Cat Electric Rope Shovel 495HD Mining Shovel Maintenance & Operation Manual - PDF DOWNLOAD

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BUCYRUS R

495HD

MINING SHOVEL

MAINTENANCE and OPERATION MANUAL SN: 141233

Manual No. 10500

BUCYRUS

495HD

141233mc.cdr Pg.

1

ac utrol

141233cl

Bucyrus International, Inc. 2007 Manual No. 10500 1100Aug. Milwaukee Ave. • P.O.Box 500 • South Milwaukee, Wisconsin 53172-0500 USA

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

Aug. 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

495HD Mining Shovel Maintenance and Operation Manual Manual No. 10500 sn: 141233 Lot 81

–Table of Contents– This manual is divided into major sections covering the various serviceable components and systems of the 495HR Mining Shovel. These sections and their contents are organized as shown below.

Section 1 - INTRODUCTION Section 2 - OPERATION Section 3 - LUBRICATION Section 4 - PREVENTIVE MAINTENANCE Section 5 - SERVICE PROCEDURES Section 6 - BRAKES AND COUPLINGS Section 7 - COMPRESSED AIR SYSTEM Section 8 - AIR FILTRATION Section 9 - ENGINEERING DATA

IMPORTANT NOTE This document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability.

© 2007 August 2007

Bucyrus International, Inc. All Rights Reserved.

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DANGER: THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/ OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.

DANGER: DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY. The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.

THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between the machine and the ground. The portable trail cable and power lines supplying electric energy to the machine must have a ground wire, ample in capacity, running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult your local electrical supplier for details.

DANGER: DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.

August 2007

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

1

Introduction Always refer to the safety information in this section of this manual before starting any maintenance procedure on this machine.

Table of Contents GENERAL INFORMATION ............................................................................................................ 3 SAFETY .................................................................................................................................. 4 SAFETY - SWINGING RESTRAINT & BALLAST BOX SUPPORT ......................................... 5 BALLAST BOX SUPPORT ................................................................................................ 5 SWINGING RESTRAINT ................................................................................................... 6 SAFETY PRECAUTIONS ........................................................................................................ 8 FIRE PREVENTION .............................................................................................................. 11 Fire Extinguisher Locations .............................................................................................. 11

MACHINE PLACARDS .......................................................................................................... 12 Safety & Stored Energy Decals ........................................................................................ 13

MACHINE OVERVIEW ................................................................................................................ 14 LOWER WORKS ....................................................................................................................... 15 Truck Frame and Crawlers ................................................................................................ 15

CRAWLERS .......................................................................................................................... 16 Crawler & Truck Frame Section View ................................................................................ 17

TRUCK FRAME .................................................................................................................... 17 SWING RACK ....................................................................................................................... 18 Swing Rack and Roller Circle ........................................................................................... 18

ROLLER CIRCLE ................................................................................................................. 18 Roller Circle Assembly ..................................................................................................... 19

PROPEL MACHINERY .......................................................................................................... 20 COLLECTOR RINGS ............................................................................................................ 21 ROTATING DECK ....................................................................................................................... 21 REVOLVING FRAME ............................................................................................................. 22 CENTER PINTLE .................................................................................................................. 22 DECK EXTENSIONS ............................................................................................................ 23 Deck Extensions and Ballast Box - Plan View .................................................................. 23

BALLAST BOX ...................................................................................................................... 23 MACHINERY HOUSE ............................................................................................................ 23 A-FRAME............................................................................................................................... 25 A- Frame and Front End Support Components ................................................................. 25

HOIST MACHINERY .............................................................................................................. 26 Hoist Machinery - Plan View ............................................................................................. 26

SWING MACHINERY ............................................................................................................. 27 Swing Machinery Components .......................................................................................... 27

August 2007

1-1

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD MACHINERY .......................................................................................................... 28 Crowd Machinery Components .......................................................................................... 28

OPERATOR’S CAB .............................................................................................................. 29 COMPRESSED AIR SYSTEM .............................................................................................. 30 AUTOMATIC LUBRICATION SYSTEM .................................................................................. 30 Lubrication Room ............................................................................................................. 31

FRONT END EQUIPMENT ......................................................................................................... 32 SUSPENSION STRANDS ..................................................................................................... 32 BOOM ................................................................................................................................... 33 Boom Assembly ............................................................................................................... 33

