Bucyrus 495HR2 Mining Shovel Service Manual BI624260
Bucyrus 495HR2 Mining Shovel Service Manual BI624260 - Image 2
Bucyrus 495HR2 Mining Shovel Service Manual BI624260 - Image 3
Bucyrus 495HR2 Mining Shovel Service Manual BI624260 - Image 4
Bucyrus 495HR2 Mining Shovel Service Manual BI624260 - Image 5

Bucyrus 495HR2 Mining Shovel Service Manual BI624260

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: BI624260
  • Number of Pages: 566
  • Size: 22.2MB
  • Format: PDF
Category:

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
  • 8.7. Stinger (Trail Cable Support)
  • 9. Rotating Deck
  • 9.1. Revolving Frame
  • 9.2. Center Pintle
  • 9.3. Deck Extensions
  • 9.4. Ballast Box
  • 9.5. Machinery House
  • 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
  • 18. Lubricant Replacement/Sampling
  • 18.1. Lubricant Change Cycle
  • 19. Automatic Lubrication System
  • 19.1. Lube Room
  • 19.2. Lube Reservoir Fill / Overflow Plumbing
  • 19.3. Lower Works Lubrication
  • 19.4. Revolving Frame Lubrication
  • 19.5. Hoist Rope Rollers Lubrication
  • 19.6. Front End Lubrication
  • 19.7. Lubricant Injectors
  • 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. Lubricant 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
  • 33. Major Component Locations
  • 34. Service Procedures
  • 35. Lower Works
  • 35.1. Truck Frame Assembly
  • 35.2. Swing Rack Assembly
  • 35.3. Roller Circle Assembly
  • 35.4. Crawler Belts
  • 35.5. Crawler Side Frame Assembly
  • 35.6. Propel Shaft Assembly
  • 35.7. Propel Machinery
  • 36. Rotating Deck
  • 36.1. Revolving Frame
  • 36.2. Center Pintle
  • 36.3. Collector Rings
  • 36.4. Stinger (Trail Cable Support)
  • 36.5. Swing Machinery
  • 36.6. Hoist Machinery
  • 36.7. Hoist Oil Cooler
  • 36.8. Crowd Machinery
  • 36.9. Operators Cab Mounting
  • 36.10. Operators Seat Replacement
  • 36.11. Joystick Replacement
  • 36.12. Wiper Arm Replacement
  • 37. Machinery House
  • 37.1. Walkways, Stairways, and Handrails
  • 38. Front End Equipment
  • 38.1. Boom Assembly
  • 38.2. Boom Limit Switch Installation
  • 38.3. Boom Point Sheaves
  • 38.4. Boom Bumper
  • 38.5. Saddle Block
  • 38.6. Dipper Handle Assembly
  • 38.7. Dipper Assembly
  • 38.8. Crowd Rope Take-up Hydraulic Unit
  • 38.9. A-Frame
  • 38.10. Auxiliary Winch
  • 38.11. Hoist Rope Support Roller
  • 38.12. Boom Support Ropes
  • 38.13. Wire Ropes
  • 38.14. Hoist Rope Reeving Replacement
  • 38.15. Crowd Rope Reeving Replacement
  • 38.16. Retract Rope Reeving Replacement
  • 38.17. Crowd and Retract Rope Tightening
  • 38.18. Dipper Trip Rope Reeving Replacement
  • 38.19. Hoist and Crowd Limit Systems
  • 39. Brakes and Couplings
  • 40. Brakes
  • 40.1. Disc Brake Operation
  • 40.2. Maintenance
  • 40.3. Brake Adjustment Specifications
  • 40.4. Hoist Brake
  • 40.5. Crowd Brake
  • 40.6. Propel Brake
  • 40.7. Swing Brake
  • 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
  • 41.2. Gear Couplings
  • 42. Compressed Air System
  • 43. Air Compressor – Dual
