Bucyrus 495HR2 Mining Shovel Service Manual BI624263
Bucyrus 495HR2 Mining Shovel Service Manual BI624263 - Image 2
Bucyrus 495HR2 Mining Shovel Service Manual BI624263 - Image 3
Bucyrus 495HR2 Mining Shovel Service Manual BI624263 - Image 4
Bucyrus 495HR2 Mining Shovel Service Manual BI624263 - Image 5

Bucyrus 495HR2 Mining Shovel Service Manual BI624263

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: BI624263
  • Number of Pages: 846
  • Size: 45.7MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 495HR2 Mining Shovel
  • 1. Safety Symbols
  • 2. Safety Precautions
  • 2.1. General Precautions
  • 2.2. Maintenance Precautions
  • 2.3. Operating Precautions
  • 2.4. Fire Prevention
  • 2.5. Common Safety Features
  • 3. Warning Signs And Decals
  • 4. About This Manual
  • 4.1. Purpose
  • 4.2. Organization
  • 4.3. Terminology
  • 4.4. Revisions
  • 4.5. Precautions and Disclaimers
  • 4.6. Contact
  • 5. Swinging Restraint Ballast Box Support
  • 5.1. Ballast Box Support
  • 5.2. Swinging Restraint
  • 6. Machine Overview
  • 7. Lower Works
  • 7.1. Crawlers
  • 7.2. Truck Frame
  • 7.3. Swing Rack
  • 7.4. Roller Circle
  • 7.5. Propel Machinery
  • 7.6. Collector Rings
  • 7.7. Stinger (Trail Cable Support)
  • 8. Rotating Deck
  • 8.1. Revolving Frame
  • 8.2. Center Pintle
  • 8.3. Deck Extensions
  • 8.4. Ballast Box
  • 8.5. Machinery House
  • 8.6. A-Frame
  • 8.7. Hoist Machinery
  • 8.8. Swing Machinery
  • 8.9. Crowd Machinery Overview
  • 8.10. Operators Cab
  • 8.11. Compressed Air System
  • 8.12. Automatic Lubrication System
  • 8.13. Lube Reservoir Fill / Overflow Plumbing
  • 9. Front End Equipment
  • 9.1. Suspension Strands
  • 9.2. Boom
  • 9.3. Running Ropes
  • 9.4. Saddle Block
  • 9.5. Dipper Handle – Hydraulic Crowd
  • 9.6. Dipper
  • 9.7. Padlocks
  • 9.8. Dipper Trip
  • 10. Machine Specifications with HydraCrowd Typical
  • 11. General Estimated Component Weights
  • 11.1. Lower Works
  • 11.2. Upper Works
  • 11.3. Front End
  • 12. Lubrication Principles
  • 13. Greasing Main A.C. Drive Motors
  • 13.1. Type of Grease
  • 13.2. Initial Commissioning
  • 13.3. Maintenance
  • 13.4. Regreasing Intervals
  • 14. Lubricant Selection
  • 15. Oil Fill Capacities
  • 15.1. Types Of Lubricants And Capacities
  • 16. Gearcase Lubricant Replacement/Sampling
  • 16.1. Lubricant Change Cycle
  • 17. Automatic Lubrication System
  • 17.1. Lube Room
  • 17.2. Lube Reservoir Fill / Overflow Plumbing
  • 17.3. Auto Lube Control Panel
  • 17.4. Lower Works Lubrication
  • 17.5. Revolving Frame Lubrication
  • 17.6. Hoist Rope Rollers Lubrication
  • 17.7. Front End Lubrication
  • 17.8. Lubricant Injectors
  • 18. Propel Machinery Lubrication
  • 19. Hoist Machinery Lubrication
  • 19.1. Hoist OGL Reservoir
  • 19.2. Hoist Oil Cooler
  • 19.3. Filter Element Cleaning
  • 20. Swing Machinery Lubrication
  • 21. Hydraulic Crowd Machinery Lubrication
  • 21.1. Pump Drive Transmission (PDT)
  • 21.2. Oil Pump
  • 22. Hydraulic Cleanliness
  • 22.1. Contamination Control
  • 22.2. Filters
  • 22.3. Moisture Removal
  • 23. Air Compressor Lubrication
  • 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
  • 29. Hydraulic Crowd Service Schedule
  • 30. HydraCrowd Health Monitoring Checks
  • 31. Major Component Locations
  • 32. Lower Works
  • 32.1. Truck Frame Assembly
  • 32.2. Swing Rack Assembly
  • 32.3. Roller Circle Assembly
  • 32.4. Crawler Belts
