Bucyrus 495HR2 Mining Shovel Maintenance Manual BI619856
Bucyrus 495HR2 Mining Shovel Maintenance Manual BI619856 - Image 2
Bucyrus 495HR2 Mining Shovel Maintenance Manual BI619856 - Image 3
Bucyrus 495HR2 Mining Shovel Maintenance Manual BI619856 - Image 4
Bucyrus 495HR2 Mining Shovel Maintenance Manual BI619856 - Image 5

Bucyrus 495HR2 Mining Shovel Maintenance Manual BI619856

$30.00

  • Type Of Manual: Maintenance Manual
  • Manual ID: BI619856
  • Number of Pages: 504
  • Size: 14.8MB
  • 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
  • 3. Swinging Restraint Ballast Box Support
  • 3.1. 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. Lubrication
  • 11. Greasing Main A.C. Drive Motors
  • 11.1. Type of Grease
  • 11.2. Initial Commissioning
  • 11.3. Maintenance
  • 11.4. Regreasing Intervals
  • 12. Lubricant Selection
  • 13. Oil Fill Capacities
  • 13.1. Types Of Lubricants And Capacities Guidelines
  • 13.1.1. Quantities for First Fill of Lubricants
  • 14. Automatic Lubrication System
  • 14.1. Lube Room
  • 14.2. Lube Reservoir fill / Overflow Plumbing
  • 14.2.1. Auto Lube Control Panel
  • 14.3. Lower Works Lubrication
  • 14.4. Propel Machinery Lubrication
  • 14.4.1. Lubricant Replacement/sampling
  • 14.5. Revolving Frame Lubrication
  • 14.6. Hoist Machinery Lubrication
  • 14.6.1. Hoist Oil Cooler
  • 14.6.2. Filter Element Cleaning
  • 14.7. Hoist Rope Rollers Lubrication
  • 14.7.1. Oil Pump
  • 14.8. Crowd Machinery Lubrication
  • 14.9. Swing Machinery Lubrication
  • 14.10. Air Compressor Lubrication
  • 14.11. Crowd Rope Take-up Mechanism Lubrication
  • 14.12. Front End Lubrication
  • 14.13. Lincoln Type SL-1 Lubricant Injectors
  • 14.13.1. SL-1 Lubricant Injector Operation
  • 14.13.2. Injector Advantages
  • 14.14. ACSL – Air Compressor (Screw-Type) Lubricant
  • 14.15. MPO – Multipurpose OIL
  • 14.16. RWRL – Running Wire Rope Lubricant
  • 14.17. EGL – Enclosed Gearcase Lubricant
  • 14.18. MPG – Multipurpose Grease
  • 14.19. OGL – Open Gear Lubricant
  • 14.20. Certified Lubricants Listing
  • 15. Preventive Maintenance
  • 15.1. Preventive Maintenance Program
  • 15.2. Elements of an Effective Maintenance Program
  • 15.3. Scheduled Preventive Maintenance Program
  • 15.4. General Safety Considerations
  • 16. Maintenance During Machine Operation
  • 16.1. Maintenance Precautions
  • 17. Preventive Maintenance for Lubrication
  • 17.1. Lubricant Cleanliness
  • 18. Frequency of Inspection and Maintenance
  • 18.1. Maintenance Inspection Check Points
  • 18.1.1. Every 100 Hours or Weekly
  • 18.1.2. Every 500 Hours Or Monthly
  • 18.1.3. Every 1250 Hours or Quarterly
  • 18.1.4. Every 2500 Hours or Semi-Annually
  • 18.1.5. Hours or Annually
  • 19. Major Component Locations
  • 20. Service Procedures
  • 20.1. Truck Frame Assembly
  • 20.2. Swing Rack Assembly
  • 20.2.1. Roller Circle Rail Replacement – Lower
  • 20.2.2. Roller Circle Rail Replacement – Upper
  • 20.3. Roller Circle Assembly
  • 20.3.1. Roller Circle Adjustment
  • 20.3.2. Adjustment Procedure
  • 20.3.3. Run-in Procedure for the Roller Circle
  • 20.3.4. Roller Circle Segment Removal
  • 20.3.5. Roller Circle – Roller Replacement
  • 20.4. Crawler Belts
  • 20.4.1. Crawler Belt Maintenance
  • 20.5. Crawler Side Frame Assembly
  • 20.5.1. Crawler Side Frame Maintenance
  • 20.5.2. Slide Bar Replacement
  • 20.6. Crawler Front Idler Roller Assembly
  • 20.6.1. Load and Idler Rollers
  • 20.7. Propel Assembly
  • 20.7.1. Installation Notes
  • 20.7.2. Main Propel Drive Shaft Removal
  • 20.7.3. Main Propel Shaft – Disassembly
  • 20.7.4. Tumbler Rebuild Procedure
  • 20.8. Propel Machinery
  • 20.8.1. Propel Gearcase Removal
