Bucyrus 495BII Mining Shovel Maintenance And Operation Manual BI616814
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Bucyrus 495BII Mining Shovel Maintenance And Operation Manual BI616814 - Image 5

Bucyrus 495BII Mining Shovel Maintenance And Operation Manual BI616814

$30.00

  • Type Of Manual: Maintenance And Operation Manual
  • Manual ID: BI616814
  • Number of Pages: 488
  • Size: 14.2MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 495BII Mining Shovel
  • 1. _1.pdf
  • 1.1. Table of Contents
  • 1.1.1. GENERAL INFORMATION
  • 1.1.2. Safety
  • 1.1.3. Machine Placards
  • 1.1.4. SAFETY PRECAUTIONS
  • 1.1.5. Fire Prevention
  • 1.1.6. Machine Overview
  • 1.1.7. Lower Works
  • 1.1.8. Truck Frame and Crawlers
  • 1.1.9. Crawlers
  • 1.1.10. Crawler Truck Frame Section View
  • 1.1.11. Truck Frame
  • 1.1.12. Swing Rack
  • 1.1.13. Swing Rack and Roller Circle
  • 1.1.14. Roller Circle
  • 1.1.15. Roller Circle Assembly
  • 1.1.16. Propel Machinery
  • 1.1.17. COLLECTOR RINGS
  • 1.1.18. Rotating Deck
  • 1.1.19. II Deck Plan
  • 1.1.20. Revolving Frame
  • 1.1.21. Center Pintle
  • 1.1.22. Deck Extensions
  • 1.1.23. Deck Extensions and Ballast Box – Plan View
  • 1.1.24. Ballast Box
  • 1.1.25. Machinery House
  • 1.1.26. Boarding Stairs
  • 1.1.27. A-Frame
  • 1.1.28. A- Frame and Front End Support Components
  • 1.1.29. Hoist Machinery
  • 1.1.30. Hoist Machinery – Plan View
  • 1.1.31. Swing Machinery
  • 1.1.32. Swing Machinery Components
  • 1.1.33. Crowd Machinery
  • 1.1.34. Crowd Machinery Components
  • 1.1.35. Operators Cab
  • 1.1.36. Compressed Air System
  • 1.1.37. Automatic Lubrication System
  • 1.1.38. Lubrication Room
  • 1.1.39. Front End Equipment
  • 1.1.40. Suspension Strands
  • 1.1.41. Boom Assembly
  • 1.1.42. Running Ropes
  • 1.1.43. Ropes – General Arrangement
  • 1.1.44. Saddle Block
  • 1.1.45. Dipper Handle
  • 1.1.46. Dipper
  • 1.1.47. Dipper Assembly
  • 1.1.48. Padlock
  • 1.1.49. Dipper Trip
  • 1.1.50. Dipper Trip – General Arrangement
  • 1.1.51. Typical Machine Specifications
  • 1.1.52. COMPONENT WEIGHTS
  • 2. _2.pdf
  • 2.1. Table of Contents
  • 2.1.1. GENERAL INFORMATION
  • 2.1.2. OPERATION NEAR ELECTRICAL LINES
  • 2.1.3. PRE-START CHECKS
  • 2.1.4. WALK-AROUND GROUND LEVEL INSPECTION
  • 2.1.5. Daily Inspection Points
  • 2.1.6. ON-BOARD INSPECTION
  • 2.1.7. On Board Inspection Points
  • 2.1.8. OPERATORS CONTROLS
  • 2.1.9. Location of the Operating Controls
  • 2.1.10. Primary Operating Controls
  • 2.1.11. Operators Control Consoles in the Cab
  • 2.1.12. Controls on the Left Console
  • 2.1.13. LEFT MASTER SWITCH
  • 2.1.14. DIPPER TRIP
  • 2.1.15. SIGNAL HORN
  • 2.1.16. Hoist Brake
  • 2.1.17. Crowd Brake
