STOPPING THE MACHINE ................................................................................................... 80
MACHINE SHUTDOWN ........................................................................................................ 80
GENERAL ESTIMATED COMPONENT WEIGHTS .................................................................... 81
295HR Shovel Specifications .......................................................................................... ( insert )
Manual No. 10710
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Dec 2008

295HR Mining Shovel

Operators Manual
GENERAL INFORMATION
This manual is designed to assist the owner in the operation and preventive maintenance 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. It is important to remember that when a systematic
and thorough maintenance/service procedure is used for this machine, a minimum of unplanned
downtime and more reliable operation will result.
Throughout this section, and the remainder of this manual, the use of the terms LEFT, RIGHT,
FRONT, and REAR refer to machine locations as viewed by the operator sitting in the operators
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
Telephone (414)-768-4000
53172-0500
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.
Dec 2008
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Manual No. 10710

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 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 eyesight, hearing or reactions.
CAUTION:
STORED ENERGY! Components on machine are heavy and

removal of pins without proper preparation and precaution can cause
serious bodily injury and/or damage to the front-end of the machine.
Safety must always be paramount!

Consult your supervisor when safety is in doubt.
Manual No. 10710
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Dec 2008

SAFETY PRECAUTIONS
General Precautions:
The employment of qualified maintenance personnel, through a scheduled maintenance
program, is the best way to minimize machine downtime and maximize productivity of
equipment.
Keep hands, feet and clothing away from rotating parts.
Wear a hard hat, safety shoes and protective lenses at all times.
Replace any and all safety and warning placards if they are defaced or removed from the
machine.
Think before you act. Carelessness is one luxury the service man cannot afford.
Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case
of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested
method of cleanup.
Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip
off of the hook if they are not functioning properly.
If a heavy item begins to fall, let it fall, dont 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.
Dec 2008
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Manual No. 10710

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.
Manual No. 10710
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Dec 2008

Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.
Always wear approved rubber gloves and use insulated hooks or tongs when handling trail
cable.
Operating Precautions:
Wear hearing protection when exposed to the following noise levels in excess of the period
indicated:
8 hours at 90 dBa
4 hours at 95 dBa
2 hours at 100 dBa
1 hour at 105 dBa
30 minutes at 110 dBa
15 minutes at 115 dBa
When in doubt about the noise level, wear approved hearing protection.
Do not attempt to get on or off the machine while it is in operation. Notify the operator prior to
any attempt to board/exit the machine.
Do not move or operate the machine without first knowing the location and purpose of all
personnel, test or support equipment, on or near the machine.
Do not allow unauthorized personnel on board the machine while in operation.
Use audible signals to warn of machine movements. A signal horn button is provided for this
purpose.
Do not propel until the travel route has been cleared of obstructions.
Do not propel the machine on a slope greater than that specified in SLOPE LIMITATIONS in
Section 2 - 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.
Dec 2008
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Manual No. 10710

FIRE PREVENTION
Always have a charged fire extinguisher on hand and know how to use it. Inspect and
service the extinguisher as indicated on its instruction plate.
DO NOT smoke while handling flammables or when near batteries.
Inspect all lines, tubes and hoses

carefully. Tighten all connections to
the recommended torque. See
Chapter 4 of this manual for the
Scheduled
Maintenance
recommendations and the Daily
Inspection procedure.
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.
Fire Extinguisher Locations
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. 10710
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Dec 2008

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.
Dec 2008
1 - 11
Manual No. 10710

Stored Energy Decals
Manual No. 10710
1 - 12
Dec 2008

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.
Nomenclature
Dec 2008
1 - 13
Manual No. 10710

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.
[graphic lwks1346 in process]
Truck Frame and Crawlers
Manual No. 10710
1 - 14
Dec 2008

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 sprockettype 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.
Crawler Assembly
Dec 2008
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Manual No. 10710

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.
Manual No. 10710
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Dec 2008

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.
Swing Rack and Roller Circle
Dec 2008
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Manual No. 10710

ROLLER CIRCLE
The roller circle is composed of the upper rails, lower rails, thrust rails, 54 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.
Roller Circle Assembly
Manual No. 10710
1 - 18
Dec 2008

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.
Dec 2008
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Manual No. 10710

COLLECTOR RINGS
High voltage collector rings between the revolving frame and truck frame transfer electric power
from the truck frame to the rotating deck. Electric power enters the truck frame between 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.
ROTATING DECK
The rotating deck consists of revolving frame, center pintle, right and left deck extensions, operators
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.
Manual No. 10710
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Dec 2008

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 Aframe, crowd machinery and boom. Provisions
are made for mounting deck extensions, operators
cab, ballast box and swing gearcases. Machined
pads on the deck locate the hoist drive motor and
machinery frames.
Refer to the following page for a view of the
revolving frame assembly with deck extensions
and ballast box.
The revolving frame is connected to the truck
frame by the center pintle.
CENTER PINTLE
The center pintle is a large diameter, hollow
cylindrical forging with a flange at the top. It is
threaded at the bottom with a lower locknut used
to hold it in place. A bronze coated steel core
spherical thrust washer between the lower locknut
and the bottom surface of the truck frame provides
a wear surface for pintle loads. The upper locknut
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.
Dec 2008
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Manual No. 10710

DECK EXTENSIONS
Right and left side deck extensions are bolted to each side of the revolving frame. They provide a
mounting area for the electrical transformers and accessory machinery as well as supporting the
machinery house walls.
Deck Extensions and Ballast Box
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. 10710
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Dec 2008

BOARDING STAIRS
A set of boarding stairs is attached to the machinery house platform on the right side of the machine.
When lowered, the stairs allow entrance to the machinery house from ground level. These stairs
must be in their raised and latched position to enable the operators controls.
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 revolving frame. The A-frame supports the boom via structural
strands.
A- Frame and Front End Support Components
Dec 2008
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Manual No. 10710

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.
[graphic hstp1346 in process]
Hoist Machinery - Plan View
Manual No. 10710
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Dec 2008

SWING MACHINERY
[graphic hstp1346 in process]
Swing Machinery Components
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.
Dec 2008
1 - 25
Manual No. 10710

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 limit switch prevents overtravel of
the dipper handle. The entire machinery unit can be removed from the machine should maintenance
or overhaul become necessary.
Crowd Machinery Components
The crowd drum drives the crowd and retract rope system. Rope grooves are machined 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 to the RH gearcase and connected to the
crowd motor using a motor coupling assembly.
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Dec 2008

OPERATORS CAB
The isolated and elevated operators 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 operators seat, a helpers seat and the standard operators display panel.
[graphic cab_1346 in process]
The cab is sound and heat insulated with interior walls made of a sound deadening steel-plasticsteel 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. Transparent sun shades
are provided in front and side windows.
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.
Dec 2008
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Manual No. 10710

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.
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 roller circle rollers, electric motors, suspension rope pins and some dipper pins are manually
accessed. All other lube points are fed from the automatic system or by oil bath.
Manual No. 10710
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Dec 2008

A single-line automatic lubrication system applies open gear lubricant (OGL) and grease via a
programmable logic controller (PLC). The system has four lube pumps (two for OGL and two for
grease), each feeding individual PLC controlled circuits. Lincoln 75:1 air powered pumps are
mounted on each of the two 85 gallon reservoirs. High pressure hoses with reusable fittings are
utilized.
Lubrication Room
The four separately controlled lube circuits provide selective distribution frequency and quantity
resulting in reduced lubricant usage and cost.
Dec 2008
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Manual No. 10710

LUBE RESERVOIR FILL / OVERFLOW PLUMBING
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.
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Dec 2008

FRONT END EQUIPMENT

The front end equipment consists of the boom, the boom point sheaves, padlock, saddle block,
dipper handle, dipper, dipper trip mechanisms, running ropes and boom suspension strands.
SUSPENSION STRANDS
The suspension strands are designed to maintain the proper boom angle. These are fixed-length
strands that support the entire weight of the boom and the load.
Dec 2008
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Manual No. 10710

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.
[graphic boom1346 in process]
Boom Assembly
The boom is supported by four pre-stressed suspension (structural) strands attached to equalizer
links on the A-frame. These inherent long life structural strands carry the working loads of the front
end equipment. A boom limit switch with soft setdown prevents boom jacking shock loads.
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Dec 2008

RUNNING ROPES
Hoist, crowd, retract and dipper trip ropes are all plastic impregnated for increased life and for
sheave and drum grooving life enhancement. The double twin hoist ropes are attached to the
center of the hoist drum using ferrule-becket anchoring for faster rope change out. Each rope
passes over a boom point sheave through the padlock and back over the boom point sheave to the
hoist drum. The dual twin hoist rope configuration stabilizes the dipper while digging by attachment
to the outer edges of the dipper body.
Ropes - General Arrangement
Crowd and retract ropes are attached to the crowd drum and work as an integral system. As the
crowd rope is wound on to the drum, the retract rope is reeled off.
Dec 2008
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Manual No. 10710

