Bucyrus 495HF2 Mining Shovel Service Manual BI012486

Bucyrus 495HF2 Mining Shovel Service Manual BI012486 - Image 2

Bucyrus 495HF2 Mining Shovel Service Manual BI012486 - Image 3

Bucyrus 495HF2 Mining Shovel Service Manual BI012486

$30.00

Type Of Manual: Service Manual
Manual ID: BI012486
Number of Pages: 808
Size: 67.2MB
Format: PDF

Category: Bucyrus Service Manual PDF

Product details

Model List:
- 495HF2 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
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
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 OGL Reservoir
22.2. Hoist Oil Cooler
22.3. Filter Element Cleaning
23. Hydraulic Crowd Machinery Lubrication
23.1. Pump Drive Transmission (PDT)
23.2. Oil Pump
24. Swing Machinery Lubrication
25. Air Compressor Lubrication
25.1. ACSL – Air Compressor (Screw-Type) Lubricant
26. Hydraulic Cleanliness
26.1. Contamination Control
26.2. Filters
26.3. Moisture Removal
27. Lubricant Specifications
27.1. EGL – Enclosed Gearcase Lubricant
27.2. MPG – Multipurpose Grease
27.3. 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. 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
38.7. Crowd Machinery Overview
38.8. Operators Cab Mounting
38.9. Operators Seat Replacement
38.10. Joystick Replacement
38.11. Wiper Arm Replacement
38.12. Wiper Blade Replacement
38.13. 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 – Dual
45.1. Compressor Start-up Procedure
45.2. Compressor Shutdown Procedure
45.3. Compressor Fluid Level Check
45.4. Recommended Lubrication Guide
45.5. General Compressor Maintenance
46. Auxiliary Air Dryer Assembly
47. Lockout Valves
48. Safety Warnings
49. Air Filtration
50. House Filter Fans
50.1. Lubrication
50.2. Dynavane Air Cleaner
51. Air Conditioner/Heater
51.1. Evaporator
51.2. Condenser
51.3. Pressurizer
51.4. Specifications
52. Engineering Data
53. Capscrew (Bolt) Grade
53.1. Bolt Tightening
54. Measurement Systems
54.1. Linear Measurements
54.2. Area Measurements
54.3. Volume Measurements
54.4. Torque Measurements
54.5. Weight Measurements – Conventional
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 1.5-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 3.5-Inch Torque Nut
57.6. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
57.7. 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
60.2. Removal from a Shaft
60.3. Mounting a Pinion or Hub on a Shaft
60.4. Pre-heat Advance Requirements – Pinions and Hubs
60.5. Motor Coupling Pre-Heat Advance Requirements
61. Open Gear Contact Check
62. Open Gear Break-In
63. Maintenance Welding
63.1. Welding Electrodes
63.2. Repair Welding of Cracks
63.3. Repair Welding of Broken Parts
63.4. Repair Welding Swing Rack Teeth
63.5. Welding and Cutting Equipment
63.6. Stress Relieving Temperature Measuring Equipment
64. Wire Rope Care and Maintenance
64.1. Storage
64.2. Checking Diameter
64.3. Handling Wire Rope
64.4. Seizing Wire Rope
64.5. End Preparations/Terminations
64.6. Wire Rope Clips
64.7. Inspection of Sheaves and Drums
64.8. Breaking In a New Wire Rope
64.9. Inspection Data
64.10. Guideline to Inspections and Reports
65. Seals
65.1. Seal Installation
65.2. Gearcase Sealing
66. Hydraulic Crowd Service Procedures
67. Hydraulic System Cleanliness
68. Hydraulic System Oil Contamination Guide
69. Crowd Machinery Overview
69.1. Hydraulic Crowd Cylinder Overview
69.2. Cylinder Control Manifold Overview
69.3. Auxiliary Power Unit Overview
69.4. Power Module/Lower Tank Overview
69.5. Lower Tank, Crowd Motor, Transmission Pumps Overview
69.6. Flushing/PDT Lube Motor Overview
69.7. Circulation Filter Overview
69.8. Manifolds Overview
69.9. Oil Circulation Manifold Overview
69.10. Pump Control Manifold Overview
69.11. Upper Hydraulic Tank Overview
69.12. Oil Circulation Pump Overview
69.13. Isolator Tank Overview
69.14. Oil Cooler Plumbing Overview
69.15. Accumulator Overview
70. Hydraulic Crowd Sensor Locations
70.1. Cylinder Sensors
70.2. Power Module Sensors
70.3. Upper Hydraulic Tank Sensors
70.4. Pump Control Manifold Sensor
70.5. Auxiliary Power Unit Sensor
70.6. Oil Cooler Sensors
71. Inspection
71.1. PDT Leak Inspection
71.2. Circulation Plumbing Inspection
71.3. Oil Circulation Pump Inspection
71.4. Isolator Troubleshooting
71.5. Isolator Tank Inspection
71.6. Isolator Manifold Inspection
71.7. Vacuum Breaker Inspection
71.8. Isolator Plumbing Inspection
71.9. Accumulator Inspection
71.10. Accumulator Pressure Test Charge
72. Service Procedures
72.1. HydraCrowd Cylinder Bleeding Process
72.2. Hydraulic Crowd Start-Up Procedure
72.3. Standard System Flushing Filtration
72.4. Complete System Flushing Filtration
72.5. Initial System Oil Fill
72.6. System Top Off
72.7. System Oil Drain – Partial
72.8. System Oil Drain – Complete
72.9. Auxiliary Power Unit Fill Filter Replacement
72.10. PDT – Initial Oil Fill
72.11. PDT – Oil Top Off
72.12. PDT – Oil Level Check
72.13. PDT – Oil Drain
73. Hydraulic Crowd Cooler Cleaning
74. Hydraulic Crowd Oil Cooler – Drain
75. Hydraulic Crowd Oil Cooler Replacement
75.1. Purging The Main Pumps
75.2. Hydraulic System Prefill Filter Replacement
75.3. Upper Tank Return Filter Cleaning
75.4. Upper Tank Return Filter Replacement
75.5. Isolator Removal And Replacement
75.6. Isolator Draining
75.7. Circulation Filter Replacement
75.8. Hydraulic Hose Replacement
75.9. Main Pump Pressure Hose Replacement
75.10. CECV Smart Module Replacement
75.11. CECVR/CECVH Valve Replacement
75.12. RECV Smart Module Replacement
75.13. RECV Valve Replacement
75.14. RV3 Module Replacement
75.15. RV3 RV4 Relief Valve Replacement
76. Hydraulic Crowd Service Schedule
77. Schematics
78. Schematics
79. Side View
80. Deck Plan
81. OGL System A B Schematic
82. Grease System C Schematic
83. HVAC Schematic
84. Air Schematic
85. Hydraulic Crowd Troubleshooting Schematics

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Bucyrus 495HF2 Mining Shovel Service Manual BI012486

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