Bucyrus 495HR2 Mining Shovel Service Manual BI624270
Bucyrus 495HR2 Mining Shovel Service Manual BI624270 - Image 2
Bucyrus 495HR2 Mining Shovel Service Manual BI624270 - Image 3
Bucyrus 495HR2 Mining Shovel Service Manual BI624270 - Image 4
Bucyrus 495HR2 Mining Shovel Service Manual BI624270 - Image 5

Bucyrus 495HR2 Mining Shovel Service Manual BI624270

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: BI624270
  • Number of Pages: 556
  • Size: 22.6MB
  • 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. Warning Signs And Decals
  • 3. Introduction
  • 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
  • 8. Rotating Deck
  • 8.1. Revolving Frame
  • 8.2. Center Pintle
  • 8.3. Deck Extensions
  • 8.4. Ballast Box
  • 8.5. Machinery House
  • 8.5.1. Boarding Stairs
  • 8.6. A-Frame
  • 8.7. Hoist Machinery
  • 8.8. Swing Machinery
  • 8.9. Crowd Machinery
  • 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
  • 9.6. Dipper
  • 9.7. Padlocks
  • 9.8. Dipper Trip
  • 10. Typical Machine Specifications
  • 11. General Estimated Component Weights
  • 11.1. Lower Works
  • 11.2. Upper Works
  • 11.3. Front End
  • 12. Lubrication
  • 13. Lubrication Principles
  • 14. Greasing Main A.C. Drive Motors
  • 14.1. Type of Grease
  • 14.2. Initial Commissioning
  • 14.3. Maintenance
  • 14.4. Regreasing Intervals
  • 15. Lubricant Selection
  • 16. Oil Fill Capacities
  • 16.1. Types Of Lubricants And Capacities
  • 16.1.1. Quantities for First Fill of Lubricants
  • 17. Gearcase Lubricant Replacement/Sampling
  • 17.1. Lubricant Change Cycle
  • 18. Automatic Lubrication System
  • 18.1. Lube Room
  • 18.2. Lube Reservoir Fill / Overflow Plumbing
  • 18.3. Auto Lube Control Panel
  • 18.4. Lower Works Lubrication
  • 18.5. Revolving Frame Lubrication
  • 18.6. Hoist Rope Rollers Lubrication
  • 18.7. Front End Lubrication
  • 18.8. Lubricant Injectors
  • 18.8.1. Lincoln Type SL-1 Lubricant Injectors
  • 18.8.2. Lincoln Type SL-V Lubricant Injectors
  • 18.8.3. Injector Advantages
  • 19. Propel Machinery Lubrication
  • 20. Hoist Machinery Lubrication
  • 20.1. Hoist OGL Reservoir
  • 20.2. Hoist Oil Cooler
  • 20.3. Filter Element Cleaning
  • 21. Swing Machinery Lubrication
  • 22. Crowd Rope Take-up Mechanism Lubrication
  • 23. Crowd Machinery Lubrication
  • 24. Air Compressor Lubrication
  • 24.1. ACSL – Air Compressor (Screw-Type) Lubricant
  • 25. Lubrication Specifications
  • 25.1. EGL – Enclosed Gearcase Lubricant
  • 25.2. MPG – Multipurpose Grease
  • 25.3. OGL – Open Gear Lubricant
  • 26. Preventive Maintenance
  • 27. Introduction
  • 27.1. Preventive Maintenance Program
  • 27.2. Elements of an Effective Maintenance Program
  • 27.3. Scheduled Preventive Maintenance Program
  • 27.4. General Safety Considerations
  • 28. Maintenance During Machine Operation
  • 28.1. Maintenance Precautions
  • 29. Preventive Maintenance for Lubrication
  • 29.1. Lubricant Cleanliness
  • 30. Frequency of Inspection and Maintenance