RUNNING ROPES ................................................................................................................ 34 Ropes - General Arrangement .......................................................................................... 34

SADDLE BLOCK .................................................................................................................. 35 DIPPER HANDLE ................................................................................................................. 35 DIPPER ................................................................................................................................. 36 Dipper Assembly .............................................................................................................. 36

PADLOCK ............................................................................................................................. 37 DIPPER TRIP ........................................................................................................................ 37 Dipper Trip - General Arrangement .................................................................................... 37

TYPICAL MACHINE SPECIFICATIONS ....................................................................................... 38 WEIGHTS .............................................................................................................................. 38 GENERAL ESTIMATED COMPONENT WEIGHTS .................................................................... 40

495HD COLOR DECK PLAN ....................................................................................... ( foldout )

Manual No. 10500

1-2

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

1

Introduction

GENERAL INFORMATION This manual is designed to assist the owner in the operation and preventive maintenance of this machine. By following easy to understand step-by-step procedures the operators and maintenance personnel can perform all tasks in a safe manner. It is important to remember that when a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.

THIS MANUAL IS NOT THE PARTS BOOK and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by group and/or product code numbers with the associated item/part numbers for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed. RIGHT and LEFT refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab. Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments. Records on each machine are filed by serial number and when given this number, your machine’s specific design and original equipment is accessed quickly by the Bucyrus International parts representative.

Periodic additions or revisions may be made to this manual. These can be ordered and will be mailed direct to you from the factory. Should you require additional information or factory service assistance contact your regional service representative or: Bucyrus International, Inc. 1100 Milwaukee Avenue P.O. Box 500 South Milwaukee, Wisconsin 53172-0500, USA Telephone (414)-768-4000 Fax: (414) 768-4210 It is Bucyrus International’s policy to improve its products whenever possible and practical to do so.

The company reserves the right to make changes or add improvements to it’s machines at any time. This will be without incurred obligation to install such changes on machines sold previously.

Due to this ongoing program of product research and development, some procedures, specifications and parts may be altered in a constant effort to improve our machines.

August 2007

1-3

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SAFETY The safety alert symbols displayed here and throughout this manual, are used to call your attention to instructions concerning your personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine.

Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions.

In the event you question your ability to safely perform any of the enclosed maintenance and operational procedures, contact your regional Bucyrus service representative or the factory.

The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.

NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken.

CAUTION:

This signal word serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to.

DANGER:

This signal word denotes an imminently dangerous hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

DANGER:

This signal word denotes an imminently dangerous electrical hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit and free from the influence of alcohol, drugs, or any medications that might impair his eyesight, hearing or reactions.

CAUTION:

STORED ENERGY! Components on machine are heavy and removal of pins without proper preparation and precaution can cause serious bodily injury and/or damage to the front-end of the machine.

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

Manual No. 10500

1-4

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SAFETY - SWINGING RESTRAINT & BALLAST BOX SUPPORT

BALLAST BOX SUPPORT Before performing any maintenance on the mining shovel, it should be resting on a firm, level surface.

Any mining shovel field work that requires the removal or lowering of the boom must incorporate additional support of the ballast box. The supports may be wooden cribbing or steel structures. Two supports positioned side-by-side on level ground are recommended. These supports are intended to accept vertical loads only. To prevent machine rotation use the swing brakes, cable stays, welded ties, etc. Refer to “SWING RESTRAINT” below.

When electric-powered, cable-style mining shovels are properly ballasted and operational, the center of gravity for the machine's upper works lies within the roller circle area. This assumes that the boom is attached to the machine and in its elevated, working position. As such, the machine should not be prone to tipping.

Boom removal or lowering will cause the center of gravity to shift toward the ballast box, decreasing machine stability. Stability is further dependent on the orientation of the upper works relative to the undercarriage. The machine may tip more easily over one of the four quadrants of the crawler mounting than it may over others.

Normally the machine is more likely to tip over the rear-most lower-roller than over the side of a crawler. Therefore, with the boom removed and the ballast box sitting over the rear of the crawlers, the machine may be unstable. Because ballast quantities differ from machine to machine and model to model, it is recommended that the ballast box be supported before beginning any procedure to lower and/or remove the boom.

