Bucyrus 495HD Mining Shovel Service Manual BI624090

Bucyrus 495HD Mining Shovel Service Manual BI624090 - Image 2

Bucyrus 495HD Mining Shovel Service Manual BI624090 - Image 3

Bucyrus 495HD Mining Shovel Service Manual BI624090

$30.00

Type Of Manual: Service Manual
Manual ID: BI624090
Number of Pages: 493
Size: 11.6MB
Format: PDF

Category: Bucyrus Service Manual PDF

Product details

Model List:
- 495HD Mining Shovel

1. Table of Contents
2. List of Revisions
3. Safety Symbols
4. Safety Precautions
4.1. General Precautions
4.2. Maintenance Precautions
4.3. Operating Precautions
4.4. Fire Prevention
4.5. Warning Signs And Decals
5. Introduction
6. About This Manual
6.1. Purpose
6.2. Organization
6.3. Terminology
6.4. Revisions
6.5. Precautions and Disclaimers
6.6. Contact
7. Swinging Restraint Ballast Box Support
7.1. Ballast Box Support
7.2. Swinging Restraint
8. Machine Overview
9. Lower Works
9.1. Crawlers
9.2. Truck Frame
9.3. Swing Rack
9.4. Roller Circle
9.5. Propel Machinery
9.6. Collector Rings
9.7. Stinger (Trail Cable Support)
10. Rotating Deck
10.1. Revolving Frame
10.2. Center Pintle
10.3. Deck Extensions
10.4. Ballast Box
10.5. Machinery House
10.5.1. Vertical Boarding Ladder, Left
10.6. Boarding Stairs
10.7. A-Frame
10.8. Hoist Machinery
10.9. Swing Machinery
10.10. Crowd Machinery
10.11. Operators Cab
10.12. Compressed Air System
10.13. Automatic Lubrication System
11. Front End Equipment
11.1. Suspension Strands
11.2. Boom
11.3. Running Ropes
11.4. Saddle Block
11.5. Dipper Handle
11.6. Dipper
11.7. Padlocks
11.8. Dipper Trip
12. Typical Machine Specifications
13. General Estimated Component Weights
13.1. Lower Works
13.2. Upper Works
13.3. Front End
14. Lubrication
15. Lubrication Principles
16. Greasing Main A.C. Drive Motors
16.1. Type of Grease
16.2. Initial Commissioning
16.3. Maintenance
16.4. Regreasing Intervals
17. Lubricant Selection
18. Oil Fill Capacities
18.1. Types Of Lubricants And Capacities Guidelines
18.1.1. Quantities for First Fill of Lubricants
19. Lubricant Replacement/Sampling
19.1. Lubricant Change Cycle
20. Automatic Lubrication System
20.1. Lube Room
20.2. Lube Reservoir Fill / Overflow Plumbing
20.2.1. Auto Lube Control Panel
20.3. Lower Works Lubrication
20.4. Revolving Frame Lubrication
20.5. Front End Lubrication
20.6. Lubricant Injectors
20.6.1. Lincoln Type SL-1 Lubricant Injectors
20.6.2. Lincoln Type SL-V Lubricant Injectors
21. Propel Machinery Lubrication
22. Hoist Machinery Lubrication
22.1. Hoist Gearcase Oil Cooler
23. Swing Machinery Lubrication
24. Air Compressor Lubrication
25. Crowd Machinery Lubrication
25.1. Crowd Rope Take-Up Mechanism Lubrication
26. Lubricant Specifications
26.1. ACSL – Air Compressor (Screw-Type) Lubricant
26.2. MPO – Multipurpose Oil
26.3. RWRL – Running Wire Rope Lubricant
26.4. EGL – Enclosed Gearcase Lubricant
26.5. MPG – Multipurpose Grease
26.6. OGL – Open Gear Lubricant
27. Preventive Maintenance
28. Introduction
28.1. Preventive Maintenance Program
28.2. Elements of an Effective Maintenance Program
28.3. Scheduled Preventive Maintenance Program
28.4. General Safety Considerations
29. Maintenance During Machine Operation
29.1. Maintenance Precautions
30. Preventive Maintenance for Lubrication
