Bucyrus 495HD Mining Shovel Maintenance And Operation Manual BI619546
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Bucyrus 495HD Mining Shovel Maintenance And Operation Manual BI619546

$30.00

  • Type Of Manual: Maintenance And Operation Manual
  • Manual ID: BI619546
  • Number of Pages: 498
  • Size: 12.5MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 495HD 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
  • 3.1.1. Ballast Box Support
  • 3.1.2. 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
  • 6.5.1. Vertical Boarding Ladder, Left
  • 6.6. Boarding Stairs
  • 6.7. A-Frame
  • 6.8. Hoist Machinery
  • 6.9. Swing Machinery
  • 6.10. Crowd Machinery
  • 6.11. Operators Cab
  • 6.12. Compressed Air System
  • 6.13. Automatic Lubrication System
  • 7. Front End Equipment
  • 7.1. Suspension Strands
  • 7.2. Running Ropes
  • 7.3. Saddle Block
  • 7.4. Dipper Handle
  • 7.5. Padlocks
  • 7.6. Dipper Trip
  • 8. Typical Machine 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. Controls
  • 12.1. Primary Operating Controls
  • 12.1.1. Controls On The Left Console
  • 12.1.2. Controls On The Right Console
  • 13. Operators Seat
  • 14. Operators Display
  • 14.1. Display Area and Indicators
  • 14.2. Display Screens
  • 15. Auxiliary Controls
  • 15.1. Remote Start Panel
  • 15.1.1. Phase Sequence Light
  • 15.1.2. Drive Cabinets Temperature Light
  • 15.1.3. PLC Power On Light
  • 15.1.4. System Ready Light
  • 15.1.5. Auxiliary Ground Fault Light
  • 15.1.6. Incomplete Sequence Light
  • 15.1.7. System Run Pushbutton
  • 15.1.8. Air Compressor Start/Stop Pushbuttons
  • 15.1.9. House Light Circuit Breakers
  • 15.1.10. Lighting Transfer Switch
  • 15.2. Lubrication Control Panel
  • 15.3. Windshield Wipers
  • 15.4. Windshield Washer
  • 16. Pre-start Checks
  • 16.1. Walk-around Ground Level Inspection
  • 16.2. On-board Inspection
  • 17. Start-up, Operation And Shutdown
  • 17.1. Machine Start-up
  • 17.2. Restarting After An Electrical Fault
  • 17.3. Machine Operation
  • 17.4. Machinery Motions
  • 17.4.1. Hoist Motion
  • 17.4.2. Crowd Motion
  • 17.4.3. Propel Motion
  • 17.4.4. Swing Motion
  • 17.4.5. Steering
  • 17.4.6. Positioning the Machine
  • 17.4.7. Start Of The Dig Cycle
  • 17.4.8. Engaging The Bank
  • 17.4.9. Slope Limitations
  • 17.5. Excavated Material
  • 17.6. Operation Checks
  • 17.7. Operating Hints
  • 17.8. Stopping the Machine
  • 17.9. Shutdown
  • 18. Lubrication
  • 19. Lubrication Principles
  • 20. Greasing Main A.C. Drive Motors
  • 20.1. Type of Grease
  • 20.2. Initial Commissioning
  • 20.3. Maintenance
  • 20.4. Regreasing Intervals
  • 21. Lubricant Selection
  • 22. Oil Fill Capacities
  • 22.1. Types Of Lubricants And Capacities Guidelines
  • 22.1.1. Quantities for First Fill of Lubricants
  • 23. Automatic Lubrication System
  • 23.1. Lube Room
  • 23.2. Lube Reservoir fill / Overflow Plumbing
  • 23.2.1. Auto Lube Control Panel
  • 23.3. Lower Works Lubrication
  • 23.4. Propel Machinery Lubrication
  • 23.4.1. Lubricant Replacement/sampling
  • 23.5. Revolving Frame Lubrication
  • 23.6. Hoist Machinery Lubrication
  • 23.6.1. Hoist Gearcase Oil Cooler
  • 23.7. Crowd Machinery Lubrication
  • 23.8. SWING MACHINERY LUBRICATION
  • 23.9. Air Compressor Lubrication
  • 23.10. Front End Lubrication
  • 23.11. Lincoln Type SL-1 Lubricant Injectors
  • 23.11.1. SL-1 Lubricant Injector Operation
  • 23.11.2. Injector Advantages
  • 24. Lubrication Benchmarks
  • 24.1. Air Compressor Lubricant
  • 24.2. MPO – Multipurpose OIL
  • 24.3. RWRL – Running Wire Rope Lubricant
  • 24.4. EGL – Enclosed Gearcase Lubricant
  • 24.5. MPG – Multipurpose Grease
  • 24.6. OGL – Open Gear Lubricant
  • 24.7. Certified Lubricants Listing
  • 25. Preventive Maintenance
  • 26. Introduction