  • 2.1.18. Swing Brake
  • 2.1.19. Propel Brake
  • 2.1.20. Left Control Console
  • 2.1.21. CLIMATE CONTROL PANEL
  • 2.1.22. WINDSHIELD WIPER SWITCH
  • 2.1.23. WINDSHIELD WASHER SWITCH
  • 2.1.24. Controls on the Right Console
  • 2.1.25. RIGHT MASTER SWITCH
  • 2.1.26. CONTROL STOP PUSHBUTTON
  • 2.1.27. CONTROL RESET PUSHBUTTON
  • 2.1.28. Right Control Console
  • 2.1.29. DIG/PROPEL Transfer Switch
  • 2.1.30. hEATED mIRRORS
  • 2.1.31. EMERGENCY STOP PUSHBUTTON
  • 2.1.32. MAIN POWER OFF PUSHBUTTON
  • 2.1.33. EARTH CONTINUITY LOCKOUT PUSHBUTTON
  • 2.1.34. TELEPHONE
  • 2.1.35. OPERATORS SEAT
  • 2.1.36. Operators Seat – Front View
  • 2.1.37. OPERATORS DISPLAY
  • 2.1.38. Operators Display Panel
  • 2.1.39. DISPLAY AREA AND INDICATORS
  • 2.1.40. DISPLAY SCREENS
  • 2.1.41. Title Screen
  • 2.1.42. Main Menu
  • 2.1.43. Main Menu – Info
  • 2.1.44. Active Alarm
  • 2.1.45. New Alarm
  • 2.1.46. Alarms Help
  • 2.1.47. Rope Reeving/Pintle Tightening
  • 2.1.48. Rope Reeving/Pintle Tightening Help
  • 2.1.49. Calibration Help
  • 2.1.50. Fault Counters/Operating Hours
  • 2.1.51. PLC Menu Screen
  • 2.1.52. Typical Bearing Temperature Screen
  • 2.1.53. Operators Screen
  • 2.1.54. BRAKE INDICATORS
  • 2.1.55. TIME/DATE WINDOW
  • 2.1.56. CONTROL STATUS INDICATORS
  • 2.1.57. LIMIT SLOWDOWN INDICATORS
  • 2.1.58. DIG/PROPEL INDICATOR
  • 2.1.59. INFORMATIONAL ICONS
  • 2.1.60. DELAYED SHUTDOWN INDICATOR
  • 2.1.61. ACTIVE ALARMS INDICATOR
  • 2.1.62. AIR PRESSURE
  • 2.1.63. Auxiliary Controls
  • 2.1.64. REMOTE START CONSOLE
  • 2.1.65. HOUSE LIGHT CIRCUIT BREAKERS
  • 2.1.66. LUBRICATION CONTROL PANEL
  • 2.1.67. FIRE SUPPRESSION SYSTEM
  • 2.1.68. CABLE REEL OPERATION
  • 2.1.69. START-UP, OPERATION, AND SHUTDOWN
  • 2.1.70. Machine START-UP
  • 2.1.71. Start-Up Control Locations
  • 2.1.72. RESTARTING AFTER AN ELECTRICAL FAULT
  • 2.1.73. Machine OPERATION
  • 2.1.74. Machinery Motions
  • 2.1.75. HOIST MOTION
  • 2.1.76. CROWD MOTION
  • 2.1.77. PROPEL MOTION
  • 2.1.78. Propel – Straight Forward/Reverse
  • 2.1.79. SWING MOTION
  • 2.1.80. PROPER SWING MOTION
  • 2.1.81. STEERING
  • 2.1.82. COUNTER-ROTATION TURNS
  • 2.1.83. POSITIONING the MACHINE
  • 2.1.84. BACK-UP METHOD
  • 2.1.85. DRIVE-BY METHOD
  • 2.1.86. START OF the DIG CYCLE
  • 2.1.87. Force the Dipper Lip into the Bank
  • 2.1.88. Variations on Dipper Penetration
  • 2.1.89. Dig with the Dipper Beneath the Boom Point
  • 2.1.90. ENGAGING THE BANK
  • 2.1.91. HOIST FORCE OPPOSES CROWD FORCE
  • 2.1.92. ENGAGE THE BANK UNDER THE BOOM POINT
  • 2.1.93. Slope Limitations
  • 2.1.94. Slope vs. Degrees
  • 2.1.95. Rollover and Operation Limits
  • 2.1.96. EXCAVATED MATERIAL
  • 2.1.97. OPERATION CHECKS
