Bucyrus 495HR Mining Shovel Maintenance And Operation Manual BI619614
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Bucyrus 495HR Mining Shovel Maintenance And Operation Manual BI619614

$30.00

  • Type Of Manual: Maintenance And Operation Manual
  • Manual ID: BI619614
  • Number of Pages: 542
  • Size: 16.8MB
  • 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
  • 3.1.1. Ballast Box Support
  • 3.2. 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. Boarding Stairs
  • 6.5.2. Vertical Boarding Ladder
  • 6.6. A-Frame
  • 6.7. Hoist Machinery
  • 6.8. Swing Machinery
  • 6.9. Crowd Machinery
  • 6.10. OPERATORS CAB
  • 6.11. Compressed Air System
  • 6.12. Automatic Lubrication System
  • 6.13. Lube Reservoir fill / Overflow Plumbing
  • 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. Operators Seat
  • 12.1. Adjustable Armrest
  • 12.2. Adjustable Footrest
  • 13. Controls
  • 13.1. Primary Operating Controls
  • 13.2. Controls On The Left Console
  • 13.2.1. Left Joystick
  • 13.2.2. Dipper Trip
  • 13.2.3. Signal Horn
  • 13.2.4. Start Pushbutton
  • 13.2.5. PLC Power On
  • 13.2.6. Drive Cabinet Temperature
  • 13.2.7. Incomplete Sequence
  • 13.2.8. System Ready
  • 13.2.9. Phase Sequence
  • 13.2.10. Auxiliary Ground Fault
  • 13.2.11. Hoist Brake
  • 13.2.12. Crowd Brake
  • 13.2.13. Swing Brake
  • 13.2.14. Propel Brake
  • 13.2.15. HVAC Unit Selector
  • 13.2.16. Temperature
  • 13.2.17. HVAC System Control
  • 13.2.18. HVAC Fan Speed
  • 13.2.19. Cabin Lights
  • 13.2.20. Controls On The Right Console
  • 13.2.21. Right Joystick
  • 13.2.22. Emergency Stop Pushbutton
  • 13.2.23. Windshield Wiper Switches
  • 13.2.24. Control Stop Pushbutton
  • 13.2.25. Control Reset Pushbutton
  • 13.2.26. Air Compressor
  • 13.2.27. Dig/propel Transfer Switch
  • 13.2.28. Main Power Off Pushbutton
  • 13.2.29. Earth Continuity Lockout Pushbutton
  • 13.2.30. Seat Position
  • 13.2.31. Radio Receiver with CD Changer
  • 14. Operators Display
  • 14.1. Display Area and Indicators
  • 14.2. Display Screens
  • 14.3. Lubrication Control Panel
  • 14.4. Fire Suppression System
  • 15. Pre-start Checks
  • 15.1. Walk-around Ground Level Inspection
  • 15.2. On-board Inspection
  • 16. Start-up, Operation And Shutdown
  • 16.1. Machine Start-up
  • 16.2. Restarting After An Electrical Fault
  • 16.3. Machine Operation
  • 16.4. Machinery Motions
  • 16.4.1. Hoist Motion
  • 16.4.2. Crowd Motion
  • 16.4.3. Propel Motion
  • 16.4.4. Swing Motion
  • 16.4.5. Steering
  • 16.4.6. Positioning the Machine
  • 16.4.7. Start Of The Dig Cycle
  • 16.4.8. Engaging The Bank
  • 16.4.9. Slope Limitations
  • 16.5. Excavated Material
  • 16.6. Operation Checks
  • 16.7. Operating Hints
  • 16.8. Stopping the Machine
  • 16.9. Shutdown
  • 17. Lubrication
  • 18. Lubrication Principles
  • 19. Greasing Main A.C. Drive Motors
  • 19.1. Type of Grease
  • 19.2. Initial Commissioning
  • 19.3. Maintenance
  • 19.4. Regreasing Intervals
  • 20. Lubricant Selection
  • 21. Oil Fill Capacities
  • 21.1. Types Of Lubricants And Capacities Guidelines
  • 21.1.1. Quantities for First Fill of Lubricants
