Bucyrus 495HR2 Mining Shovel Service Manual BI619864
Bucyrus 495HR2 Mining Shovel Service Manual BI619864 - Image 2
Bucyrus 495HR2 Mining Shovel Service Manual BI619864 - Image 3
Bucyrus 495HR2 Mining Shovel Service Manual BI619864 - Image 4
Bucyrus 495HR2 Mining Shovel Service Manual BI619864 - Image 5

Bucyrus 495HR2 Mining Shovel Service Manual BI619864

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: BI619864
  • Number of Pages: 753
  • Size: 26.1MB
  • 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
  • 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. Boarding Stairs
  • 8.7. A-Frame
  • 8.8. Hoist Machinery
  • 8.9. Swing Machinery
  • 8.10. Crowd Machinery Overview
  • 8.11. Operators Cab
  • 8.12. Compressed Air System
  • 8.13. Automatic Lubrication System
  • 8.14. 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. Typical Machine with HydraCrowd 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 Guidelines
  • 17. Automatic Lubrication System
  • 17.1. Lube Room
  • 17.2. Lube Reservoir Fill / Overflow Plumbing
  • 17.3. Lower Works Lubrication
  • 17.4. Propel Machinery Lubrication
  • 17.5. Revolving Frame Lubrication
  • 17.6. Hoist Machinery Lubrication
  • 17.7. Hoist Rope Rollers Lubrication
  • 17.8. Hydraulic Crowd Machinery Lubrication
  • 17.9. Pump Drive Transmission (PDT)
  • 17.10. Swing Machinery Lubrication
  • 17.11. Air Compressor Lubrication
  • 17.12. Front End Lubrication
  • 17.13. Lincoln Type SL-1 Lubricant Injectors
  • 17.14. Lincoln Type SL-V Lubricant Injectors
  • 17.15. ACSL – Air Compressor (Screw-Type) Lubricant
  • 18. Hydraulic Cleanliness
  • 18.1. Contamination Control
  • 18.2. Filters
  • 18.3. Moisture Removal
  • 18.4. MPO – Multipurpose OIL
  • 18.5. RWRL – Running Wire Rope Lubricant
  • 18.6. EGL – Enclosed Gearcase Lubricant
  • 18.7. MPG – Multipurpose Grease
  • 18.8. OGL – Open Gear Lubricant
  • 18.9. Certified Lubricants Listing
  • 19. Preventive Maintenance
  • 20. Introduction
  • 20.1. Preventive Maintenance Program
  • 20.2. Elements of an Effective Maintenance Program
  • 20.3. Scheduled Preventive Maintenance Program
  • 20.4. General Safety Considerations
  • 21. Maintenance During Machine Operation
  • 21.1. Maintenance Precautions
  • 22. Preventive Maintenance for Lubrication
  • 22.1. Lubricant Cleanliness
  • 23. Frequency of Inspection and Maintenance
  • 24. Maintenance Schedules
  • 24.1. Maintenance Inspection Check Points
  • 25. Hydraulic Crowd Service Schedule
  • 26. Service Procedures
  • 27. Lower Works
  • 27.1. Truck Frame Assembly
  • 27.2. Swing Rack Assembly
  • 27.3. Roller Circle Assembly
  • 27.4. Crawler Belts
  • 27.5. Crawler Side Frame Assembly
  • 27.6. Propel Assembly
  • 27.7. Propel Machinery
  • 28. Rotating Deck
  • 28.1. Revolving Frame
  • 28.2. Center Pintle
  • 28.3. Collector Rings
  • 28.4. Cable Reel
  • 28.5. Stinger (Trail Cable Support)
  • 28.6. Swing Machinery
  • 28.7. Hoist Machinery
  • 28.8. Crowd Machinery Overview
  • 28.9. Operators Cab Mounting
  • 28.10. Operators Cab Isolator Mount Replacement
  • 28.11. Operators Seat Replacement
  • 28.12. Joystick Replacement
  • 28.13. Wiper Arm Replacement
  • 29. Machinery House