  • 2.1.98. OPERATING HINTS
  • 2.1.99. STOPPING THE MACHINE
  • 2.1.100. SHUTDOWN
  • 3. _3.pdf
  • 3.1. Table of Contents
  • 3.1.1. LUBRICATION PRINCIPLES
  • 3.1.2. Greasing Main A.C. Drive Motors
  • 3.1.3. Type of grease
  • 3.1.4. Initial commissioning
  • 3.1.5. Maintenance
  • 3.1.6. Regreasing intervals
  • 3.1.7. LUBRICANT SELECTION
  • 3.1.8. AUTOMATIC LUBRICATION SYSTEM
  • 3.1.9. LUBE ROOM
  • 3.1.10. Lubrication Room Details
  • 3.1.11. Auto Lube Control Panel
  • 3.1.12. LOWER WORKS LUBRICATION
  • 3.1.13. Lube System A2 – Lower Works OGL Piping
  • 3.1.14. Lube System A2 – Lower Works OGL Manifold
  • 3.1.15. Lube System C2 – Lower Works Grease Piping
  • 3.1.16. PROPEL MACHINERY LUBRICATION
  • 3.1.17. Roller Axle Positioning for Proper Lubrication
  • 3.1.18. LUBRICANT REPLACEMENT/SAMPLING
  • 3.1.19. REVOLVING FRAME LUBRICATION
  • 3.1.20. HOIST MACHINERY LUBRICATION
  • 3.1.21. Hoist Oil Cooler
  • 3.1.22. Oil Pump
  • 3.1.23. Guard, Hoist Gearcase Cooler Piping
  • 3.1.24. CROWD MACHINERY LUBRICATION
  • 3.1.25. SWING MACHINERY LUBRICATION
  • 3.1.26. Swing Machinery Components
  • 3.1.27. AIR COMPRESSOR LUBRICATION
  • 3.1.28. Power Step Lubrication
  • 3.1.29. Crowd Rope Take-Up Mechanism Lubrication
  • 3.1.30. Front End
  • 3.1.31. LINCOLN TYPE SL-1 LUBRICANT INJECTORS
  • 3.1.32. Lubricant Injector Operation
  • 3.1.33. Injector Advantages
  • 3.1.34. LUBRICATION BENCHMARKS
  • 3.1.35. MPG – Multi-Purpose Grease
  • 3.1.36. Specific Requirements for MPG Lubricants
  • 3.1.37. ACSL – AIR COMPRESSOR (SCREW-TYPE) LUBRICANT
  • 3.1.38. LUBRICANT RECOMMENDATIONS
  • 3.1.39. MPO – Multipurpose OIL
  • 3.1.40. OGL – OPEN GEAR LUBRICANT
  • 3.1.41. RGL – REGULAR GEAR LUBRICANT
  • 3.1.42. General Requirements for RGL Lubricants
  • 3.1.43. RWL – RUNNING WIRE ROPE LUBRICANT
  • 3.1.44. SCHEMATICS – AUTOMATIC LUBRICATION
  • 3.1.45. OGL Circuit A1 BOOM
  • 3.1.46. OGL Circuit A2 LOWER WORKS
  • 3.1.47. OGL Circuit B1 REVOLVING FRAME
  • 3.1.48. OGL Circuit B2 SADDLE BLOCK
  • 3.1.49. MPG Circuit C1 BEARINGS
  • 3.1.50. MPG Circuit C2 PROPEL
  • 4. _4.pdf
  • 4.1. Table of Contents
  • 4.1.1. INTRODUCTION
  • 4.1.2. ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM
  • 4.1.3. SCHEDULED PREVENTIVE MAINTENANCE PROGRAM
  • 4.1.4. General Safety Considerations
  • 4.1.5. Maintenance During Machine Operation
  • 4.1.6. Maintenance Precautions
  • 4.1.7. PREVENTIVE MAINTENANCE FOR Lubrication
  • 4.1.8. Lubricant CLEANLINESS
  • 4.1.9. Frequency of inspection and maintenance
  • 4.1.10. MAINTENANCE SCHEDULES
  • 4.1.11. DAILY Check Points
  • 4.1.12. WEEKLY Check Points
  • 4.1.13. MONTHLY Check Points
  • 4.1.14. MONTHLY Check Points
  • 4.1.15. QUARTERLY Check Points