  • 20.8.2. Propel Gearcase Installation
  • 20.8.3. Propel Planetary Gearcase
  • 20.8.4. Propel Motors
  • 21. Rotating Deck
  • 21.1. Revolving Frame
  • 21.2. Center Pintle
  • 21.2.1. Center Pintle Adjustment
  • 21.2.2. Center Pintle Sleeve Removal
  • 21.3. Collector Rings
  • 21.3.1. Collector Ring Inspection
  • 21.3.2. Collector Ring Repair
  • 21.4. Cable Reel
  • 21.5. Swing Machinery
  • 21.5.1. Swing Support Mounting Bolts
  • 21.5.2. Swing Motor
  • 21.5.3. Swing Planetary Gearcase
  • 21.5.4. Swing Pinion Shafts
  • 21.6. Hoist Machinery
  • 21.6.1. Hoist Motor Removal
  • 21.6.2. Motor Coupling Shaft
  • 21.6.3. Hoist Gearcase Assembly
  • 21.6.4. Hoist Gearcase Repair
  • 21.6.5. Hoist Drum Assembly
  • 21.6.6. Hoist Oil Cooler
  • 21.6.7. Hoist Mounting Bolts
  • 21.6.8. Hoist Limit Switch
  • 21.7. Crowd Machinery
  • 21.8. Gearcase Repair
  • 21.8.1. Crowd Gearcase Disassembly
  • 21.8.2. Crowd Gearcase Assembly
  • 21.8.3. Crowd Motor
  • 21.9. Operators Cab Mounting
  • 21.10. Joystick Replacement
  • 21.10.1. Joystick Calibration
  • 21.11. Wiper Arm Replacement
  • 21.11.1. Wiper Blade Replacement
  • 21.11.2. Wiper Motor Replacement
  • 22. Machinery House
  • 22.1. Walkways, Stairways, and Handrails
  • 22.1.1. Boarding Stairs
  • 22.1.2. Vertical Boarding Ladder, left
  • 23. Front End Equipment
  • 23.1. Boom Assembly
  • 23.2. Boom Repair
  • 23.3. Boom Limit Switch Installation
  • 23.4. Boom Point Sheaves
  • 23.4.1. Boom Point Sheave Removal and Disassembly
  • 23.4.2. Boom Point Sheave Reassembly and Installation
  • 23.5. Boom Bumper
  • 23.6. Saddle Block
  • 23.6.1. Saddle Block Repair
  • 23.6.2. Saddle Block Removal
  • 23.7. Dipper Handle
  • 23.7.1. Dipper Handle Removal
  • 23.7.2. Crowd Rope Take-Up Mechanism
  • 23.7.3. Retract Rope Take-up Mechanism
  • 23.7.4. Spreader Repair
  • 23.8. Dipper Assembly
  • 23.9. Dipper Door
  • 23.9.1. Latch Lever Assembly
  • 23.9.2. Rope Bracket and Deflector Assembly
  • 23.9.3. Latch Bar Adjusting
  • 23.9.4. Dipper Door bumpers
  • 23.9.5. Dipper Removal Installation
  • 23.9.6. Dipper Door Snubbers
  • 23.9.7. Dipper Pitch Brace
  • 23.9.8. Dipper Padlock
  • 23.9.9. Dipper Trip Assembly
  • 23.10. A-Frame
  • 23.11. Auxiliary Winch
  • 23.12. Hoist Rope Support Roller
  • 23.13. Boom Support Ropes
  • 23.14. Wire Ropes
  • 23.14.1. Wire Rope Inspection
  • 23.15. Crowd Rope Take-up Hydraulic Unit
  • 23.16. Hoist Rope Reeving Replacement
  • 23.17. Crowd Rope Reeving Replacement
  • 23.18. Retract Rope Reeving Replacement
  • 23.19. Crowd Rope Tightening
  • 23.20. Retract Rope Tightening
  • 23.21. Dipper Trip Rope Reeving Replacement
  • 23.22. Hoist and Crowd Limit Systems
  • 23.22.1. Setting Limits In The Hoist Crowd System
  • 24. Brakes and Couplings
  • 24.1. Disc Brake Operation
  • 24.2. Maintenance
  • 24.3. Brake Adjustment Specifications
  • 24.4. Hoist Brake
  • 24.4.1. Hoist Brake Adjustment
  • 24.4.2. Hoist Brake Installation
  • 24.4.3. Hoist Brake Wear Release Switches
  • 24.5. Crowd Brake
  • 24.5.1. Crowd Brake Installation
  • 24.5.2. Crowd Brake Wear Release Switches
  • 24.6. Propel Brake
  • 24.6.1. Propel Brake Adjustment
  • 24.6.2. Propel Brake Installation
  • 24.6.3. Tachometer Mounting Alignment
  • 24.7. Swing Brake
  • 24.7.1. Swing Brake Installation
  • 24.7.2. Swing Brake Wear Release Switches
  • 24.7.3. Swing Brake Burnishing
  • 24.8. Spring Replacement All Brakes
  • 24.9. Friction Disc Replacement All Brakes
  • 24.10. O-Ring Replacement All Brakes
  • 24.11. Brake Wear Release Switches Single Disc Brakes
  • 24.12. Brake Wear Release Switches Multiple Disc Brakes
  • 25. Couplings
  • 25.1. Grid Couplings
  • 25.1.1. Lubrication