August 2007

1-5

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWINGING RESTRAINT Before performing any maintenance on the mining shovel, it should be resting on a firm, level surface. A small ground slope is enough to cause the machine to freely rotate if the brakes are not set or other restraints are not used. Once moving, it will keep going.

The following shows the relation between an out-of-level or slope and the resulting difference in elevation over a 14 ft. swing rack:

Slope

%

Difference in Elevation

0.25o

0.4%

0.75”

1.0o

1.7%

2.9”

5.0o

8.7%

14.7”

Where possible, all work on the swing brakes, motors, gearcases, or rack pinions should occur with the dipper attached to the machine and the full weight of the dipper on the ground. If the dipper is not resting firmly on the ground, then an external means of preventing machine upper works rotation is required. Tie the upper works to the lower works using the preferred method mentioned below.

Mining shovels rotate using multiple swing units. Power is transferred from electric motors through individual gearcases, to pinions and into a fixed swing rack. Electric motor control prevents inadvertent machine rotation during operation. Should machine electric power be lost, spring-set brakes on the swing drive motors lock the geartrain to prevent machine rotation.

When working on the brakes, motors, or geartrains, it is an accepted practice to set the dipper on the ground. The weight of the dipper and handle will prevent machine rotation. EVEN IF ALL BRAKES, MOTORS, OR SWING GEARCASES ARE REMOVED the machine should not rotate.

In certain circumstances it may not be possible to rest the full weight of the dipper firmly on the ground. For instance, the dipper, handle or the boom may not be attached to the machine.

To prevent machine rotation, with any of the major structures removed, two swing motor brakes should be set. A single brake in good operational condition is acceptable. However, a minimum of two brakes is recommended due to the possibility that the proper operation of a single brake may be unknown.

Caution:

Manual No. 10500

ON MACHINES USING PLANETARY DUAL-OUTPUT SWING DRIVES, BOTH SWING PINIONS PER DRIVE MUST BE ENGAGED WITH THE SWING RACK IN ORDER FOR THE SWING BRAKE TO BE EFFECTIVE. The internal differential drive in the gearcase allows one pinion to rotate, even if the brake is set, when the other pinion has been removed.

1-6

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

An external means of preventing machine rotation must be used - if the dipper is not resting firmly on the ground and if any of the following are true: •

Two brakes are not effectively set and coupled to the motors, or

•

The motors and geartrain are not fully coupled to the swing pinions, or

•

The swing pinions are not engaged to the swing rack

The preferred method to prevent machine rotation is to use a pair of one inch diameter steel cables to tie the upper works to the lower works. Other alternatives such as welded plates etc. can also be used.

To use the steel cables, attach one end of each cable to the bottom surface of the revolving frame.

Attach the other end of each cable to the top surface of the truck frame. This arrangement will prevent relative motion between the revolving frame and the truck frame. Installation of these cable restraints should become a part of the lockout procedure if conditions so warrant.

For typical part numbers and locating dimensions, refer to Bucyrus drawing E021447

August 2007

1-7

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SAFETY PRECAUTIONS

General Precautions: • The employment of qualified maintenance personnel, through a scheduled maintenance program, is the best way to minimize machine downtime and maximize productivity of equipment.

• Keep hands, feet and clothing away from rotating parts.

• Wear a hard hat, safety shoes and protective lenses at all times.

• Replace any and all safety and warning placards if they are defaced or removed from the machine.

• Think before you act. Carelessness is one luxury the service man cannot afford.

• Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested method of cleanup.

• Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip off of the hook if they are not functioning properly.

• If a heavy item begins to fall, let it fall, don’t try to catch it.

• Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.

• Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure all spillage is cleaned up.

• Electrical cords and wet metal floors make a dangerous combination.

• Regularly inspect for any loose bolts or locking devices and properly secure them.

• Use extreme caution while working near any electrical lines or equipment whether it be high or low voltage. Never attempt electrical repairs unless you are qualified.

• Check limit switches for proper operation.

• After servicing, be sure all tools, parts or servicing equipment are removed from the machine and secured in an appropriate storage area.

• Mechanical Brakes are designed for use as static holding brakes only. Use as a motion (dynamic) brake in emergency situations only.

• Use proper interior and exterior lighting.

• Install and maintain proper grounding and ground fault protection systems.

• Allow electrical inspection and maintenance to be performed only by a qualified electrician.