  • 4.1.16. SEMI-ANNUAL Check Points
  • 4.1.17. ANNUAL Check Points
  • 5. _5.pdf
  • 5.1. Table of Contents
  • 5.1.1. LOWER WORKS
  • 5.1.2. PROPEL MACHINERY
  • 5.1.3. CRAWLER FRAMES AND TRUCK FRAME
  • 5.1.4. CRAWLER BELTS
  • 5.1.5. Crawler Link Assembly
  • 5.1.6. BELT Adjustment
  • 5.1.7. Crawler Belt Tension Adjustment
  • 5.1.8. BELT Replacement
  • 5.1.9. Crawler Belt Support
  • 5.1.10. Crawler Links
  • 5.1.11. Crawler Links Section View
  • 5.1.12. LINK INSPECTION
  • 5.1.13. Take-Up Tumbler and AXLE
  • 5.1.14. Tumbler Repair
  • 5.1.15. Upper Rollers
  • 5.1.16. UPPER ROLLER REPAIR
  • 5.1.17. Lower Rollers
  • 5.1.18. Lower Roller Repair
  • 5.1.19. Drive Tumbler
  • 5.1.20. TUMBLER Repair
  • 5.1.21. TUMBLER REBUILD
  • 5.1.22. Drive Tumbler Rebuild
  • 5.1.23. Tumbler Drive Shaft
  • 5.1.24. SHAFT REPAIR
  • 5.1.25. ASSEMBLY INSTRUCTIONS
  • 5.1.26. Propel Motor
  • 5.1.27. PROPEL Planetary Gearcase
  • 5.1.28. Swing Rack
  • 5.1.29. Roller Circle
  • 5.1.30. Roller Circle Assembly
  • 5.1.31. ROLLER CIRCLE Repair
  • 5.1.32. Roller Circle Section View
  • 5.1.33. Roller Circle and Rails
  • 5.1.34. Roller Circle Exploded View
  • 5.1.35. swing Rack Dust Curtains
  • 5.1.36. Center Pintle
  • 5.1.37. CENTER PINTLE ADJUSTMENT
  • 5.1.38. Center Pintle Section View
  • 5.1.39. CENTER PINTLE REPAIR
  • 5.1.40. Collector Rings
  • 5.1.41. COLLECTOR RING Inspection
  • 5.1.42. COLLECTOR RING Repair
  • 5.1.43. Cable Reel
  • 5.1.44. REVOLVING FRAME
  • 5.1.45. II Deck Plan
  • 5.1.46. Swing Machinery
  • 5.1.47. Swing Motor
  • 5.1.48. Swing Blower
  • 5.1.49. SWING MOTOR Removal
  • 5.1.50. Swing Motor Installation
  • 5.1.51. Swing Planetary Gearcase
  • 5.1.52. Swing GEARCASE Removal
  • 5.1.53. Gearcase Inspection
  • 5.1.54. Swing Planetary Gearcase Section View
  • 5.1.55. Swing Shafts and Pinions
  • 5.1.56. Swing Shaft, Dual Output – Section View
  • 5.1.57. SWING PINION Removal
  • 5.1.58. SWING PINION Installation
  • 5.1.59. Swing Shaft Removal
  • 5.1.60. Swing Shaft and Pinion Exploded View
  • 5.1.61. SWING SHAFT Installation
  • 5.1.62. Proximity Switch Clamp Collar
  • 5.1.63. Swing Shaft End Play
  • 5.1.64. HOIST MACHINERY
  • 5.1.65. Hoist Machinery Assembly
  • 5.1.66. Hoist Machinery – Plan View
  • 5.1.67. Hoist Motor
  • 5.1.68. Hoist Motor Mounting – Plan View
  • 5.1.69. MOTOR COUPLING SHAFT
  • 5.1.70. Guard over Coupling Shaft
  • 5.1.71. Coupling Alignment Fixture
  • 5.1.72. HOIST GEARCASE ASSEMBLY
  • 5.1.73. Installation of the Hoist Gearcase
  • 5.1.74. HOIST GEARCASE REPAIR
  • 5.1.75. Hoist Gearcase Section View
  • 5.1.76. HOIST DRUM ASSEMBLY
  • 5.1.77. HOIST GEAR REPLACEMENT
  • 5.1.78. BEARING REPLACEMENT
