Bucyrus 495HR Mining Shovel Technical Manual BI616900
Bucyrus 495HR Mining Shovel Technical Manual BI616900 - Image 2
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Bucyrus 495HR Mining Shovel Technical Manual BI616900 - Image 5

Bucyrus 495HR Mining Shovel Technical Manual BI616900

$30.00

  • Type Of Manual: Technical Manual
  • Manual ID: BI616900
  • Number of Pages: 481
  • Size: 12.0MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 495HR Mining Shovel
  • 1. pdf
  • 1.1. COVER PAGE
  • 1.2. TABLE OF CONTENTS
  • 1.3. WARNINGS
  • 1.4. INTRODUCTION
  • 1.4.1. GENERAL INFORMATION
  • 1.4.1.1. SAFETY – SWINGING RESTRAINT BALLAST BOX SUPPORT
  • 1.4.1.2. SAFETY PRECAUTIONS
  • 1.4.1.3. FIRE PREVENTION
  • 1.4.1.4. WARNING SIGNS AND DECALS
  • 1.4.2. MACHINE OVERVIEW
  • 1.4.3. LOWER WORKS
  • 1.4.3.1. TRUCK FRAME AND CRAWLERS
  • 1.4.3.2. CRAWLERS
  • 1.4.3.3. TRUCK FRAME
  • 1.4.3.4. SWING RACK
  • 1.4.3.5. ROLLER CIRCLE
  • 1.4.3.6. PROPEL MACHINERY
  • 1.4.3.7. COLLECTOR RINGS
  • 1.4.4. STINGER (TRAIL CABLE SUPPORT)
  • 1.4.5. ROTATING DECK
  • 1.4.5.1. DECK PLAN
  • 1.4.5.2. REVOLVING FRAME
  • 1.4.5.3. CENTER PINTLE
  • 1.4.5.4. DECK EXTENSIONS
  • 1.4.5.5. BALLAST BOX
  • 1.4.5.6. MACHINERY HOUSE
  • 1.4.5.7. VERTICAL BOARDING LADDER
  • 1.4.5.8. BOARDING STAIRS – RIGHT
  • 1.4.5.9. POWER STEP
  • 1.4.5.10. A-FRAME
  • 1.4.5.11. HOIST MACHINERY
  • 1.4.5.12. SWING MACHINERY
  • 1.4.5.13. CROWD MACHINERY
  • 1.4.5.14. OPERATORS CAB
  • 1.4.5.15. COMPRESSED AIR SYSTEM
  • 1.4.6. FRONT END EQUIPTMENT
  • 1.4.6.1. SUSPENSION STRANDS
  • 1.4.6.2. RUNNING ROPES
  • 1.4.6.3. SADDLE BLOCK
  • 1.4.6.4. DIPPER HANDLE
  • 1.4.6.5. PADLOCK
  • 1.4.6.6. DIPPER TRIP
  • 1.4.7. TYPICAL MACHINE SPECIFICATIONS
  • 1.4.8. COMPONENT WEIGHTS
  • 1.5. OPERATION
  • 1.5.1. GENERAL INFORMATION
  • 1.5.1.1. OPERATION NEAR ELECTRICAL LINES
  • 1.5.2. OPERATORS CONTROLS
  • 1.5.2.1. PRIMARY OPERATING CONTROLS
  • 1.5.3. OPERATORS DISPLAY
  • 1.5.3.1. DISPLAY AREA AND INDICATORS
  • 1.5.3.2. DISPLAY SCREENS
  • 1.5.3.3. LUBRICATION CONTROL PANEL
  • 1.5.3.4. FIRE SUPPRESSION SYSTEM
  • 1.5.4. PRE-START CHECKS
  • 1.5.4.1. WALK-AROUND GROUND LEVEL INSPECTION
  • 1.5.4.2. ON-BOARD INSPECTION
  • 1.5.5. START-UP, OPERATION AND SHUTDOWN
  • 1.5.5.1. MACHINE START-UP
  • 1.5.5.2. RESTARTING AFTER AN ELECTRICAL FAULT
  • 1.5.5.3. MACHINE OPERATION
  • 1.5.5.4. MACHINERY MOTIONS
