Bucyrus 495HR2 Mining Shovel Maintenance Manual BI619580
Bucyrus 495HR2 Mining Shovel Maintenance Manual BI619580 - Image 2
Bucyrus 495HR2 Mining Shovel Maintenance Manual BI619580 - Image 3
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Bucyrus 495HR2 Mining Shovel Maintenance Manual BI619580 - Image 5

Bucyrus 495HR2 Mining Shovel Maintenance Manual BI619580

$30.00

  • Type Of Manual: Maintenance Manual
  • Manual ID: BI619580
  • Number of Pages: 494
  • Size: 17.6MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 495HR2 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
  • 2.1. SWINGING RESTRAINT BALLAST BOX SUPPORT
  • 2.2. Ballast Box Support
  • 2.3. Swinging Restraint
  • 3. Machine Overview
  • 4. Lower Works
  • 4.1. Crawlers
  • 4.2. Truck Frame
  • 4.3. Swing Rack
  • 4.4. Roller Circle
  • 4.5. Propel Machinery
  • 4.6. Collector Rings
  • 5. Rotating Deck
  • 5.1. Revolving Frame
  • 5.2. Center Pintle
  • 5.3. Deck Extensions
  • 5.4. Ballast Box
  • 5.5. Machinery House
  • 5.5.1. Boarding Stairs
  • 5.5.2. Vertical Boarding Ladder
  • 5.6. A-Frame
  • 5.7. Hoist Machinery
  • 5.8. Swing Machinery
  • 5.9. Crowd Machinery
  • 5.10. OPERATORS CAB
  • 5.11. Compressed Air System
  • 5.12. Automatic Lubrication System
  • 5.13. Lube Reservoir fill / Overflow Plumbing
  • 6. Front End Equipment
  • 6.1. Suspension Strands
  • 6.2. Running Ropes
  • 6.3. Saddle Block
  • 6.4. Dipper Handle
  • 6.5. Padlocks
  • 6.6. Dipper Trip
  • 7. Typical Machine Specifications
  • 8. General Estimated Component Weights
  • 8.1. Lower Works
  • 8.2. Upper Works
  • 8.3. Front End
  • 9. Lubrication
  • 10. Greasing Main A.C. Drive Motors
  • 10.1. Type of Grease
  • 10.2. Initial Commissioning
  • 10.3. Maintenance
  • 10.4. Regreasing Intervals
  • 11. Lubricant Selection
  • 12. Oil Fill Capacities
  • 12.1. Types Of Lubricants And Capacities Guidelines
  • 12.1.1. Quantities for First Fill of Lubricants
  • 13. Automatic Lubrication System
  • 13.1. Lube Room
  • 13.2. Lube Reservoir fill / Overflow Plumbing
  • 13.2.1. Auto Lube Control Panel
  • 13.3. Lower Works Lubrication
  • 13.4. Propel Machinery Lubrication
  • 13.4.1. Lubricant Replacement/sampling
  • 13.5. Revolving Frame Lubrication
  • 13.6. Hoist Machinery Lubrication
  • 13.6.1. Hoist Oil Cooler
  • 13.6.2. Filter Element Cleaning
  • 13.7. Hoist Rope Rollers Lubrication
  • 13.7.1. Oil Pump
  • 13.8. Crowd Machinery Lubrication
  • 13.9. Swing Machinery Lubrication
  • 13.10. Air Compressor Lubrication
  • 13.11. Crowd Rope Take-up Mechanism Lubrication
  • 13.12. Front End Lubrication
  • 13.13. Lincoln Type SL-1 Lubricant Injectors
  • 13.13.1. SL-1 Lubricant Injector Operation
  • 13.13.2. Injector Advantages
  • 13.14. ACSL – Air Compressor (Screw-Type) Lubricant
  • 13.15. MPO – Multipurpose OIL
  • 13.16. RWRL – Running Wire Rope Lubricant
  • 13.17. EGL – Enclosed Gearcase Lubricant
  • 13.18. MPG – Multipurpose Grease