  • 32.5. Crawler Side Frame Assembly
  • 32.6. Crawler Front Idler Roller Assembly
  • 32.7. Propel Shaft Assembly
  • 32.8. Propel Machinery
  • 33. Rotating Deck
  • 33.1. Revolving Frame
  • 33.2. Center Pintle
  • 33.3. Collector Rings
  • 33.4. Cable Reel
  • 33.5. Stinger (Trail Cable Support)
  • 33.6. Swing Machinery
  • 33.7. Hoist Machinery
  • 33.8. Hoist Oil Cooler
  • 33.9. Crowd Machinery Overview
  • 33.10. Operators Cab Mounting
  • 33.11. Operators Seat Replacement
  • 33.12. Joystick Replacement
  • 33.13. Wiper Arm Replacement
  • 33.14. Wiper Blade Replacement
  • 33.15. Wiper Motor Replacement
  • 34. Machinery House
  • 34.1. Light Locations
  • 34.2. House Light Locations
  • 34.3. Electrical Outlet Locations
  • 34.4. Walkways, Stairways, and Handrails
  • 35. Front End Equipment
  • 35.1. Boom Assembly
  • 35.2. Boom Limit Switch Installation
  • 35.3. Boom Point Sheaves
  • 35.4. Boom Bumper
  • 35.5. Saddle Block
  • 35.6. Dipper Handle – Hydraulic Crowd
  • 35.7. Dipper Assembly
  • 35.8. Dipper Removal Installation
  • 35.9. Dipper Trip Assembly
  • 35.10. A-Frame
  • 35.11. Auxiliary Winch
  • 35.12. Hoist Rope Support Roller
  • 35.13. Boom Support Ropes
  • 35.14. Wire Ropes
  • 35.15. Hoist Rope Reeving Replacement
  • 35.16. Dipper Trip Rope Reeving Replacement
  • 35.17. Hoist and Crowd Limit Systems
  • 36. Brakes
  • 36.1. Disc Brake Operation
  • 36.2. Maintenance
  • 36.3. Brake Adjustment Specifications
  • 36.4. Hoist Brake
  • 36.5. Propel Brake
  • 36.6. Swing Brake
  • 36.7. Spring Replacement All Brakes
  • 36.8. Friction Disc Replacement All Brakes
  • 36.9. O-Ring Replacement All Brakes
  • 36.10. Brake Wear Release Switches Single Disc Brakes
  • 36.11. Brake Wear Release Switches Multiple Disc Brakes
  • 37. Couplings
  • 37.1. Grid Couplings
  • 37.2. Gear Couplings
  • 38. Air Compressor – Dual
  • 38.1. Kaeser SK-25 General Specifications
  • 39. Lockout Valves
  • 40. Safety Warnings
  • 41. House Filter Fans
  • 41.1. Lubrication
  • 41.2. Dynavane Air Cleaner
  • 42. Air Filtration System
  • 42.1. Description
  • 42.2. Operation
  • 42.3. Compressed Air Installation
  • 42.4. Filter Removal
  • 42.5. Solid-State Timer Installation
  • 42.6. Delta P Plus
  • 42.7. Setpoint Adjustments
  • 43. Air Conditioner/Heater
  • 43.1. Evaporator
  • 43.2. Condenser
  • 43.3. Pressurizer
  • 43.4. Specifications
  • 44. Capscrew (Bolt) Grade
  • 44.1. Bolt Tightening
  • 45. Measurement Systems
  • 45.1. Linear Measurements
  • 45.2. Area Measurements
  • 45.3. Volume Measurements
  • 45.4. Torque Measurements
  • 45.5. Weight Measurements – Conventional
  • 45.6. 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 3.5-Inch Torque Nut
  • 48.5. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
  • 48.6. Tightening Procedures – Expansion Bolts
  • 49. Torque Nut Removal Procedure
  • 49.1. Thread Lubrication
  • 50. Torque Nut Helpful Hints
  • 51. Locking Assemblies
  • 51.1. Locking Assembly Removal
  • 51.2. Removal from a Shaft
  • 51.3. Mounting a Pinion or Hub on a Shaft
  • 51.4. Pre-heat Advance Requirements – Pinions and Hubs
  • 51.5. Motor Coupling Pre-Heat Advance Requirements
  • 52. Open Gear Contact Check
  • 53. Open Gear Break-In
  • 54. Maintenance Welding
  • 54.1. Welding Electrodes
  • 54.2. Repair Welding of Cracks
  • 54.3. Repair Welding of Broken Parts
  • 54.4. Repair Welding Swing Rack Teeth
  • 54.5. Welding and Cutting Equipment