  • 1.5.6. EXCAVATED MATERIAL
  • 1.5.7. OPERATION CHECKS
  • 1.5.8. OPERATING HINTS
  • 1.5.9. STOPPING THE MACHINE
  • 1.5.10. SHUTDOWN
  • 1.6. LUBRICATION
  • 1.6.1. LUBRICATION PRINCIPLES
  • 1.6.2. GREASING MAIN A.C. DRIVE MOTORS
  • 1.6.2.1. TYPE OF GREASE
  • 1.6.2.2. INITIAL COMMISSIONING
  • 1.6.2.3. MAINTENANCE
  • 1.6.2.4. REGREASING INTERVALS
  • 1.6.3. LUBRICANT SELECTION
  • 1.6.4. AUTOMATIC LUBRICATION SYSTEM
  • 1.6.4.1. LUBE ROOM
  • 1.6.4.2. LOWER WORKS LUBRICATION
  • 1.6.4.3. PROPEL MACHINERY LUBRICATION
  • 1.6.4.4. REVOLVING FRAME LUBRICATION
  • 1.6.4.5. HOIST MACHINERY LUBRICATION
  • 1.6.4.6. CROWD MACHINERY LUBRICATION
  • 1.6.4.7. SWING MACHINERY LUBRICATION
  • 1.6.4.8. AIR COMPRESSOR LUBRICATION
  • 1.6.4.9. CROWD ROPE TAKE-UP MECHANISM LUBRICATION
  • 1.6.4.10. FRONT END LUBRICATION
  • 1.6.4.11. LINCOLN TYPE SL-1 LUBRICANT INJECTORS
  • 1.6.5. LUBRICATION BENCHMARKS
  • 1.6.5.1. MPG – MULTIPURPOSE GREASE
  • 1.6.5.2. ACSL – AIR COMPRESSOR (SCREW TYPE) LUBRICANT
  • 1.6.5.3. LUBRICANT RECOMMENDATIONS
  • 1.6.5.4. MPO – MULTIPURPOSE OIL
  • 1.6.5.5. OGL – OPEN GEAR LUBRICANT
  • 1.6.5.6. RGL – REGULAR GEAR LUBRICANT
  • 1.6.5.7. RWL – RUNNING WIRE ROPE LUBRICANT
  • 1.6.6. SCHEMATICS – AUTOMATIC LUBRICATION
  • 1.6.6.1. OGL CIRUIT A1 BOOM
  • 1.6.6.2. OGL CIRUIT A2 LOWER WORKS
  • 1.6.6.3. OGL CIRUIT B1 REVOLVING FRAME
  • 1.6.6.4. OGL CIRUIT B2 SADDLE BLOCK
  • 1.6.6.5. MPG CIRCUIT C1 BEARINGS
  • 1.6.6.6. MPG CIRCUIT C2 PROPEL
  • 1.7. PREVENTATIVE MAINTENANCE
  • 1.7.1. INTRODUCTION
  • 1.7.1.1. ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM
  • 1.7.1.2. SCHEDULED PREVENTATIVE MAINTENANCE PROGRAM
  • 1.7.1.3. GENERAL SAFETY CONSIDERATIONS
  • 1.7.2. MAINTENANCE DURING MACHINE OPERATION
  • 1.7.3. MAINTENANCE PRECAUTIONS
  • 1.7.4. PREVENTATIVE MAINTENANCE FOR LUBRICATION
  • 1.7.4.1. LUBRICANT CLEANLINESS
  • 1.7.5. FREQUENCY OF INSPECTION AND MAINTENANCE
  • 1.7.6. MAINTENANCE SCHEDULES
  • 1.7.6.1. DAILY CHECK POINTS
  • 1.7.6.2. WEEKLY CHECK POINTS
  • 1.7.6.3. MONTHLY CHECK POINTS
  • 1.7.6.4. QUARTERY CHECK POINTS
  • 1.7.6.5. SEMI-ANNUAL CHECK POINTS
  • 1.7.6.6. ANNUAL CHECK POINTS
  • 1.7.7. MAJOR COMPONENT LOCATIONS
  • 1.7.7.1. MACHINE NOMENCLATURE
  • 1.7.7.2. LOWER WORKS AND CRAWLERS
  • 1.7.7.3. CRAWLER ASSEMBLY
  • 1.7.7.4. CRAWLER LINK ASSEMBLY
  • 1.7.7.5. PROPEL MACHINERY
  • 1.7.7.6. STINGER (TRAIL CABLE SUPPORT)
