Bucyrus 495HR Mining Shovel Maintenance And Operation Manual BI617169
Bucyrus 495HR Mining Shovel Maintenance And Operation Manual BI617169 - Image 2
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Bucyrus 495HR Mining Shovel Maintenance And Operation Manual BI617169 - Image 5

Bucyrus 495HR Mining Shovel Maintenance And Operation Manual BI617169

$30.00

  • Type Of Manual: Maintenance And Operation Manual
  • Manual ID: BI617169
  • Number of Pages: 532
  • Size: 16.0MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 495HR Mining Shovel
  • 1. Safety Precautions
  • 1.1. General Precautions
  • 1.2. Maintenance Precautions
  • 1.3. Operating Precautions
  • 1.4. Fire Prevention
  • 1.5. Warning Signs And Decals
  • 2. Introduction
  • 3. General Information
  • 3.1. SWINGING RESTRAINT BALLAST BOX SUPPORT
  • 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. Stinger (Trail Cable Support)
  • 7. Rotating Deck
  • 7.1. Revolving Frame
  • 7.2. Center Pintle
  • 7.3. Deck Extensions
  • 7.4. Ballast Box
  • 7.5. Machinery House
  • 7.6. A-Frame
  • 7.7. Hoist Machinery
  • 7.8. Swing Machinery
  • 7.9. Crowd Machinery
  • 7.10. OPERATORS CAB
  • 7.11. Compressed Air System
  • 7.12. Automatic Lubrication System
  • 7.13. Lube Reservoir fill / Overflow Plumbing
  • 8. Front End Equipment
  • 8.1. Suspension Strands
  • 8.2. Running Ropes
  • 8.3. Saddle Block
  • 8.4. Dipper Handle
  • 8.5. Padlocks
  • 8.6. Dipper Trip
  • 9. Typical Machine Specifications
  • 10. General Estimated Component Weights
  • 10.1. Lower Works
  • 10.2. Upper Works
  • 10.3. Front End
  • 11. Side View
  • 12. Deck Plan
  • 13. Operation
  • 14. General Information
  • 14.1. Operation Near Electrical Lines
  • 15. Controls
  • 16. Primary Operating Controls
  • 16.1. Controls On The Left Console
  • 16.2. Controls On The Right Console
  • 17. Operators Display
  • 17.1. Display Area and Indicators
  • 17.2. Display Screens
  • 17.3. Lubrication Control Panel
  • 17.4. Fire Suppression System
  • 18. Pre-start Checks
  • 18.1. Walk-around Ground Level Inspection
  • 18.2. On-board Inspection
  • 19. Start-up, Operation And Shutdown
  • 19.1. Machine Start-up
  • 19.2. Restarting After An Electrical Fault
  • 19.3. Machine Operation
  • 19.4. Machinery Motions
  • 19.5. Excavated Material
  • 19.6. Operation Checks
  • 19.7. Operating Hints
  • 19.8. Stopping the Machine
  • 19.9. Shutdown
  • 20. Lubrication
  • 21. Lubrication Principles
  • 22. Greasing Main A.C. Drive Motors
  • 22.1. Type of Grease
  • 22.2. Initial Commissioning
  • 22.3. Maintenance
  • 22.4. Regreasing Intervals
  • 23. Lubricant Selection
  • 24. Oil Fill Capacities
  • 24.1. Types Of Lubricants And Capacities Guidelines
  • 25. Automatic Lubrication System
  • 25.1. Lube Room
  • 25.2. Lube Reservoir fill / Overflow Plumbing
  • 25.3. Lower Works Lubrication
  • 25.4. Propel Machinery Lubrication
  • 25.5. Revolving Frame Lubrication
