Bucyrus 495HF2 Mining Shovel Service Manual BI619865

Bucyrus 495HF2 Mining Shovel Service Manual BI619865 - Image 2

Bucyrus 495HF2 Mining Shovel Service Manual BI619865 - Image 3

Bucyrus 495HF2 Mining Shovel Service Manual BI619865

$30.00

Type Of Manual: Service Manual
Manual ID: BI619865
Number of Pages: 753
Size: 21.0MB
Format: PDF

Category: Bucyrus Service Manual PDF

Product details

Model List:
- 495HF2 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
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
17. Lubricant Replacement/Sampling
17.1. Lubricant Change Cycle
18. Automatic Lubrication System
18.1. Lube Room
18.2. Lube Reservoir Fill / Overflow Plumbing
18.3. Lower Works Lubrication
18.4. Revolving Frame Lubrication
18.5. Hoist Rope Rollers Lubrication
18.6. Front End Lubrication
18.7. Lincoln Type SL-V Lubricant Injectors
19. Propel Machinery Lubrication
20. Hoist Machinery Lubrication
20.1. Hoist Oil Cooler
20.2. Filter Element Cleaning
21. Swing Machinery Lubrication
22. Air Compressor 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
24.4. Air Compressor Lubricant
24.5. ACSL – Air Compressor (Screw-Type) Lubricant
24.6. RWRL – Running Wire Rope Lubricant
24.7. EGL – Enclosed Gearcase Lubricant
24.8. MPG – Multipurpose Grease
24.9. OGL – Open Gear Lubricant
25. Preventive Maintenance
26. Introduction
26.1. Preventive Maintenance Program
26.2. Elements of an Effective Maintenance Program
26.3. Scheduled Preventive Maintenance Program
26.4. General Safety Considerations
27. Maintenance During Machine Operation
27.1. Maintenance Precautions
28. Preventive Maintenance for Lubrication
28.1. Lubricant Cleanliness
29. Frequency of Inspection and Maintenance
30. Maintenance Schedules
30.1. Maintenance Inspection Check Points
31. Hydraulic Crowd Service Schedule
32. Major Component Locations
33. Service Procedures
34. Lower Works
34.1. Truck Frame Assembly
34.2. Swing Rack Assembly
34.3. Roller Circle Assembly
34.4. Crawler Belts
34.5. Crawler Side Frame Assembly
34.6. Propel Assembly
34.7. Propel Machinery
35. Rotating Deck
35.1. Revolving Frame
35.2. Center Pintle
35.3. Collector Rings
35.4. Swing Machinery
35.5. Hoist Machinery
35.6. Hoist Oil Cooler
35.7. Crowd Machinery Overview
35.8. Operators Cab Mounting
35.9. Operators Cab Isolator Mount Replacement
35.10. Operators Seat Replacement
35.11. Joystick Replacement
35.12. Wiper Arm Replacement
36. Machinery House
36.1. Walkways, Stairways, and Handrails
36.2. Boarding Stairs
37. Front End Equipment
37.1. Boom Assembly
37.2. Boom Limit Switch Installation
37.3. Boom Point Sheaves
37.4. Dipper Handle – Hydraulic Crowd
37.5. LatchFreeTM Dipper Assembly
37.6. A-Frame
37.7. Auxiliary Winch
37.8. Hoist Rope Support Roller
37.9. Boom Support Ropes
37.10. Wire Ropes
37.11. Hoist Rope Reeving Replacement
37.12. Dipper Trip Rope Reeving Replacement
37.13. Hoist and Crowd Limit Systems
38. Brakes and Couplings
39. Brakes
39.1. Disc Brake Operation
39.2. Maintenance
39.3. Brake Adjustment Specifications
39.4. Hoist Brake
39.5. Propel Brake
39.6. Swing Brake
39.7. Spring Replacement All Brakes
39.8. Friction Disc Replacement All Brakes
39.9. O-Ring Replacement All Brakes
39.10. Brake Wear Release Switches Single Disc Brakes
39.11. Brake Wear Release Switches Multiple Disc Brakes
40. Couplings
40.1. Grid Couplings
40.2. Gear Couplings
41. Compressed Air System
42. Air Compressor – Dual
42.1. Compressor Start-up Procedure
42.2. Compressor Shutdown Procedure
42.3. Compressor Fluid Level Check
42.4. Recommended Lubrication Guide
42.5. General Compressor Maintenance
42.6. Lockout Valves
43. Safety Warnings
44. Air Filtration
45. House Filter Fans
45.1. Lubrication
45.2. Dynavane Air Cleaner
46. Air Conditioner/Heater
46.1. Evaporator
46.2. Condenser
46.3. Pressurizer
46.4. Specifications
47. Engineering Data
48. Capscrew (Bolt) Grade
48.1. Bolt Tightening
49. Measurement Systems
49.1. Linear Measurements
49.2. Area Measurements
49.3. Volume Measurements
49.4. Torque Measurements
50. Wire Locking Capscrews
51. Torque Nut Installation
52. Expansion Bolt Installation
52.1. Tightening Procedure for 1.25-Inch Torque Nut
