Bucyrus 495HR2 Mining Shovel Service Manual BI624092

Bucyrus 495HR2 Mining Shovel Service Manual BI624092 - Image 2

Bucyrus 495HR2 Mining Shovel Service Manual BI624092 - Image 3

Bucyrus 495HR2 Mining Shovel Service Manual BI624092

$30.00

Type Of Manual: Service Manual
Manual ID: BI624092
Number of Pages: 556
Size: 20.4MB
Format: PDF

Category: Bucyrus Service Manual PDF

Product details

Model List:
- 495HR2 Mining Shovel

1. Table of Contents
2. Safety Symbols
3. Safety Precautions
3.1. General Precautions
3.2. Maintenance Precautions
3.3. Operating Precautions
3.4. Fire Prevention
3.5. Warning Signs And Decals
4. Introduction
5. About This Manual
5.1. Purpose
5.2. Organization
5.3. Terminology
5.4. Revisions
5.5. Precautions and Disclaimers
5.6. Contact
6. Swinging Restraint Ballast Box Support
6.1. Ballast Box Support
6.2. 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. Boarding Stairs
9.5.2. Vertical Boarding Ladder
9.6. A-Frame
9.7. Hoist Machinery
9.8. Swing Machinery
9.9. Crowd Machinery
9.10. Operators Cab
9.11. Compressed Air System
9.12. Automatic Lubrication System
9.13. Lube Reservoir Fill / Overflow Plumbing
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
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. Hoist Rope Rollers Lubrication
19.6. Front End Lubrication
19.7. Lubricant Injectors
19.7.1. Lincoln Type SL-1 Lubricant Injectors
19.7.2. Lincoln Type SL-V Lubricant Injectors
19.7.3. Injector Advantages
20. Propel Machinery Lubrication
21. Hoist Machinery Lubrication
21.1. Hoist OGL Reservoir
21.2. Hoist Oil Cooler
21.3. Filter Element Cleaning
22. Swing Machinery Lubrication
23. Crowd Rope Take-up Mechanism Lubrication
24. Crowd Machinery Lubrication
25. Air Compressor Lubrication
25.1. ACSL – Air Compressor (Screw-Type) Lubricant
26. Lubrication Specifications
26.1. RWRL – Running Wire Rope Lubricant
26.2. EGL – Enclosed Gearcase Lubricant
26.3. MPG – Multipurpose Grease
26.4. 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 Assembly
35.2. Swing Rack Assembly
35.2.1. Roller Circle Rail Replacement – Lower
35.2.2. Roller Circle Rail Replacement – Upper
35.3. Roller Circle Assembly
35.3.1. Roller Circle Adjustment
35.3.2. Adjustment Procedure
35.3.3. Run-in Procedure for the Roller Circle
35.3.4. Roller Circle Segment Removal
35.3.5. Roller Circle – Roller Replacement
35.4. Crawler Belts
35.4.1. Crawler Belt Maintenance
35.5. Crawler Side Frame Assembly
35.5.1. Crawler Side Frame Maintenance
35.5.2. Crawler Front Idler Roller Assembly
35.5.3. Load Rollers and Rear Idler Rollers
35.6. Propel Shaft Assembly
35.6.1. Installation Notes
35.6.2. Main Propel Drive Shaft Removal
35.6.3. Main Propel Shaft – Disassembly
35.6.4. Tumbler Rebuild Procedure
35.7. Propel Machinery
35.7.1. Propel Planetary Gearcase
35.7.2. Propel Motors
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. Cable Reel
36.4.1. Dos and Donts of Reel Operation
36.4.2. Cable Reel Operation
36.4.3. Hydraulic Drive Start Instructions
36.4.4. Unloading Valve Operating Instructions
36.4.5. Cable Reel Frame
36.4.6. Cable Reel Drum
36.4.7. Cable Reel Drive
36.4.8. Level Wind
36.4.9. Collector Ring
36.4.10. Cable Reel Maintenance
36.4.11. Lubrication
36.4.12. Hydraulic System
36.5. Swing Machinery
36.5.1. Swing Support Mounting Bolts
36.5.2. Swing Motor
36.5.3. Swing Planetary Gearcase
36.5.4. Swing Pinion Shafts
36.6. Hoist Machinery
36.6.1. Hoist Motor Removal
36.6.2. Motor Coupling Shaft
36.6.3. Hoist Gearcase Assembly
36.6.4. Hoist Drum Assembly
36.6.5. Hoist Gear Start-Up Inspections
36.6.6. Hoist Gear Replacement
36.7. Hoist Oil Cooler
36.7.1. Hoist Mounting Bolts
36.7.2. Hoist Limit Switch
36.8. Crowd Machinery
36.8.1. Crowd Gearcase Disassembly
36.8.2. Crowd Gearcase Assembly
36.8.3. Crowd Motor
36.8.4. Crowd Gear and Drum
36.9. Operators Cab Mounting
36.9.1. Operators Cab Isolator Mount Replacement
36.10. Operators Seat Replacement
36.11. Joystick Replacement
36.11.1. Joystick Calibration
36.12. Wiper Arm Replacement
36.12.1. Wiper Blade Replacement
36.12.2. Wiper Motor Replacement
37. Machinery House
37.1. Walkways, Stairways, and Handrails