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.
[graphic sdbk1346 in process]
DIPPER HANDLE
The dipper is attached to one end of the large diameter handle. The crowd rope half-sheave is
attached to the other end. A hydraulic rope take-up mechanism at the dipper end, and the crowd
rope adjusting mechanism are used to remove slack from the crowd/retract rope system. The
dipper handle crowds out and retracts within the saddle block.
An electrical rate reduction circuit, along with the crowd ropes, absorb digging shock loads
encountered when the dipper is crowded into the bank.
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Dec 2008

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 doors swinging action.
Dipper Assembly
Dec 2008
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Manual No. 10710

PADLOCKS
Padlocks connect the hoist ropes to the outer edges of the dipper while still permitting fore and aft
and sideways movement.
Left and Right Padlocks
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Dec 2008

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.
Dipper Trip Motor and Dipper Trip Sheave
Dec 2008
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Manual No. 10710

PRIMARY OPERATING CONTROLS
Operators Control Consoles in the Cab
Manual No. 10710
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Dec 2008

CONTROLS ON THE LEFT CONSOLE

LEFT JOYSTICK
omsL1346
The Left Joystick controls the crowd/horn/dipper trip and propel. It is the vertical handle mounted
on the left console of the operators seat. This joystick will spring return to neutral when released.
During normal operation, pushing the joystick forward will extend the dipper handle and dipper into
the bank. Pulling the joystick rearward will retract the dipper handle and dipper toward the machine.
The neutral position between the crowd and retract functions is defined by a detent that is easily
felt. The rate of motion is controlled by varying the distance the joystick is moved from the neutral
(center) position. Full forward or full rearward position provides maximum speed to the handle.
Moving the joystick to neutral will cause a braking action slowing the crowding or retracting handle.
Reversing the joystick will cause the motion to stop and if the joystick is held in this position, it will
change the direction of the motion.
With the propel transfer switch in the PROPEL position, pushing the joystick forward will cause the
left crawler to move forward. Pulling the joystick to the rear will cause the left crawler to move in the
reverse direction. The crowd/retract motion is locked out electrically when the machine is in the
propel mode.
Refer to JOYSTICK CONFIGURATION in this section of the manual to view the standard and
alternate configurations for the Right and Left Joysticks.
DIPPER TRIP
The dipper trip is part of the left joystick function in the standard configuration. Moving the joystick
to the right will activate the dipper trip mechanism which releases the dipper door latch. The dipper
trip is operational throughout the entire range of the crowd motion.
SIGNAL HORN
Moving the Left Joystick (in the standard configuration) to the left will activate the signal horn. The
signal horn is operational throughout the entire movement range of the crowd motion.
RADIO
The radio supplied with your machine is an AM/FM Stereo radio with cassette player.
Dec 2008
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Manual No. 10710

HOIST BRAKE
A selector switch used to set or release
the Hoist Brake.
CROWD BRAKE
the Crowd Brake.
SWING BRAKE
the Swing Brake.
PROPEL BRAKE
the Propel Brake.
Left Control Console
CLIMATE CONTROL PANEL

The Climate Control Panel contains a rheostat controller on the top portion of the panel which is
used to tailor the temperature of the air delivered to the operators cab within the selected mode of
operation.
The Mode switch is provided to set the basic mode of operation for the roof mounted air conditioning/
heater unit.
The Blower Speed switch controls the volume of air being moved by the unit.
WINDSHIELD WIPER SWITCH
The windshield wiper switch is located on the Operator Display monitor console at the left of the left
operators console. It controls the speed of the wipers, as well as the starting and stopping of the
wipers.
WINDSHIELD WASHER SWITCH
The windshield washer switch is located with the windshield wiper switch on the Operator Display
monitor console. It controls the supply to the washer reservoir which powers the washers.
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Dec 2008

CONTROLS ON THE RIGHT CONSOLE
RIGHT JOYSTICK
omsR1346
The Right Joystick controls the hoist/swing and propel. It is a joystick mounted on the right console
of the operators seat. The joystick is used to control the hoist, swing and right crawler motions of
the machine. The position of the propel transfer switch will determine whether this joystick controls
the hoist motion or the crawler motion.
With the propel transfer switch in the dig position, and during normal operation, pushing the joystick
forward will lower the dipper. Pulling the joystick to the rear will hoist the dipper. The neutral
position between the hoist and lower functions is defined by a detent that is easily felt. The speed
of moving the dipper is controlled by varying the distance the joystick is moved from the neutral
(center) position. The full forward or full rearward position provides maximum speed to the dipper.
Moving the joystick to neutral will cause a braking action slowing the hoisting or lowering motion.
Reversing the joystick will cause the motion to stop and if the joystick is held in this position, it will
change the direction of the motion.
NOTE: When the right joystick is used in the hoist/lower mode it is a spring returned switch.
That is, it will return to the neutral position when it is released.
Moving the joystick to the left from the neutral position will cause the machine to swing to the left.
Moving the joystick to the right will cause the machine to rotate to the right. The swing motion is
operational throughout the entire movement range of hoisting or lowering the dipper. The swing
rate of acceleration is controlled by varying the distance the joystick is moved from the neutral
position. Moving the joystick to the neutral position will not stop the swing motion but will allow the
machine to coast. To stop or change direction the control joystick is moved past the neutral point
in the opposite direction. The rate of deceleration is controlled by varying the distance the joystick
is moved from the neutral position in the opposite direction.
Refer to JOYSTICK CONFIGURATION in this section of the manual to view the alternate
configurations for the Right and Left Joysticks.
With the propel transfer switch in the propel position, pushing the joystick forward will cause the
right crawler to move forward. Pulling the joystick to the rear will cause the right crawler to move in
the reverse direction. The hoist motion is locked out electrically when the machine is in the propel
mode.
NOTE: When the JOYSTICK is used in the swing mode the switch is a spring returned switch.
That is, it will return to the neutral position when it is released.
Dec 2008
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Manual No. 10710

CONTROL STOP PUSHBUTTON

The control stop pushbutton is a pushbutton located on the right operators 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
OPERATORS 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.
Right Control Console
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 operators console. The reset
pushbutton restores control to all motions if no additional faults exist. This pushbutton is inoperative
until the main power start control has been actuated.
If a control fault occurs that shuts down a motion, all motions will automatically be shut down
together. At this time the operator should set all brakes. If the fault clears, the motion may be reset
by pressing this pushbutton. If the fault does not clear, the unfaulted motions can be restarted by
pressing this pushbutton to enable these motions to re-position themselves.
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Dec 2008

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 Operators screen on the Operators
Display.
IMPORTANT:
WHILE IN THE DIG MODE, THE PROPEL CONTROLS ARE DISABLED.
WHILE IN THE PROPEL MODE, THE DIG CONTROLS ARE DISABLED.
The recommended procedure to transfer from dig to propel is to bring all motions to a controlled
stop by the operator. Turn the hoist brake switch to the SET position and then press the control
stop pushbutton. Turn the transfer switch from DIG to PROPEL. When the indicator on the Operator
Display screen indicates that the transfer has been completed, turn the propel brake switch to
release.
EMERGENCY STOP PUSHBUTTON
The machine stop/emergency stop pushbutton is located on the right operators console. It is used
to remove power from the machine motions after the motions have been stopped in the normal
manner. A second purpose of the pushbutton is to stop the machine under operational emergency
conditions. Pushing this button will provide electrical and immediate mechanical braking
simultaneously. Therefore, this button should only be used if the operator intends the harshest
braking of all motions. If the machine is in motion, power will remain on the motions in order to
provide electrical braking for a few seconds. If the machine is in motion or stopped, this button will
power the DC bus to approximately zero voltage quickly after the time delay.
CAUTION:
PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY

RESULT IN COMPONENT DAMAGE.
A second pushbutton that also provides the functions as described above is located in the remote
start console and is labeled machine stop.
MAIN POWER OFF PUSHBUTTON
The main power off pushbutton is located on the right operators console. It is used only to immediately
remove power from the drives in case of an electrical emergency involving component failure or
fire.
CAUTION:
Dec 2008
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.
1 - 43
Manual No. 10710

CONTROL STOP PUSHBUTTON

The control stop pushbutton is a pushbutton located on the right operators 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
OPERATORS 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.
Right Control Console
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 operators console. The reset
pushbutton restores control to all motions if no additional faults exist. This pushbutton is inoperative
until the main power start control has been actuated.
If a control fault occurs that shuts down a motion, all motions will automatically be shut down
together. At this time the operator should set all brakes. If the fault clears, the motion may be reset
by pressing this pushbutton. If the fault does not clear, the unfaulted motions can be restarted by
pressing this pushbutton to enable these motions to re-position themselves.
Manual No. 10710
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Dec 2008