  • 1.7.7.7. ROLLER CIRCLE SECTION VIEW
  • 1.7.7.8. ROLLER CIRCLE ASSEMBLY
  • 1.7.7.9. COLLECTOR RINGS, AUXILIARY
  • 1.7.7.10. COLLECTOR RINGS, HIGH VOLTAGE
  • 1.7.7.11. CENTER PINTLE ASSEMBLY
  • 1.7.7.12. DECK PLAN
  • 1.7.7.13. REVOLVING FRAME DECK EXTENSIONS
  • 1.7.7.14. HOIST MACHINERY
  • 1.7.7.15. SWING MACHINERY
  • 1.7.7.16. CROWD MACHINERY
  • 1.7.7.17. LUBRICATION RESERVOIRS
  • 1.7.7.18. OPERATORS CAB
  • 1.7.7.19. BOARDING STAIRWAY
  • 1.7.7.20. BOARDING LADDER
  • 1.7.7.21. POWER STEP
  • 1.7.7.22. MACHINERY HOUSE WALKWAYS AND PLATFORMS
  • 1.7.7.23. FRONT END EQUIPTMENT
  • 1.7.7.24. BOOM SUPPORT ROPES
  • 1.7.7.25. DIPPER ASSEMBLY
  • 1.8. SERVICE PROCEDURES
  • 1.8.1. LOWER WORKS
  • 1.8.1.1. TRUCK FRAME ASSEMBLY
  • 1.8.1.2. SWING RACK ASSEMBLY
  • 1.8.1.3. ROLLER CIRCLE ASSEMBLY
  • 1.8.2. CRAWLER BELTS
  • 1.8.2.1. CRAWLER BELT MAINTENANCE
  • 1.8.2.2. CRAWLER SIDE FRAME ASSEMBLY
  • 1.8.3. PROPEL ASSEMBLY
  • 1.8.3.1. PROPEL DRIVE SHAFT ASSEMBLY – EXPLODED VIEW
  • 1.8.3.2. PROPEL DRIVE SHAFT ASSEMBLY – SECTION VIEW
  • 1.8.3.3. INSTALLATION NOTES
  • 1.8.3.4. MAIN PROPEL DRIVE SHAFT REMOVAL
  • 1.8.3.5. PROPEL MACHINERY
  • 1.8.3.6. CENTER PINTLE
  • 1.8.3.7. COLLECTOR RINGS
  • 1.8.4. STINGER (TRAIL CABLE SUPPORT)
  • 1.8.5. REVOLVING FRAME
  • 1.8.5.1. DECK PLAN
  • 1.8.5.2. SWING MACHINERY
  • 1.8.5.3. HOIST MACHINERY
  • 1.8.5.4. CROWD MACHINERY
  • 1.8.5.5. MACHINERY HOUSE
  • 1.8.5.6. BOARDING STAIRS – RIGHT
  • 1.8.5.7. POWER STEP
  • 1.8.6. FRONT END EQUIPTMENT
  • 1.8.6.1. BOOM ASSEMBLY
  • 1.8.6.2. BOOM LIMIT SWITCH INSTALLATION
  • 1.8.6.3. BOOM BUMPER
  • 1.8.6.4. SADDLE BLOCK
  • 1.8.6.5. DIPPER HANDLE
  • 1.8.6.6. DIPPER ASSEMBLY
  • 1.8.6.7. DIPPER TRIP ASSEMBLY
  • 1.8.6.8. A-FRAME
  • 1.8.6.9. AUXILARY WINCH
  • 1.8.6.10. HOIST ROPE SUPPORT ROLLER
  • 1.8.6.11. BOOM SUSPENSION ROPES
  • 1.8.6.12. WIRE ROPES
  • 1.8.6.13. CROWD ROPE TAKE-UP HYDRAULIC UNIT
  • 1.8.6.14. HOIST ROPE REEVING REPLACEMENT
  • 1.8.6.15. HOIST AND CROWD LIMIT SYSTEMS
  • 1.9. BRAKES AND COUPLINGS
  • 1.9.1. MACHINE MOTION BRAKES
  • 1.9.2. DISC BREAK OPERATION
  • 1.9.3. MAINTENANCE
  • 1.9.4. SWING BREAK
  • 1.9.5. SWING BREAK INSTALLATION
  • 1.9.6. SWING BREAK ASSEMBLY
  • 1.9.7. SWING BREAK DISC INSPECTION
  • 1.9.8. SWING BREAK BURNINSHING
  • 1.9.9. CROWD BREAK
  • 1.9.10. CROWD BREAK ASSEMBLY
  • 1.9.11. CROWD BRAKE TACHOMETER
  • 1.9.12. HOIST BRAKE
