Bucyrus 495HF Mining Shovel Maintenance And Operation Manual BI619632

Bucyrus 495HF Mining Shovel Maintenance And Operation Manual BI619632 - Image 2

Bucyrus 495HF Mining Shovel Maintenance And Operation Manual BI619632 - Image 3

Bucyrus 495HF Mining Shovel Maintenance And Operation Manual BI619632

$30.00

Type Of Manual: Maintenance And Operation Manual
Manual ID: BI619632
Number of Pages: 660
Size: 25.8MB
Format: PDF

Category: Bucyrus Operator Manual PDF

Product details

Model List:
- 495HF Mining Shovel

1. Safety Precautions
1.1. General Precautions
1.2. Maintenance Precautions
1.3. Operating Precautions
1.4. Warning Signs And Decals
2. Introduction
3. General Information
3.1. SWINGING RESTRAINT BALLAST BOX SUPPORT
3.2. Swinging Restraint
4. Machine Overview
5. Lower Works
5.1. Crawlers
5.2. Truck Frame
5.3. Swing Rack
5.4. Roller Circle
5.5. Propel Machinery
5.6. Collector Rings
6. Rotating Deck
6.1. Revolving Frame
6.2. Center Pintle
6.3. Deck Extensions
6.4. Ballast Box
6.5. Machinery House
6.6. A-Frame
6.7. Hoist Machinery
6.8. Swing Machinery
6.9. Crowd Machinery Overview
6.10. OPERATORS CAB
6.11. Compressed Air System
6.12. Automatic Lubrication System
6.13. Lube Reservoir fill / Overflow Plumbing
7. Front End Equipment
7.1. Suspension Strands
7.2. Running Ropes
7.3. Saddle Block
7.4. Dipper Handle – Hydraulic Crowd
7.5. Padlocks
7.6. Dipper Trip
8. Typical Machine with HydraCrowd Specifications
9. General Estimated Component Weights
9.1. Lower Works
9.2. Upper Works
9.3. Front End
10. Operation
11. General Information
11.1. Operation Near Electrical Lines
12. Operators Seat
12.1. Adjustable Armrest
12.2. Adjustable Footrest
13. Controls
13.1. Primary Operating Controls
13.2. Controls On The Left Console
13.3. Controls On The Right Console
14. Operators Display
14.1. Display Area and Indicators
14.2. Display Screens
14.3. Lubrication Control Panel
14.4. Fire Suppression System
15. Pre-start Checks
15.1. Walk-around Ground Level Inspection
15.2. On-board Inspection
16. Start-up, Operation And Shutdown
16.1. Machine Start-up
16.2. Restarting After An Electrical Fault
16.3. Machine Operation
16.4. Machinery Motions
16.5. Excavated Material
16.6. Operation Checks
16.7. Operating Hints
16.8. Stopping the Machine
16.9. Shutdown
17. Lubrication
18. Lubrication Principles
19. Greasing Main A.C. Drive Motors
19.1. Type of Grease
19.2. Initial Commissioning
19.3. Maintenance
19.4. Regreasing Intervals
20. Lubricant Selection
21. Oil Fill Capacities
21.1. Types Of Lubricants And Capacities Guidelines
22. Automatic Lubrication System
22.1. Lube Room
22.2. Lube Reservoir fill / Overflow Plumbing
22.3. Lower Works Lubrication
22.4. Propel Machinery Lubrication
22.5. Revolving Frame Lubrication
22.6. Hoist Machinery Lubrication
22.7. Hoist Rope Rollers Lubrication
22.8. Hydraulic Crowd Machinery Lubrication
22.9. Pump Drive Transmission (Pdt)
22.10. Swing Machinery Lubrication
22.11. Air Compressor Lubrication
22.12. Front End Lubrication
22.13. Lincoln Type SL-1 Lubricant Injectors
22.14. Air Compressor Lubricant
23. Hydraulic Cleanliness
23.1. Contamination Control
23.2. Filters
23.3. Moisture Removal
23.4. MPO – Multipurpose OIL
23.5. RWRL – Running Wire Rope Lubricant
