Bucyrus 495HF2 Mining Shovel Service Manual BI619866
Bucyrus 495HF2 Mining Shovel Service Manual BI619866 - Image 2
Bucyrus 495HF2 Mining Shovel Service Manual BI619866 - Image 3
Bucyrus 495HF2 Mining Shovel Service Manual BI619866 - Image 4
Bucyrus 495HF2 Mining Shovel Service Manual BI619866 - Image 5

Bucyrus 495HF2 Mining Shovel Service Manual BI619866

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: BI619866
  • Number of Pages: 761
  • Size: 35.8MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 495HF2 Mining Shovel
  • 1. General Precautions
  • 2. Maintenance Precautions
  • 3. Operating Precautions
  • 4. Fire Prevention
  • 5. Warning Signs And Decals
  • 6. Purpose
  • 7. Organization
  • 8. Terminology
  • 9. Revisions
  • 10. Precautions and Disclaimers
  • 11. Contact
  • 12. Swinging Restraint Ballast Box Support
  • 12.1. Ballast Box Support
  • 12.2. Swinging Restraint
  • 13. Machine Overview
  • 14. Lower Works
  • 14.1. Crawlers
  • 14.2. Truck Frame
  • 14.3. Swing Rack
  • 14.4. Roller Circle
  • 14.5. Propel Machinery
  • 14.6. Collector Rings
  • 14.7. Revolving Frame
  • 14.8. Center Pintle
  • 14.9. Deck Extensions
  • 14.10. Ballast Box
  • 14.11. Machinery House
  • 14.12. Boarding Stairs
  • 14.13. A-Frame
  • 14.14. Hoist Machinery
  • 14.15. Swing Machinery
  • 14.16. Crowd Machinery Overview
  • 14.17. Operators Cab
  • 14.18. Compressed Air System
  • 14.19. Automatic Lubrication System
  • 14.20. Lube Reservoir Fill / Overflow Plumbing
  • 15. Front End Equipment
  • 15.1. Suspension Strands
  • 15.2. Boom
  • 15.3. Running Ropes
  • 15.4. Saddle Block
  • 15.5. Dipper Handle – Hydraulic Crowd
  • 15.6. Dipper
  • 15.7. Padlocks
  • 15.8. Dipper Trip
  • 16. Typical Machine with HydraCrowd Specifications
  • 17. General Estimated Component Weights
  • 17.1. Lower Works
  • 17.2. Upper Works
  • 17.3. Front End
  • 18. Greasing Main A.C. Drive Motors
  • 18.1. Type of Grease
  • 18.2. Initial Commissioning
  • 18.3. Maintenance
  • 18.4. Regreasing Intervals
  • 19. Lubricant Selection
  • 20. Oil Fill Capacities
  • 20.1. Types Of Lubricants And Capacities Guidelines
  • 21. Automatic Lubrication System
  • 21.1. Lube Room
  • 21.2. Lube Reservoir Fill / Overflow Plumbing
  • 21.3. Lower Works Lubrication
  • 21.4. Propel Machinery Lubrication
  • 21.5. Revolving Frame Lubrication
  • 21.6. Hoist Machinery Lubrication
  • 21.7. Hoist Rope Rollers Lubrication
  • 21.8. Hydraulic Crowd Machinery Lubrication
  • 21.9. Pump Drive Transmission (PDT)
  • 21.10. Swing Machinery Lubrication
  • 21.11. Air Compressor Lubrication
  • 21.12. Front End Lubrication
  • 21.13. Lincoln Type SL-1 Lubricant Injectors
  • 21.14. Lincoln Type SL-V Lubricant Injectors
  • 21.15. ACSL – Air Compressor (Screw-Type) Lubricant
  • 22. Hydraulic Cleanliness
  • 22.1. Contamination Control
  • 22.2. Filters
  • 22.3. Moisture Removal
  • 22.4. MPO – Multipurpose OIL
  • 22.5. RWRL – Running Wire Rope Lubricant
  • 22.6. EGL – Enclosed Gearcase Lubricant
  • 22.7. MPG – Multipurpose Grease
  • 22.8. OGL – Open Gear Lubricant
  • 22.9. Certified Lubricants Listing
  • 22.10. Preventive Maintenance Program
  • 22.11. Elements of an Effective Maintenance Program
  • 22.12. Scheduled Preventive Maintenance Program
  • 22.13. General Safety Considerations
  • 23. Maintenance During Machine Operation
  • 23.1. Maintenance Precautions
  • 24. Preventive Maintenance for Lubrication
  • 24.1. Lubricant Cleanliness
