Bucyrus 495HR2 Mining Shovel Service Manual BI624239
Bucyrus 495HR2 Mining Shovel Service Manual BI624239 - Image 2
Bucyrus 495HR2 Mining Shovel Service Manual BI624239 - Image 3
Bucyrus 495HR2 Mining Shovel Service Manual BI624239 - Image 4
Bucyrus 495HR2 Mining Shovel Service Manual BI624239 - Image 5

Bucyrus 495HR2 Mining Shovel Service Manual BI624239

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: BI624239
  • Number of Pages: 834
  • Size: 56.2MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 495HR2 Mining Shovel
  • 1. Table of Contents
  • 2. Revision History
  • 3. Safety Symbols
  • 4. Safety Precautions
  • 4.1. General Precautions
  • 4.2. Maintenance Precautions
  • 4.3. Operating Precautions
  • 4.4. Fire Prevention
  • 4.5. Warning Signs And Decals
  • 5. Introduction
  • 6. About This Manual
  • 6.1. Purpose
  • 6.2. Organization
  • 6.3. Terminology
  • 6.4. Revisions
  • 6.5. Precautions and Disclaimers
  • 6.6. Contact
  • 7. Swinging Restraint Ballast Box Support
  • 7.1. Ballast Box Support
  • 7.2. Swinging Restraint
  • 8. Machine Overview
  • 9. Lower Works
  • 9.1. Crawlers
  • 9.2. Truck Frame
  • 9.3. Swing Rack
  • 9.4. Roller Circle
  • 9.5. Propel Machinery
  • 9.6. Collector Rings
  • 9.7. Stinger (Trail Cable Support)
  • 10. Rotating Deck
  • 10.1. Revolving Frame
  • 10.2. Center Pintle
  • 10.3. Deck Extensions
  • 10.4. Ballast Box
  • 10.5. Machinery House
  • 10.6. A-Frame
  • 10.7. Hoist Machinery
  • 10.8. Swing Machinery
  • 10.9. Crowd Machinery Overview
  • 10.10. Operators Cab
  • 10.11. Compressed Air System
  • 10.12. Automatic Lubrication System
  • 10.13. Lube Reservoir Fill / Overflow Plumbing
  • 11. Front End Equipment
  • 11.1. Suspension Strands
  • 11.2. Boom
  • 11.3. Running Ropes
  • 11.4. Saddle Block
  • 11.5. Dipper Handle – Hydraulic Crowd
  • 11.6. Dipper
  • 11.7. Padlocks
  • 11.8. Dipper Trip
  • 12. Machine Specifications with HydraCrowdTypical
  • 13. General Estimated Component Weights
  • 13.1. Lower Works
  • 13.2. Upper Works
  • 13.3. Front End
  • 14. Lubrication
  • 15. Lubrication Principles
  • 16. Greasing Main A.C. Drive Motors
  • 16.1. Type of Grease
  • 16.2. Initial Commissioning
  • 16.3. Maintenance
  • 16.4. Regreasing Intervals
  • 17. Lubricant Selection
  • 18. Oil Fill Capacities
  • 18.1. Types Of Lubricants And Capacities
  • 19. Gearcase Lubricant Replacement/Sampling
  • 19.1. Lubricant Change Cycle
  • 20. Automatic Lubrication System
  • 20.1. Lube Room
  • 20.2. Lube Reservoir Fill / Overflow Plumbing
  • 20.3. Auto Lube Control Panel
  • 20.4. Lower Works Lubrication
  • 21. Propel Machinery Lubrication
  • 21.1. Revolving Frame Lubrication
  • 22. Hoist Machinery Lubrication
  • 22.1. Hoist Oil Cooler
  • 22.2. Filter Element Cleaning
  • 22.3. Hoist Rope Rollers Lubrication
  • 22.4. Oil Pump
  • 23. Hydraulic Crowd Machinery Lubrication
  • 23.1. Pump Drive Transmission (PDT)
  • 24. Swing Machinery Lubrication
  • 24.1. Front End Lubrication
  • 24.2. Lubricant Injectors
  • 25. Hydraulic Cleanliness
  • 25.1. Contamination Control
  • 25.2. Filters
  • 25.3. Moisture Removal
  • 26. Air Compressor Lubrication
  • 26.1. ACSL – Air Compressor (Screw-Type) Lubricant
  • 27. Lubricant Specifications
  • 27.1. RWRL – Running Wire Rope Lubricant
  • 27.2. EGL – Enclosed Gearcase Lubricant
  • 27.3. MPG – Multipurpose Grease
  • 27.4. OGL – Open Gear Lubricant
  • 28. Preventive Maintenance
  • 29. Introduction
  • 29.1. Preventive Maintenance Program
  • 29.2. Elements of an Effective Maintenance Program
  • 29.3. Scheduled Preventive Maintenance Program
  • 29.4. General Safety Considerations
  • 30. Maintenance During Machine Operation
  • 30.1. Maintenance Precautions
  • 31. Preventive Maintenance for Lubrication
