Bucyrus 495HF2 Mining Shovel Service Manual BI624134

Bucyrus 495HF2 Mining Shovel Service Manual BI624134 - Image 2

Bucyrus 495HF2 Mining Shovel Service Manual BI624134 - Image 3

Bucyrus 495HF2 Mining Shovel Service Manual BI624134

$30.00

Type Of Manual: Service Manual
Manual ID: BI624134
Number of Pages: 808
Size: 54.4MB
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. Fire Prevention
4.6. 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 HydraCrowd Typical
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. 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. Lower Works Lubrication
20.4. Revolving Frame Lubrication
20.5. Hoist Rope Rollers Lubrication
20.6. Front End Lubrication
20.7. 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
38.7. Crowd Machinery Overview
38.8. Power Module/Lower Hydraulic Tank
38.9. Main Pump Replacement
38.10. PDT Removal
38.11. Pump Timing Installation
38.12. Crowd Motor Removal Installation
38.13. Tuning Set-up Procedure
38.14. Tachometer Removal Installation
38.15. Boom Tube Removal Replacement
38.16. Power Module Removal
38.17. Expansion Joint Tightening Procedure
38.18. Oil Circulation Pump Removal Replacement
38.19. Flushing/PDT Lube Motor Disassembly Replacement
38.20. Operators Cab Mounting
38.21. Operators Seat Replacement
38.22. Joystick Replacement
38.23. Wiper Arm Replacement
38.24. Wiper Blade Replacement
38.25. 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
61. Pinion and Hub Installation
61.1. Removal from a Shaft
61.2. Mounting a Pinion or Hub on a Shaft
61.3. Pre-heat Advance Requirements – Pinions and Hubs
61.4. Motor Coupling Pre-Heat Advance Requirements
62. Open Gear Contact Check
63. Open Gear Break-In
64. Maintenance Welding
64.1. Welding Electrodes
64.2. Repair Welding of Cracks
64.3. Repair Welding of Broken Parts
64.4. Repair Welding Swing Rack Teeth
64.5. Welding and Cutting Equipment
64.6. Stress Relieving Temperature Measuring Equipment
65. Wire Rope Care and Maintenance
65.1. Storage
65.2. Checking Diameter
65.3. Handling Wire Rope
65.4. Seizing Wire Rope
65.5. End Preparations/Terminations
65.6. Wire Rope Clips
65.7. Inspection of Sheaves and Drums
65.8. Breaking In a New Wire Rope
65.9. Inspection Data
65.10. Guideline to Inspections and Reports
66. Seals
66.1. Seal Installation
66.2. Gearcase Sealing
67. Hydraulic Crowd Service Procedures
68. Hydraulic System Cleanliness
69. Hydraulic System Oil Contamination Guide
69.1. Crowd Machinery Overview
69.2. Hydraulic Crowd Cylinder Overview
69.3. Cylinder Control Manifold Overview
69.4. Auxiliary Power Unit Overview
69.5. Power Module/Lower Tank Overview
69.6. Lower Tank, Crowd Motor, Transmission Pumps Overview
69.7. Flushing/PDT Lube Motor Overview
69.8. Circulation Filter Overview
69.9. Manifolds Overview
69.10. Oil Circulation Manifold Overview
69.11. Pump Control Manifold Overview
69.12. Upper Hydraulic Tank Overview
70. Oil Circulation Pump Overview
70.1. Isolator Tank Overview
70.2. Oil Cooler Plumbing Overview
70.3. Accumulator Overview
71. Hydraulic Crowd Sensor Locations
71.1. Cylinder Sensors
71.2. Power Module Sensors
71.3. Upper Hydraulic Tank Sensors
71.4. Pump Control Manifold Sensor
71.5. Auxiliary Power Unit Sensor
71.6. Oil Cooler Sensors
72. Inspection
72.1. PDT Leak Inspection
72.2. Circulation Plumbing Inspection
72.3. Oil Circulation Pump Inspection
72.4. Isolator Troubleshooting
72.5. Isolator Tank Inspection
72.6. Isolator Manifold Inspection
72.7. Vacuum Breaker Inspection
72.8. Isolator Plumbing Inspection
72.9. Accumulator Inspection
72.10. Accumulator Pressure Test Charge
73. Service Procedures
73.1. HydraCrowd Cylinder Bleeding Process
73.2. Hydraulic Crowd Start-Up Procedure
73.3. Standard System Flushing Filtration
73.4. Complete System Flushing Filtration
73.5. Initial System Oil Fill
73.6. System Top Off
73.7. System Oil Drain – Partial
73.8. System Oil Drain – Complete
73.9. Auxiliary Power Unit Fill Filter Replacement
73.10. PDT – Initial Oil Fill
73.11. PDT – Oil Top Off
73.12. PDT – Oil Level Check
73.13. PDT – Oil Drain
74. Hydraulic Crowd Cooler Cleaning
75. Hydraulic Crowd Oil Cooler – Drain
76. Hydraulic Crowd Oil Cooler Replacement
76.1. Purging The Main Pumps
76.2. Hydraulic System Prefill Filter Replacement
76.3. Upper Tank Return Filter Cleaning
76.4. Upper Tank Return Filter Replacement
76.5. Isolator Removal And Replacement
76.6. Isolator Draining
76.7. Circulation Filter Replacement
76.8. Hydraulic Hose Replacement
76.9. Main Pump Pressure Hose Replacement
76.10. CECV Smart Module Replacement
76.11. CECVR/CECVH Valve Replacement
76.12. RECV Smart Module Replacement
76.13. RECV Valve Replacement
76.14. RV3 Module Replacement
76.15. RV3 RV4 Relief Valve Replacement
77. Hydraulic Crowd Service Schedule
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

Rate this product

Bucyrus 495HF2 Mining Shovel Service Manual BI624134

Product details

Related products

Bucyrus 45-R Blast Hole Drill Mechanical Maintenance Manual BI379559

Bucyrus 49RII Electric Blast Hole Drill Mechanical Maintenance Manual BI379332

Bucyrus 45-R Blast Hole Drill Mechanical Maintenance BI379433

Bucyrus Sroib Brakes For UN-A-TRAC Products Installation And Maintenance Manual BI000841

Bucyrus 49-R, 49-RH Electric Blast Hole Drill Mechanical Maintenance Manual BI379581