  • 22. Automatic Lubrication System
  • 22.1. Lube Room
  • 22.2. Lube Reservoir fill / Overflow Plumbing
  • 22.2.1. Auto Lube Control Panel
  • 22.3. Lower Works Lubrication
  • 22.4. Propel Machinery Lubrication
  • 22.4.1. Lubricant Replacement/sampling
  • 22.5. Revolving Frame Lubrication
  • 22.6. Hoist Machinery Lubrication
  • 22.6.1. Hoist Oil Cooler
  • 22.6.2. Filter Element Cleaning
  • 22.7. Hoist Rope Rollers Lubrication
  • 22.7.1. Oil Pump
  • 22.8. Crowd Machinery Lubrication
  • 22.9. Swing Machinery Lubrication
  • 22.10. Air Compressor Lubrication
  • 22.11. Crowd Rope Take-Up Mechanism Lubrication
  • 22.12. Front End Lubrication
  • 22.13. Lincoln Type SL-1 Lubricant Injectors
  • 22.13.1. SL-1 Lubricant Injector Operation
  • 22.13.2. Injector Advantages
  • 22.14. Air Compressor Lubricant
  • 22.15. MPO – Multipurpose OIL
  • 22.16. RWRL – Running Wire Rope Lubricant
  • 22.17. EGL – Enclosed Gearcase Lubricant
  • 22.18. MPG – Multipurpose Grease
  • 22.19. OGL – Open Gear Lubricant
  • 22.20. Certified Lubricants Listing
  • 23. Preventive Maintenance
  • 24. Introduction
  • 24.1. Preventive Maintenance Program
  • 24.2. Elements of an Effective Maintenance Program
  • 24.3. Scheduled Preventive Maintenance Program
  • 24.4. General Safety Considerations
  • 25. Maintenance During Machine Operation
  • 25.1. Maintenance Precautions
  • 26. Preventive Maintenance for Lubrication
  • 26.1. Lubricant Cleanliness
  • 27. Frequency of Inspection and Maintenance
  • 28. Maintenance Schedules
  • 28.1. Maintenance Inspection Check Points
  • 28.1.1. Every 100 Hours or Weekly
  • 28.1.2. Every 500 Hours Or Monthly
  • 28.1.3. Every 1250 Hours or Quarterly
  • 28.1.4. Every 2500 Hours or Semi-Annually
  • 28.1.5. Hours or Annually
  • 29. Major Component Locations
  • 30. Service Procedures
  • 31. Lower Works
  • 31.1. Truck Frame Assembly
  • 31.2. Swing Rack Assembly
  • 31.2.1. Roller Circle Rail Replacement – Lower
  • 31.2.2. Roller Circle Rail Replacement – Upper
  • 31.3. Roller Circle Assembly
  • 31.3.1. Roller Circle Adjustment
  • 31.3.2. Adjustment Procedure
  • 31.3.3. Run-in Procedure for the Roller Circle
  • 31.3.4. Roller Circle Segment Removal
  • 31.3.5. Roller Circle – Roller Replacement
  • 31.4. Crawler Belts
  • 31.4.1. Crawler Belt Maintenance
  • 31.5. Crawler Side Frame Assembly
  • 31.5.1. Crawler Side Frame Maintenance
  • 31.5.2. Slide Bar Replacement
  • 31.5.3. Load and Idler Rollers
  • 31.6. Propel Assembly
  • 31.6.1. Installation Notes
  • 31.6.2. Main Propel Drive Shaft Removal
  • 31.6.3. Main Propel Shaft – Disassembly
  • 31.6.4. Tumbler Rebuild Procedure
  • 31.7. Propel Machinery
  • 31.7.1. Propel Gearcase Removal
  • 31.7.2. Propel Gearcase Installation
  • 31.7.3. Propel Planetary Gearcase
  • 31.7.4. Propel Motors
  • 31.8. Revolving Frame
  • 31.9. Center Pintle
  • 31.9.1. Center Pintle Adjustment
  • 31.9.2. Center Pintle Sleeve Removal
  • 31.10. Collector Rings
  • 31.10.1. Collector Ring Inspection
  • 31.10.2. Collector Ring Repair
  • 31.11. Cable Reel
  • 32. Rotating Deck
  • 32.1. Swing Machinery
