Bucyrus 495HR2 Mining Shovel Service Manual BI624284

Bucyrus 495HR2 Mining Shovel Service Manual BI624284 - Image 2

Bucyrus 495HR2 Mining Shovel Service Manual BI624284 - Image 3

Bucyrus 495HR2 Mining Shovel Service Manual BI624284

$30.00

Type Of Manual: Service Manual
Manual ID: BI624284
Number of Pages: 792
Size: 52.9MB
Format: PDF

Category: Bucyrus Service Manual PDF

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 Overview
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 – Hydraulic Crowd
10.6. LatchFreeTM Dipper Assembly
10.7. Padlocks
10.8. Dipper Trip
11. Machine Specifications with HydraCrowd Typical
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. Gearcase 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. Auto Lube Control Panel
19.4. Lower Works Lubrication
19.5. Revolving Frame Lubrication
19.6. Hoist Rope Rollers Lubrication
19.7. Front End Lubrication
19.8. 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. Hydraulic Crowd Machinery Lubrication
23.1. Pump Drive Transmission (PDT)
23.2. Oil Pump
24. Hydraulic Cleanliness
24.1. Contamination Control
24.2. Filters
24.3. Moisture Removal
25. Air Compressor Lubrication
25.1. ACSL – Air Compressor (Screw-Type) Lubricant
26. Lubricant Specifications
26.1. EGL – Enclosed Gearcase Lubricant
26.2. MPG – Multipurpose Grease
26.3. 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. Hydraulic Crowd Service Schedule
34. HydraCrowd Health Monitoring Checks
35. Major Component Locations
36. Service Procedures
37. Lower Works
37.1. Truck Frame Assembly
37.2. Swing Rack Assembly
37.3. Roller Circle Assembly
37.4. Crawler Belts
37.5. Crawler Side Frame Assembly
37.6. Crawler Front Idler Roller Assembly
37.7. Propel Shaft Assembly
37.8. Propel Machinery
38. Rotating Deck
38.1. Revolving Frame
38.2. Center Pintle
38.3. Collector Rings
38.4. Stinger (Trail Cable Support)
38.5. Swing Machinery
38.6. Hoist Machinery
38.7. Hoist Oil Cooler
38.8. Crowd Machinery Overview
38.9. Operators Cab Mounting
38.10. Operators Seat Replacement
38.11. Joystick Replacement
38.12. Wiper Arm Replacement
38.13. Wiper Blade Replacement
38.14. Wiper Motor Replacement
39. Machinery House
39.1. Walkways, Stairways, and Handrails
40. Front End Equipment
40.1. Boom Assembly
40.2. Boom Limit Switch Installation
40.3. Boom Point Sheaves
40.4. Boom Bumper
40.5. Saddle Block
40.6. Dipper Handle – Hydraulic Crowd
40.7. LatchFreeTM Dipper Assembly
40.8. Dipper Removal Installation
40.9. Dipper Trip Assembly
40.10. A-Frame
40.11. Auxiliary Winch
40.12. Hoist Rope Support Roller
40.13. Boom Support Ropes
40.14. Wire Ropes
40.15. Hoist Rope Reeving Replacement
40.16. Dipper Trip Rope Reeving Replacement
40.17. Hoist and Crowd Limit Systems
41. Brakes and Couplings
42. Brakes
42.1. Disc Brake Operation
42.2. Maintenance
42.3. Brake Adjustment Specifications
42.4. Hoist Brake
42.5. Propel Brake
42.6. Swing Brake
42.7. Spring Replacement All Brakes
42.8. Friction Disc Replacement All Brakes
42.9. O-Ring Replacement All Brakes
42.10. Brake Wear Release Switches Single Disc Brakes
42.11. Brake Wear Release Switches Multiple Disc Brakes
43. Couplings
43.1. Grid Couplings
43.2. Gear Couplings
44. Compressed Air System
45. Air Compressor
46. Lockout Valves
47. Safety Warnings
48. Air Filtration
49. House Filter Fans
49.1. Lubrication
49.2. Dynavane Air Cleaner
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
53.6. Split Flange Assembly Procedure
54. Wire Locking Capscrews
55. Torque Nut Installation
56. Expansion Bolt Installation
56.1. Tightening Procedure for 1.25-Inch Torque Nut
56.2. Tightening Procedure for 2-Inch Torque Nut
56.3. Tightening Procedure for 2-Inch Torque Nut
56.4. Tightening Procedure for 3.5-Inch Torque Nut
56.5. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
56.6. Tightening Procedures – Expansion Bolts
57. Torque Nut Removal Procedure
57.1. Thread Lubrication
58. Torque Nut Helpful Hints