  • 1.9.13. HOIST BRAKE ADJUSTMENT
  • 1.9.14. HOIST BRAKE INSTALLATION
  • 1.9.15. PROPEL BRAKE
  • 1.9.16. PROPEL BRAKE ADJUSTMENT
  • 1.9.17. SPRING REPLACEMENT – ALL BRAKES
  • 1.9.18. COUPLINGS
  • 1.9.18.1. GRID COUPLINGS
  • 1.9.18.2. GEAR COUPLINGS
  • 1.10. COMPRESSED AIR SYSTEM
  • 1.10.1. AIR COMPRESSOR
  • 1.10.1.1. AIR COMPRESSOR INSTALLATION
  • 1.10.1.2. AIR COMPRESSOR
  • 1.10.1.3. THE COMPRESSION CYCLE
  • 1.10.1.4. AIR FLOW
  • 1.10.1.5. OIL FLOW
  • 1.10.1.6. COMPRESSOR MAINTENANCE
  • 1.10.1.7. SAFETY WARNINGS
  • 1.11. AIR FILTRATION
  • 1.11.1. HOUSE FILTER FANS
  • 1.11.1.1. LUBRICATION
  • 1.11.1.2. DYNAVANE AIR CLEANER
  • 1.11.1.3. TENKAY FILTER
  • 1.11.2. AIR CONDITIONER
  • 1.11.2.1. SPECIFICATIONS
  • 1.12. ENGINEERING DATA
  • 1.12.1. CAPSCREW (BOLT) GRADE
  • 1.12.2. BOLT TIGHTENING
  • 1.12.2.1. TORQUE WRENCH METHOD
  • 1.12.2.2. TURN-OF-NUT METHOD
  • 1.12.3. WIRE LOCKING CAPSCREWS
  • 1.12.3.1. PATTERNS FOR WIRELOCKING CAPSCREWS
  • 1.12.4. TORQUE NUT INSTALLATION
  • 1.12.4.1. TIGHTENING PROCEDURE FOR ONE 2-INCH TORQUE NUT
  • 1.12.4.2. TIGHTENING PROCEDURE FOR ONE 3-INCH TORQUE NUT
  • 1.12.4.3. TIGHTENING PROCEDURE TORQUE ROD, TAPERED SLEEVE 1.O INCH NUT
  • 1.12.4.4. TIGHTENING PROCEDURE TORQUE ROD, TAPERED SLEEVE 1.62 INCH NUT
  • 1.12.4.5. TIGHTENING PROCEDURE SWING TORQUE ROD TAPERED SLEEVE
  • 1.12.4.6. TORQUE NUT REMOVAL PROCEDURE
  • 1.12.4.7. TORQUE NUT HELPFUL HINTS
  • 1.12.5. LOCKING ASSEMBLIES
  • 1.12.5.1. LOCKING ASSEMBLY REMOVAL
  • 1.12.6. PINION AND HUB INSTALLATION
  • 1.12.6.1. REMOVAL FROM A SHAFT
  • 1.12.6.2. MOUNTING A PINION OR HUB ON A SHAFT
  • 1.12.7. MAINTENANCE WELDING
  • 1.12.7.1. WELDING ELECTRODES
  • 1.12.7.2. REPAIR WELDING OF CRACKS
  • 1.12.7.3. REPAIR WELDING OF BROKEN PARTS
  • 1.12.7.4. REPAIR WELDING SWING RACK TEETH
  • 1.12.8. WELDING AND CUTTING EQUIPTMENT
  • 1.12.9. STRESS RELIEVING TEMPERATURE MEASURING EQUIPTMENT
  • 1.12.10. WIRE ROPE CARE AND MAINTENANCE
  • 1.12.10.1. STORAGE
  • 1.12.10.2. CHECKING DIAMETER
  • 1.12.10.3. HANDLING WIRE ROPE
  • 1.12.10.4. SEIZING WIRE ROPE
  • 1.12.10.5. END PREPARATIONS/TERMINATIONS
  • 1.12.10.6. WIRE ROPE CLIPS
  • 1.12.10.7. INSPECTION OF SHEAVES AND DRUMS
  • 1.12.10.8. BREAKING IN A NEW WIRE ROPE
  • 1.12.10.9. INSPECTION DATA
  • 1.12.10.10. SEAL INSTALLATION
  • 1.12.10.11. GEARCASE SEALING
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