  • 32.1.1. Swing Support Mounting Bolts
  • 32.1.2. Swing Motor
  • 32.1.3. Swing Planetary Gearcase
  • 32.1.4. Swing Pinion Shafts
  • 32.2. Hoist Machinery
  • 32.2.1. Hoist Motor Removal
  • 32.2.2. Motor Coupling Shaft
  • 32.2.3. Hoist Gearcase Assembly
  • 32.2.4. Hoist Gearcase Repair
  • 32.2.5. Hoist Drum Assembly
  • 32.2.6. Hoist Oil Cooler
  • 32.2.7. Hoist Mounting Bolts
  • 32.2.8. Hoist Limit Switch
  • 32.3. Crowd Machinery
  • 32.4. GEARCASE REPAIR
  • 32.4.1. Crowd Gearcase Disassembly
  • 32.4.2. Crowd Gearcase Assembly
  • 32.4.3. Crowd Motor
  • 32.5. Operators Cab Mounting
  • 32.6. Operators Seat Installation
  • 32.7. Footrest Installation
  • 32.8. Machinery House
  • 32.8.1. Walkways, Stairways, and Handrails
  • 32.8.2. Boarding Stairs
  • 32.8.3. Vertical Boarding Ladder, left
  • 33. Front End Equipment
  • 33.1. Boom Assembly
  • 33.2. Boom Repair
  • 33.3. Boom Limit Switch Installation
  • 33.4. Boom Point Sheaves
  • 33.4.1. Boom Point Sheave Removal and Disassembly
  • 33.4.2. Boom Point Sheave Reassembly and Installation
  • 33.5. Boom Bumper
  • 33.6. Saddle Block
  • 33.6.1. Saddle Block Repair
  • 33.6.2. Saddle Block Removal
  • 33.7. Dipper Handle
  • 33.7.1. Dipper Handle Removal
  • 33.7.2. Crowd Rope Take-Up Mechanism
  • 33.7.3. Retract Rope Take-up Mechanism
  • 33.7.4. Spreader Repair
  • 33.8. LatchFreeTM Dipper Assembly
  • 33.9. Dipper Assembly
  • 33.9.1. Latch Bar Adjusting
  • 33.9.2. Dipper Door bumpers
  • 33.10. DIPPER INSPECTION
  • 33.10.1. Dipper Removal Installation
  • 33.10.2. Dipper Door Snubbers
  • 33.10.3. Dipper Pitch Brace
  • 33.10.4. Dipper Padlock
  • 33.11. Dipper Trip Assembly
  • 33.12. A-Frame
  • 33.13. Auxiliary Winch
  • 33.14. Hoist Rope Support Roller
  • 33.15. Boom Support Ropes
  • 33.16. Wire Ropes
  • 33.16.1. Wire Rope Inspection
  • 33.17. Crowd Rope Take-up Hydraulic Unit
  • 33.18. Hoist Rope Reeving Replacement
  • 33.19. Crowd Rope Reeving Replacement
  • 33.20. Retract Rope Reeving Replacement
  • 33.21. Crowd Rope Tightening
  • 33.22. Retract Rope Tightening
  • 33.23. Dipper Trip Rope Reeving Replacement
  • 33.24. Hoist and Crowd Limit Systems
  • 33.24.1. Setting Limits In The Hoist Crowd System
  • 34. Brakes and Couplings
  • 34.1. Disc Brake Operation
  • 34.2. Maintenance
  • 34.3. Brake Adjustment Specifications
  • 34.4. Hoist Brake
  • 34.4.1. Hoist Brake Adjustment
  • 34.4.2. Hoist Brake Installation
  • 34.4.3. Hoist Brake Wear Release Switches
  • 34.5. Crowd Brake
  • 34.5.1. Crowd Brake Installation
  • 34.5.2. Crowd Brake Wear Release Switches
  • 34.6. Propel Brake
  • 34.6.1. Propel Brake Adjustment
  • 34.6.2. Propel Brake Installation
  • 34.6.3. Tachometer Mounting Alignment
  • 34.7. Swing Brake
  • 34.7.1. Swing Brake Installation
  • 34.7.2. Swing Brake Wear Release Switches
  • 34.7.3. Swing Brake Burnishing
  • 34.8. Spring Replacement All Brakes
  • 34.9. Friction Disc Replacement All Brakes
  • 34.10. O-Ring Replacement All Brakes
  • 34.11. Brake Wear Release Switches Single Disc Brakes
  • 34.12. Brake Wear Release Switches Multiple Disc Brakes
  • 35. Couplings