23.6. EGL – Enclosed Gearcase Lubricant
23.7. MPG – Multipurpose Grease
23.8. OGL – Open Gear Lubricant
23.9. Certified Lubricants Listing
24. Preventive Maintenance
25. Introduction
25.1. Preventive Maintenance Program
25.2. Elements of an Effective Maintenance Program
25.3. Scheduled Preventive Maintenance Program
25.4. General Safety Considerations
26. Maintenance During Machine Operation
26.1. Maintenance Precautions
27. Preventive Maintenance for Lubrication
27.1. Lubricant Cleanliness
28. Frequency of Inspection and Maintenance
29. Maintenance Schedules
29.1. Maintenance Inspection Check Points
29.2. Hydraulic Crowd Service Schedule
30. Service Procedures
31. Lower Works
31.1. Truck Frame Assembly
31.2. Swing Rack Assembly
31.3. Roller Circle Assembly
31.4. Crawler Belts
31.5. Crawler Side Frame Assembly
32. Propel Assembly
32.1. Installation Notes
32.2. Main Propel Drive Shaft Removal
32.3. Propel Machinery
32.4. Revolving Frame
32.5. Center Pintle
32.6. Collector Rings
33. Rotating Deck
33.1. Swing Machinery
33.2. Hoist Machinery
33.3. Crowd Machinery Overview
33.4. Operators Cab Mounting
33.5. Operators Seat Installation
33.6. Footrest Installation
33.7. Machinery House
33.8. Boom Assembly
33.9. Boom Repair
33.10. Boom Limit Switch Installation
33.11. Boom Point Sheaves
33.12. Boom Bumper
33.13. Saddle Block
33.14. Dipper Handle – Hydraulic Crowd
33.15. LatchFreeTM Dipper Assembly
33.16. Dipper Assembly
34. Dipper Removal Installation
34.1. Dipper Door Snubbers
34.2. Dipper Pitch Brace
34.3. Dipper Padlock
34.4. Dipper Trip Assembly
34.5. A-Frame
34.6. Auxiliary Winch
34.7. Hoist Rope Support Roller
34.8. Boom Support Ropes
34.9. Wire Ropes
34.10. Hoist Rope Reeving Replacement
34.11. Dipper Trip Rope Reeving Replacement
34.12. Hoist and Crowd Limit Systems
35. Brakes and Couplings
35.1. Disc Brake Operation
35.2. Maintenance
35.3. Brake Adjustment Specifications
35.4. Hoist Brake
35.5. Propel Brake
35.6. Swing Brake
35.7. Spring Replacement All Brakes
35.8. Friction Disc Replacement All Brakes
35.9. O-Ring Replacement All Brakes
35.10. Brake Wear Release Switches Single Disc Brakes
35.11. Brake Wear Release Switches Multiple Disc Brakes
36. Couplings
36.1. Grid Couplings
36.2. Gear Couplings
37. Compressed Air System
38. Air Compressor
38.1. Lockout Valves
38.2. Safety Warnings
39. Air Filtration
40. House Filter Fans
40.1. Lubrication
40.2. Dynavane Air Cleaner
41. Air Conditioner
41.1. Specifications
42. Engineering Data
43. Capscrew (Bolt) Grade
43.1. Bolt Tightening
44. Measurement Systems
44.1. Linear Measurements
44.2. Area Measurements
44.3. Volume Measurements
44.4. Torque Measurements
45. Split Flange Assembly Procedure
46. Wire Locking Capscrews
47. Torque Nut Installation
48. Expansion Bolt Installation
48.1. Tightening Procedure for 1.25-Inch Torque Nut
48.2. Tightening Procedure for 1.5-Inch Torque Nut
48.3. Tightening Procedure for 2-Inch Torque Nut
48.4. Tightening Procedure for 2-Inch Torque Nut
48.5. Tightening Procedure for 3.5-Inch Torque Nut
48.6. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
48.7. Tightening Procedures – Expansion Bolts
49. Torque Nut Removal Procedure
49.1. Thread Lubrication
50. Torque Nut Helpful Hints
