Bucyrus 495HF Mining Shovel Service Manual BI624138
Bucyrus 495HF Mining Shovel Service Manual BI624138 - Image 2
Bucyrus 495HF Mining Shovel Service Manual BI624138 - Image 3
Bucyrus 495HF Mining Shovel Service Manual BI624138 - Image 4
Bucyrus 495HF Mining Shovel Service Manual BI624138 - Image 5

Bucyrus 495HF Mining Shovel Service Manual BI624138

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: BI624138
  • Number of Pages: 790
  • Size: 51.1MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 495HF 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
  • 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. Boarding Stairs
  • 9.7. A-Frame
  • 9.8. Hoist Machinery
  • 9.9. Swing Machinery
  • 10. Crowd Machinery Overview
  • 10.1. Operators Cab
  • 10.2. Compressed Air System
  • 10.3. Automatic Lubrication System
  • 10.4. 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
  • 20.5. Revolving Frame Lubrication
  • 20.6. Hoist Rope Rollers Lubrication
  • 20.7. Front End Lubrication
  • 20.8. Lubricant Injectors
  • 21. Propel Machinery Lubrication
  • 22. Hoist Machinery Lubrication
  • 22.1. Hoist Oil Cooler
  • 22.2. Filter Element Cleaning
  • 23. Swing Machinery Lubrication
  • 24. Air Compressor Lubrication
  • 25. Hydraulic Crowd Machinery Lubrication
  • 25.1. Pump Drive Transmission (PDT)
  • 25.2. Oil Pump
  • 26. Hydraulic Cleanliness
  • 26.1. Contamination Control
  • 26.2. Filters
  • 26.3. Moisture Removal
  • 26.4. ACSL – Air Compressor (Screw-Type) Lubricant
  • 26.5. RWRL – Running Wire Rope Lubricant
  • 26.6. EGL – Enclosed Gearcase Lubricant
  • 26.7. MPG – Multipurpose Grease
  • 26.8. 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. Propel Shaft Assembly
  • 37.7. Propel Machinery
  • 38. Rotating Deck
  • 38.1. Revolving Frame
  • 38.2. Center Pintle
  • 38.3. Collector Rings
  • 38.4. Swing Machinery
  • 38.5. Hoist Machinery
  • 38.6. Hoist Oil Cooler
  • 39. Crowd Machinery Overview
  • 39.1. Power Module/Lower Hydraulic Tank
  • 39.2. Main Pump Replacement
  • 39.3. PDT Removal
  • 39.4. Pump Timing Installation
  • 39.5. Crowd Motor Removal Installation
  • 39.6. Tuning Set-up Procedure
  • 39.7. Tachometer Removal Installation
  • 39.8. Boom Tube Removal Replacement
  • 39.9. Power Module Removal
  • 39.10. Expansion Joint Tightening Procedure
  • 39.11. Oil Circulation Pump Removal Replacement
  • 39.12. Flushing/PDT Lube Motor Disassembly Replacement
  • 40. Operators Cab Mounting
  • 41. Machinery House
  • 41.1. Walkways, Stairways, and Handrails
  • 41.2. Boarding Stairs
  • 41.3. Vertical Boarding Ladder, left
  • 42. Front End Equipment
  • 42.1. Boom Assembly
  • 42.2. Boom Limit Switch Installation
  • 42.3. Boom Point Sheaves
  • 42.4. Boom Bumper
  • 42.5. Saddle Block
  • 42.6. Dipper Handle – Hydraulic Crowd
  • 42.7. Dipper Assembly
  • 42.8. Dipper Trip Assembly
  • 42.9. A-Frame
  • 42.10. Auxiliary Winch
  • 42.11. Hoist Rope Support Roller
  • 42.12. Boom Support Ropes
  • 42.13. Wire Ropes
  • 42.14. Hoist Rope Reeving Replacement
  • 42.15. Dipper Trip Rope Reeving Replacement