  • 13.19. OGL – Open Gear Lubricant
  • 13.20. Certified Lubricants Listing
  • 14. Preventive Maintenance
  • 14.1. Preventive Maintenance Program
  • 14.2. Elements of an Effective Maintenance Program
  • 14.3. Scheduled Preventive Maintenance Program
  • 14.4. General Safety Considerations
  • 15. Maintenance During Machine Operation
  • 15.1. Maintenance Precautions
  • 16. Preventive Maintenance for Lubrication
  • 16.1. Lubricant Cleanliness
  • 17. Frequency of Inspection and Maintenance
  • 17.1. Maintenance Inspection Check Points
  • 17.1.1. Every 100 Hours or Weekly
  • 17.1.2. Every 500 Hours Or Monthly
  • 17.1.3. Every 1250 Hours or Quarterly
  • 17.1.4. Every 2500 Hours or Semi-Annually
  • 17.1.5. Hours or Annually
  • 18. Major Component Locations
  • 19. Service Procedures
  • 19.1. Truck Frame Assembly
  • 19.2. Swing Rack Assembly
  • 19.2.1. Roller Circle Rail Replacement – Lower
  • 19.2.2. Roller Circle Rail Replacement – Upper
  • 19.3. Roller Circle Assembly
  • 19.3.1. Roller Circle Adjustment
  • 19.3.2. Adjustment Procedure
  • 19.3.3. Run-in Procedure for the Roller Circle
  • 19.3.4. Roller Circle Segment Removal
  • 19.3.5. Roller Circle – Roller Replacement
  • 19.4. Crawler Belts
  • 19.4.1. Crawler Belt Maintenance
  • 19.5. Crawler Side Frame Assembly
  • 19.5.1. Crawler Side Frame Maintenance
  • 19.5.2. Slide Bar Replacement
  • 19.5.3. Crawler Front Idler Roller Assembly
  • 19.5.4. Load and Idler Rollers
  • 19.6. Propel Assembly
  • 19.6.1. Installation Notes
  • 19.6.2. Main Propel Drive Shaft Removal
  • 19.6.3. Main Propel Shaft – Disassembly
  • 19.6.4. Tumbler Rebuild Procedure
  • 19.7. Propel Machinery
  • 19.7.1. Propel Gearcase Removal
  • 19.7.2. Propel Gearcase Installation
  • 19.7.3. Propel Planetary Gearcase
  • 19.7.4. Propel Motors
  • 20. Rotating Deck
  • 20.1. Revolving Frame
  • 20.2. Center Pintle
  • 20.2.1. Center Pintle Adjustment
  • 20.2.2. Center Pintle Sleeve Removal
  • 20.3. Collector Rings
  • 20.3.1. Collector Ring Inspection
  • 20.3.2. Collector Ring Repair
  • 20.4. Swing Machinery
  • 20.4.1. Swing Support Mounting Bolts
  • 20.4.2. Swing Motor
  • 20.4.3. Swing Planetary Gearcase
  • 20.4.4. Swing Pinion Shafts
  • 20.5. Hoist Machinery
  • 20.5.1. Hoist Motor Removal
  • 20.5.2. Motor Coupling Shaft
  • 20.5.3. Hoist Gearcase Assembly
  • 20.5.4. Hoist Gearcase Repair
  • 20.5.5. Hoist Drum Assembly
  • 20.5.6. Hoist Oil Cooler
  • 20.5.7. Hoist Mounting Bolts
  • 20.5.8. Hoist Limit Switch
  • 20.6. Crowd Machinery
  • 20.7. GEARCASE REPAIR
  • 20.7.1. Crowd Gearcase Disassembly
  • 20.7.2. Crowd Gearcase Assembly
  • 20.7.3. Crowd Motor
  • 20.8. Operators Cab Mounting
  • 20.9. JOYSTICK REPLACEMENT
  • 20.9.1. JOYSTICK CALIBRATION
  • 20.10. Wiper Arm Replacement
  • 20.10.1. Wiper Blade Replacement
  • 20.10.2. Wiper MOTOR REPLACEMENT
  • 20.11. Machinery House
  • 20.11.1. Walkways, Stairways, and Handrails
  • 20.11.2. Boarding Stairs