30.1. Lubricant Cleanliness
31. Frequency of Inspection and Maintenance
32. Maintenance Schedules
32.1. Maintenance Inspection Check Points
32.1.1. Daily
32.1.2. Every 100 Hours or Weekly
32.1.3. Every 500 Hours Or Monthly
32.1.4. Every 1250 Hours or Quarterly
32.1.5. Every 2500 Hours or Semi-Annually
32.1.6. Every 5000 Hours or Annually
33. Major Component Locations
34. Service Procedures
35. Lower Works
35.1. Truck Frame
35.2. Swing Rack
35.2.1. Swing Rack Dust Curtains
35.3. Roller Circle
35.3.1. Roller Circle Repair
35.4. Crawler Belts
35.4.1. Belt Adjustment
35.4.2. Belt Replacement
35.4.3. Crawler Links
35.5. Crawlers
35.5.1. Upper Rollers
35.5.2. Lower Rollers
35.5.3. Take-up Tumbler Axle
35.6. Propel Assembly
35.6.1. Drive Tumbler
35.6.2. Tumbler Drive Shaft
35.7. Propel Machinery
35.7.1. Propel Motor
35.7.2. Propel Planetary Gearcase
36. Rotating Deck
36.1. Revolving Frame
36.2. Center Pintle
36.2.1. Center Pintle Adjustment
36.2.2. Center Pintle Sleeve Removal
36.3. Collector Rings
36.3.1. Collector Ring Inspection
36.3.2. Collector Ring Repair
36.4. Stinger (Trail Cable Support)
36.5. Swing Machinery
36.5.1. Swing Blower
36.5.2. Swing Motor
36.5.3. Swing Planetary Gearcase
36.5.4. Swing Shafts and Pinions
36.6. Hoist Machinery
36.6.1. Hoist Motor
36.6.2. Hoist Gearcase Assembly
36.6.3. Motor Coupling Shaft
36.6.4. Hoist Drum Assembly
36.6.5. Hoist Gear Replacement
36.6.6. Hoist Mounting Bolts
36.6.7. Hoist Limit Switch
36.7. Crowd Machinery
36.7.1. Gearcase Repair
36.7.2. Crowd Motor
36.7.3. Crowd Gear and Drum
37. Machinery House
37.1. Walkways, Stairways, and Handrails
37.2. Vertical Boarding Ladder, left
37.3. Boarding Stairs
38. Front End Equipment
38.1. Boom Assembly
38.1.1. Boom Repair
38.1.2. Boom Limit Switch
38.1.3. Boom Point Sheaves
38.1.4. Boom Point Sheave Removal and Disassembly
38.2. Boom Bumper
38.3. Saddle Block
38.3.1. Saddle Block Repair
38.3.2. Saddle Block Removal
38.4. Dipper Handle
38.4.1. Dipper Handle Removal
38.4.2. Crowd Rope Take-Up Mechanism
38.4.3. Retract Rope Take-up Mechanism
38.4.4. Spreader Repair
38.5. Dipper Assembly
38.5.1. Latch Bar Adjusting
38.5.2. Dipper Door Bumpers
38.5.3. Dipper Door Snubbers
38.5.4. Dipper Padlock
38.5.5. Dipper Pitch Brace
38.5.6. Dipper Trip Assembly
38.6. A-Frame
38.7. Auxiliary Winch
38.8. Hoist Rope Support Roller
38.9. Boom Support Ropes
38.10. Wire Ropes
38.10.1. Wire Rope Inspection
38.11. Crowd Rope Take-up Hydraulic Unit
38.12. Hoist Rope Reeving Replacement
38.13. Crowd Rope Reeving Replacement
38.14. Retract Rope Reeving Replacement
38.15. Crowd Rope Tightening
38.16. Retract Rope Tightening
38.17. Dipper Trip Rope Reeving Replacement
38.18. Hoist and Crowd Limit Systems
38.18.1. Setting Limits In The Hoist Crowd System
39. Brakes and Couplings
40. Brakes
40.1. Disc Brake Operation
40.2. Maintenance
40.3. Brake Adjustment Specifications
40.4. Hoist Brake
40.4.1. Hoist Brake Adjustment
40.4.2. Hoist Brake Installation
40.4.3. Hoist Brake Wear Release Switches
40.5. Crowd Brake
40.5.1. Crowd Brake Installation
40.5.2. Crowd Brake Wear Release Switches
40.6. Propel Brake
40.6.1. Propel Brake Adjustment
40.6.2. Propel Brake Installation
40.6.3. Tachometer Mounting Alignment
40.7. Swing Brake