  • 26.1. Preventive Maintenance Program
  • 26.2. Elements of an Effective Maintenance Program
  • 26.3. Scheduled Preventive Maintenance Program
  • 26.4. General Safety Considerations
  • 27. Maintenance During Machine Operation
  • 27.1. Maintenance Precautions
  • 28. Preventive Maintenance for Lubrication
  • 28.1. Lubricant Cleanliness
  • 29. Frequency of Inspection and Maintenance
  • 30. Maintenance Schedules
  • 30.1. Maintenance Inspection Check Points
  • 30.1.1. Every 100 Hours or Weekly
  • 30.1.2. Every 500 Hours Or Monthly
  • 30.1.3. Every 1250 Hours or Quarterly
  • 30.1.4. Every 2500 Hours or Semi-Annually
  • 30.1.5. Hours or Annually
  • 31. Major Component Locations
  • 32. Service Procedures
  • 33. Lower Works
  • 33.1. Propel Machinery
  • 33.2. Crawler Frames and Truck Frame
  • 33.2.1. Crawler Belts
  • 33.2.2. Crawler Links
  • 33.2.3. Upper Rollers
  • 33.2.4. Lower Rollers
  • 33.2.5. Drive Tumbler
  • 33.2.6. Tumbler Drive Shaft
  • 33.3. Propel Motor
  • 33.4. Propel Planetary Gearcase
  • 33.5. Swing Rack
  • 33.6. Roller Circle
  • 33.6.1. Roller Circle Repair
  • 33.7. Swing Rack Dust Curtains
  • 33.8. Center Pintle
  • 33.8.1. Center Pintle Adjustment
  • 33.8.2. Center Pintle Sleeve Removal
  • 33.9. Collector Rings
  • 33.9.1. Collector Ring Inspection
  • 33.9.2. Collector Ring Repair
  • 34. Swing Machinery
  • 34.1. Swing Blower
  • 34.2. Swing Motor
  • 34.2.1. Swing Motor Removal
  • 34.2.2. Swing Motor Installation
  • 34.3. Swing Planetary Gearcase
  • 34.3.1. Gearcase Inspection
  • 34.4. Swing Shafts and Pinions
  • 34.4.1. Swing Pinion Removal
  • 34.5. Swing Pinion Installation
  • 34.6. Swing Shaft Removal
  • 34.6.1. Swing Shaft Installation
  • 35. Hoist Machinery
  • 35.1. Hoist Motor
  • 35.2. Hoist Gearcase Assembly
  • 35.2.1. Hoist Gearcase Installation
  • 35.2.2. Hoist Gearcase Repair
  • 35.2.3. Motor Coupling Shaft
  • 35.2.4. Hoist Drum Assembly
  • 35.3. Hoist Mounting Bolts
  • 35.4. Hoist Limit Switch
  • 35.5. Hoist Motor
  • 36. Crowd Machinery
  • 36.1. Gearcase Repair
  • 37. Crowd Motor
  • 37.1. Crowd Gear and Drum
  • 37.2. Crowd Drum Removal
  • 38. Machinery House
  • 38.1. Walkways, Stairways, and Handrails
  • 38.1.1. Vertical Boarding Ladder, left
  • 38.2. Boarding Stairs
  • 39. Front End Equipment
  • 39.1. Boom Assembly
  • 39.1.1. Boom Repair
  • 39.2. Boom Limit Switch
  • 39.2.1. Limit Switch Inspection
  • 39.2.2. Limit Switch Adjustment
  • 39.3. Boom Point Sheaves
  • 39.3.1. Boom Point Sheave Removal and Disassembly
  • 39.3.2. Boom Point Sheave Reassembly and Installation
  • 39.4. Boom Bumper
  • 39.5. Saddle Block
  • 39.5.1. Saddle Block Repair
  • 39.5.2. Saddle Block Removal
  • 39.6. Dipper Handle
  • 39.6.1. Dipper Handle Removal
  • 39.6.2. Retract Rope Take-up Mechanism
  • 39.6.3. Spreader Repair
  • 40. Dipper Assembly
  • 40.1. Latch Bar Adjusting
  • 40.2. Dipper Door bumpers
  • 40.2.1. Dipper Door Snubbers
  • 40.3. Dipper Padlock
  • 40.4. Dipper Pitch Brace
  • 40.5. Dipper Trip Assembly
  • 40.6. A-Frame
  • 40.7. Auxiliary Winch
  • 40.8. Hoist Rope Support Roller
  • 40.9. Boom Support Ropes
  • 40.10. Wire Ropes
  • 40.10.1. Wire Rope Inspection
  • 40.11. Hoist Rope Reeving Replacement
  • 40.11.1. Crowd Rope Reeving Replacement
  • 41. Retract Rope Reeving Replacement
  • 41.1. Retract Rope Tightening
  • 41.2. Dipper Trip Rope Reeving Replacement
  • 41.3. Hoist and Crowd Limit Systems
  • 41.3.1. Setting Limits In The Hoist Crowd System
  • 42. Brakes and Couplings
  • 42.1. Disc Brake Operation
  • 42.2. Maintenance
  • 42.3. Brake Adjustment Specifications
  • 42.4. Hoist Brake
  • 42.4.1. Hoist Brake Adjustment
  • 42.4.2. Hoist Brake Installation
  • 42.4.3. Hoist Brake Wear Release Switches
  • 42.5. Crowd Brake