  • 20.11.3. Vertical Boarding Ladder, left
  • 21. Front End Equipment
  • 21.1. Boom Assembly
  • 21.2. Boom Repair
  • 21.3. Boom Limit Switch Installation
  • 21.4. Boom Point Sheaves
  • 21.4.1. Boom Point Sheave Removal and Disassembly
  • 21.4.2. Boom Point Sheave Reassembly and Installation
  • 21.5. Boom Bumper
  • 21.6. Saddle Block
  • 21.6.1. Saddle Block Repair
  • 21.6.2. Saddle Block Removal
  • 21.7. Dipper Handle
  • 21.7.1. Dipper Handle Removal
  • 21.7.2. Crowd Rope Take-Up Mechanism
  • 21.7.3. Retract Rope Take-up Mechanism
  • 21.7.4. Spreader Repair
  • 21.8. Dipper Assembly
  • 21.8.1. Latch Bar Adjusting
  • 21.8.2. Dipper Door bumpers
  • 21.8.3. Dipper Removal Installation
  • 21.8.4. Dipper Door Snubbers
  • 21.8.5. Dipper Pitch Brace
  • 21.8.6. Dipper Padlock
  • 21.8.7. Dipper Trip Assembly
  • 21.9. A-Frame
  • 21.10. Auxiliary Winch
  • 21.11. Hoist Rope Support Roller
  • 21.12. Boom Support Ropes
  • 21.13. Wire Ropes
  • 21.13.1. Wire Rope Inspection
  • 21.14. Crowd Rope Take-up Hydraulic Unit
  • 21.15. Hoist Rope Reeving Replacement
  • 21.16. Crowd Rope Reeving Replacement
  • 21.17. Retract Rope Reeving Replacement
  • 21.18. Crowd Rope Tightening
  • 21.19. Retract Rope Tightening
  • 21.20. Dipper Trip Rope Reeving Replacement
  • 21.21. Hoist and Crowd Limit Systems
  • 21.21.1. Setting Limits In The Hoist Crowd System
  • 22. Brakes and Couplings
  • 22.1. Disc Brake Operation
  • 22.2. Maintenance
  • 22.3. Brake Adjustment Specifications
  • 22.4. Hoist Brake
  • 22.4.1. Hoist Brake Adjustment
  • 22.4.2. Hoist Brake Installation
  • 22.4.3. Hoist Brake Wear Release Switches
  • 22.5. Crowd Brake
  • 22.5.1. Crowd Brake Installation
  • 22.5.2. Crowd Brake Wear Release Switches
  • 22.6. Propel Brake
  • 22.6.1. Propel Brake Adjustment
  • 22.6.2. Propel Brake Installation
  • 22.6.3. Tachometer Mounting Alignment
  • 22.7. Swing Brake
  • 22.7.1. Swing Brake Installation
  • 22.7.2. Swing Brake Wear Release Switches
  • 22.7.3. Swing Brake Burnishing
  • 22.8. Spring Replacement All Brakes
  • 22.9. Friction Disc Replacement All Brakes
  • 22.10. O-Ring Replacement All Brakes
  • 22.11. Brake Wear Release Switches Single Disc Brakes
  • 22.12. Brake Wear Release Switches Multiple Disc Brakes
  • 23. Couplings
  • 23.1. Grid Couplings
  • 23.1.1. Lubrication
  • 23.1.2. Coupling Disassembly and Grid Removal
  • 23.1.3. Grid Coupling Installation
  • 23.1.4. Seal Replacement without Hub Removal
  • 23.1.5. Grid Coupling Alignment
  • 23.2. Gear Couplings
  • 23.2.1. Coupling Installation
  • 23.2.2. Gear Coupling Alignment
  • 23.2.3. Hoist Coupling Shaft Alignment
  • 24. Compressed Air System
  • 24.1. Lockout Valves
  • 24.2. Safety Warnings
  • 25. Air Filtration
  • 25.1. Lubrication
  • 25.2. Dynavane Air Cleaner
  • 26. Air Conditioner/heater
  • 26.1. Evaporator
  • 26.2. Condenser
  • 26.3. Pressurizer
  • 26.3.1. Cleaning The Washable Filter
  • 26.4. Specifications
  • 27. Engineering Data