  • 43.1. Compressor Start-up Procedure
  • 43.2. Compressor Shutdown Procedure
  • 43.3. Compressor Fluid Level Check
  • 43.4. Recommended Lubrication Guide
  • 43.5. General Compressor Maintenance
  • 44. Air Dryer Assembly
  • 45. Lockout Valves
  • 46. Safety Warnings
  • 47. Air Filtration
  • 48. House Filter Fans
  • 48.1. Lubrication
  • 48.2. Dynavane Air Cleaner
  • 49. Air Filtration System
  • 49.1. Description
  • 49.2. Operation
  • 49.3. Compressed Air Installation
  • 49.4. Filter Removal
  • 49.5. Solid-State Timer Installation
  • 49.6. Delta P Plus
  • 49.7. Setpoint Adjustments
  • 50. Air Conditioner/Heater
  • 50.1. Evaporator
  • 50.2. Condenser
  • 50.3. Pressurizer
  • 50.4. Specifications
  • 51. Engineering Data
  • 52. Capscrew (Bolt) Grade
  • 52.1. Bolt Tightening
  • 53. Measurement Systems
  • 53.1. Linear Measurements
  • 53.2. Area Measurements
  • 53.3. Volume Measurements
  • 53.4. Torque Measurements
  • 53.5. Weight Measurements – Conventional
  • 54. Split Flange Assembly Procedure
  • 55. Wire Locking Capscrews
  • 56. Torque Nut Installation
  • 57. Expansion Bolt Installation
  • 57.1. Tightening Procedure for 1.25-Inch Torque Nut
  • 57.2. Tightening Procedure for 2-Inch Torque Nut
  • 57.3. Tightening Procedure for 2-Inch Torque Nut
  • 57.4. Tightening Procedure for 2-Inch Torque Nut
  • 57.5. Tightening Procedure for 2.5-Inch Torque Nut
  • 57.6. Tightening Procedure for 3-Inch Torque Nut
  • 57.7. Tightening Procedure for 3.5-Inch Torque Nut
  • 57.8. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
  • 57.9. Tightening Procedures – Expansion Bolts
  • 58. Torque Nut Removal Procedure
  • 58.1. Thread Lubrication
  • 59. Torque Nut Helpful Hints
  • 60. Locking Assemblies
  • 60.1. Locking Assembly Removal
  • 61. Pinion and Hub Installation
  • 61.1. Removal from a Shaft
  • 61.2. Mounting a Pinion or Hub on a Shaft
  • 61.3. Pre-heat Advance Requirements – Pinions and Hubs
  • 61.4. Motor Coupling Pre-Heat Advance Requirements
  • 62. Open Gear Contact Check
  • 63. Open Gear Break-In
  • 64. Maintenance Welding
  • 64.1. Welding Electrodes
  • 64.2. Repair Welding of Cracks
  • 64.3. Repair Welding of Broken Parts
  • 64.4. Repair Welding Swing Rack Teeth
  • 64.5. Welding and Cutting Equipment
  • 64.6. Stress Relieving Temperature Measuring Equipment
  • 65. Wire Rope Care and Maintenance
  • 65.1. Storage
  • 65.2. Checking Diameter
  • 65.3. Handling Wire Rope
  • 65.4. Seizing Wire Rope
  • 65.5. End Preparations/Terminations
  • 65.6. Wire Rope Clips
  • 65.7. Inspection of Sheaves and Drums
  • 65.8. Breaking In a New Wire Rope
  • 65.9. Inspection Data
  • 65.10. Guideline to Inspections and Reports
  • 66. Seals
  • 66.1. Seal Installation
  • 66.2. Gearcase Sealing
  • 67. Schematics
  • 68. Schematics
  • 69. Side View
  • 70. Deck Plan
  • 71. OGL System A B Schematic
  • 72. Grease System C Schematic
  • 73. HVAC Schematic
  • 74. Air Schematic
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