37.1.1. Boarding Stairs
37.1.2. Vertical Boarding Ladder, left
38. Front End Equipment
38.1. Boom Assembly
38.1.1. Boom Repair
38.2. Boom Limit Switch Installation
38.3. Boom Point Sheaves
38.3.1. Boom Point Sheave Removal and Disassembly
38.3.2. Boom Point Sheave Reassembly and Installation
38.4. Boom Bumper
38.5. Saddle Block
38.5.1. Saddle Block Repair
38.5.2. Saddle Block Removal
38.6. Dipper Handle Assembly
38.6.1. Dipper Handle Removal
38.6.2. Crowd Rope Take-Up Mechanism
38.7. Dipper Assembly
38.7.1. Dipper Door
38.7.2. Dipper Door Bumpers
38.7.3. Dipper Door Snubbers
38.7.4. Dipper Pitch Brace
38.7.5. Dipper Padlock
38.8. Dipper Removal Installation
38.9. Dipper Trip Assembly
38.10. Crowd Rope Take-up Hydraulic Unit
38.11. A-Frame
38.12. Auxiliary Winch
38.13. Hoist Rope Support Roller
38.14. Boom Support Ropes
38.15. Wire Ropes
38.15.1. Wire Rope Inspection
38.16. Hoist Rope Reeving Replacement
38.17. Crowd Rope Reeving Replacement
38.18. Retract Rope Reeving Replacement
38.19. Crowd and Retract Rope Tightening
38.20. Dipper Trip Rope Reeving Replacement
38.21. Hoist and Crowd Limit Systems
38.21.1. 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
44. Lockout Valves
45. Safety Warnings
46. Air Filtration
47. House Filter Fans
47.1. Lubrication
47.2. Dynavane Air Cleaner
48. Air Conditioner/Heater
48.1. Evaporator
48.2. Condenser
48.3. Pressurizer
48.3.1. Cleaning The Washable Filter
48.4. Specifications
49. Engineering Data
50. Capscrew (Bolt) Grade
50.1. Bolt Tightening
50.1.1. Torque Wrench Method
50.1.2. Turn-of-Nut Method
51. Measurement Systems
51.1. Linear Measurements
51.2. Area Measurements
51.3. Volume Measurements
51.4. Torque Measurements
51.5. Weight Measurements – Conventional
52. Split Flange Assembly Procedure
53. Wire Locking Capscrews
54. Torque Nut Installation
55. Expansion Bolt Installation
55.1. Tightening Procedure for 1.25-Inch Torque Nut
55.2. Tightening Procedure for 2-Inch Torque Nut
55.3. Tightening Procedure for 2-Inch Torque Nut
55.4. Tightening Procedure for 2-Inch Torque Nut
55.5. Tightening Procedure for 2.5-Inch Torque Nut
55.6. Tightening Procedure for 3-Inch Torque Nut
55.7. Tightening Procedure for 3.5-Inch Torque Nut
55.8. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
55.8.1. Initial Tensioning
55.8.2. Final Tensioning
55.9. Tightening Procedures – Expansion Bolts
55.9.1. Rack Roller Torque Rod, Tapered Sleeve 1.0 Inch Torque Nut
55.9.2. Hoist Torque Rod, Tapered Sleeve 1.62 Inch Torque Nut
55.9.3. Swing Torque Rod Tapered Sleeve 3.25 Inch Torque Nut
56. Torque Nut Removal Procedure
56.1. Thread Lubrication
57. Torque Nut Helpful Hints
58. Locking Assemblies
58.1. Locking Assembly Removal
59. Pinion and Hub Installation
59.1. Removal from a Shaft
59.2. Mounting a Pinion or Hub on a Shaft
59.3. Pre-heat Advance Requirements – Pinions and Hubs
59.4. Motor Coupling Pre-Heat Advance Requirements
60. Open Gear Contact Check
61. Open Gear Break-In
62. Maintenance Welding
62.1. Welding Electrodes
62.2. Repair Welding of Cracks
62.2.1. Preheat
62.2.2. Welding Technique
62.3. Repair Welding of Broken Parts
62.4. Repair Welding Swing Rack Teeth
62.4.1. Preparation
62.4.2. Swing Rack Welding Electrodes
62.4.3. Preheat
62.4.4. Welding Procedure
62.5. Welding and Cutting Equipment
62.6. Stress Relieving Temperature Measuring Equipment
63. Wire Rope Care and Maintenance
63.1. Storage
63.2. Checking Diameter
63.3. Handling Wire Rope
63.4. Seizing Wire Rope
63.5. End Preparations/Terminations
63.6. Wire Rope Clips
63.6.1. Wire Rope Clip Application
63.6.2. Wedge Sockets
63.7. Inspection of Sheaves and Drums
63.8. Breaking In a New Wire Rope
63.9. Inspection Data
63.10. Guideline to Inspections and Reports
63.10.1. Wire Rope Inspection Criteria
64. Seals
64.1. Seal Installation
64.2. Gearcase Sealing
65. Schematics
66. Schematics
67. Side View
68. Deck Plan
69. OGL System A B Schematic
70. Grease System C Schematic
71. HVAC Schematic
72. Air Schematic

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Bucyrus 495HR2 Mining Shovel Service Manual BI624092

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