  • 31.1. Lubricant Cleanliness
  • 32. Frequency of Inspection and Maintenance
  • 33. Maintenance Schedules
  • 33.1. Maintenance Inspection Check Points
  • 34. Hydraulic Crowd Service Schedule
  • 35. HydraCrowd Health Monitoring Checks
  • 36. Major Component Locations
  • 37. Service Procedures
  • 38. Lower Works
  • 38.1. Truck Frame Assembly
  • 38.2. Swing Rack Assembly
  • 38.3. Roller Circle Assembly
  • 38.4. Crawler Belts
  • 38.5. Crawler Side Frame Assembly
  • 38.6. Propel Shaft Assembly
  • 38.7. Propel Machinery
  • 39. Rotating Deck
  • 39.1. Revolving Frame
  • 39.2. Center Pintle
  • 39.3. Collector Rings
  • 39.4. Stinger (Trail Cable Support)
  • 39.5. Swing Machinery
  • 39.6. Hoist Machinery
  • 39.7. Hoist Oil Cooler
  • 39.8. Crowd Machinery Overview
  • 39.9. Operators Cab Mounting
  • 39.10. Operators Seat Replacement
  • 39.11. Joystick Replacement
  • 39.12. Wiper Arm Replacement
  • 39.13. Wiper Blade Replacement
  • 39.14. Wiper Motor Replacement
  • 40. Machinery House
  • 40.1. Walkways, Stairways, and Handrails
  • 41. Front End Equipment
  • 41.1. Boom Assembly
  • 41.2. Boom Limit Switch Installation
  • 41.3. Boom Point Sheaves
  • 41.4. Boom Bumper
  • 41.5. Saddle Block
  • 41.6. Dipper Handle – Hydraulic Crowd
  • 41.7. Dipper Assembly
  • 41.8. Dipper Removal Installation
  • 41.9. Dipper Trip Assembly
  • 41.10. A-Frame
  • 41.11. Auxiliary Winch
  • 41.12. Hoist Rope Support Roller
  • 41.13. Boom Support Ropes
  • 41.14. Wire Ropes
  • 41.15. Hoist Rope Reeving Replacement
  • 41.16. Dipper Trip Rope Reeving Replacement
  • 41.17. Hoist and Crowd Limit Systems
  • 42. Brakes and Couplings
  • 43. Brakes
  • 43.1. Disc Brake Operation
  • 43.2. Maintenance
  • 43.3. Brake Adjustment Specifications
  • 43.4. Hoist Brake
  • 43.5. Propel Brake
  • 43.6. Swing Brake
  • 43.7. Spring Replacement All Brakes
  • 43.8. Friction Disc Replacement All Brakes
  • 43.9. O-Ring Replacement All Brakes
  • 43.10. Brake Wear Release Switches Single Disc Brakes
  • 43.11. Brake Wear Release Switches Multiple Disc Brakes
  • 44. Couplings
  • 44.1. Grid Couplings
  • 44.2. Gear Couplings
  • 45. Compressed Air System
  • 46. Air Compressor
  • 47. Lockout Valves
  • 48. Safety Warnings
  • 49. Air Filtration
  • 50. House Filter Fans
  • 50.1. Lubrication
  • 50.2. Dynavane Air Cleaner
  • 51. Air Filtration System
  • 51.1. Description
  • 51.2. Operation
  • 51.3. Compressed Air Installation
  • 51.4. Filter Removal
  • 51.5. Solid-State Timer Installation
  • 51.6. Delta P Plus
  • 51.7. Setpoint Adjustments
  • 52. Air Conditioner/Heater
  • 52.1. Evaporator
  • 52.2. Condenser
  • 52.3. Pressurizer
  • 52.4. Specifications
  • 53. Engineering Data
  • 54. Capscrew (Bolt) Grade
  • 54.1. Bolt Tightening
  • 55. Measurement Systems
  • 55.1. Linear Measurements
  • 55.2. Area Measurements
  • 55.3. Volume Measurements
  • 55.4. Torque Measurements
  • 55.5. Weight Measurements – Conventional
  • 56. Split Flange Assembly Procedure
  • 57. Wire Locking Capscrews
  • 58. Torque Nut Installation
  • 59. Expansion Bolt Installation
  • 59.1. Tightening Procedure for 1.25-Inch Torque Nut
  • 59.2. Tightening Procedure for 2-Inch Torque Nut
  • 59.3. Tightening Procedure for 2-Inch Torque Nut
  • 59.4. Tightening Procedure for 3.5-Inch Torque Nut
  • 59.5. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
  • 59.6. Tightening Procedures – Expansion Bolts
  • 60. Torque Nut Removal Procedure
  • 60.1. Thread Lubrication
  • 61. Torque Nut Helpful Hints
  • 62. Locking Assemblies
  • 62.1. Locking Assembly Removal
  • 62.2. Pinion and Hub Installation
  • 62.3. Removal from a Shaft
  • 62.4. Mounting a Pinion or Hub on a Shaft
  • 62.5. Pre-heat Advance Requirements – Pinions and Hubs
  • 62.6. Motor Coupling Pre-Heat Advance Requirements