52.2. Tightening Procedure for 2-Inch Torque Nut
52.3. Tightening Procedure for 2-Inch Torque Nut
52.4. Tightening Procedure for 3.5-Inch Torque Nut
52.5. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
52.6. Tightening Procedures – Expansion Bolts
53. Torque Nut Removal Procedure
53.1. Thread Lubrication
54. Torque Nut Helpful Hints
55. Locking Assemblies
55.1. Locking Assembly Removal
56. Open Gear Contact Check
57. Open Gear Break-In
58. Maintenance Welding
58.1. Welding Electrodes
58.2. Repair Welding of Cracks
58.3. Repair Welding of Broken Parts
58.4. Repair Welding Swing Rack Teeth
58.5. Welding and Cutting Equipment
58.6. Stress Relieving Temperature Measuring Equipment
59. Wire Rope Care and Maintenance
59.1. Storage
59.2. Checking Diameter
59.3. Handling Wire Rope
59.4. Seizing Wire Rope
59.5. End Preparations/Terminations
59.6. Wire Rope Clips
59.7. Inspection of Sheaves and Drums
59.8. Breaking In a New Wire Rope
59.9. Inspection Data
59.10. Guideline to Inspections and Reports
60. Seals
60.1. Seal Installation
60.2. Gearcase Sealing
61. Hydraulic Crowd Service Procedures
62. Hydraulic System Cleanliness
63. Hydraulic System Oil Contamination Guide
63.1. Crowd Machinery Overview
64. Hydraulic Crowd Cylinder Overview
65. Cylinder Control Manifold Overview
66. Auxiliary Power Unit Overview
67. Power Module/Lower Tank Overview
68. Lower Tank, Crowd Motor, Transmission Pumps Overview
69. Flushing/PDT Lube Motor Overview
70. Circulation Filter Overview
71. Manifolds Overview
72. Oil Circulation Manifold Overview
73. Pump Control Manifold Overview
74. Upper Hydraulic Tank Overview
74.1. Oil Cooler Plumbing Overview
75. Isolator Tank Overview
75.1. Oil Cooler Plumbing Overview
76. Accumulator Overview
77. Hydraulic Crowd Sensor Locations
77.1. Cylinder Sensors
77.2. Power Module Sensors
77.3. Upper Hydraulic Tank Sensors
77.4. Pump Control Manifold Sensor
77.5. Auxiliary Power Unit Sensor
77.6. Oil Cooler Sensors
78. Inspection
78.1. PDT Leak Inspection
78.2. Circulation Plumbing Inspection
78.3. Oil Circulation Pump Inspection
79. Isolator Troubleshooting
80. Isolator Tank Inspection
81. Isolator Manifold Inspection
82. Vacuum Breaker Inspection
83. Isolator Plumbing Inspection
84. Accumulator Inspection
84.1. Intervals Between Checking Gas Precharge Pressure
85. Accumulator Pressure Test Charge
86. Service Procedures
86.1. Hydraulic Crowd Start-up Procedure
86.2. Standard System Flushing Filtration
86.3. Complete System Flushing Filtration
87. Initial System Oil Fill
88. System Top Off
89. System Oil Drain – Partial
90. System Oil Drain – Complete
91. Auxiliary Power Unit Fill Filter Replacement
92. PDT – Initial Oil Fill
93. PDT – Oil Top Off
94. PDT – Oil Level Check
95. PDT – Oil Drain
96. Hydraulic Crowd Cooler Cleaning
97. Hydraulic Crowd Oil Cooler – Drain
98. Hydraulic Crowd Oil Cooler Replacement
99. Purging The Main Pumps
100. Hydraulic System Prefill Filter Replacement
101. Upper Tank Return Filter Cleaning
102. Upper Tank Return Filter Replacement
103. Isolator Removal And Replacement
104. Isolator Draining
105. Circulation Filter Replacement
106. Boom Saddle Block Pressure Hose Replacement
107. Pressure Hose Positioning
108. Boom Saddle Block Return Hose Replacement
109. Return Hose Positioning
110. Main Pump Pressure Hose Removal Installation
111. CECV Smart Module Replacement
112. CECVR/CECVH Valve Replacement
113. RECV Smart Module Replacement
114. RECV Valve Replacement
115. RV3 Module Replacement
116. RV3 RV4 Relief Valve Replacement
117. Hydraulic Crowd Service Schedule
118. Schematics
119. Schematics
120. Side View
121. Deck Plan
122. OGL System A B Schematic
123. Grease System C Schematic
124. HVAC Schematic
125. Air Schematic

Rate this product

Bucyrus 495HF2 Mining Shovel Service Manual BI619865

Product details

Related products

Bucyrus 488D UN-A-TRAC Troubleshooting Guide BI000922

Bucyrus Compact Loader Service Manual BI014597

Bucyrus 1260-W Walking Dragline Mechanical Maintenance BI379366

Bucyrus 59HR Blast Hole Drill Electrical Service Manual BI380998 Vol 2

Bucyrus 495HF2 Mining Shovel Service Manual BI012486