  • 42.16. Hoist and Crowd Limit Systems
  • 43. Brakes and Couplings
  • 44. Brakes
  • 44.1. Disc Brake Operation
  • 44.2. Maintenance
  • 44.3. Brake Adjustment Specifications
  • 44.4. Hoist Brake
  • 44.5. Propel Brake
  • 44.6. Swing Brake
  • 44.7. Spring Replacement All Brakes
  • 44.8. Friction Disc Replacement All Brakes
  • 44.9. O-Ring Replacement All Brakes
  • 44.10. Brake Wear Release Switches Single Disc Brakes
  • 44.11. Brake Wear Release Switches Multiple Disc Brakes
  • 45. Couplings
  • 45.1. Grid Couplings
  • 45.2. Gear Couplings
  • 46. Compressed Air System
  • 47. Air Compressor – Dual
  • 47.1. Compressor Start-Up Procedure
  • 47.2. Compressor Shutdown Procedure
  • 47.3. Compressor Fluid Level Check
  • 48. Compressor Maintenance
  • 48.1. Fluid Fluid Filter Change Procedure
  • 48.2. Air Filter Maintenance
  • 48.3. Air/Fluid Separator Element Change
  • 48.4. Recommended Lubrication Guide
  • 49. Auxiliary Air Dryer Assembly
  • 50. In-line Prefilters
  • 51. Machinery House Hose Reels
  • 52. Additional Maintenance Requirements
  • 53. Lockout Valves
  • 54. Safety Warnings
  • 55. Air Filtration
  • 56. House Filter Fans
  • 56.1. Lubrication
  • 56.2. Dynavane Air Cleaner
  • 57. Air Conditioner
  • 57.1. Specifications
  • 58. Engineering Data
  • 59. Capscrew (Bolt) Grade
  • 59.1. Bolt Tightening
  • 60. Measurement Systems
  • 60.1. Linear Measurements
  • 60.2. Area Measurements
  • 60.3. Volume Measurements
  • 60.4. Torque Measurements
  • 60.5. Weight Measurements – Conventional
  • 61. Split Flange Assembly Procedure
  • 62. Wire Locking Capscrews
  • 63. Torque Nut Installation
  • 64. Expansion Bolt Installation
  • 64.1. Tightening Procedure for 1.25-Inch Torque Nut
  • 64.2. Tightening Procedure for 1.5-Inch Torque Nut
  • 64.3. Tightening Procedure for 2-Inch Torque Nut
  • 64.4. Tightening Procedure for 2-Inch Torque Nut
  • 64.5. Tightening Procedure for 3-Inch Torque Nut
  • 64.6. Procedure For Use Of Mechanical Tensioner On 3.0 Inch Crawler Rods
  • 64.7. Tightening Procedures – Expansion Bolts
  • 65. Torque Nut Removal Procedure
  • 65.1. Thread Lubrication
  • 66. Torque Nut Helpful Hints
  • 67. Locking Assemblies
  • 67.1. Installation, Series B115
  • 67.2. Removal, Series B115
  • 67.3. Locking Assembly Removal
  • 67.4. Removal from a Shaft
  • 67.5. Mounting a Pinion or Hub on a Shaft
  • 67.6. Pre-heat Advance Requirements – Pinions and Hubs
  • 67.7. Motor Coupling Pre-Heat Advance Requirements
  • 68. Open Gear Contact Check
  • 69. Open Gear Break-In
  • 70. Maintenance Welding
  • 70.1. Welding Electrodes
  • 70.2. Repair Welding of Cracks
  • 70.3. Repair Welding of Broken Parts
  • 70.4. Repair Welding Swing Rack Teeth
  • 70.5. Welding and Cutting Equipment
  • 70.6. Stress Relieving Temperature Measuring Equipment
  • 71. Wire Rope Care and Maintenance
  • 71.1. Storage
  • 71.2. Checking Diameter
  • 71.3. Handling Wire Rope
  • 71.4. Seizing Wire Rope
  • 71.5. End Preparations/Terminations
  • 71.6. Wire Rope Clips
  • 71.7. Inspection of Sheaves and Drums