59. Locking Assemblies
59.1. Locking Assembly Removal
59.2. Removal from a Shaft
59.3. Mounting a Pinion or Hub on a Shaft
59.4. Pre-heat Advance Requirements – Pinions and Hubs
59.5. 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
62.3. Repair Welding of Broken Parts
62.4. Repair Welding Swing Rack Teeth
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
63.7. Inspection of Sheaves and Drums
63.8. Breaking In a New Wire Rope
63.9. Inspection Data
63.10. Guideline to Inspections and Reports
64. Seals
64.1. Seal Installation
64.2. Gearcase Sealing
65. Hydraulic Crowd Service Procedures
66. Hydraulic System Cleanliness
67. Hydraulic System Oil Contamination Guide
68. Crowd Machinery Overview
68.1. Hydraulic Crowd Cylinder Overview
68.2. Cylinder Control Manifold Overview
68.3. Auxiliary Power Unit Overview
68.4. Power Module/Lower Tank Overview
68.5. Lower Tank, Crowd Motor, Transmission Pumps Overview
68.6. Flushing/PDT Lube Motor Overview
68.7. Circulation Filter Overview
68.8. Manifolds Overview
68.9. Oil Circulation Manifold Overview
68.10. Pump Control Manifold Overview
68.11. Upper Hydraulic Tank Overview
68.12. Oil Circulation Pump Overview
68.13. Isolator Tank Overview
68.14. Oil Cooler Plumbing Overview
68.15. Accumulator Overview
69. Hydraulic Crowd Sensor Locations
69.1. Cylinder Sensors
69.2. Power Module Sensors
69.3. Upper Hydraulic Tank Sensors
69.4. Pump Control Manifold Sensor
69.5. Auxiliary Power Unit Sensor
69.6. Oil Cooler Sensors
70. Inspection
70.1. PDT Leak Inspection
70.2. Circulation Plumbing Inspection
70.3. Oil Circulation Pump Inspection
70.4. Isolator Troubleshooting
70.5. Isolator Tank Inspection
70.6. Isolator Manifold Inspection
70.7. Vacuum Breaker Inspection
70.8. Isolator Plumbing Inspection
70.9. Accumulator Inspection
70.10. Accumulator Pressure Test Charge
71. Service Procedures
71.1. HydraCrowd Cylinder Bleeding Process
71.2. Hydraulic Crowd Start-Up Procedure
71.3. Standard System Flushing Filtration
71.4. Complete System Flushing Filtration
71.5. Initial System Oil Fill
71.6. System Top Off
71.7. System Oil Drain – Partial
71.8. System Oil Drain – Complete
71.9. Auxiliary Power Unit Fill Filter Replacement
71.10. PDT – Initial Oil Fill
71.11. PDT – Oil Top Off
71.12. PDT – Oil Level Check
71.13. PDT – Oil Drain
72. Hydraulic Crowd Cooler Cleaning
73. Hydraulic Crowd Oil Cooler – Drain
74. Hydraulic Crowd Oil Cooler Replacement
74.1. Purging The Main Pumps
74.2. Hydraulic System Prefill Filter Replacement
74.3. Upper Tank Return Filter Cleaning
74.4. Upper Tank Return Filter Replacement
74.5. Isolator Removal And Replacement
74.6. Isolator Draining
74.7. Circulation Filter Replacement
74.8. Hydraulic Hose Replacement
74.9. Main Pump Pressure Hose Replacement
74.10. CECV Smart Module Replacement
74.11. CECVR/CECVH Valve Replacement
74.12. RECV Smart Module Replacement
74.13. RECV Valve Replacement
74.14. RV3 Module Replacement
74.15. RV3 RV4 Relief Valve Replacement
75. Hydraulic Crowd Service Schedule
76. Schematics
77. Schematics
78. Side View
79. Deck Plan
80. OGL System A B Schematic
81. Grease System C Schematic
82. HVAC Schematic
83. Air Schematic
84. Hydraulic Crowd Troubleshooting Schematics
85. SM141473-EN-BrakesAndCouplings.pdf
85.1. Brakes and Couplings
85.2. Brakes
85.3. Couplings
86. SM141473-EN-PreventiveMaintenance.pdf
86.1. Preventive Maintenance
86.2. Introduction
86.3. Maintenance During Machine Operation
86.4. Preventive Maintenance for Lubrication
86.5. Frequency of Inspection and Maintenance
86.6. Maintenance Schedules
86.7. Hydraulic Crowd Service Schedule
86.8. HydraCrowd Health Monitoring Checks
86.9. Major Component Locations
87. SM141473-EN-BrakesAndCouplings.pdf
87.1. Brakes and Couplings
87.2. Brakes
87.3. Couplings

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Bucyrus 495HR2 Mining Shovel Service Manual BI624284

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