  • 25. Frequency of Inspection and Maintenance
  • 25.1. Maintenance Inspection Check Points
  • 26. Hydraulic Crowd Service Schedule
  • 27. Major Component Locations
  • 27.1. Truck Frame Assembly
  • 27.2. Swing Rack Assembly
  • 27.3. Roller Circle Assembly
  • 27.4. Crawler Belts
  • 27.5. Crawler Side Frame Assembly
  • 27.6. Propel Assembly
  • 27.7. Propel Machinery
  • 27.8. Revolving Frame
  • 27.9. Center Pintle
  • 27.10. Collector Rings
  • 27.11. Swing Machinery
  • 27.12. Hoist Machinery
  • 28. Hoist Gear Start-Up Inspections
  • 28.1. Hoist Gear Replacement
  • 28.2. Bearing Removal
  • 28.3. Bearing Installation
  • 28.4. Hoist Oil Cooler
  • 28.5. Hoist Mounting Bolts
  • 28.6. Hoist Limit Switch
  • 28.7. Crowd Machinery Overview
  • 28.8. Operators Cab Mounting
  • 28.9. Operators Cab Isolator Mount Replacement
  • 28.10. Operators Seat Replacement
  • 28.11. Joystick Replacement
  • 28.12. Wiper Arm Replacement
  • 29. Machinery House
  • 29.1. Walkways, Stairways, and Handrails
  • 29.2. Boarding Stairs
  • 30. Front End Equipment
  • 30.1. Boom Assembly
  • 30.2. Boom Repair
  • 30.3. Boom Limit Switch Installation
  • 30.4. Boom Point Sheaves
  • 30.5. Boom Bumper
  • 30.6. Saddle Block
  • 30.7. Dipper Handle – Hydraulic Crowd
  • 30.8. LatchFreeTM Dipper Assembly
  • 30.9. A-Frame
  • 30.10. Auxiliary Winch
  • 30.11. Hoist Rope Support Roller
  • 30.12. Boom Support Ropes
  • 30.13. Wire Ropes
  • 30.14. Hoist Rope Reeving Replacement
  • 30.15. Dipper Trip Rope Reeving Replacement
  • 30.16. Hoist and Crowd Limit Systems
  • 30.17. Disc Brake Operation
  • 30.18. Maintenance
  • 30.19. Brake Adjustment Specifications
  • 30.20. Hoist Brake
  • 30.21. Propel Brake
  • 30.22. Swing Brake
  • 30.23. Spring Replacement All Brakes
  • 30.24. Friction Disc Replacement All Brakes
  • 30.25. O-Ring Replacement All Brakes
  • 30.26. Brake Wear Release Switches Single Disc Brakes
  • 30.27. Brake Wear Release Switches Multiple Disc Brakes
  • 31. Couplings
  • 31.1. Grid Couplings
  • 31.2. Gear Couplings
  • 31.3. Compressor Start-up Procedure
  • 31.4. Compressor Shutdown Procedure
  • 31.5. Compressor Fluid Level Check
  • 31.6. Recommended Lubrication Guide
  • 31.7. General Compressor Maintenance
  • 32. Auxiliary Air Dryer Assembly
  • 32.1. Lockout Valves
  • 33. Safety Warnings
  • 33.1. Lubrication
  • 33.2. Dynavane Air Cleaner
  • 33.3. Evaporator
  • 33.4. Condenser
  • 33.5. Pressurizer
  • 33.6. Specifications
  • 33.7. Bolt Tightening
  • 33.8. Linear Measurements
  • 33.9. Area Measurements
  • 33.10. Volume Measurements
  • 33.11. Torque Measurements
  • 34. Wire Locking Capscrews
  • 35. Torque Nut Installation
  • 35.1. Tightening Procedure for 1.25-Inch Torque Nut
  • 35.2. Tightening Procedure for 1.5-Inch Torque Nut
  • 35.3. Tightening Procedure for 2-Inch Torque Nut
  • 35.4. Tightening Procedure for 2-Inch Torque Nut
  • 35.5. Tightening Procedure for 3.5-Inch Torque Nut
  • 35.6. Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods
  • 35.7. Tightening Procedures – Expansion Bolts
  • 36. Torque Nut Removal Procedure
  • 36.1. Thread Lubrication
  • 37. Torque Nut Helpful Hints
  • 38. Locking Assemblies
  • 38.1. Locking Assembly Removal
  • 39. Open Gear Contact Check
  • 40. Open Gear Break-In
  • 41. Maintenance Welding
  • 41.1. Welding Electrodes
  • 41.2. Repair Welding of Cracks
  • 41.3. Repair Welding of Broken Parts
  • 41.4. Repair Welding Swing Rack Teeth
  • 41.5. Welding and Cutting Equipment