51. Locking Assemblies
51.1. Installation, Series B115
51.2. Removal, Series B115
51.3. Locking Assembly Removal
51.4. Pinion and Hub Installation
51.5. Removal from a Shaft
51.6. Mounting a Pinion or Hub on a Shaft
52. Maintenance Welding
52.1. Welding Electrodes
52.2. Repair Welding of Cracks
52.3. Repair Welding of Broken Parts
52.4. Repair Welding Swing Rack Teeth
52.5. Welding and Cutting Equipment
52.6. Stress Relieving Temperature Measuring Equipment
53. Wire Rope Care and Maintenance
53.1. Storage
53.2. Checking Diameter
53.3. Handling Wire Rope
53.4. Seizing Wire Rope
53.5. End Preparations/Terminations
53.6. Wire Rope Clips
53.7. Inspection of Sheaves and Drums
53.8. Breaking In a New Wire Rope
53.9. Inspection Data
53.10. Guideline to Inspections and Reports
53.11. Seal Installation
53.12. Gearcase Sealing
54. Hydraulic Crowd Service Procedures
55. Hydraulic System Cleanliness
56. Hydraulic System Oil Contamination Guide
56.1. Crowd Machinery Overview
57. Hydraulic Crowd Cylinder Overview
58. Cylinder Control Manifold Overview
59. Auxiliary Power Unit Overview
60. Power Module/lower Tank Overview
61. Lower Tank, Crowd Motor, Transmission Pumps Overview
62. Flushing/pdt Lube Motor Overview
63. Circulation Filter Overview
64. Manifolds Overview
65. Oil Circulation Manifold Overview
66. Pump Control Manifold Overview
67. Upper Hydraulic Tank Overview
68. Oil Circulation Pump Overview
69. Isolator Tank Overview
70. Oil Cooler Plumbing Overview
71. Hydraulic Crowd Sensor Locations
71.1. Cylinder Sensors
71.2. Power Module Sensors
71.3. Upper Hydraulic Tank Sensors
71.4. Pump Control Manifold Sensor
71.5. Auxiliary Power Unit Sensor
72. Inspection
73. Pdt Leak Inspection
74. Circulation Plumbing Inspection
75. Oil Circulation Pump Inspection
76. Isolator Troubleshooting
77. Isolator Tank Inspection
78. Isolator Manifold Inspection
79. Vacuum Breaker Inspection
80. Isolator Plumbing Inspection
81. Service Procedures
82. Hydraulic Crowd Start-up Procedure
83. Standard System Flushing Filtration
84. Complete System Flushing Filtration
85. Initial System Oil Fill
86. System Top Off
87. System Oil Drain – Partial
88. System Oil Drain – Complete
89. Auxiliary Power Unit Fill Filter Replacement
90. Pdt – Initial Oil Fill
91. Pdt – Oil Top Off
92. Pdt – Oil Level Check
93. Pdt – Oil Drain
94. Hydraulic Crowd Cooler Cleaning
95. Purging The Main Pumps
96. Hydraulic System Prefill Filter Replacement
97. Upper Tank Return Filter Cleaning Replacement
98. Isolator Removal And Replacement
99. Isolator Draining
100. Circulation Filter Replacement
101. Boom Pressure Hose Removal Installation
102. Pressure Hose Positioning
103. Boom Return Hose Removal Installation
104. Return Hose Positioning
105. Main Pump Pressure Hose Removal Installation
105.1. Hydraulic Crowd Service Schedule
106. Schematics
107. Schematics
108. Side View
109. Deck Plan
110. OGL System A B Schematic
111. Grease System C Schematic
112. Air Schematic
113. Hydraulic Crowd Troubleshooting Schematics
114. _5-31z.pdf
115. _5-31z.pdf

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Bucyrus 495HF Mining Shovel Maintenance And Operation Manual BI619632

Product details

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