  • 25.6. Hoist Machinery Lubrication
  • 25.7. Hoist Rope Rollers Lubrication
  • 25.8. Crowd Machinery Lubrication
  • 25.9. Swing Machinery Lubrication
  • 25.10. Air Compressor Lubrication
  • 25.11. Crowd Rope Take-Up Mechanism Lubrication
  • 25.12. Front End Lubrication
  • 25.13. Lincoln Type SL-1 Lubricant Injectors
  • 25.14. Air Compressor Lubricant
  • 25.15. ACSL – Air Compressor (Screw-Type) Lubricant
  • 25.16. MPO – Multipurpose OIL
  • 25.17. RWRL – Running Wire Rope Lubricant
  • 25.18. EGL – Enclosed Gearcase Lubricant
  • 25.19. MPG – Multipurpose Grease
  • 25.20. OGL – Open Gear Lubricant
  • 25.21. Certified Lubricants Listing
  • 26. Schematics – Automatic Lubrication
  • 27. OGL System A B Schematic
  • 28. Grease System C Schematic
  • 29. Preventive Maintenance
  • 30. Introduction
  • 30.1. Preventive Maintenance Program
  • 30.2. Elements of an Effective Maintenance Program
  • 30.3. Scheduled Preventive Maintenance Program
  • 30.4. General Safety Considerations
  • 31. Maintenance During Machine Operation
  • 31.1. Maintenance Precautions
  • 32. Preventive Maintenance for Lubrication
  • 32.1. Lubricant Cleanliness
  • 33. Frequency of Inspection and Maintenance
  • 34. Maintenance Schedules
  • 34.1. Maintenance Inspection Check Points
  • 35. Major Component Locations
  • 36. Service Procedures
  • 37. Lower Works
  • 37.1. Truck Frame Assembly
  • 37.2. Swing Rack Assembly
  • 37.3. Roller Circle Assembly
  • 38. Crawler Belts
  • 38.1. Crawler Belt Maintenance
  • 38.2. Crawler Side Frame Assembly
  • 39. Propel Assembly
  • 39.1. Installation Notes
  • 39.2. Main Propel Drive Shaft Removal
  • 39.3. Propel Machinery
  • 39.4. Center Pintle
  • 39.5. Collector Rings
  • 40. Stinger (Trail Cable Support)
  • 41. Rotating Deck
  • 42. Swing Machinery
  • 42.1. Swing Support Mounting Bolts
  • 42.2. Swing Motor
  • 42.3. Swing Planetary Gearcase
  • 42.4. Hoist Machinery
  • 42.5. Hoist Mounting Bolts
  • 42.6. Hoist Limit Switch
  • 43. Crowd Machinery
  • 43.1. Crowd Gearcase Disassembly
  • 43.2. Crowd Gearcase Assembly
  • 44. Crowd Motor
  • 44.1. Crowd Gear and Drum
  • 44.2. Crowd Drum Removal
  • 44.3. Operators Cab Mounting
  • 45. Machinery House
  • 45.1. Walkways, Stairways, and Handrails
  • 45.2. Boarding Stairs
  • 45.3. Vertical Boarding Ladder, left
  • 45.4. Boom Assembly
  • 45.5. Boom Limit Switch Installation
  • 45.6. Boom Bumper
  • 45.7. Saddle Block
  • 45.8. Dipper Handle
  • 46. Dipper Assembly
  • 46.1. Dipper Door
  • 46.2. Dipper Door bumpers
  • 46.3. Dipper Pitch BracE
  • 46.4. Dipper Padlock
  • 46.5. Dipper Trip Assembly
  • 46.6. A-Frame
  • 46.7. Auxiliary Winch
  • 46.8. Hoist Rope Support Roller
  • 46.9. Boom Support Ropes
  • 46.10. Wire Ropes
  • 47. Crowd Rope Take-up Hydraulic Unit
  • 47.1. Hoist Rope Reeving Replacement
  • 48. Retract Rope Reeving Replacement
  • 48.1. Crowd Rope Tightening
  • 48.2. Retract Rope Tightening