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 Operators screen on the Operators
Display.
IMPORTANT:
WHILE IN THE DIG MODE, THE PROPEL CONTROLS ARE DISABLED.
WHILE IN THE PROPEL MODE, THE DIG CONTROLS ARE DISABLED.
The recommended procedure to transfer from dig to propel is to bring all motions to a controlled
stop by the operator. Turn the hoist brake switch to the SET position and then press the control
stop pushbutton. Turn the transfer switch from DIG to PROPEL. When the indicator on the Operator
Display screen indicates that the transfer has been completed, turn the propel brake switch to
release.
EMERGENCY STOP PUSHBUTTON
The machine stop/emergency stop pushbutton is located on the right operators console. It is used
to remove power from the machine motions after the motions have been stopped in the normal
manner. A second purpose of the pushbutton is to stop the machine under operational emergency
conditions. Pushing this button will provide electrical and immediate mechanical braking
simultaneously. Therefore, this button should only be used if the operator intends the harshest
braking of all motions. If the machine is in motion, power will remain on the motions in order to
provide electrical braking for a few seconds. If the machine is in motion or stopped, this button will
power the DC bus to approximately zero voltage quickly after the time delay.
CAUTION:
PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY

RESULT IN COMPONENT DAMAGE.
A second pushbutton that also provides the functions as described above is located in the remote
start console and is labeled machine stop.
MAIN POWER OFF PUSHBUTTON
The main power off pushbutton is located on the right operators console. It is used only to immediately
remove power from the drives in case of an electrical emergency involving component failure or
fire.
CAUTION:
Dec 2008
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.
1 - 45
Manual No. 10710

EARTH CONTINUITY LOCKOUT PUSHBUTTON

The earth continuity lockout pushbutton is used to trip the breaker that supplies power to the machine.
When the machine is operating, this pushbutton should be used to shutdown the machine only
when removal of power to the machine is required.
TELEPHONE
A telephone is located at the rear of the right control console. This telephone is connected to other
phone stations throughout the machine.
OPERATORS SEAT
Operators Seat - Front View
Manual No. 10710
1 - 46
Dec 2008

The operators seat has been selected to provide a maximum of operator comfort along with easy
control access for increased productivity. The seat has numerous adjustments allowing it to be
tailored to meet the individual needs of each operator.
Weight Adjustment
The seat should be adjusted for the operators weight by pulling the actuator lever of the automatic
weight and height adjuster while the operator is sitting in the seat and the machine is stationary.
Height Adjustment
The seat height is adjusted pneumatically by pulling or pressing the adjustment lever as required to
obtain the position required. DO NOT operate the compressor unit for more that 1 minute
continuously.
Seat Cushion Angle Adjustment
The angle of the seat cushion can be adjusted individually from the back. Lift the handle and exert
pressure in the desired direction while seated. Release handle once the required position is achieved.
Seat Depth Adjustment
The depth of the seat pan can be individually adjusted. Lift the handle and slide the seat pan
forward or backwards to position. Release the handle when the desired position is obtained.
Armrest Adjustment
The armrests can be adjusted to fit the individual needs of each operator or folded up and placed
out of the way.
To adjust the armrest height loosen the manual friction knobs on the outboard side of the armrest
allowing the armrests to pivot. Move the armrest to any desired position within its range and retighten when desired.
To raise the arm rests; lift at front and stow vertically.
Headrest Adjustment
The headrest can easily be adjusted by lifting, or tilting, headrest to the desired position.
Lumbar Support
The curvature of the backrest can be adjusted pneumatically by pressing the switches on the lower
left rear of the backrest.
Backrest Adjustment
The backrest is adjusted by lifting the lever and then releasing once the desired position is obtained.
Dec 2008
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Manual No. 10710

OPERATORS DISPLAY
A PC based Operators Display is used to provide the operator with an interface to the machine and
its functional areas. From this informational display the operator can make inputs that affect machine
operation, monitor systems and make system adjustments. Through this display terminal the
operator will receive pertinent fault data to identify potential problems and prevent machine damage.
Operators Display Panel
The display panel is mounted on an arm assembly protruding from a pedestal on the right side of
the operator. The arm allows individual operators to locate the screen in any desired position. The
monitor screen can be rotated along the horizontal and vertical axes.
Manual No. 10710
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Dec 2008

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.
All the machine controls can be found on the Operators Display Panel touch sensitive screen or
the left and right Control Consoles of the operators seat.
Dec 2008
1 - 49
Manual No. 10710

AUXILIARY CONTROLS
REMOTE START CONSOLE

The remote start panel is located on the right
side of the machine just inside the machinery
house door. The panel contains the following
switches and indicator lights used to initially start
the machine:
Phase Sequence Light
This green indicator light, when lit, indicates that
incoming power sequence is correct. If the light
is OFF, have electrical maintenance change the
trail cable phase sequence.
Drive Cabinets Temperature Light
This green indicator light, when lit, indicates that
the drive electronic cabinets are at the correct
operating temperature. Too low or too high
cabinet temperatures will not allow the machine
to start.
PLC Power On Light
This green indicator light, when lit, indicates that PLC and drive control power is on. This light
should be lit about 20 seconds after the UPS mg set is started.
System Ready Light
This green indicator light, when lit, indicates the system is ready to start. When the system run
pushbutton is pressed and the system successfully started, this light will go out.
Auxiliary Ground Fault Light
This green indicator light, when lit, indicates that no auxiliary power ground fault exists. If the light is
OFF, alert an electrician as soon as possible.
Manual No. 10710
1 - 50
Dec 2008

Incomplete Sequence Light

This red indicator light, when lit, indicates the automatic start-up sequence did not complete in a
preset time period. Have an electrician troubleshoot the sequence. If this indicator does not light
up, the start-up sequence is progressing properly and machine start-up can continue.
System Run Pushbutton
This pushbutton will energize the drive system when pressed if the system ready light is on.
Air Compressor Start/Stop Pushbuttons
The air compressor start and stop pushbuttons are used to control the auxiliary air compressor.
The stop pushbutton is only used for complete machine shutdown or when maintenance is being
performed on the air compressor.
HOUSE LIGHT CIRCUIT BREAKERS

The house light circuit breakers are located on the right side wall of
the machinery house next to the remote start console. A main light
circuit breaker is located on the auxiliary control cabinet. The breakers
protect the lights from over-current loads.
Dec 2008
1 - 51
Manual No. 10710

LIGHTING TRANSFER SWITCH
The lighting transfer switch is located on the right side wall of the
machinery house near the lighting control center. This switch is used
to transfer power for lighting from on machine source to off machine
source.
LUBRICATION CONTROL PANEL

The top row on this panel consists of a group of indicating lights. A red light indicating that the
system has a fault and a green light indicating that power for the system is provided for each
independent lubricating system (A, B & C). Isolating switches are used to provide power to each
system and a means of isolating each system from electrical power. They are also used to reset
lubrication faults. These switches are normally on. Manual lube buttons are also provided.
Manual No. 10710
1 - 52
Dec 2008

WINDSHIELD WIPERS
There are two electrically operated windshield wipers on the front window of the cab: one for the
lower portion of the window and one for the upper portion of the window.
Check the wiper blades to make sure they swing freely across the window without contacting the
window frame. Reposition the pantograph arm on the wiper motor shaft if necessary to prevent
contact with the window frame.
Frequently check the condition of the wiper blades and replace if damaged.
WINDSHIELD WASHER
An optional electric operated windshield washer unit supplies a cleaning agent to the windshield
through spray nozzles when activated. When operating in warm climates, water may be used as
the agent. In areas where freezing temperatures are encountered, a suitable commercial windshield
washer solvent with anti-freezing characteristics is recommended.
Dec 2008
1 - 53
Manual No. 10710