  • 63. Open Gear Contact Check
  • 64. Open Gear Break-In
  • 65. Maintenance Welding
  • 65.1. Welding Electrodes
  • 65.2. Repair Welding of Cracks
  • 65.3. Repair Welding of Broken Parts
  • 65.4. Repair Welding Swing Rack Teeth
  • 65.5. Welding and Cutting Equipment
  • 65.6. Stress Relieving Temperature Measuring Equipment
  • 66. Wire Rope Care and Maintenance
  • 66.1. Storage
  • 66.2. Checking Diameter
  • 66.3. Handling Wire Rope
  • 66.4. Seizing Wire Rope
  • 66.5. End Preparations/Terminations
  • 66.6. Wire Rope Clips
  • 66.7. Inspection of Sheaves and Drums
  • 66.8. Breaking In a New Wire Rope
  • 66.9. Inspection Data
  • 66.10. Guideline to Inspections and Reports
  • 67. Seals
  • 67.1. Seal Installation
  • 67.2. Gearcase Sealing
  • 68. Hydraulic Crowd Service Procedures
  • 69. Hydraulic System Cleanliness
  • 70. Hydraulic System Oil Contamination Guide
  • 71. Crowd Machinery Overview
  • 71.1. Hydraulic Crowd Cylinder Overview
  • 71.2. Cylinder Control Manifold Overview
  • 71.3. Auxiliary Power Unit Overview
  • 71.4. Power Module/Lower Tank Overview
  • 71.5. Lower Tank, Crowd Motor, Transmission Pumps Overview
  • 71.6. Flushing/PDT Lube Motor Overview
  • 71.7. Circulation Filter Overview
  • 71.8. Manifolds Overview
  • 71.9. Oil Circulation Manifold Overview
  • 71.10. Pump Control Manifold Overview
  • 71.11. Upper Hydraulic Tank Overview
  • 71.12. Oil Circulation Pump Overview
  • 71.13. Isolator Tank Overview
  • 71.14. Oil Cooler Plumbing Overview
  • 71.15. Accumulator Overview
  • 72. Hydraulic Crowd Sensor Locations
  • 72.1. Cylinder Sensors
  • 72.2. Power Module Sensors
  • 72.3. Upper Hydraulic Tank Sensors
  • 72.4. Pump Control Manifold Sensor
  • 72.5. Auxiliary Power Unit Sensor
  • 72.6. Oil Cooler Sensors
  • 73. Inspection
  • 73.1. PDT Leak Inspection
  • 73.2. Circulation Plumbing Inspection
  • 73.3. Oil Circulation Pump Inspection
  • 73.4. Isolator Troubleshooting
  • 73.5. Isolator Tank Inspection
  • 73.6. Isolator Manifold Inspection
  • 73.7. Vacuum Breaker Inspection
  • 73.8. Isolator Plumbing Inspection
  • 73.9. Accumulator Inspection
  • 73.10. Accumulator Pressure Test Charge
  • 74. Service Procedures
  • 74.1. HydraCrowd Cylinder Bleeding Process
  • 74.2. Hydraulic Crowd Start-Up Procedure
  • 74.3. Standard System Flushing Filtration
  • 74.4. Complete System Flushing Filtration
  • 74.5. Initial System Oil Fill
  • 74.6. System Top Off
  • 74.7. System Oil Drain – Partial
  • 74.8. System Oil Drain – Complete
  • 74.9. Auxiliary Power Unit Fill Filter Replacement
  • 74.10. PDT – Initial Oil Fill
  • 74.11. PDT – Oil Top Off
  • 74.12. PDT – Oil Level Check
  • 74.13. PDT – Oil Drain
  • 75. Hydraulic Crowd Cooler Cleaning
  • 76. Hydraulic Crowd Oil Cooler – Drain
  • 77. Hydraulic Crowd Oil Cooler Replacement
  • 77.1. Purging The Main Pumps
  • 77.2. Hydraulic System Prefill Filter Replacement
  • 77.3. Upper Tank Return Filter Cleaning
  • 77.4. Upper Tank Return Filter Replacement
  • 77.5. Isolator Removal And Replacement
  • 77.6. Isolator Draining
  • 77.7. Circulation Filter Replacement
  • 77.8. Hydraulic Hose Replacement
  • 77.9. Main Pump Pressure Hose Replacement
  • 77.10. CECV Smart Module Replacement
  • 77.11. CECVR/CECVH Valve Replacement
  • 77.12. RECV Smart Module Replacement
  • 77.13. RECV Valve Replacement
  • 77.14. RV3 Module Replacement
  • 77.15. RV3 RV4 Relief Valve Replacement
  • 78. Hydraulic Crowd Service Schedule
  • 79. Schematics
  • 80. Schematics
  • 81. Side View
  • 82. Deck Plan
  • 83. OGL System A B Schematic
  • 84. Grease System C Schematic
  • 85. HVAC Schematic
  • 86. Air Schematic
  • 87. Hydraulic Crowd Troubleshooting Schematics
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