Bucyrus 495HD Mining Shovel Service Manual BI624129
Bucyrus 495HD Mining Shovel Service Manual BI624129 - Image 2
Bucyrus 495HD Mining Shovel Service Manual BI624129 - Image 3
Bucyrus 495HD Mining Shovel Service Manual BI624129 - Image 4
Bucyrus 495HD Mining Shovel Service Manual BI624129 - Image 5

Bucyrus 495HD Mining Shovel Service Manual BI624129

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: BI624129
  • Number of Pages: 479
  • Size: 11.4MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 495HD Mining Shovel
  • 1. Table of Contents
  • 2. Revision History
  • 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
  • 6.7. Swinging Restraint Ballast Box Support
  • 6.8. Ballast Box Support
  • 6.9. Swinging Restraint
  • 7. Machine Overview
  • 8. Lower Works
  • 8.1. Crawlers
  • 8.2. Truck Frame
  • 8.3. Swing Rack
  • 8.4. Roller Circle
  • 8.5. Propel Machinery
  • 8.6. Collector Rings
  • 9. Rotating Deck
  • 9.1. Revolving Frame
  • 9.2. Center Pintle
  • 9.3. Deck Extensions
  • 9.4. Ballast Box
  • 9.5. Machinery House
  • 9.5.1. Vertical Boarding Ladder, Left
  • 9.6. Boarding Stairs
  • 9.7. A-Frame
  • 9.8. Hoist Machinery
  • 9.9. Swing Machinery
  • 9.10. Crowd Machinery
  • 9.11. Operators Cab
  • 9.12. Compressed Air System
  • 9.13. Automatic Lubrication System
  • 10. Front End Equipment
  • 10.1. Suspension Strands
  • 10.2. Boom
  • 10.3. Running Ropes
  • 10.4. Saddle Block
  • 10.5. Dipper Handle
  • 10.6. Dipper
  • 10.7. Padlocks
  • 10.8. Dipper Trip
  • 11. Typical Machine Specifications
  • 12. General Estimated Component Weights
  • 12.1. Lower Works
  • 12.2. Upper Works
  • 12.3. Front End
  • 13. Lubrication
  • 14. Lubrication Principles
  • 15. Greasing Main A.C. Drive Motors
  • 15.1. Type of Grease
  • 15.2. Initial Commissioning
  • 15.3. Maintenance
  • 15.4. Regreasing Intervals
  • 16. Lubricant Selection
  • 17. Oil Fill Capacities
  • 17.1. Types Of Lubricants And Capacities Guidelines
  • 17.1.1. Quantities for First Fill of Lubricants
  • 18. Lubricant Replacement/Sampling
  • 18.1. Lubricant Change Cycle
  • 19. Automatic Lubrication System
  • 19.1. Lube Room
  • 19.2. Lube Reservoir Fill / Overflow Plumbing
  • 19.2.1. Auto Lube Control Panel
  • 19.3. Lower Works Lubrication
  • 19.4. Revolving Frame Lubrication
  • 19.5. Front End Lubrication
  • 19.6. Lubricant Injectors
  • 19.6.1. Lincoln Type SL-1 Lubricant Injectors
  • 19.6.2. Lincoln Type SL-V Lubricant Injectors
  • 20. Propel Machinery Lubrication
  • 21. Hoist Machinery Lubrication
  • 21.1. Hoist Gearcase Oil Cooler
  • 22. Swing Machinery Lubrication
  • 23. Air Compressor Lubrication
  • 24. Crowd Machinery Lubrication
  • 25. Lubricant Specifications
  • 25.1. ACSL – Air Compressor (Screw-Type) Lubricant
  • 25.2. MPO – Multipurpose Oil
  • 25.3. RWRL – Running Wire Rope Lubricant
  • 25.4. EGL – Enclosed Gearcase Lubricant
  • 25.5. MPG – Multipurpose Grease
  • 25.6. OGL – Open Gear Lubricant
  • 26. Preventive Maintenance
  • 27. Introduction
  • 27.1. Preventive Maintenance Program
  • 27.2. Elements of an Effective Maintenance Program
  • 27.3. Scheduled Preventive Maintenance Program
  • 27.4. General Safety Considerations
  • 28. Maintenance During Machine Operation
  • 28.1. Maintenance Precautions
  • 29. Preventive Maintenance for Lubrication
  • 29.1. Lubricant Cleanliness
  • 30. Frequency of Inspection and Maintenance
  • 31. Maintenance Schedules
  • 31.1. Maintenance Inspection Check Points
  • 31.1.1. Daily