PRE-START CHECKS
Before starting, inspect the machine to ensure it is ready to be put into operation. Failure to make
such a routine check could result in unnecessary downtime. For example: an undetected oil leak
could result in a dry gearcase, eventually leading to excessive gear wear or destruction, seized
bearings or other mechanical problems. Broken strands in the hoist ropes, crowd rope, retract
rope or structural strands could, if undetected, result in serious injury or damage to the machine or
haulage unit. A few minutes spent inspecting the machine often results in considerable savings in
time and machine efficiency. Section 4 of this manual contains reproducible checklists to assist in
record keeping and ensure that adequate inspection standards are met.
WALKAROUND GROUND LEVEL INSPECTION
Check the following areas daily during a general walkaround inspection:
1.
Check the areas under and around the crawlers for signs of oil leaks. If single droplets are
noticed, leakage is minimal. Determine the point of leakage and make a note of it on the log
sheet. If pooling of oil is noticed, determine the source and take corrective action immediately.
Determine if loose hardware, a defective gasket, a combination of both, or a similar problem
is responsible. Tighten hardware or replace defective gaskets.
2.
Inspect the crawler belts for missing links or lock pins, excessive belt sag, cracked shoes or
other deterioration. Check the oil level in the propel planetary gearcase. Add oil as required.
3.
Check the swing rack and pinion guards for rocks, dirt and other debris that will interfere with
the operation of the machine. Inspect the swing rack gear and rollers for the proper lubricant
film.
DANGER:
HIGH VOLTAGE! THE MACHINE TRAIL CABLE CARRIES A LETHAL

VOLTAGE. Handle the cable in an approved manner with appropriate
rubber gloves and insulated hooks or tongs.
4.
Visually inspect the trail cable for cuts, abrasions and other damage.
5.
Visually inspect exterior of machinery house for damage or evidence of internal leakage.
6.
Inspect the dipper trip mechanism, rope, latch bar and associated hardware for damage,
adjustment and wear.
7.
Inspect the dipper door, hardware and bumpers for damage and excessive wear.
8.
Inspect fulcrum attachment points, take up cylinders and spacers, and dipper handle for
damage, excessive wear and evidence of adequate lubrication.
9.
Inspect boom bumper for security and damage.
Manual No. 10710
1 - 54
Dec 2008

10.
Inspect the dipper and tooth adapters for tightness and excessive wear.
11.
Inspect padlocks for damage, wear and evidence of adequate lubrication.
12.
Check both the running ropes and the boom structural strands for broken strands and loose
sockets.
ON-BOARD INSPECTION
Check the following areas daily on board the machine:
1.
Visually inspect the swing, crowd and hoist gearcases for oil levels and leaks. Repair or
service as required.
2.
Visually inspect all machinery for loose bolts, nuts, clamps or unusual deterioration. Repair
as required.
3.
Visually inspect the open gears of the swing, crowd and hoist machinery for proper lubricant
film and evidence of adequate lubrication from the automatic lubricant dispensing system.
4.
Visually inspect hoist and crowd ropes for wear, lubrication and evidence of birdcaging near
the drum attachment beckets.
5.
Check the oil level in the air compressor. Add oil if required.
6.
Check lubricant supply level in the air system lubricator and lube system lubricators.
7.
Inspect the automatic lubrication central pumping stations for any signs of malfunctioning.
Check the lubricant supply and refill tanks if required.
8.
Visually inspect swing, crowd and hoist brake assemblies for damage, wear and evidence of
an overheated condition.
9.
Check the operators 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 operators cab.
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Manual No. 10710

11.
Inspect all walkways and stairways to ensure there are no obstructions or fluids creating a
safety hazard.
12.
Ensure ladder(s), steps and/or man basket are raised and properly stowed.
13.
Perform the following manual lubrication points. Detailed information on the proper servicing
of these components can be found in Sections 3 and 4 of this manual.
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Dec 2008

MACHINE START-UP, OPERATION AND SHUTDOWN

START-UP
Whether starting the machine for the first time, or starting after the machine has been in service for
some time, the procedures are essentially the same.
1.
Perform all pre-start checks listed in PRE-START CHECKS in this section of the manual.
2.
Raise the boarding stair, making sure it is secured in the raised position. The limit switch at
the top of the stair will not close and the controls will not energize if the stair is not in the fullyraised position.
[graphic stpl1346 in process]
Start-Up Control Locations
3.
In the operators cab check that all brake switches are in the SET position and that the
joysticks are in the neutral position. Then go to the electrical room at the rear of the machinery
house.
4.
At the AC control cabinet verify that the uninterruptable breaker is in the ON position. At the
motor control cabinet, verify that all breakers are in the ON position.
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Manual No. 10710

5.
At the remote starting console in the machinery house, use the following sequence to start
the machine:
a.
Verify that the green AUXILIARY GROUND FAULT light is lit.
CAUTION:
b.
IF THE AUXILIARY GROUND FAULT LIGHT IS OFF, ALERT AN

ELECTRICIAN AS SOON AS POSSIBLE. The machine may be
operated with one fault but a second fault could cause damage to the
machine and/or become a safety hazard. The fault should be cleared
as soon as possible.
Verify that the green PHASE SEQUENCE light is lit. This indicates that the incoming
power sequence is correct. If not, the light will be out and the machine will not start.
Electrical maintenance personnel must correct the problem.
NOTE: This PHASE SEQUENCE light also indicates auxiliary power phase unbalance, phase
loss or under-voltage. Any of these faults occurring while the machine is running will
produce an alarm. In the event of such an alarm an electrician should be notified,
however the machine may be operated.
6.
c.
Verify that the PLC and drive cabinets green temperature lights are lit. If the cabinet
temperature is too low or too high, the machine cannot be started.
d.
Press the UNINTERRUPTABLE POWER SUPPLY on pushbutton. A second start

pushbutton is located on the UPS control cabinet.
e.
Verify that the green PLC POWER ON light is lit. This light should be on about 20
seconds after the UPS motor is started.
f.
Turn the AIR COMPRESSOR RUN switch to the run position or press the start
pushbutton.
g.
Verify that the green SYSTEM READY light is lit.
h.
Press the SYSTEM RUN pushbutton. When this button is pressed, the system ready
light will go out and the drive system will automatically power up.
i.
Verify that the red INCOMPLETE SEQUENCE light is out. If lit, call the electrician to
troubleshoot the sequence.
In the operators cab, verify that the air pressure displayed on the operators display is correct.
The machine cannot be operated until the air pressure is at the specified rating.
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Dec 2008

7.
Verify that the brake switches are in the set position, the joysticks are in the neutral position
and the air pressure is at the correct pressure. Sound the signal horn and be sure all personnel
are clear of machine.
8.
Turn the propel transfer switch to the DIG position. When the Operator Display lights indicate
that the process is complete, press the control reset pushbutton to activate the controls.
9.
Turn the hoist, crowd, swing and propel brake switches to their RELEASED position.
10.
Briefly actuate swing, crowd, hoist and propel controls to make sure each motion is operational.
RESTARTING AFTER AN ELECTRICAL FAULT

To restart the machine after the electrical control system has gone into a fault condition, proceed
as follows:
NOTE: Before any or all motions can be reset, the following conditions must be met:
a.
No operators monitor special screens should be activated.
b.
For hoist/propel motion the hoist/propel transfer switch is in the position called for by the
operators mode selector switch.
c.
The joystick for the motion being reset must be in the neutral position.
d.
The motion mechanical brake selector switch must be in the released position.
1.
For hoist or crowd travel limit faults, the motion will first slow down and then will stop, but the
controls will remain active. Reversing the joystick will remove the fault and allow continued
operation.
2.
For a boom jacking fault, the motion will stop but the controls will remain active. Reversing
the left joystick will remove the fault and allow continued operation.
3.
If the boarding ladder is pulled down while the machine is in operation, an alarm message will
be sent to the operator and swing and propel motions will be shut down. The hoist and crowd
motions will remain active.
Once the ladder is back in position, the motions may be restarted by pressing the control
reset pushbutton.
4.
For most other faults, the machine will be shut down and the brakes set. In these situations,
the controls cannot be reset until the fault has been corrected by an electrician.
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Manual No. 10710

5.
At the remote starting console in the machinery house, use the following sequence to start
the machine:
a.
Verify that the green AUXILIARY GROUND FAULT light is lit.
CAUTION:
b.
IF THE AUXILIARY GROUND FAULT LIGHT IS OFF, ALERT AN

ELECTRICIAN AS SOON AS POSSIBLE. The machine may be
operated with one fault but a second fault could cause damage to the
machine and/or become a safety hazard. The fault should be cleared
as soon as possible.
Verify that the green PHASE SEQUENCE light is lit. This indicates that the incoming
power sequence is correct. If not, the light will be out and the machine will not start.
Electrical maintenance personnel must correct the problem.
NOTE: This PHASE SEQUENCE light also indicates auxiliary power phase unbalance, phase
loss or under-voltage. Any of these faults occurring while the machine is running will
produce an alarm. In the event of such an alarm an electrician should be notified,
however the machine may be operated.
6.
c.
Verify that the PLC and drive cabinets green temperature lights are lit. If the cabinet
temperature is too low or too high, the machine cannot be started.
d.
Press the UNINTERRUPTABLE POWER SUPPLY on pushbutton. A second start

pushbutton is located on the UPS control cabinet.
e.
Verify that the green PLC POWER ON light is lit. This light should be on about 20
seconds after the UPS motor is started.
f.
Turn the AIR COMPRESSOR RUN switch to the run position or press the start
pushbutton.
g.
Verify that the green SYSTEM READY light is lit.
h.
Press the SYSTEM RUN pushbutton. When this button is pressed, the system ready
light will go out and the drive system will automatically power up.
i.
Verify that the red INCOMPLETE SEQUENCE light is out. If lit, call the electrician to
troubleshoot the sequence.
In the operators cab, verify that the air pressure displayed on the operators display is correct.
The machine cannot be operated until the air pressure is at the specified rating.
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Dec 2008