  • 71.8. Breaking In a New Wire Rope
  • 71.9. Inspection Data
  • 71.10. Guideline to Inspections and Reports
  • 72. Seals
  • 72.1. Seal Installation
  • 72.2. Gearcase Sealing
  • 73. HydraCrowd Service Procedures
  • 74. Hydraulic System Cleanliness
  • 74.1. Hydraulic System Oil Contamination Guide
  • 75. Crowd Machinery Overview
  • 75.1. Hydraulic Crowd Cylinder Overview
  • 75.2. Cylinder Control Manifold Overview
  • 75.3. Auxiliary Power Unit Overview
  • 75.4. Power Module/Lower Tank Overview
  • 75.5. Lower Tank, Crowd Motor, Transmission Pumps Overview
  • 75.6. Flushing/PDT Lube Motor Overview
  • 75.7. Circulation Filter Overview
  • 75.8. Manifolds Overview
  • 75.9. Oil Circulation Manifold Overview
  • 75.10. Pump Control Manifold Overview
  • 75.11. Upper Hydraulic Tank Overview
  • 75.12. Oil Circulation Pump Overview
  • 75.13. Accumulator Overview
  • 75.14. Isolator Tank Overview
  • 75.15. Oil Cooler Plumbing Overview
  • 76. Hydraulic Crowd Sensor Locations
  • 76.1. Cylinder Sensors
  • 76.2. Power Module Sensors
  • 76.3. Upper Hydraulic Tank Sensors
  • 76.4. Pump Control Manifold Sensor
  • 76.5. Auxiliary Power Unit Sensor
  • 76.6. Oil Cooler Sensors
  • 77. Inspection
  • 77.1. PDT Leak Inspection
  • 77.2. Circulation Plumbing Inspection
  • 77.3. Oil Circulation Pump Inspection
  • 77.4. Isolator Troubleshooting
  • 77.5. Isolator Tank Inspection
  • 77.6. Isolator Manifold Inspection
  • 77.7. Vacuum Breaker Inspection
  • 77.8. Isolator Plumbing Inspection
  • 77.9. Accumulator Inspection
  • 77.10. Accumulator Pressure Test Charge
  • 78. Service Procedures
  • 78.1. HydraCrowd Cylinder Bleeding Process
  • 78.2. Hydraulic Crowd Start-Up Procedure
  • 78.3. Standard System Flushing Filtration
  • 78.4. Complete System Flushing Filtration
  • 78.5. Initial System Oil Fill
  • 78.6. System Top Off
  • 78.7. System Oil Drain – Partial
  • 78.8. System Oil Drain – Complete
  • 78.9. Auxiliary Power Unit Fill Filter Replacement
  • 78.10. PDT – Initial Oil Fill
  • 78.11. PDT – Oil Top Off
  • 78.12. PDT – Oil Level Check
  • 78.13. PDT – Oil Drain
  • 78.14. Purging The Main Pumps
  • 78.15. Hydraulic System Prefill Filter Replacement
  • 78.16. Upper Tank Return Filter Cleaning
  • 78.17. Upper Tank Return Filter Replacement
  • 78.18. Isolator Removal And Replacement
  • 78.19. Isolator Draining
  • 78.20. Circulation Filter Replacement
  • 78.21. Hydraulic Hose Replacement
  • 78.22. Main Pump Pressure Hose Replacement
  • 78.23. CECV Smart Module Replacement
  • 78.24. CECVR/CECVH Valve Replacement
  • 78.25. RECV Smart Module Replacement
  • 78.26. RECV Valve Replacement
  • 78.27. RV3 Module Replacement
  • 78.28. RV3 RV4 Relief Valve Replacement
  • 79. Hydraulic Crowd Service Schedule
  • 80. Hydraulic Crowd Symbol Definitions
  • 81. Schematics
  • 82. Schematics
  • 83. Side View
  • 84. Deck Plan
  • 85. OGL System A B Schematic
  • 86. Grease System C Schematic
  • 87. Air Schematic
  • 88. Hydraulic Crowd Troubleshooting Schematics
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