Manual No. 10500

1-8

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Maintenance Precautions: • Do not wear rings, wristwatches or loose fitting clothing when working on machinery. They could get caught on moving parts causing serious injury.

• Always wear a safety belt or harness when the danger of falling exists.

• Always have a second person to monitor the lifeline when working in confined spaces.

• Do not start an engine indoors unless adequate exhaust ventilators are provided and in operation.

• Never utilize the machine air or hydraulic systems for support when working on the machine.

Deactivate or isolate the entire system prior to performing maintenance.

• Equipment should be parked on level ground at all times during machine servicing and periods of idleness.

• Cranes and hoists must be of sufficient capacity to lift the heavier components. Always work within the limitations of the equipment being utilized.

• Be sure heavy items are properly rigged and supported from cranes or hoists before removing supporting members from the machine.

• Utilize guide lines or ropes to minimize the swing of suspended heavy components.

• Have sufficient service personnel available when removing or installing large heavy items to maintain control at all times.

• Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load, they could fail.

• When disassembling a machine, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.

• When using an oxy/acetylene torch, always wear welding goggles and gloves. Keep a charged fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart.

• Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Always be sure to wear safety glasses.

• Use extreme caution when using compressed air to dry parts. Use approved air blowguns, do not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding to protect everyone in the work area.

• Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

• Protective eye goggles should be worn at all times when working on the air conditioning system.

Work on the air conditioning system only in a well ventilated area.

• Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.

• Always wear approved rubber gloves and use insulated hooks or tongs when handling trail cable.

August 2007

1-9

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Operating Precautions: • Wear hearing protection when exposed to the following noise levels in excess of the period indicated: 8 hours at 90 dBa 4 hours at 95 dBa 2 hours at 100 dBa 1 hour at 105 dBa 30 minutes at 110 dBa 15 minutes at 115 dBa • When in doubt about the noise level, wear approved hearing protection.

• Do not attempt to get on or off the machine while it is in operation. Notify the operator prior to any attempt to board/exit the machine.

• Do not move or operate the machine without first knowing the location and purpose of all personnel, test or support equipment, on or near the machine.

• Do not allow unauthorized personnel on board the machine while in operation.

• Use audible signals to warn of machine movements. A signal horn button is provided for this purpose.

• Do not propel until the travel route has been cleared of obstructions.

• Do not propel the machine on a slope greater than that specified in SLOPE LIMITATIONS in Section 2 ~ OPERATION. • Prevent trail cable from being dragged on the ground for long distances or at high speeds.

• Limit the amount of cable being pulled by the machine. Pulling too much cable will damage both the cable and the machine.

Manual No. 10500

1 - 10

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

FIRE PREVENTION •

Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate.

•

DO NOT smoke while handling flammables or when near batteries.

•

Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque. See Chapter 4 of this manual for the Scheduled Maintenance recommendations and the Daily Inspection procedure.

Fire Extinguisher Locations

•

Repair or replace loose or damaged lines, tubes and hoses as soon as possible.

•

Make certain all clamps, guards and shields are replaced correctly so as to prevent vibration and the chafing of parts during operation.

•

DO NOT carry flammable fluids such as gasoline or solvents on board the machine.

•

DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged lines, tubes, or hoses. Replace them immediately.

•

DO NOT start the machine or move any of the controls if a warning tag is attached to the controls or the start panel.

•

Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.

•

Keep all structural frame compartments, walkways and work areas clean and free of lubricant residue.

•

NEVER weld, burn, or perform service on the machine alone.

•

If a motor or other component is running hot, shut down the machine until it has cooled and the cause is determined and repaired.

August 2007

1 - 11

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MACHINE PLACARDS The placards depicted below are mounted on your machine as delivered from Bucyrus International, Inc. These hazard warning placards convey information to operators, maintenance personnel, or anyone who will be on or near the machine. The information is designed to help prevent situations which may result in injury to personnel or damage to the machine.

Manual No. 10500

1 - 12

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Safety & Stored Energy Decals

August 2007

1 - 13

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MACHINE OVERVIEW The 495HD Electric Mining Shovel is designed and constructed to provide efficient service under the most severe conditions. The machine is built to the highest possible standards and will provide trouble free operation if properly maintained. This section of the manual introduces the machine and its functional capabilities/limitations.