7.
Verify that the brake switches are in the set position, the joysticks are in the neutral position
and the air pressure is at the correct pressure. Sound the signal horn and be sure all personnel
are clear of machine.
8.
Turn the propel transfer switch to the DIG position. When the Operator Display lights indicate
that the process is complete, press the control reset pushbutton to activate the controls.
9.
Turn the hoist, crowd, swing and propel brake switches to their RELEASED position.
10.
Briefly actuate swing, crowd, hoist and propel controls to make sure each motion is operational.
RESTARTING AFTER AN ELECTRICAL FAULT

To restart the machine after the electrical control system has gone into a fault condition, proceed
as follows:
NOTE: Before any or all motions can be reset, the following conditions must be met:
a.
No operators monitor special screens should be activated.
b.
For hoist/propel motion the hoist/propel transfer switch is in the position called for by the
operators mode selector switch.
c.
The joystick for the motion being reset must be in the neutral position.
d.
The motion mechanical brake selector switch must be in the released position.
1.
For hoist or crowd travel limit faults, the motion will first slow down and then will stop, but the
controls will remain active. Reversing the joystick will remove the fault and allow continued
operation.
2.
For a boom jacking fault, the motion will stop but the controls will remain active. Reversing
the left joystick will remove the fault and allow continued operation.
3.
If the boarding ladder is pulled down while the machine is in operation, an alarm message will
be sent to the operator and swing and propel motions will be shut down. The hoist and crowd
motions will remain active.
Once the ladder is back in position, the motions may be restarted by pressing the control
reset pushbutton.
4.
For most other faults, the machine will be shut down and the brakes set. In these situations,
the controls cannot be reset until the fault has been corrected by an electrician.
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Manual No. 10710

OPERATION
Efficient operation is essentially the result of understanding and applying the basic techniques
related to each machine motion, to achieve fast, smooth and safe load cycles. The interrelated
coordination of the hoist, swing and crowd motions results in efficient machine operation.
Each motion is described in the following paragraphs. The operator should thoroughly learn each
motion, its purpose and how this knowledge can be applied in becoming a better operator.
When learning to handle the operator controls, be sure that all personnel are clear of the machine
and that there is ample clearance with no danger spots around the machine, such as culverts,
ditches, embankments and that the machine is not too close to the digging face or overhanging
ledge and large rocks.
Use the Operator Display panel, in the operators cab, to assist in the operation of the machine.
The monitor allows a large number of messages to be sent to the operator from all portions of the
control system. These messages fit into four basic categories:
1.
Normal routine operational messages.
2.
Alarm only.
3.
Delayed shutdown messages.
4.
Immediate faults and shutdowns.
This monitor also allows the setting of certain operating parameters for the machine. Refer to
OPERATORS DISPLAY in this section of the manual for detailed descriptions of the Operator
Display monitor screens and how they relate to the proper operation of the machine.
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Dec 2008

MACHINERY MOTIONS
HOIST MOTION
In standard configuration, Hoist motion is controlled by the operators right joystick. Set the propel
transfer switch in the DIG mode. The crawlers should be positioned so that the digging is done over
the front of the crawlers. Move the joystick between hoist and lower until a feel is developed for the
height, depth range and speed at which the dipper moves. Practice the hoist function until movement
can be stopped smoothly.
CAUTION:
NOTE:
Dec 2008
This joystick also controls the swing motion through left and right
motions.
The following represents the standard configuration.
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Manual No. 10710

CROWD MOTION
In standard configuration, Crowd motion is controlled by the operators 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:
NOTE:
This joystick also controls the signal horn and dipper trip.
The following represents the standard configuration.
Practice the crowd and retract functions until the movement can be stopped smoothly. Combine
the crowd and hoist functions and practice until smooth coordinated motions and subsequent
machine effectiveness are achieved.
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Dec 2008

PROPEL MOTION
Propel motion is controlled by placing the propel transfer switch in the propel mode and actuating
the left or right joystick. To propel in a straight forward direction, push forward on both the left and
right joysticks at the same time. The speed is increased as the levers are displaced farther from
neutral. To propel straight in reverse, pull equally both joysticks to the rear.
NOTE: The control stop pushbutton must be pressed before the propel transfer switch can be
activated.
DANGER:
THE HOIST BRAKE MUST BE SET WHENEVER IN THE PROPEL

MODE.
Propel - Straight Forward/Reverse
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Manual No. 10710

SWING MOTION
In standard configuration, Swing motion is controlled by the operators right joystick. To swing in
either direction, move the joystick lever in the direction of swing. Practice swinging in each direction
until a feel is developed for start-up and stopping.
NOTE: The joy stick also controls the hoisting and lowering of the dipper through forward and
backward motions.
DANGER:
Each motion - hoist or swing - is fully operational throughout the

complete movement of the other motion.
NOTE: When this joystick is used for propelling the machine, the hoist and swing motions are
electrically locked out.
NOTE: The following represents the standard configuration.
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Dec 2008

PROPER SWING MOTION

Proper swing motion means smooth control and an efficient swing cycle. The swing motion is
begun toward the haulage unit when the dipper is filled and is clear of the bank.
DANGER:
EXTENSIVE DAMAGE TO THE DIPPER HANDLE AND DIPPER CAN

OCCUR IF THE MACHINE IS ROTATED BEFORE THE DIPPER
CLEARS THE BANK.
The swing motion begins with acceleration to an optimum point at which the excavator is brought to
a stop over the haulage unit. Maximum efficiency and minimum swing machinery wear are direct
results of mastering the swing motion.
NOTE: Improper swing motion results in erratic control and an inefficient swing cycle.
DANGER:
Dec 2008
THE DIPPER SHOULD NEVER BE POSITIONED OVER PERSONNEL,

TRAIL CABLES, RELATED ELECTRICAL EQUIPMENT OR OTHER
EQUIPMENT. When the dipper is loaded, accidental tripping of the
dipper door could result in death or serious injury to personnel and
extensive damage to equipment. Empty dippers may contain small
fragments of material that can be extremely dangerous when
dropped from a considerable height. On long moves open the door
on an empty dipper and lower the dipper to a point that permits
moving without striking the ground.
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Manual No. 10710

Time is required to accelerate any motion from zero to working speed and also to decelerate from
working speed back to zero. THE TIME EXPENDED FOR ACCELERATING AND DECELERATING
THE SWING REPRESENTS THE MAJOR PART OF THE ENTIRE DIG CYCLE. Therefore, the
swing arcs must be kept to a minimum to obtain maximum operating efficiency. As an example:
assuming that a 90 swing results in 100 percent of the maximum output, increasing the swing arc
to 180 reduces output to 70 percent, while decreasing the swing arc to 45 increased the output to
126 percent. Therefore, a swing arc of 90 or less should usually be used.
Haul units should be positioned so their center line is approximately under or not more than slightly
outside the swing path of the boom point. This substantially reduces the amount of dipper
maneuvering required of the operator when positioning the dipper for dumping. Positioning of the
haulage unit inside or outside the boom point makes it necessary to retract or crowd the dipper
handle and dipper, which breaks the operators natural rhythm.
A clean, level pit floor must be maintained. A good operator will always clean the floor before
moving into the bank. A clean and level floor grade is a requisite to safe and stable machine
operation and reduces damage to crawler links and related components.
DANGER:
SWEEPING SHOULD NEVER BE ATTEMPTED WITH THE

MACHINE. Sweeping consists of lowering the dipper to the ground
and using the swing motion of the machine to move the dipper from
side-to-side and sweep the pit floor. THE DIPPER, DIPPER
HANDLE AND BOOM STRUCTURES CAN BE DAMAGED BY
SWEEPING. A bulldozer or loader should be used to help the
machine operator maintain a clean pit floor in conjunction with the
shovel.
STEERING
To make a gradual forward right turn, move the

LEFT joystick (crowd) forward and leave the right
joystick (hoist) in neutral.
To make a gradual forward left turn, move the

RIGHT joystick (hoist) forward and leave the left
joystick (crowd) in neutral.
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Dec 2008

Whenever possible, gradual turns should be made in short increments of 15 to 20 maximum.