  • 31. Maintenance Schedules
  • 31.1. Maintenance Inspection Check Points
  • 31.1.1. Daily
  • 31.1.2. Every 100 Hours or Weekly
  • 31.1.3. Every 500 Hours or Monthly
  • 31.1.4. Every 1250 Hours or Quarterly
  • 31.1.5. Every 2500 Hours or Semi-Annually
  • 31.1.6. Every 5000 Hours or Annually
  • 32. Major Component Locations
  • 33. Service Procedures
  • 34. Lower Works
  • 34.1. Truck Frame Assembly
  • 34.2. Swing Rack Assembly
  • 34.2.1. Roller Circle Rail Replacement – Lower
  • 34.2.2. Roller Circle Rail Replacement – Upper
  • 34.3. Roller Circle Assembly
  • 34.3.1. Roller Circle Adjustment
  • 34.3.2. Adjustment Procedure
  • 34.3.3. Run-in Procedure for the Roller Circle
  • 34.3.4. Roller Circle Segment Removal
  • 34.3.5. Roller Circle – Roller Replacement
  • 34.4. Crawler Belts
  • 34.4.1. Crawler Belt Maintenance
  • 34.5. Crawler Side Frame Assembly
  • 34.5.1. Crawler Side Frame Maintenance
  • 34.5.2. Load Rollers and Rear Idler Rollers
  • 34.6. Propel Shaft Assembly
  • 34.6.1. Installation Notes
  • 34.6.2. Main Propel Drive Shaft Removal
  • 34.6.3. Main Propel Shaft – Disassembly
  • 34.6.4. Tumbler Rebuild Procedure
  • 34.7. Propel Machinery
  • 34.7.1. Propel Planetary Gearcase
  • 34.7.2. Propel Motors
  • 35. Rotating Deck
  • 35.1. Revolving Frame
  • 35.2. Center Pintle
  • 35.2.1. Center Pintle Adjustment
  • 35.2.2. Center Pintle Sleeve Removal
  • 35.3. Collector Rings
  • 35.3.1. Collector Ring Inspection
  • 35.3.2. Collector Ring Repair
  • 35.4. Swing Machinery
  • 35.4.1. Swing Support Mounting Bolts
  • 35.4.2. Swing Motor
  • 35.4.3. Swing Planetary Gearcase
  • 35.4.4. Swing Pinion Shafts
  • 35.5. Hoist Machinery
  • 35.5.1. Hoist Motor Removal
  • 35.5.2. Motor Coupling Shaft
  • 35.5.3. Hoist Gearcase Assembly
  • 35.5.4. Hoist Drum Assembly
  • 35.5.5. Hoist Gear Start-Up Inspections
  • 35.5.6. Hoist Gear Replacement
  • 35.6. Hoist Oil Cooler
  • 35.6.1. Hoist Mounting Bolts
  • 35.6.2. Hoist Limit Switch
  • 35.7. Crowd Machinery
  • 35.7.1. Crowd Gearcase Disassembly
  • 35.7.2. Crowd Gearcase Assembly
  • 35.7.3. Crowd Motor
  • 35.7.4. Crowd Gear and Drum
  • 35.8. Operators Cab Mounting
  • 35.8.1. Operators Cab Isolator Mount Replacement
  • 35.9. Operators Seat Replacement
  • 35.10. Joystick Replacement
  • 35.10.1. Joystick Calibration
  • 35.11. Wiper Arm Replacement
  • 35.12. Wiper Blade Replacement
  • 35.13. Wiper Motor Replacement
  • 36. Machinery House
  • 36.1. Walkways, Stairways, and Handrails
  • 36.1.1. Boarding Stairs
  • 37. Front End Equipment
  • 37.1. Boom Assembly
  • 37.1.1. Boom Repair
  • 37.2. Boom Limit Switch Installation
  • 37.3. Boom Point Sheaves
  • 37.3.1. Boom Point Sheave Removal and Disassembly
  • 37.3.2. Boom Point Sheave Reassembly and Installation
  • 37.4. Boom Bumper
  • 37.5. Saddle Block
  • 37.5.1. Saddle Block Repair
  • 37.5.2. Saddle Block Removal
  • 37.6. Dipper Handle Assembly
  • 37.6.1. Dipper Handle Removal
  • 37.6.2. Crowd Rope Take-Up Mechanism