  • 35.1. Grid Couplings
  • 35.1.1. Lubrication
  • 35.1.2. Coupling Disassembly and Grid Removal
  • 35.1.3. Grid Coupling Installation
  • 35.1.4. Seal Replacement without Hub Removal
  • 35.1.5. Grid Coupling Alignment
  • 35.2. Gear Couplings
  • 35.2.1. Coupling Installation
  • 35.2.2. Gear Coupling Alignment
  • 35.2.3. Hoist Coupling Shaft Alignment
  • 36. Compressed Air System
  • 37. Air Compressor
  • 37.1. Lockout Valves
  • 37.2. Safety Warnings
  • 38. Air Filtration
  • 39. House Filter Fans
  • 39.1. Lubrication
  • 39.2. Dynavane Air Cleaner
  • 40. Air Filtration System
  • 41. Air Conditioner
  • 41.1. Specifications
  • 42. Engineering Data
  • 43. Capscrew (Bolt) Grade
  • 43.1. Bolt Tightening
  • 43.1.1. Torque Wrench Method
  • 43.1.2. Turn-of-nut Method
  • 44. Measurement Systems
  • 44.1. Linear Measurements
  • 44.2. Area Measurements
  • 44.3. Volume Measurements
  • 44.4. Torque Measurements
  • 44.4.1. Weight Measurements – Conventional
  • 45. Split Flange Assembly Procedure
  • 46. Wire Locking Capscrews
  • 47. Torque Nut Installation
  • 48. Expansion Bolt Installation
  • 48.1. Tightening Procedure for 1.25-Inch Torque Nut
  • 48.2. Tightening Procedure for 2-Inch Torque Nut
  • 48.3. Tightening Procedure for 2-Inch Torque Nut
  • 48.4. Tightening Procedure for 2-Inch Torque Nut
  • 48.5. Tightening Procedure for 2.5-Inch Torque Nut
  • 48.6. Tightening Procedure for 3-Inch Torque Nut
  • 48.7. Tightening Procedure for 3.5-Inch Torque Nut
  • 48.8. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
  • 48.8.1. Initial Tensioning
  • 48.8.2. Final Tensioning
  • 48.9. Tightening Procedures – Expansion Bolts
  • 48.9.1. Rack Roller Torque Rod, Tapered Sleeve 1.0 Inch Torque Nut
  • 48.9.2. Hoist Torque Rod, Tapered Sleeve 1.62 Inch Torque Nut
  • 48.9.3. Swing Torque Rod Tapered Sleeve 3.25 Inch Torque Nut
  • 49. Torque Nut Removal Procedure
  • 49.1. Thread Lubrication
  • 50. Torque Nut Helpful Hints
  • 51. Locking Assemblies
  • 51.1. Locking Assembly Removal
  • 51.2. Pinion and Hub Installation
  • 51.3. Removal from a Shaft
  • 51.4. Mounting a Pinion or Hub on a Shaft
  • 51.4.1. Pre-heat Advance Requirements – Pinions and Hubs
  • 51.4.2. Motor Coupling Pre-Heat Advance Requirements
  • 52. Maintenance Welding
  • 52.1. Welding Electrodes
  • 52.2. Repair Welding of Cracks
  • 52.2.1. Preheat
  • 52.2.2. Welding Technique
  • 52.3. Repair Welding of Broken Parts
  • 52.4. Repair Welding Swing Rack Teeth
  • 52.4.1. Preparation
  • 52.4.2. Swing Rack Welding Electrodes
  • 52.4.3. Preheat
  • 52.4.4. Welding Procedure
  • 52.5. Welding and Cutting Equipment
  • 52.6. Stress Relieving Temperature Measuring Equipment
  • 53. Wire Rope Care and Maintenance
  • 53.1. Storage
  • 53.2. Checking Diameter
  • 53.3. Handling Wire Rope
  • 53.4. Seizing Wire Rope
  • 53.5. End Preparations/Terminations
  • 53.6. Wire Rope Clips
  • 53.6.1. Wire Rope Clip Application
  • 53.6.2. Wedge Sockets
  • 53.7. Inspection of Sheaves and Drums
  • 53.8. Breaking In a New Wire Rope
  • 53.9. Inspection Data
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