Propel straight for a short distance (usually 1/2 the length of the crawler belts) to clear the crawler
belts of stone and other debris; then make another 15 to 20 turn. Continue until the turn is
completed.
NOTE: When steering in soft material such as sand, clay, etc., increments of less than 15 to
20 should be used to minimize material build up on the crawler belt roller path.
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Manual No. 10710

COUNTER-ROTATION TURNS
Although possible, a single sharp turn should be
avoided to minimize material build up on the
crawler belt roller path. This results in high
loading of the crawler belt and associated propel
components.
To make a sharp right turn, move the LEFT
joystick forward and pull the RIGHT joystick to
the rear.
To make a sharp left turn, move the RIGHT

joystick forward and pull the LEFT joystick to the
rear.
CAUTION:
When using the counter-rotation method for turning, have a helper

ensure that the trail cable does not get fouled and/or torn from the
machine.
NOTE: The ability of the machine to turn sharply is dependent on the surface on which the
machine is setting. A soft surface will cause the crawlers to dig-in and machine to bogdown.
CAUTION:
The propel brakes are released when either joystick is moved from
neutral. The propel brakes are set when both joysticks are returned
to neutral.
When moving the machine in a straight line, propel forward, which is in the direction of the take-up
axle to reduce strain on the crawler belts and propel mechanism. When not possible and propelling
to the rear, make sure the trail cable is clear of the machine and follow the signals given by the
helper. The machine should be rotated in a position to allow the operator to face the direction of
travel.
NOTE: Turning when propelling to the rear requires that the master control be positioned in a
direction opposite the actual direction in which the turn takes place.
The machine should be moved close to the bank in short and frequent moves to maintain digging
efficiency. Movement should occur between the loadings of haul units.
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Dec 2008

POSITIONING THE MACHINE

There are two basic methods for positioning the machine at the working face of the bank: the
back-up method and the drive-by method. Both methods are acceptable and effective.
BACK-UP METHOD
When using the back-up method, position the machine at the bank with the front of the machine
facing the digging face. The haul units are spotted on both sides of the machine. The bank can be
excavated until a 180 circular area of material has been removed from the bank. Once the material
is removed, a 90 or greater swing will be required in order to load the haul units, requiring the
machine to be moved.
To reposition the machine, propel to the rear, away from the bank, at an approximate 45 angle to
the bank. When the machine is centered in-line with the untouched edge of the previous excavation,
propel straight toward the bank and position the machine for further digging.
The back-up method will minimize the swing arc and reduce moving time, produce less bank toe
area clean up and simplify handling of the trail cable, cable standard and trail cable boat.
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Manual No. 10710

DRIVE-BY METHOD
NOTE: If mine conditions or equipment prevent the use of the following procedures, use the
Back-up Method instead.
Position the machine crawlers parallel to the bank with the outer set of crawler tracks directly in line
with the bank toe.
The haul units must approach the machine from the front, making a turn away from the machine as
the units front wheel approaches the outside crawler. Haul units then stop in a position to allow
backing toward the point of the bank for loading.
During the load cycle, swing arc is to one side only and should not exceed 90. The cycle time from
one full haul unit to the next empty unit should not exceed the cycle time between successive
dipper loads to each unit.
During the load cycle, the swing arc should not exceed 90. The time between finishing one truck
to the first digging cycle of the next should not exceed that of any cycle during a load.
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Dec 2008

START OF THE DIG CYCLE
The crowd motion forces the

dipper lip into the bank at the
start of the digging cycle. It is
the crowd thrust which
enables the dipper lip and
front opening to get into a
column of material of
sufficient cross section to fill
the dipper rapidly.
Force the Dipper Lip into the Bank
There is a direct relationship between crowd depth of bank penetration and the distance the dipper
must rise in the bank to fill the dipper. The deeper the bite the quicker the dipper will be filled,
providing the hoist force is sufficient to cut the column of material. Do not attempt to lift the entire
bank with each pass. As soon as the dipper is full, retract it from the bank and swing the machine
to fill the truck.
Crowd penetration should be rapid just at the arc of entry and rise as the dipper enters the bank.
This will permit as much digging as possible near the base of the bank. This is of particular
advantage when digging loose or blasted material. The greater the hoist force and crowd thrust,
the faster the dipper filling time of the dig cycle. The crowd thrust should be maintained to hold the
dipper in the bank while it is being hoisted. An added benefit of proper crowd thrust and hoist force
is that the opposing vertical resistance of the bank material tends to have a ramming effect in the
dipper front opening, minimizing voids and producing larger dipper loads.
It is important that the full

cutting surface of the dipper
contact the bank on each
pass. A full face cut combined
with deep bank penetration will
result in a full dipper for the
least amount of hoist. A partial
cut, even with deep bank
penetration, requires a greater
rise and tends to leave voids
in the dipper, requiring
additional passes to fill the
haulage unit.
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Manual No. 10710

Shallow bank penetration of the arc of

entry and rise is ineffective and
inefficient. A shaving cut dribbles
material into the dipper resulting in
voids and making additional passes
necessary while accelerating dipper lip
wear.
NOTE: A Deeper Bite = Quicker Fill Times
Digging should take place under the boom point for maximum shovel effectiveness. If necessary,
the machine should be moved closer to the bank face, rather than extending the dipper handle.
Reaching for material results in a partially filled dipper and excessive crowd and retract time. Use
caution not to damage the boom point sheaves when operating close to the high wall.
Variations on Dipper Penetration
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Dec 2008

Overcrowding with the dipper

lowered can result in lifting the
boom. This jacking action can
result in damaged components.
Overcrowding the dipper in the
bank slows up the dipper loading
process, thereby reducing
machine efficiency.
Dig with the Dipper Beneath the Boom Point
ENGAGING THE BANK
To make maximum use of the hoist rope pull, the

dipper rise should be as close to vertical as possible.
The dipper should enter the bank approximately under
and behind the boom point. The actual cut should
start a few degrees behind an imaginary vertical line
from the front of the boom point sheaves. Proper
bank engagement results in maximum hoisting force
in line with the cut. When the dipper is too far forward,
bank penetration will be minimal and the hoist and
crowd forces will oppose each other rather than
working together.
Make Effective Use of the Hoist Effort
Dipper capacity rating is the struck measure cubic

yard capacity. When digging, a load greater or less
than the rated capacity may be obtained, depending
on the type of material. An efficient operation can be
measured by the number of dipper loads required to
load a haulage unit. When the dipper capacity is
efficiently sized to the truck capacity, not less than
three or more than five dippers full should be required
to load a unit. Other factors such as improper sizing
of haulage units to dipper, improper material
fragmentation, etc., also must be considered.
Hoist Force Opposes Crowd Force
Dec 2008
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Manual No. 10710

In all types of digging the skilled operator must carefully

control the desired depth of cut and control the hoist
power requirements. Often, digging situations are
encountered which require hoist and crowd motions
to maneuver around oversize or lodged obstructions
in the bank, rather than attempting to lift the entire
bank.
DANGER:
MAINTAIN A DIGGING FACE WHICH AVOIDS ANY MAJOR SLIDES

WHICH COULD CAUSE AN ACCIDENT. Examine the digging face for
large boulders, large rocks, or frozen material which could slide and
cause an accident. Avoid overhanging material.
Do not repeatedly stall the dipper in the bank, nor

maintain a stall condition. The life expectancy of the
hoist machinery and hoist ropes is directly related to
the operators skill in avoiding stalling. Whenever stall
conditions are encountered, back off on the hoist
motion, retract the dipper, or do both. Avoid stall
conditions at all times.
DANGER:
DO NOT SUSPEND A LOADED OR EMPTY DIPPER IN THE AIR WITH

THE BRAKES SET FOR LONG TIME PERIODS. Lower the dipper to
the ground if the machine is to be idle or unattended for any length
of time. Failure to comply can result in personal injury or death of
anyone beneath the dipper.
For most efficient production, the dipper should be

loaded from the most remote point while waiting for a
truck. When the truck is positioned, excavating should
begin close to the haulage unit, progressively working
away from the unit.
This technique saves time by allowing smooth, short
dig cycles and eliminates excessive swing, crowd and
retract motions.
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Dec 2008

EXCAVATED MATERIAL
It is important that the operator not only know the controls but recognize other aspects of the mining
operation. Chief among these is the type of material to be excavated. It plays a great part in the
overall efficiency of the machine.
Materials can be roughly divided into four categories.
1.
EASY DIGGING - This category includes all loose, free-flowing materials, such as sand and
gravel deposits, stock pile materials such as finely crushed stone, ore fines, coal fines and
any other similar materials. The dipper will usually obtain a heaped load.
2.
MEDIUM DIGGING - This category includes only materials which can be excavated from
their natural beds without blasting and which break up in bulk with some voids. Such material
includes clay, dry earth, clay-gravel mixtures, gravel with some boulders, certain types of
ores and coal. The dipper will usually obtain a full load, with filling augmented by the materials
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.
Dec 2008
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Manual No. 10710