  • 37.7. Dipper Assembly
  • 37.7.1. Dipper Door
  • 37.7.2. Latch Bar Adjusting
  • 37.7.3. Dipper Door Bumpers
  • 37.7.4. Dipper Door Snubbers
  • 37.7.5. Dipper Pitch Brace
  • 37.7.6. Dipper Padlock
  • 37.8. Dipper Removal Installation
  • 37.9. Dipper Trip Assembly
  • 37.10. Crowd Rope Take-up Hydraulic Unit
  • 37.11. A-Frame
  • 37.12. Auxiliary Winch
  • 37.13. Hoist Rope Support Roller
  • 37.14. Boom Support Ropes
  • 37.15. Wire Ropes
  • 37.15.1. Wire Rope Inspection
  • 37.16. Hoist Rope Reeving Replacement
  • 37.17. Crowd Rope Reeving Replacement
  • 37.18. Retract Rope Reeving Replacement
  • 37.19. Crowd and Retract Rope Tightening
  • 37.20. Dipper Trip Rope Reeving Replacement
  • 37.21. Hoist and Crowd Limit Systems
  • 37.21.1. Setting Limits In The Hoist Crowd System
  • 38. Brakes and Couplings
  • 39. Brakes
  • 39.1. Disc Brake Operation
  • 39.2. Maintenance
  • 39.3. Brake Adjustment Specifications
  • 39.4. Hoist Brake
  • 39.4.1. Hoist Brake Adjustment
  • 39.4.2. Hoist Brake Installation
  • 39.4.3. Hoist Brake Wear Release Switches
  • 39.5. Crowd Brake
  • 39.5.1. Crowd Brake Installation
  • 39.5.2. Crowd Brake Wear Release Switches
  • 39.6. Propel Brake
  • 39.6.1. Propel Brake Adjustment
  • 39.6.2. Propel Brake Installation
  • 39.6.3. Tachometer Mounting Alignment
  • 39.7. Swing Brake
  • 39.7.1. Swing Brake Installation
  • 39.7.2. Swing Brake Wear Release Switches
  • 39.7.3. Swing Brake Burnishing
  • 39.8. Spring Replacement All Brakes
  • 39.9. Friction Disc Replacement All Brakes
  • 39.10. O-Ring Replacement All Brakes
  • 39.11. Brake Wear Release Switches Single Disc Brakes
  • 39.12. Brake Wear Release Switches Multiple Disc Brakes
  • 40. Couplings
  • 40.1. Grid Couplings
  • 40.1.1. Lubrication
  • 40.1.2. Coupling Disassembly and Grid Removal
  • 40.1.3. Grid Coupling Installation
  • 40.1.4. Seal Replacement without Hub Removal
  • 40.1.5. Grid Coupling Alignment
  • 40.2. Gear Couplings
  • 40.2.1. Coupling Installation
  • 40.2.2. Gear Coupling Alignment
  • 40.2.3. Hoist Coupling Shaft Alignment
  • 41. Compressed Air System
  • 42. Air Compressor
  • 43. Lockout Valves
  • 44. Safety Warnings
  • 45. Air Filtration
  • 46. House Filter Fans
  • 46.1. Lubrication
  • 46.2. Dynavane Air Cleaner
  • 47. Air Filtration System
  • 47.1. Description
  • 47.2. Operation
  • 47.2.1. Operational Checklist
  • 47.3. Compressed Air Installation
  • 47.4. Filter Removal
  • 47.5. Solid-State Timer Installation
  • 47.5.1. Solenoid Connection
  • 47.5.2. Timer and Solenoid Specifications
  • 47.6. Delta P Plus
  • 47.6.1. Operation
  • 47.6.2. Alarm
  • 47.7. Setpoint Adjustments
  • 47.7.1. Quick Start Instructions
  • 47.7.2. Adjustments
  • 47.7.3. Password Protected Settings
  • 47.7.4. Delta P Plus Control Calibration
  • 47.7.5. Preliminary Start-Up Check
  • 47.7.6. Maintenance Information
  • 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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