  • 31.1.2. Every 100 Hours or Weekly
  • 31.1.3. Every 500 Hours Or Monthly
  • 31.1.4. Every 1250 Hours or Quarterly
  • 31.1.5. Every 2500 Hours or Semi-Annually
  • 31.1.6. Every 5000 Hours or Annually
  • 32. Major Component Locations
  • 33. Service Procedures
  • 34. Lower Works
  • 34.1. Truck Frame
  • 34.2. Swing Rack
  • 34.2.1. Swing Rack Dust Curtains
  • 34.3. Roller Circle
  • 34.3.1. Roller Circle Repair
  • 34.4. Crawler Belts
  • 34.4.1. Belt Adjustment
  • 34.4.2. Belt Replacement
  • 34.4.3. Crawler Links
  • 34.5. Crawlers
  • 34.5.1. Upper Rollers
  • 34.5.2. Lower Rollers
  • 34.5.3. Take-up Tumbler Axle
  • 34.6. Propel Assembly
  • 34.6.1. Drive Tumbler
  • 34.6.2. Tumbler Drive Shaft
  • 34.7. Propel Machinery
  • 34.7.1. Propel Motor
  • 34.7.2. Propel Planetary Gearcase
  • 35. Rotating Deck
  • 35.1. Revolving Frame
  • 35.2. Center Pintle
  • 35.2.1. Center Pintle Adjustment
  • 35.2.2. Center Pintle Sleeve Removal
  • 35.3. Collector Rings
  • 35.3.1. Collector Ring Inspection
  • 35.3.2. Collector Ring Repair
  • 35.4. Swing Machinery
  • 35.4.1. Swing Blower
  • 35.4.2. Swing Motor
  • 35.4.3. Swing Planetary Gearcase
  • 35.4.4. Swing Shafts and Pinions
  • 35.5. Hoist Machinery
  • 35.5.1. Hoist Motor
  • 35.5.2. Hoist Gearcase Assembly
  • 35.5.3. Motor Coupling Shaft
  • 35.5.4. Hoist Drum Assembly
  • 35.5.5. Hoist Gear Replacement
  • 35.5.6. Hoist Mounting Bolts
  • 35.5.7. Hoist Limit Switch
  • 35.6. Crowd Machinery
  • 35.6.1. Gearcase Repair
  • 35.6.2. Crowd Motor
  • 35.6.3. Crowd Gear and Drum
  • 36. Machinery House
  • 36.1. Walkways, Stairways, and Handrails
  • 36.2. Vertical Boarding Ladder, left
  • 36.3. Boarding Stairs
  • 37. Front End Equipment
  • 37.1. Boom Assembly
  • 37.1.1. Boom Repair
  • 37.1.2. Boom Limit Switch
  • 37.1.3. Boom Point Sheaves
  • 37.1.4. Boom Point Sheave Removal and Disassembly
  • 37.2. Boom Bumper
  • 37.3. Saddle Block
  • 37.3.1. Saddle Block Repair
  • 37.3.2. Saddle Block Removal
  • 37.4. Dipper Handle
  • 37.4.1. Dipper Handle Removal
  • 37.4.2. Retract Rope Take-up Mechanism
  • 37.4.3. Spreader Repair
  • 37.5. Dipper Assembly
  • 37.5.1. Latch Bar Adjusting
  • 37.5.2. Dipper Door Bumpers
  • 37.5.3. Dipper Door Snubbers
  • 37.5.4. Dipper Padlock
  • 37.5.5. Dipper Pitch Brace
  • 37.5.6. Dipper Trip Assembly
  • 37.6. A-Frame
  • 37.7. Auxiliary Winch
  • 37.8. Hoist Rope Support Roller
  • 37.9. Boom Support Ropes
  • 37.10. Wire Ropes
  • 37.10.1. Wire Rope Inspection
  • 37.11. Hoist Rope Reeving Replacement
  • 37.12. Crowd Rope Reeving Replacement
  • 37.13. Retract Rope Reeving Replacement
  • 37.14. Crowd Rope Tightening
  • 37.15. Retract Rope Tightening
  • 37.16. Dipper Trip Rope Reeving Replacement
  • 37.17. Hoist and Crowd Limit Systems
  • 37.17.1. Setting Limits In The Hoist Crowd System
  • 38. Brakes and Couplings
  • 39. Brakes
  • 39.1. Disc Brake Operation
  • 39.2. Maintenance
  • 39.3. Brake Adjustment Specifications
  • 39.4. Hoist Brake
  • 39.4.1. Hoist Brake Adjustment
  • 39.4.2. Hoist Brake Installation
  • 39.4.3. Hoist Brake Wear Release Switches
  • 39.5. Crowd Brake
  • 39.5.1. Crowd Brake Installation
  • 39.5.2. Crowd Brake Wear Release Switches
  • 39.6. Propel Brake
  • 39.6.1. Propel Brake Adjustment
  • 39.6.2. Propel Brake Installation
  • 39.6.3. Tachometer Mounting Alignment
  • 39.7. Swing Brake
  • 39.7.1. Swing Brake Installation
  • 39.7.2. Swing Brake Wear Release Switches
  • 39.7.3. Swing Brake Burnishing
  • 39.8. Spring Replacement All Brakes