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.
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Dec 2008

OPERATING HINTS
The following hints are reminders of the dos and donts related to excavator operation:
Dec 2008
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.
1 - 79
Manual No. 10710

STOPPING THE MACHINE

1.
Return left and right joysticks to their center positions and set all brake switches.
2.
After all motions are stopped and brakes are set, press the CONTROL STOP pushbutton.
This action will remove power to the control units and set the brakes. The controls will
become inoperative.
3.
To stop the machine completely and remove power from the drives, press the MACHINE
STOP Pushbutton on the right operators console.
MACHINE SHUTDOWN
When shutting down the machine at the end of a shift proceed as follows:
1.
Park the machine on firm ground in a position where it cannot be damaged by a slide, falling
rocks or flooding. In cold climates, be sure the crawler belts will not freeze into the ground.
2.
Place the dipper firmly on the ground.
3.
Make sure left and right joysticks are in their center positions.
4.
Make sure all brake switches are in their SET positions.
5.
Press the CONTROL STOP pushbutton. All primary controls should be de-energized.
6.
To de-energize the DC bus, press the MACHINE STOP pushbutton on the remote start console
or the MACHINE STOP/EMERGENCY STOP pushbutton on the operators console.
7.
Place the air compressor switch on the remote start console in the STOP position.
8.
Close all windows in the cab and lock all cab doors.
Manual No. 10710
1 - 80
Dec 2008

GENERAL ESTIMATED COMPONENT WEIGHTS

CAUTION:
These are estimated weights only. Contact your Bucyrus

International service representative for the exact weight of
components on your specific machine before rigging and lifting.
Quantity
Weight Each
(U.S. Pounds)
Frame And Swing Rack Components

Roller Frame Assembly
Roller, Roller Frame
Guard, Roller Circle
Revolving Frame
Center Pintle
Support, Crowd Machy
Base, Crowd Motor
Rail, Upper-Center
Rail,Center-Upper
Segment, Rail
Rail, Upper End
Rail, Upper End
Pintle, Center, Fld Assy
Sleeve, Ctr Pintle
Nut, Lock, Lwr, Ctr Pin
Thrust Washer, Pintle, Mach
Nut, Lock, Upper, Ctr Pin
Pin, Boom Foot
Pin, A-Frame
Swing Rack, Field Assy
Swing Rack
Rail, Lower
Rail Segment
Truck Frame Assy
Hub, Center Pintle
Bushing
Cover, Bot. Plate
Cover, Plate
Cover, Manhole
Dec 2008
1
54
2
1
1
2
1
4
4
4
4
4
1
1
1
1
1
2
4
1
1
15
15
1
1
1
1
1
3
1 - 81
17,400
290
100
80,200
5,710
815
575
120
225
215
140
140
7,170
5,210
1,080
325
480
315
295
23,600
21,100
225
215
104,000
2,810
270
725
105
60
Manual No. 10710

Quantity
Weight Each
(U.S. Pounds)
Propel Components
Motor, Propel/Guards Field Assy
Propel Motor, 400HP
Propel Blower, 3HP
Brake, Propel
Adapter, Propel Brake
Coupling, Propel
Guard, Propel Cplg
Support, Propel Motor
Duct Assy, Propel Blower
Inlet Guard
1
2
2
2
2
2
2
2
2
2
17,100
4,000
230
490
225
140
80
2,840
220
130
Crawler Components
Crawler Field Assembly
Crawler, Ship Assy
Crawler, Shop Assy
Crawler, Frame Weldment
Flange, Mounting
Retainer
Roller, Load, Rear
Roller, Load, Mech Assy
Roller, Front Idler
Sprocket, Crawler
Shaft, Roller - Front
Shaft, Roller - Rear
Adjusting Block Assy
Shaft, Idler
Shaft,Main Propel
Bearing, Roller, Crawler Sprocket
Rod,w/Torquenut Assembly
Gearcase Assy, Propel
Cabinet, Lube, Crawler
Belt,Crawler
Link, Crawler, 72 Inch
1
2
2
2
1
1
2
16
2
2
16
2
4
2
2
2
40
2
2
2
96
218,000
94,000
93,500
58,000
2,680
190
2,230
1,140
3,480
4,980
410
530
460
1,060
3,180
335
85
12,600
280
69,000
1,370
Manual No. 10710
1 - 82
Dec 2008

Quantity
Weight Each
(U.S. Pounds)
Operator Cab Components

Operator Cab, Ship Assy
Operator Cab, FOPS
Oper. Cab Support
Console, Oper Control
Door & Frame Assy
Glass, Door
Window, 1pc .Front Assy
Duct Assy, HVAC
Base, Oper Seat
Air Conditioner
Ducting, Air Cond
1
1
1
1
1
1
1
1
1
1
1
10,800
6,970
5,950
315
275
50
455
305
145
930
100
Collector Ring Components

Housing, Front, Coll Ring
Guard, Hose
Support, Swivel Housing
Air Swivel, 4-Line
Ring, Collector
Ring, Collector
Ring, Collector
Ring, Collector
Support, Shoe
Support, Shoe
Ring, Collector
2
1
1
1
1
1
1
1
2
2
1
135
85
710
150
125
100
80
55
60
60
230
Boom & Dipper Handle Components

Boom Assembly, 59ft
Hub, Shipper Shaft
Foot, Boom
Bushing, Tube
Bumper, Boom, Shop Assy
Support, Bumper
Clamp, Boom Bumper
Plate, Impact, Boom Bumper
Sheave, Boom Point
Shaft, Boom Point
Housing, Boom Point
1
2
2
4
2
1
2
1
2
2
4
85,000
1,650
850
85
1,630
1,400
160
1,120
4,130
1,130
875
Dec 2008
1 - 83
Manual No. 10710

Quantity
Weight Each
(U.S. Pounds)
Boom & Dipper Handle Components (cont.)

Bearing, Boom Point
Shipper Shaft
2
1
280
4,500
Dipper Trip Components

Base, Dipper Trip
Guard, Dipper Trip Drum
Drum, Dipper Trip
Gear, Machined Dipper Trip
Support, Deflector
Support, Dipper Trip
Pad, Mtg, Dipper Trip Rear
Pad, Mtg, Dipper Trip Front
Motor, Dipper Trip - 5hp
Rope, Dipper Trip
1
1
1
1
1
1
1
1
1
1
750
65
95
160
95
200
95
125
695
80
Swing Machinery
Retainer, Brg, Vert. Swing Shaft
Pinion, Vert. Swing, Induct.
Gear, Swing - Machined 89T
Bearing, Taper Roller
Bearing, Roller
Guard, Swing Pinion
Retainer, Brg, Int.Shaft
Pinion Shaft, 2nd Red.,14T
Bearing, Taper, Roller
Gearcase & Cover
Cover, Swing Gearcase
Gearcase, Swing
Hub, Swing Gearcase
Gear, Int Swing Shaft
Motor, Swing - 505HP
Blower, Swing Motor
Adapter,Swing Blower
Swing Brake
Adapter,Swing Brake
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
2
2
85
1,110
1,710
100
180
105
100
220
100
6,580
1,670
5,880
1,790
1,030
3,600
230
1,760
490
210
Manual No. 10710
1 - 84
Dec 2008

Quantity
Weight Each
(U.S. Pounds)
Crowd Machinery
Crowd Frame
Motor, Crowd - 505HP
Blower, Crowd Motor
Duct Assy, Crwd Mtr Blower
Brake, Crowd
Crowd Drum
Coupling, Crowd Input Shaft
Rope, Wire, Cwd & Retr.
Gear,1st. Red. Crowd 205T
Pinion, Shaft, 1st. Red.-31T
Guard, Pinion - Crowd Machy
Guard, Gear - Crowd
Guard, Gear - Crowd
Pinion, 2nd Reduction 20T
Shaft, 1st. Int. Crowd Machy
Bearing, Roller
Pinion, Shaft, 3rd.Red,16T
Gear, 2nd Inter. 89T
Bearing, Roller
Bearing, Roller
End Cap
Bearing, Spherical Roller
Gear, Crowd Drum 100T
Cap,Bearing-Crowd
Pin, Crowd - Frt
Guard, Crd.Whole Split
Cover, Crowd Gearcase
Cover, Plate
Dec 2008
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
4
1
2
1
1 - 85
14,800
3,500
230
270
490
12,700
1,690
70
1,380
170
130
90
195
105
1,260
55
1,920
1,300
115
60
80
105
3,990
500
65
85
1,400
100
Manual No. 10710