40.7.1. Swing Brake Installation
40.7.2. Swing Brake Wear Release Switches
40.7.3. Swing Brake Burnishing
40.8. Spring Replacement All Brakes
40.9. Friction Disc Replacement All Brakes
40.10. O-Ring Replacement All Brakes
40.11. Brake Wear Release Switches Single Disc Brakes
40.12. Brake Wear Release Switches Multiple Disc Brakes
41. Couplings
41.1. Grid Couplings
41.1.1. Lubrication
41.1.2. Coupling Disassembly and Grid Removal
41.1.3. Grid Coupling Installation
41.1.4. Seal Replacement without Hub Removal
41.1.5. Grid Coupling Alignment
41.2. Gear Couplings
41.2.1. Coupling Installation
41.2.2. Gear Coupling Alignment
41.2.3. Hoist Coupling Shaft Alignment
42. Compressed Air System
43. Air Compressor
43.1. Lubrication
43.2. Fluid Level Check
43.3. Fluid Filter
43.4. Fluid Change
43.5. V-Belt Tension
43.6. V-Belt Removal and Replacement
43.7. Pressure Switch
43.8. Lockout Valves
43.9. Safety Warnings
44. Air Filtration
45. House Filter Fans
45.1. Lubrication
45.2. Dynavane Air Cleaner
45.3. Tenkay Filter
46. Air Conditioner
46.1. Specifications
47. Engineering Data
48. Capscrew (Bolt) Grade
48.1. Bolt Tightening
48.1.1. Torque Wrench Method
48.1.2. Turn-of-nut Method
49. Measurement Systems
49.1. Linear Measurements
49.2. Area Measurements
49.3. Volume Measurements
49.4. Torque Measurements
49.5. Weight Measurements – Conventional
50. Split Flange Assembly Procedure
51. Wire Locking Capscrews
52. Torque Nut Installation
53. Expansion Bolt 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-Inch Torque Nut
53.4. Tightening Procedure for 2.5-Inch Torque Nut
53.5. Tightening Procedure for 3-Inch Torque Nut
53.6. Tightening Procedures – Expansion Bolts
53.6.1. Hoist Torque Rod, Tapered Sleeve 1.62 Inch Torque Nut
54. Torque Nut Removal Procedure
54.1. Thread Lubrication
55. Torque Nut Helpful Hints
56. Locking Assemblies
56.1. Locking Assembly Removal
57. Pinion and Hub Installation
57.1. Removal from a Shaft
57.2. Mounting a Pinion or Hub on a Shaft
57.3. Pre-heat Advance Requirements – Pinions and Hubs
57.4. Motor Coupling Pre-Heat Advance Requirements
58. Maintenance Welding
58.1. Welding Electrodes
58.2. Repair Welding of Cracks
58.2.1. Preheat
58.2.2. Welding Technique
58.3. Repair Welding of Broken Parts
58.4. Repair Welding Swing Rack Teeth
58.4.1. Preparation
58.4.2. Swing Rack Welding Electrodes
58.4.3. Preheat
58.4.4. Welding Procedure
58.5. Welding and Cutting Equipment
58.6. Stress Relieving Temperature Measuring Equipment
59. Wire Rope Care and Maintenance
59.1. Storage
59.2. Checking Diameter
59.3. Handling Wire Rope
59.4. Seizing Wire Rope
59.5. End Preparations/Terminations
59.6. Wire Rope Clips
59.6.1. Wire Rope Clip Application
59.6.2. Wedge Sockets
59.7. Inspection of Sheaves and Drums
59.8. Breaking In a New Wire Rope
59.9. Inspection Data
59.10. Guideline to Inspections and Reports
59.10.1. Wire Rope Inspection Criteria
60. Seals
60.1. Seal Installation
60.2. Gearcase Sealing
61. Schematics
62. Schematics
63. Side View
64. Deck Plan
65. OGL System A B Schematic
66. Grease System C Schematic
67. Air Schematic

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Bucyrus 495HD Mining Shovel Service Manual BI624090

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