  • 5.1.79. Hoist Oil Cooler
  • 5.1.80. Hoist Mounting Bolts
  • 5.1.81. Hoist Limit Switch
  • 5.1.82. Crowd Machinery
  • 5.1.83. Crowd Gearcase
  • 5.1.84. CROWD GEARCASE DISASSEMBLY
  • 5.1.85. Crowd Motor Pinion Exploded View
  • 5.1.86. Crowd 1st Reduction Exploded View
  • 5.1.87. Crowd 2nd Reduction Exploded View
  • 5.1.88. CROWD GEARCASE ASSEMBLY
  • 5.1.89. Crowd Motor
  • 5.1.90. Crowd Gear And Drum
  • 5.1.91. Crowd Drum Removal
  • 5.1.92. Machinery House
  • 5.1.93. Walkways, Stairways and Handrails
  • 5.1.94. Operators Cab
  • 5.1.95. Windshield Wipers
  • 5.1.96. Windshield Washer
  • 5.1.97. Boom ASSEMBLY
  • 5.1.98. BOOM Repair
  • 5.1.99. Boom Limit Switch
  • 5.1.100. LIMIT SWITCH Inspection
  • 5.1.101. LIMIT SWITCH Adjustment
  • 5.1.102. Boom Point Sheaves
  • 5.1.103. BOOM POINT SHEAVE Removal and Disassembly
  • 5.1.104. BOOM POINT SHEAVE Reassembly and Installation
  • 5.1.105. Boom Bumper
  • 5.1.106. Saddle Block
  • 5.1.107. Saddle Block Bushing Arrangement
  • 5.1.108. SADDLE BLOCK Repair
  • 5.1.109. SADDLE BLOCK Removal
  • 5.1.110. Saddle Block Sheave
  • 5.1.111. Dipper Handle
  • 5.1.112. Dipper HANDLE Removal
  • 5.1.113. Crowd Rope Take-Up Mechanism
  • 5.1.114. Crowd Rope Take-Up Mechanism Disassembly
  • 5.1.115. Crowd Rope Take-Up Mechanism Assembly
  • 5.1.116. Retract Rope Take-Up Mechanism
  • 5.1.117. Spreader Repair
  • 5.1.118. Dipper ASSEMBLY
  • 5.1.119. Dipper Door Latch Bar and Lever
  • 5.1.120. DIPPER DOOR BUMPERS
  • 5.1.121. Dipper Door Bumper Adjustment
  • 5.1.122. DIPPER DOOR SNUBBERS
  • 5.1.123. SNUBBER ADJUSTMENT
  • 5.1.124. Dipper Padlock
  • 5.1.125. Dipper Pitch Braces
  • 5.1.126. Dipper Trip Assembly
  • 5.1.127. A-Frame
  • 5.1.128. Auxiliary Winch
  • 5.1.129. Hoist Rope Support Roller
  • 5.1.130. Boom Structural Strands
  • 5.1.131. Wire Ropes
  • 5.1.132. Wire Rope Inspection
  • 5.1.133. Crowd Rope Take-up Hydraulic unit
  • 5.1.134. Hydraulic Schematic Crowd Screw Hydraulic Unit
  • 5.1.135. Hoist Rope Reeving Replacement
  • 5.1.136. Shim for Hoist Rope Socket
  • 5.1.137. Crowd Rope Reeving Replacement
  • 5.1.138. Crowd Rope Reeving
  • 5.1.139. CROWD ROPE TERMINATION DETAILS
  • 5.1.140. Retract Rope Reeving Replacement
  • 5.1.141. Retract Rope Reeving
  • 5.1.142. Crowd Rope Tightening
  • 5.1.143. Retract Rope Tightening
  • 5.1.144. Dipper Trip Rope Reeving Replacement
  • 5.1.145. Hoist and Crowd Limit Systems
  • 5.1.146. SETTING ROPE LIMITS
  • 5.1.147. CROWD STOP END LIMIT
  • 5.1.148. RETRACT SLOWDOWN/STOP LIMITS
  • 5.1.149. HOIST SLOWDOWN/STOP LIMITS
  • 5.1.150. CROWD SLOWDOWN/STOP LIMITS
  • 6. _6.pdf
  • 6.1. Table of Contents
  • 6.1.1. BRAKES
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