  • 42.5.1. Crowd Brake Installation
  • 42.5.2. Crowd Brake Wear Release Switches
  • 42.6. Propel Brake
  • 42.6.1. Propel Brake Adjustment
  • 42.6.2. Propel Brake Installation
  • 42.6.3. Tachometer Mounting Alignment
  • 42.7. Swing Brake
  • 42.7.1. Swing Brake Installation
  • 42.7.2. Swing Brake Wear Release Switches
  • 42.7.3. Swing Brake Burnishing
  • 42.8. Spring Replacement All Brakes
  • 42.9. Friction Disc Replacement All Brakes
  • 42.10. O-Ring Replacement All Brakes
  • 42.11. Brake Wear Release Switches Single Disc Brakes
  • 42.12. Brake Wear Release Switches Multiple Disc Brakes
  • 43. Couplings
  • 43.1. Grid Couplings
  • 43.1.1. Lubrication
  • 43.1.2. Coupling Disassembly and Grid Removal
  • 43.1.3. Grid Coupling Installation
  • 43.1.4. Seal Replacement without Hub Removal
  • 43.1.5. Grid Coupling Alignment
  • 43.2. Gear Couplings
  • 43.2.1. Coupling Installation
  • 43.2.2. Gear Coupling Alignment
  • 43.2.3. Hoist Coupling Shaft Alignment
  • 44. Compressed Air System
  • 45. Air Compressor
  • 45.1. Lubrication
  • 45.2. Fluid Level Check
  • 45.3. Fluid Filter
  • 45.4. Fluid Change
  • 45.5. V-Belt Tension
  • 45.6. V-Belt Removal and Replacement
  • 45.7. Pressure Switch
  • 45.8. Lockout Valves
  • 45.9. Safety Warnings
  • 46. Air Filtration
  • 47. House Filter Fans
  • 47.1. Lubrication
  • 47.2. Dynavane Air Cleaner
  • 47.3. Air Conditioner
  • 47.4. Specifications
  • 48. Engineering Data
  • 49. Capscrew (Bolt) Grade
  • 49.1. Bolt Tightening
  • 49.1.1. Torque Wrench Method
  • 49.1.2. Turn-of-nut Method
  • 50. Measurement Systems
  • 50.1. Linear Measurements
  • 50.2. Area Measurements
  • 50.3. Volume Measurements
  • 50.4. Torque Measurements
  • 50.4.1. Weight Measurements – Conventional
  • 51. Split Flange Assembly Procedure
  • 52. Wire Locking Capscrews
  • 53. Torque Nut Installation
  • 53.1. Tightening Procedure for 2-Inch Torque Nut
  • 53.2. Tightening Procedure for 2-Inch Torque Nut
  • 53.3. Tightening Procedure for 2.5-Inch Torque Nut
  • 53.4. Tightening Procedure for 3-Inch Torque Nut
  • 54. Expansion Bolt Installation
  • 54.1. Tightening Procedures – Expansion Bolts
  • 54.1.1. Hoist Torque Rod, Tapered Sleeve 1.0 Inch Torque Nut
  • 55. Torque Nut Removal Procedure
  • 55.1. Thread Lubrication
  • 56. Torque Nut Helpful Hints
  • 57. Locking Assemblies
  • 57.1. Locking Assembly Removal
  • 58. Pinion and Hub Installation
  • 58.1. Removal from a Shaft
  • 58.2. Mounting a Pinion or Hub on a Shaft
  • 58.2.1. Hub Adapter Pre-heat Advance Requirements
  • 58.2.2. Motor Coupling Pre-Heat Advance Requirements
  • 59. Maintenance Welding
  • 59.1. Welding Electrodes
  • 59.2. Repair Welding of Cracks
  • 59.2.1. Preheat
  • 59.2.2. Welding Technique
  • 59.3. Repair Welding of Broken Parts
  • 59.4. Repair Welding Swing Rack Teeth
  • 59.4.1. Preparation
  • 59.4.2. Swing Rack Welding Electrodes
  • 59.4.3. Preheat
  • 59.4.4. Welding Procedure
  • 59.5. Welding and Cutting Equipment
  • 59.6. Stress Relieving Temperature Measuring Equipment
  • 60. Wire Rope Care and Maintenance
  • 60.1. Storage
  • 60.2. Checking Diameter
  • 60.3. Handling Wire Rope
  • 60.4. Seizing Wire Rope
  • 60.5. End Preparations/Terminations
  • 60.6. Wire Rope Clips
  • 60.6.1. Wire Rope Clip Application
  • 60.6.2. Wedge Sockets
  • 60.7. Inspection of Sheaves and Drums
  • 60.8. Breaking In a New Wire Rope
  • 60.9. Inspection Data
  • 60.10. Guideline to Inspections and Reports
  • 60.10.1. Wire Rope Inspection Criteria
  • 60.11. Seal Installation
  • 60.12. Gearcase Sealing
  • 61. Schematics
  • 62. Schematics – Automatic Lubrication
  • 63. Side View
  • 64. Deck Plan
  • 65. OGL System A B Schematic
  • 66. Grease System C Schematic
  • 67. Air Schematic
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