  • 29.1. Walkways, Stairways, and Handrails
  • 29.2. Boarding Stairs
  • 30. Front End Equipment
  • 30.1. Boom Assembly
  • 30.2. Boom Repair
  • 30.3. Boom Limit Switch Installation
  • 30.4. Boom Point Sheaves
  • 30.5. Boom Bumper
  • 30.6. Saddle Block
  • 30.7. Dipper Handle – Hydraulic Crowd
  • 30.8. LatchFreeTM Dipper Assembly
  • 30.9. A-Frame
  • 30.10. Auxiliary Winch
  • 30.11. Hoist Rope Support Roller
  • 30.12. Boom Support Ropes
  • 30.13. Wire Ropes
  • 30.14. Hoist Rope Reeving Replacement
  • 30.15. Dipper Trip Rope Reeving Replacement
  • 30.16. Hoist and Crowd Limit Systems
  • 31. Brakes and Couplings
  • 32. Brakes
  • 32.1. Disc Brake Operation
  • 32.2. Maintenance
  • 32.3. Brake Adjustment Specifications
  • 32.4. Hoist Brake
  • 32.5. Propel Brake
  • 32.6. Swing Brake
  • 32.7. Spring Replacement All Brakes
  • 32.8. Friction Disc Replacement All Brakes
  • 32.9. O-Ring Replacement All Brakes
  • 32.10. Brake Wear Release Switches Single Disc Brakes
  • 32.11. Brake Wear Release Switches Multiple Disc Brakes
  • 33. Couplings
  • 33.1. Grid Couplings
  • 33.2. Gear Couplings
  • 34. Compressed Air System
  • 35. Air Compressor
  • 35.1. General Compressor Maintenance
  • 35.2. Lockout Valves
  • 36. Safety Warnings
  • 37. Air Filtration
  • 38. House Filter Fans
  • 38.1. Lubrication
  • 38.2. Dynavane Air Cleaner
  • 39. Air Conditioner/heater
  • 39.1. Evaporator
  • 39.2. Condenser
  • 39.3. Pressurizer
  • 39.4. Specifications
  • 40. Engineering Data
  • 41. Capscrew (Bolt) Grade
  • 41.1. Bolt Tightening
  • 42. Measurement Systems
  • 42.1. Linear Measurements
  • 42.2. Area Measurements
  • 42.3. Volume Measurements
  • 42.4. Torque Measurements
  • 42.5. Split Flange Assembly Procedure
  • 43. Wire Locking Capscrews
  • 44. Torque Nut Installation
  • 45. Expansion Bolt Installation
  • 45.1. Tightening Procedure for 1.25-Inch Torque Nut
  • 45.2. Tightening Procedure for 2-Inch Torque Nut
  • 45.3. Tightening Procedure for 2-Inch Torque Nut
  • 45.4. Tightening Procedure for 3.5-Inch Torque Nut
  • 45.5. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
  • 45.6. Tightening Procedures – Expansion Bolts
  • 46. Torque Nut Removal Procedure
  • 46.1. Thread Lubrication
  • 47. Torque Nut Helpful Hints
  • 48. Locking Assemblies
  • 48.1. Locking Assembly Removal
  • 49. Pinion and Hub Installation
  • 49.1. Removal from a Shaft
  • 49.2. Mounting a Pinion or Hub on a Shaft
  • 49.3. Pre-heat Advance Requirements – Pinions and Hubs
  • 49.4. Motor Coupling Pre-Heat Advance Requirements
  • 50. Maintenance Welding
  • 50.1. Welding Electrodes
  • 50.2. Repair Welding of Cracks
  • 50.3. Repair Welding of Broken Parts
  • 50.4. Repair Welding Swing Rack Teeth
  • 50.5. Welding and Cutting Equipment
  • 50.6. Stress Relieving Temperature Measuring Equipment
  • 51. Wire Rope Care and Maintenance
  • 51.1. Storage
  • 51.2. Checking Diameter
  • 51.3. Handling Wire Rope
  • 51.4. Seizing Wire Rope
  • 51.5. End Preparations/Terminations
  • 51.6. Wire Rope Clips
  • 51.7. Inspection of Sheaves and Drums
  • 51.8. Breaking In a New Wire Rope
  • 51.9. Inspection Data
  • 51.10. Guideline to Inspections and Reports
  • 52. Seals
  • 52.1. Seal Installation