  • 39.9. Friction Disc Replacement All Brakes
  • 39.10. O-Ring Replacement All Brakes
  • 39.11. Brake Wear Release Switches Single Disc Brakes
  • 39.12. Brake Wear Release Switches Multiple Disc Brakes
  • 40. Couplings
  • 40.1. Grid Couplings
  • 40.1.1. Lubrication
  • 40.1.2. Coupling Disassembly and Grid Removal
  • 40.1.3. Grid Coupling Installation
  • 40.1.4. Seal Replacement without Hub Removal
  • 40.1.5. Grid Coupling Alignment
  • 40.2. Gear Couplings
  • 40.2.1. Coupling Installation
  • 40.2.2. Gear Coupling Alignment
  • 40.2.3. Hoist Coupling Shaft Alignment
  • 41. Compressed Air System
  • 42. Air Compressor
  • 42.1. Compressor Maintenance
  • 42.2. Lubrication
  • 42.3. Fluid Level Check
  • 42.4. Fluid Filter
  • 42.5. Fluid Change
  • 42.6. V-Belt Tension
  • 42.7. V-Belt Removal and Replacement
  • 42.8. Pressure Switch
  • 42.9. Lockout Valves
  • 42.10. Safety Warnings
  • 43. Air Filtration
  • 44. House Filter Fans
  • 44.1. Lubrication
  • 44.2. Dynavane Air Cleaner
  • 44.3. Tenkay Filter
  • 45. Air Conditioner
  • 45.1. Specifications
  • 46. Engineering Data
  • 47. Capscrew (Bolt) Grade
  • 47.1. Bolt Tightening
  • 47.1.1. Torque Wrench Method
  • 47.1.2. Turn-of-nut Method
  • 48. Measurement Systems
  • 48.1. Linear Measurements
  • 48.2. Area Measurements
  • 48.3. Volume Measurements
  • 48.4. Torque Measurements
  • 48.5. Weight Measurements – Conventional
  • 49. Split Flange Assembly Procedure
  • 50. Wire Locking Capscrews
  • 51. Torque Nut Installation
  • 52. Expansion Bolt Installation
  • 52.1. Tightening Procedure for 2-Inch Torque Nut
  • 52.2. Tightening Procedure for 2-Inch Torque Nut
  • 52.3. Tightening Procedure for 2-Inch Torque Nut
  • 52.4. Tightening Procedure for 2.5-Inch Torque Nut
  • 52.5. Tightening Procedure for 3-Inch Torque Nut
  • 52.6. Tightening Procedures – Expansion Bolts
  • 52.6.1. Hoist Torque Rod, Tapered Sleeve 1.62 Inch Torque Nut
  • 53. Torque Nut Removal Procedure
  • 53.1. Thread Lubrication
  • 54. Torque Nut Helpful Hints
  • 55. Locking Assemblies
  • 55.1. Locking Assembly Removal
  • 56. Pinion and Hub Installation
  • 56.1. Removal from a Shaft
  • 56.2. Mounting a Pinion or Hub on a Shaft
  • 56.3. Pre-heat Advance Requirements – Pinions and Hubs
  • 56.4. Motor Coupling Pre-Heat Advance Requirements
  • 57. Maintenance Welding
  • 57.1. Welding Electrodes
  • 57.2. Repair Welding of Cracks
  • 57.2.1. Preheat
  • 57.2.2. Welding Technique
  • 57.3. Repair Welding of Broken Parts
  • 57.4. Repair Welding Swing Rack Teeth
  • 57.4.1. Preparation
  • 57.4.2. Swing Rack Welding Electrodes
  • 57.4.3. Preheat
  • 57.4.4. Welding Procedure
  • 57.5. Welding and Cutting Equipment
  • 57.6. Stress Relieving Temperature Measuring Equipment
  • 58. Wire Rope Care and Maintenance
  • 58.1. Storage
  • 58.2. Checking Diameter
  • 58.3. Handling Wire Rope
  • 58.4. Seizing Wire Rope
  • 58.5. End Preparations/Terminations
  • 58.6. Wire Rope Clips
  • 58.6.1. Wire Rope Clip Application
  • 58.6.2. Wedge Sockets
  • 58.7. Inspection of Sheaves and Drums
  • 58.8. Breaking In a New Wire Rope
  • 58.9. Inspection Data
  • 58.10. Guideline to Inspections and Reports
  • 58.10.1. Wire Rope Inspection Criteria
  • 59. Seals
  • 59.1. Seal Installation
  • 59.2. Gearcase Sealing
  • 60. Schematics
  • 61. Schematics
  • 62. Side View
  • 63. Deck Plan
  • 64. OGL System A B Schematic
  • 65. Grease System C Schematic
  • 66. Air Schematic
Rate this product

Related products