  • 25.1.2. Coupling Disassembly and Grid Removal
  • 25.1.3. Grid Coupling Installation
  • 25.1.4. Seal Replacement without Hub Removal
  • 25.1.5. Grid Coupling Alignment
  • 25.2. Gear Couplings
  • 25.2.1. Coupling Installation
  • 25.2.2. Gear Coupling Alignment
  • 25.2.3. Hoist Coupling Shaft Alignment
  • 26. Compressed Air System
  • 26.1. Lockout Valves
  • 26.2. Safety Warnings
  • 27. Air Filtration
  • 27.1. Lubrication
  • 27.2. Dynavane Air Cleaner
  • 28. Air Filtration System
  • 28.1. Description
  • 28.2. Operation
  • 28.3. Operational Checklist
  • 28.3.1. Compressed Air Installation
  • 28.3.2. Filter Removal
  • 28.3.3. Solid-State Timer Installation
  • 28.3.4. Delta P Plus
  • 28.3.5. Setpoint Adjustments
  • 28.3.6. Delta P Plus Control Calibration
  • 28.3.7. Preliminary Start-Up Check
  • 28.3.8. Maintenance Information
  • 29. Air Conditioner/heater
  • 29.1. Evaporator
  • 29.2. Condenser
  • 29.3. Pressurizer
  • 29.3.1. Cleaning The Washable Filter
  • 29.4. Specifications
  • 30. Engineering Data
  • 30.1. Bolt Tightening
  • 30.1.1. Torque Wrench Method
  • 30.1.2. Turn-of-nut Method
  • 31. Measurement Systems
  • 31.1. Linear Measurements
  • 31.2. Area Measurements
  • 31.3. Volume Measurements
  • 31.4. Torque Measurements
  • 31.4.1. Weight Measurements – Conventional
  • 32. Split Flange Assembly Procedure
  • 33. Wire Locking Capscrews
  • 34. Torque Nut Installation
  • 34.1. Tightening Procedure for 1.25-Inch Torque Nut
  • 34.2. Tightening Procedure for 2-Inch Torque Nut
  • 34.3. Tightening Procedure for 2-Inch Torque Nut
  • 34.4. Tightening Procedure for 2-Inch Torque Nut
  • 34.5. Tightening Procedure for 2.5-Inch Torque Nut
  • 34.6. Tightening Procedure for 3-Inch Torque Nut
  • 34.7. Tightening Procedure for 3.5-Inch Torque Nut
  • 34.8. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
  • 34.8.1. Initial Tensioning
  • 34.8.2. Final Tensioning
  • 34.9. Tightening Procedures – Expansion Bolts
  • 34.9.1. Rack Roller Torque Rod, Tapered Sleeve 1.0 Inch Torque Nut
  • 34.9.2. Hoist Torque Rod, Tapered Sleeve 1.62 Inch Torque Nut
  • 34.9.3. Swing Torque Rod Tapered Sleeve 3.25 Inch Torque Nut
  • 34.10. Thread Lubrication
  • 35. Locking Assemblies
  • 35.1. Locking Assembly Removal
  • 36. Pinion and Hub Installation
  • 36.1. Removal from a Shaft
  • 36.2. Mounting a Pinion or Hub on a Shaft
  • 36.2.1. Pre-heat Advance Requirements – Pinions and Hubs
  • 36.2.2. Motor Coupling Pre-Heat Advance Requirements
  • 37. Maintenance Welding
  • 37.1. Welding Electrodes
  • 37.2. Repair Welding of Cracks
  • 37.2.1. Preheat
  • 37.2.2. Welding Technique
  • 37.3. Repair Welding of Broken Parts
  • 37.4. Repair Welding Swing Rack Teeth
  • 37.4.1. Preparation
  • 37.4.2. Swing Rack Welding Electrodes
  • 37.4.3. Preheat
  • 37.4.4. Welding Procedure
  • 37.5. Welding and Cutting Equipment
  • 37.6. Stress Relieving Temperature Measuring Equipment
  • 38. Wire Rope Care and Maintenance
  • 38.1. Storage
  • 38.2. Checking Diameter
  • 38.3. Handling Wire Rope
  • 38.4. Seizing Wire Rope
  • 38.5. End Preparations/Terminations
  • 38.6. Wire Rope Clips
  • 38.6.1. Wire Rope Clip Application
  • 38.6.2. Wedge Sockets
  • 38.7. Inspection of Sheaves and Drums
  • 38.8. Breaking In a New Wire Rope
  • 38.9. Inspection Data
  • 38.10. Guideline to Inspections and Reports
  • 38.10.1. Wire Rope Inspection Criteria
  • 38.11. Seal Installation
  • 38.12. Gearcase Sealing
  • 39. Schematics
  • 40. Side View
  • 41. Deck Plan
  • 42. HVAC Schematic
  • 43. OGL System A B Schematic
  • 44. Grease System C Schematic
  • 45. Air Schematic
  • 46. ServiceProcedures X30.pdf
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