  • 52.2. Gearcase Sealing
  • 53. Hydraulic Crowd Service Procedures
  • 54. Hydraulic System Cleanliness
  • 55. Hydraulic System Oil Contamination Guide
  • 55.1. Crowd Machinery Overview
  • 56. Hydraulic Crowd Cylinder Overview
  • 57. Cylinder Control Manifold Overview
  • 58. Auxiliary Power Unit Overview
  • 59. Power Module/Lower Tank Overview
  • 60. Lower Tank, Crowd Motor, Transmission Pumps Overview
  • 61. Flushing/PDT Lube Motor Overview
  • 62. Circulation Filter Overview
  • 63. Manifolds Overview
  • 64. Oil Circulation Manifold Overview
  • 65. Pump Control Manifold Overview
  • 66. Upper Hydraulic Tank Overview
  • 67. Oil Circulation Pump Overview
  • 68. Isolator Tank Overview
  • 68.1. Oil Cooler Plumbing Overview
  • 69. Accumulator Overview
  • 70. Hydraulic Crowd Sensor Locations
  • 70.1. Cylinder Sensors
  • 70.2. Power Module Sensors
  • 70.3. Upper Hydraulic Tank Sensors
  • 70.4. Pump Control Manifold Sensor
  • 70.5. Auxiliary Power Unit Sensor
  • 70.6. Oil Cooler Sensors
  • 71. Inspection
  • 71.1. PDT Leak Inspection
  • 71.2. Circulation Plumbing Inspection
  • 71.3. Oil Circulation Pump Inspection
  • 72. Isolator Troubleshooting
  • 73. Isolator Tank Inspection
  • 74. Isolator Manifold Inspection
  • 75. Vacuum Breaker Inspection
  • 76. Isolator Plumbing Inspection
  • 77. Accumulator Inspection
  • 77.1. Intervals Between Checking Gas Precharge Pressure
  • 78. Accumulator Pressure Test Charge
  • 79. Service Procedures
  • 79.1. Hydraulic Crowd Start-up Procedure
  • 79.2. Standard System Flushing Filtration
  • 79.3. Complete System Flushing Filtration
  • 80. Initial System Oil Fill
  • 81. System Top Off
  • 82. System Oil Drain – Partial
  • 83. System Oil Drain – Complete
  • 84. Auxiliary Power Unit Fill Filter Replacement
  • 85. PDT – Initial Oil Fill
  • 86. PDT – Oil Top Off
  • 87. PDT – Oil Level Check
  • 88. PDT – Oil Drain
  • 89. Hydraulic Crowd Cooler Cleaning
  • 90. Hydraulic Crowd Oil Cooler – Drain
  • 91. Hydraulic Crowd Oil Cooler Replacement
  • 92. Purging The Main Pumps
  • 93. Hydraulic System Prefill Filter Replacement
  • 94. Upper Tank Return Filter Cleaning
  • 95. Upper Tank Return Filter Replacement
  • 96. Isolator Removal And Replacement
  • 97. Isolator Draining
  • 98. Circulation Filter Replacement
  • 99. Boom Saddle Block Pressure Hose Replacement
  • 100. Pressure Hose Positioning
  • 101. Boom Saddle Block Return Hose Replacement
  • 102. Return Hose Positioning
  • 103. Main Pump Pressure Hose Removal Installation
  • 104. CECV Smart Module Replacement
  • 105. CECVR/CECVH Valve Replacement
  • 106. RECV Smart Module Replacement
  • 107. RECV Valve Replacement
  • 108. RV3 Module Replacement
  • 109. RV3 RV4 Relief Valve Replacement
  • 110. Hydraulic Crowd Service Schedule
  • 111. Schematics
  • 112. Schematics
  • 113. Side View
  • 114. Deck Plan
  • 115. OGL System A B Schematic
  • 116. Grease System C Schematic
  • 117. HVAC Schematic
  • 118. Air Schematic
  • 119. SM141439-EN-ServiceProcedures.pdf
  • 119.1. Service Procedures
  • 119.2. Lower Works
  • 119.3. Rotating Deck
  • 119.4. Machinery House
  • 119.5. Front End Equipment
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