Quantity
Weight Each
(U.S. Pounds)
Machinery House Components

Machinery House
Ballast Box
Ballast
Lube Room-Machy House
Lube Reservoir
Lube Pump
Heater, Lube Room
Hoist, Lube Room
Heater, Control Room
Air Compressor, 30HP
Support, Aux. Winch
Drum, Aux Winch
Rope, Wire,.75 Dia x 220 Ft
Duct, Transition
Bleed Duct
Duct, Transition
Duct, Cleanout
Duct, Cleanout
Filter, Air-15 Double Cell
Filter, Air-9 Double Cell
Hood, Dual Fan
Leg, Front, A-Frame
Foot, A-Frame
Pin, A-Frame
Back Leg, A-Frame
Platform Assy, A-Frame
Equalizer Link
Rope Pendant
Manual No. 10710
1
1
1
1
2
4
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
4
2
1
2
4
1 - 86
35,900
101,000
352,000
6,550
330
65
80
181
155
1,670
745
205
210
135
60
380
340
455
2,050
1,330
800
16,600
700
295
4,030
3,120
395
1,700
Dec 2008

Quantity
Weight Each
(U.S. Pounds)
Dipper Components
Dipper Assy, 25yd
Pin, Dipper
Pin, Dipper
Dipper Body,Weldment
Liners,Body,25yd Dipper
Latch Keeper
Dipper Door, Weldment
Latch Mechanism
Lever, Latch
Latch Bar
Snubber Assembly
Plate, Pressure,Snubber
Housing, Spring
Link, Snubber
Support, Snubber
Frame, Padlock
Link, R.H.Padlock
Link, L.H.Padlock
Sheave, Padlock
Bushing, Manganese
Bushing, Manganese
Pin, Padlock
Pin
Pin, Clad
Pitch Brace Assembly
Pitch Brace w/Mang Bushing
Pitch Brace, Welded
Pin, Pitch Brace
Dipper Shrouds & Teeth Assy
Dec 2008
1
2
2
1
1
1
1
1
1
1
2
2
2
2
2
2
1
1
2
8
2
2
2
2
2
2
2
4
1
1 - 87
61,200
290
235
44,300
4,360
1,060
12,400
1,050
260
495
1,190
160
205
210
215
1,480
750
750
750
90
50
370
250
370
660
315
275
165
10,100
Manual No. 10710

Quantity
Weight Each
(U.S. Pounds)
Hoist Components
Cover, Bearing, Hoist
Shaft & Pinion, Interm.-15T
Bearing, Roller
Bearing, Roller
End, Plate
Cover, Hoist Brg,RH
Pin, Bearing Housing
Pin, Bearing Housing
Retainer, Whole-Split
Seal, Split-Machined
Retainer, L.H.- Hoist Drum
Retainer, Brg.Hst. Dr. Assy
Housing, Brg, RH,Machined
Housing, Bearing
Spider, LH, Machined
Gear, Hoist Drum
Bearing, Roller
Cover, Plate
Cover, Gear-Front
Cover, Gear-Lower
Cover, Gear-Rear
Cover, Gearcase
Carrier, RH-Int.Shaft & Pinion
LH Side Frame/Gearcase
Bolt, Rod, 2.5 x 41
Support, RH Drum
Guard, Hoist Coupling
Drum, Hoist
Brake, Hoist
Hub, Horiz. Brake
Adapter, Hoist Brake
Motor, Hoist - 1500HP
Blower, Hoist Motor
Adapter Plate, Hoist Blower
Manual No. 10710
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1 - 88
210
2,150
120
410
165
250
470
210
170
120
200
255
2,830
2,780
5,390
8,520
510
290
600
1,160
710
3,460
1,280
13,100
55
5,400
95
13,500
1,030
135
420
13,000
430
260
Dec 2008

Quantity
Weight Each
(U.S. Pounds)
Hoist Components (cont.)

Rope, Wire, Hoist
Gear, 1st.Red.Hoist 157T
Coupling, Gear, Motor
Pinion, Shaft-1st Red.-17T
Spider, RH-Fin. Machined
1
2
2
1
1
5,300
5,950
430
520
2,680
Dipper Handle Components

Dipper Handle, Field Assy
Handle, Lower End
Dipper Handle, Welded
Handle End,Weldment
Support, Take-Up-Welded
Spreader, Retract-Welded
Retract Take-Up
Nut, Take-Up, 2.375 In Rope
Nut, Take-Up, Rough Casting
Cylinder, Hyd. Take-Up
Guide, Take-Up
Cylinder Guard Support
Guard, Shim
Sheave, Half-Fixed Crowd
Saddle Block
Retainer Seal, Sdl Blk
Sheave, Crowd
Bearing, Tapered Roller
Bushing, Saddle Block
Collar, Whole-Split
Bushing, Liner, Sdl Blk
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
4
2
2
2
2
2
38,400
34,200
28,800
10,900
1,300
2,030
3,020
1,120
1,270
110
455
125
145
3,960
15,600
120
2,600
350
95
115
1,290
Dec 2008
1 - 89
Manual No. 10710

Quantity
Weight Each
(U.S. Pounds)
Electrical Components
Skid, IGBT Drive
Transformer, DPT
Transformer, Aux Pwr
Switch Disc, High Voltage
Motor Control Ctr (MCC1)
Fan, Intake Front 40HP
Fan, Intake Rear 25HP
Motor,Reeving Winch 5HP
Transformer, CVT
Transformer, DTT
Transformer, LTT
Duct, IGBT Skid
Fan, DPT Exhaust
Manual No. 10710
1
1
1
1
1
1
1
1
1
1
1
2
1
1 - 90
18,000
11,500
2,750
1,800
1,500
1,190
820
610
300
240
240
150
70
Dec 2008

295HR - Operator's Manual PDF

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BUCYRUS

FOR REVIEW ONLY

Manual No. 10710

Bucyrus International, Inc.

BUCYRUS INTERNATIONAL, Inc.

Preliminary - For Review Only

Manual No. 10710

BUCYRUS INTERNATIONAL, Inc.

Preliminary - For Review Only

Manual No. 10710

BUCYRUS INTERNATIONAL, Inc.

Preliminary - For Review Only

Manual No. 10710

Bucyrus International, Inc.

Preliminary - For Review Only

295HR Mining Shovel

MACHINE OVERVIEW ................................................................................................................ 13

LOWER WORKS ....................................................................................................................... 14

TRUCK FRAME .................................................................................................................... 16

ROLLER CIRCLE ................................................................................................................. 18

PROPEL MACHINERY .......................................................................................................... 19

BALLAST BOX ...................................................................................................................... 22

Bucyrus International, Inc. All Rights Reserved.

Manual No. 10710

Bucyrus International, Inc.

Preliminary - For Review Only

HOIST MACHINERY .............................................................................................................. 24

SWING MACHINERY ............................................................................................................. 25

CROWD MACHINERY .......................................................................................................... 26

OPERATORS CAB .............................................................................................................. 27

LUBE RESERVOIR FILL / OVERFLOW PLUMBING ............................................................ 30

FRONT END EQUIPMENT ......................................................................................................... 31

RUNNING ROPES ................................................................................................................ 33

SADDLE BLOCK .................................................................................................................. 34

DIPPER TRIP ........................................................................................................................ 37

PRIMARY OPERATING CONTROLS ................................................................................... 38

CONTROLS ON THE LEFT CONSOLE ......................................................................... 39

CLIMATE CONTROL PANEL ..................................................................................... 40

CONTROL RESET PUSHBUTTON .......................................................................... 42

Manual No. 10710

Bucyrus International, Inc.

Preliminary - For Review Only

DIG/PROPEL TRANSFER SWITCH ............................................................................... 43

CONTROL RESET PUSHBUTTON .......................................................................... 44

OPERATORS DISPLAY ............................................................................................................. 48

DISPLAY AREA AND INDICATORS ....................................................................................... 49

RESTARTING AFTER AN ELECTRICAL FAULT ................................................................... 59

SWING MOTION ............................................................................................................. 66

Manual No. 10710

Bucyrus International, Inc.

Preliminary - For Review Only

POSITIONING THE MACHINE .................................................................................................... 71

ENGAGING THE BANK ................................................................................................... 75

295HR Shovel Specifications .......................................................................................... ( insert )

Manual No. 10710

Bucyrus International, Inc.

Preliminary - For Review Only

295HR Mining Shovel

Manual No. 10710

Bucyrus International, Inc.

Preliminary - For Review Only

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

This signal word denotes an imminently dangerous hazard which will