  • 48.3. Dipper Trip Rope Reeving Replacement
  • 48.4. Hoist and Crowd Limit Systems
  • 49. Brakes and Couplings
  • 49.1. Disc Brake Operation
  • 49.2. Maintenance
  • 49.3. Brake Adjustment Specifications
  • 49.4. Hoist Brake
  • 49.5. Crowd Brake
  • 49.6. Propel Brake
  • 49.7. Swing Brake
  • 49.8. Spring Replacement All Brakes
  • 49.9. Friction Disc Replacement All Brakes
  • 49.10. O-Ring Replacement All Brakes
  • 49.11. Brake Wear Release Switches Single Disc Brakes
  • 49.12. Brake Wear Release Switches Multiple Disc Brakes
  • 50. Couplings
  • 50.1. Grid Couplings
  • 50.2. Gear Couplings
  • 51. Compressed Air System
  • 52. Air Compressor
  • 52.1. Lockout Valves
  • 52.2. Safety Warnings
  • 53. Air Schematic
  • 54. Air Filtration
  • 55. House Filter Fans
  • 55.1. Lubrication
  • 55.2. Dynavane Air Cleaner
  • 55.3. Air Conditioner
  • 55.4. Specifications
  • 56. Engineering Data
  • 57. Capscrew (Bolt) Grade
  • 57.1. Bolt Tightening
  • 58. Measurement Systems
  • 58.1. Linear Measurements
  • 58.2. Area Measurements
  • 58.3. Volume Measurements
  • 58.4. Torque Measurements
  • 59. Split Flange Assembly Procedure
  • 60. Wire Locking Capscrews
  • 61. Torque Nut Installation
  • 61.1. Tightening Procedure for 1.25-Inch Torque Nut
  • 61.2. Tightening Procedure for 2-Inch Torque Nut
  • 61.3. Tightening Procedure for 2-Inch Torque Nut
  • 61.4. Tightening Procedure for 2.5-Inch Torque Nut
  • 61.5. Tightening Procedure for 3-Inch Torque Nut
  • 61.6. Tightening Procedure for 3.5-Inch Torque Nut
  • 61.7. Procedure for Use of Mechanical Tensioner on Crawler Rods
  • 62. Expansion Bolt Installation
  • 62.1. Tightening Procedures – Expansion Bolts
  • 63. Torque Nut Removal Procedure
  • 63.1. Thread Lubrication
  • 64. Torque Nut Helpful Hints
  • 65. Locking Assemblies
  • 65.1. Locking Assembly Removal
  • 65.2. Pinion and Hub Installation
  • 65.3. Removal from a Shaft
  • 65.4. Mounting a Pinion or Hub on a Shaft
  • 66. Maintenance Welding
  • 66.1. Welding Electrodes
  • 66.2. Repair Welding of Cracks
  • 66.3. Repair Welding of Broken Parts
  • 66.4. Repair Welding Swing Rack Teeth
  • 66.5. Welding and Cutting Equipment
  • 66.6. Stress Relieving Temperature Measuring Equipment
  • 66.7. Storage
  • 66.8. Checking Diameter
  • 66.9. Handling Wire Rope
  • 66.10. Seizing Wire Rope
  • 66.11. End Preparations/Terminations
  • 66.12. Wire Rope Clips
  • 66.13. Inspection of Sheaves and Drums
  • 66.14. Breaking In a New Wire Rope
  • 66.15. Inspection Data
  • 66.16. Guideline to Inspections and Reports
  • 66.17. Seal Installation
  • 66.18. Gearcase Sealing
  • 67. pdf
  • 67.1. Preventive Maintenance
  • 67.2. Introduction
  • 67.3. Maintenance During Machine Operation
  • 67.4. Preventive Maintenance for Lubrication
  • 67.5. Frequency of Inspection and Maintenance
  • 67.6. Maintenance Schedules
  • 67.7. Major Component Locations
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