  • 41.6. Stress Relieving Temperature Measuring Equipment
  • 41.7. Storage
  • 41.8. Checking Diameter
  • 41.9. Handling Wire Rope
  • 41.10. Seizing Wire Rope
  • 41.11. End Preparations/Terminations
  • 41.12. Wire Rope Clips
  • 41.13. Inspection of Sheaves and Drums
  • 41.14. Breaking In a New Wire Rope
  • 41.15. Inspection Data
  • 41.16. Guideline to Inspections and Reports
  • 41.17. Seal Installation
  • 41.18. Gearcase Sealing
  • 42. Hydraulic System Oil Contamination Guide
  • 42.1. Crowd Machinery Overview
  • 43. Hydraulic Crowd Cylinder Overview
  • 44. Cylinder Control Manifold Overview
  • 45. Auxiliary Power Unit Overview
  • 46. Power Module/Lower Tank Overview
  • 47. Lower Tank, Crowd Motor, Transmission Pumps Overview
  • 48. Flushing/PDT Lube Motor Overview
  • 49. Circulation Filter Overview
  • 50. Manifolds Overview
  • 51. Oil Circulation Manifold Overview
  • 52. Pump Control Manifold Overview
  • 53. Upper Hydraulic Tank Overview
  • 54. Oil Circulation Pump Overview
  • 55. Isolator Tank Overview
  • 55.1. Oil Cooler Plumbing Overview
  • 56. Accumulator Overview
  • 57. Hydraulic Crowd Sensor Locations
  • 57.1. Cylinder Sensors
  • 57.2. Power Module Sensors
  • 57.3. Upper Hydraulic Tank Sensors
  • 57.4. Pump Control Manifold Sensor
  • 57.5. Auxiliary Power Unit Sensor
  • 57.6. Oil Cooler Sensors
  • 58. Inspection
  • 58.1. PDT Leak Inspection
  • 58.2. Circulation Plumbing Inspection
  • 58.3. Oil Circulation Pump Inspection
  • 59. Isolator Troubleshooting
  • 60. Isolator Tank Inspection
  • 61. Isolator Manifold Inspection
  • 62. Vacuum Breaker Inspection
  • 63. Isolator Plumbing Inspection
  • 64. Accumulator Inspection
  • 64.1. Intervals Between Checking Gas Precharge Pressure
  • 65. Accumulator Pressure Test Charge
  • 66. Service Procedures
  • 66.1. Hydraulic Crowd Start-up Procedure
  • 66.2. Standard System Flushing Filtration
  • 66.3. Complete System Flushing Filtration
  • 67. Initial System Oil Fill
  • 68. System Top Off
  • 69. System Oil Drain – Partial
  • 70. System Oil Drain – Complete
  • 71. Auxiliary Power Unit Fill Filter Replacement
  • 72. PDT – Initial Oil Fill
  • 73. PDT – Oil Top Off
  • 74. PDT – Oil Level Check
  • 75. PDT – Oil Drain
  • 76. Hydraulic Crowd Cooler Cleaning
  • 77. Hydraulic Crowd Oil Cooler – Drain
  • 78. Hydraulic Crowd Oil Cooler Replacement
  • 79. Purging The Main Pumps
  • 80. Hydraulic System Prefill Filter Replacement
  • 81. Upper Tank Return Filter Cleaning
  • 82. Upper Tank Return Filter Replacement
  • 83. Isolator Removal And Replacement
  • 84. Isolator Draining
  • 85. Circulation Filter Replacement
  • 86. Boom Saddle Block Pressure Hose Replacement
  • 87. Pressure Hose Positioning
  • 88. Boom Saddle Block Return Hose Replacement
  • 89. Return Hose Positioning
  • 90. Main Pump Pressure Hose Removal Installation
  • 91. CECV Smart Module Replacement
  • 92. CECVR/CECVH Valve Replacement
  • 93. RECV Smart Module Replacement
  • 94. RECV Valve Replacement
  • 95. RV3 Module Replacement
  • 96. RV3 RV4 Relief Valve Replacement
  • 97. Hydraulic Crowd Service Schedule
  • 98. Side View
  • 99. Deck Plan
  • 100. OGL System A B Schematic
  • 101. Grease System C Schematic
  • 102. HVAC Schematic
  • 103. Air Schematic
  • 104. SM141424-EN-ServiceProcedures.pdf
  • 104.1. Service Procedures
  • 104.2. Lower Works
  • 104.3. Rotating Deck
  • 104.4. Machinery House
  • 104.5. Front End Equipment
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