  • 54.6. Stress Relieving Temperature Measuring Equipment
  • 55. Wire Rope Care and Maintenance
  • 55.1. Storage
  • 55.2. Checking Diameter
  • 55.3. Handling Wire Rope
  • 55.4. Seizing Wire Rope
  • 55.5. End Preparations/Terminations
  • 55.6. Wire Rope Clips
  • 55.7. Inspection of Sheaves and Drums
  • 55.8. Breaking In a New Wire Rope
  • 55.9. Inspection Data
  • 55.10. Guideline to Inspections and Reports
  • 56. Seals
  • 56.1. Seal Installation
  • 56.2. Gearcase Sealing
  • 57. Hydraulic System Cleanliness
  • 58. Hydraulic System Oil Contamination Guide
  • 59. Crowd Machinery Overview
  • 59.1. Hydraulic Crowd Cylinder Overview
  • 59.2. Cylinder Control Manifold Overview
  • 59.3. Auxiliary Power Unit Overview
  • 59.4. Power Module/Lower Tank Overview
  • 59.5. Lower Tank, Crowd Motor, Transmission Pumps Overview
  • 59.6. Flushing/PDT Lube Motor Overview
  • 59.7. Circulation Filter Overview
  • 59.8. Manifolds Overview
  • 59.9. Oil Circulation Manifold Overview
  • 59.10. Pump Control Manifold Overview
  • 59.11. Upper Hydraulic Tank Overview
  • 59.12. Oil Circulation Pump Overview
  • 59.13. Isolator Tank Overview
  • 59.14. Oil Coolers Plumbing Overview
  • 59.15. Accumulator Overview
  • 60. Hydraulic Crowd Sensor Locations
  • 60.1. Cylinder Sensors
  • 60.2. Power Module Sensors
  • 60.3. Upper Hydraulic Tank Sensors
  • 60.4. Pump Control Manifold Sensor
  • 60.5. Auxiliary Power Unit Sensor
  • 60.6. Oil Cooler Sensors
  • 61. Inspection
  • 61.1. PDT Leak Inspection
  • 61.2. Circulation Plumbing Inspection
  • 61.3. Oil Circulation Pump Inspection
  • 61.4. Isolator Troubleshooting
  • 61.5. Isolator Tank Inspection
  • 61.6. Isolator Manifold Inspection
  • 61.7. Vacuum Breaker Inspection
  • 61.8. Isolator Plumbing Inspection
  • 61.9. Accumulator Inspection
  • 61.10. Accumulator Pressure Test Charge
  • 62. Service Procedures
  • 62.1. HydraCrowd Cylinder Bleeding Process
  • 62.2. Hydraulic Crowd Start-Up Procedure
  • 62.3. Standard System Flushing Filtration
  • 62.4. Complete System Flushing Filtration
  • 62.5. Initial System Oil Fill
  • 62.6. System Top Off
  • 62.7. System Oil Drain – Partial
  • 62.8. System Oil Drain – Complete
  • 62.9. Auxiliary Power Unit Fill Filter Replacement
  • 62.10. PDT – Initial Oil Fill
  • 62.11. PDT – Oil Top Off
  • 62.12. PDT – Oil Level Check
  • 62.13. PDT – Oil Drain
  • 63. Hydraulic Crowd Cooler Cleaning
  • 64. Hydraulic Crowd Oil Cooler – Drain
  • 65. Hydraulic Crowd Oil Cooler Replacement
  • 65.1. Purging The Main Pumps
  • 65.2. Hydraulic System Prefill Filter Replacement
  • 65.3. Upper Tank Return Filter Cleaning
  • 65.4. Upper Tank Return Filter Replacement
  • 65.5. Isolator Removal And Replacement
  • 65.6. Isolator Draining
  • 65.7. Circulation Filter Replacement
  • 65.8. Hydraulic Hose Replacement
  • 65.9. Main Pump Pressure Hose Replacement
  • 65.10. CECV Smart Module Replacement
  • 65.11. CECVR/CECVH Valve Replacement
  • 65.12. RECV Smart Module Replacement
  • 65.13. RECV Valve Replacement
  • 65.14. RV3 Module Replacement
  • 65.15. RV3 RV4 Relief Valve Replacement
  • 66. Hydraulic Crowd Service Schedule
  • 67. Schematics
  • 68. Side View
  • 69. Deck Plan
  • 70. OGL System A B Schematic
  • 71. Grease System C Schematic
  • 72. HVAC Schematic
  • 73. Air Schematic
  • 74. Hydraulic Crowd Troubleshooting Schematics
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