  • 27.1. Bolt Tightening
  • 27.1.1. Torque Wrench Method
  • 27.1.2. Turn-of-nut Method
  • 28. Measurement Systems
  • 28.1. Linear Measurements
  • 28.2. Area Measurements
  • 28.3. Volume Measurements
  • 28.4. Torque Measurements
  • 28.4.1. Weight Measurements – Conventional
  • 29. Split Flange Assembly Procedure
  • 30. Wire Locking Capscrews
  • 31. Torque Nut Installation
  • 32. Expansion Bolt Installation
  • 32.1. Tightening Procedure for 1.25-Inch Torque Nut
  • 32.2. Tightening Procedure for 2-Inch Torque Nut
  • 32.3. Tightening Procedure for 2-Inch Torque Nut
  • 32.4. Tightening Procedure for 2-Inch Torque Nut
  • 32.5. Tightening Procedure for 2.5-Inch Torque Nut
  • 32.6. Tightening Procedure for 3-Inch Torque Nut
  • 32.7. Tightening Procedure for 3.5-Inch Torque Nut
  • 32.8. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
  • 32.8.1. Initial Tensioning
  • 32.8.2. Final Tensioning
  • 32.9. Tightening Procedures – Expansion Bolts
  • 32.9.1. Rack Roller Torque Rod, Tapered Sleeve 1.0 Inch Torque Nut
  • 32.9.2. Hoist Torque Rod, Tapered Sleeve 1.62 Inch Torque Nut
  • 32.9.3. Swing Torque Rod Tapered Sleeve 3.25 Inch Torque Nut
  • 33. Torque Nut Removal Procedure
  • 33.1. Thread Lubrication
  • 34. Torque Nut Helpful Hints
  • 35. Locking Assemblies
  • 35.1. Locking Assembly Removal
  • 35.2. Pinion and Hub Installation
  • 35.3. Removal from a Shaft
  • 35.4. Mounting a Pinion or Hub on a Shaft
  • 35.4.1. Pre-heat Advance Requirements – Pinions and Hubs
  • 35.4.2. Motor Coupling Pre-Heat Advance Requirements
  • 36. Maintenance Welding
  • 36.1. Welding Electrodes
  • 36.2. Repair Welding of Cracks
  • 36.2.1. Preheat
  • 36.2.2. Welding Technique
  • 36.3. Repair Welding of Broken Parts
  • 36.4. Repair Welding Swing Rack Teeth
  • 36.4.1. Preparation
  • 36.4.2. Swing Rack Welding Electrodes
  • 36.4.3. Preheat
  • 36.4.4. Welding Procedure
  • 36.5. Welding and Cutting Equipment
  • 36.6. Stress Relieving Temperature Measuring Equipment
  • 37. Wire Rope Care and Maintenance
  • 37.1. Storage
  • 37.2. Checking Diameter
  • 37.3. Handling Wire Rope
  • 37.4. Seizing Wire Rope
  • 37.5. End Preparations/Terminations
  • 37.6. Wire Rope Clips
  • 37.6.1. Wire Rope Clip Application
  • 37.6.2. Wedge Sockets
  • 37.7. Inspection of Sheaves and Drums
  • 37.8. Breaking In a New Wire Rope
  • 37.9. Inspection Data
  • 37.10. Guideline to Inspections and Reports
  • 37.10.1. Wire Rope Inspection Criteria
  • 37.11. Seal Installation
  • 37.12. Gearcase Sealing
  • 38. Schematics
  • 39. Side View
  • 40. Deck Plan
  • 41. HVAC Schematic
  • 42. OGL System A B Schematic
  • 43. Grease System C Schematic
  • 44. Air Schematic
  • 45. Safety.pdf
  • 45.1. Safety Precautions
  • 45.1.1. General Precautions
  • 45.1.2. Maintenance Precautions
  • 45.1.3. Operating Precautions
  • 45.1.4. Fire Prevention
  • 45.1.5. Warning Signs And Decals
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