Crowd Half Crowd Rope Sheave Adjusting Mechanism Suspension Strands

Electrical Control Room Filter House Filters

Crowd Rope Hydraulic Adjusting Unit Equalizers A-Frame Air Conditioner Operator’s Dipper Trip Cab Machinery

Machinery House Electrical Control Room

Boom Point Sheaves Boom

BUCYRUS

Saddle Block Dipper Handle Retract Rope

Shipper Shaft

495HD ac utrol

Boom Bumper

Crawler Assembly

Take-Up Cylinders Hoist Ropes Pitch Brace

Crowd Dipper Machinery Trip Swing Rack Rope

Padlocks Dipper

Dipper Door Boarding Stair

Manual No. 10500

141233nm

1 - 14

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LOWER WORKS The lower works is comprised of the truck frame, right and left crawler frames, crawler belts, propel machinery, swing rack, roller circle and collector ring system.

Truck Frame and Crawlers

August 2007

1 - 15

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CRAWLERS The machine is provided with a crawler type mounting composed of two belts, one on each side of the truck frame. Each belt consists of links driven by a sprocket type drive tumbler. Individual crawler links are heavy alloy steel castings connected by heat treated pins.

Innovative drive tumblers made from large diameter steel castings have lugs extending beyond the tumbler rims. They are mounted on forged alloy steel shafts which turn on large anti-friction bearings mounted within the crawler frame. The sprocket type lugs provide a large area of contact against the crawler links, extending the life of both links and tumblers.

Upper and lower rollers rotate on forged steel shafts cantilever mounted from the crawler side frames for ease of maintenance and inspection. Four (4) 55" (1.39m) diameter lower rollers per frame are specially suited to withstand the periodic single point ground reaction caused by uneven pit floors. Teepee style dirt deflectors combined with vee-ring face seals prevent dirt entry into lower roller bushings. Five upper rollers on each frame support the upper crawler belt, reducing propel friction and drag. These side frames are stress relieved weldments comprised of steel castings and cold weather steel plates.

The hook surface on the inner lower edge of the crawler frame engages a rail on the bottom of the truck frame. Both parts are factory machined to ensure solid contact.

Manual No. 10500

1 - 16

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Cast take-up tumblers are mounted on each end of the take-up axle. These tumblers are fitted with manganese-bronze bushings protected by a sealed hubcap. A vee-ring face seal protects the take-up bushing from dirt contamination.

A square take-up axle fits into rectangular slots in the crawler frame which permits the axle to be moved forward and backward for belt adjustment. Shims are inserted fore and aft of the axle in these slots to position, tension and locate the tumbler and crawler belt.

Crawler & Truck Frame Section View

TRUCK FRAME The truck frame is a stress relieved welded cellular box structure which utilizes impact resistant steel in the major load carrying members. The low temperature toughness of the steel assures adequate strength and durability across a wide range of temperatures frequently encountered in machine applications. A fabricated support structure welded integrally into the truck frame supports the center pintle hub area.

The inner diameter of the hub is machined to accept the center pintle bushing. Truck frame surfaces which mate to crawler side frames and swing rack are shop machined to assure proper alignment and solid foundation.

August 2007

1 - 17

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING RACK The swing rack is a large diameter external tooth gear mounted on the top of the truck frame concentric with the center pintle bore. The rack is constructed of a one-piece forged steel rim welded to a cast support core and welded to the truck frame during erection.

Swing Rack and Roller Circle

ROLLER CIRCLE The roller circle is comprised of upper and lower rails, 56 tapered rollers and inner/outer roller frames. Lower rail segments are secured to the top surface of the swing rack forming a continuous rolling path for the rollers. Upper rails attach to the bottom of the revolving frame, fore and aft of the center pintle. Upper rail ends are tapered to provide a smooth approach for the rollers. Rollers are tapered to ensure non-skid contact with rails. The rollers are spaced and aligned with pins and low maintenance polyurethane bushings.

Manual No. 10500

1 - 18

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Roller Circle Assembly

August 2007

1 - 19

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PROPEL MACHINERY The propel machinery is driven by two AC motors, each horizontally mounted to a shelf, cantilevered off the truck frame. The motors are coupled to twin planetary gearcases high up off the pit floor for protection from water and rock damage. The planetary gearcases bolt to the crawler frames. One low inertia, spring-set, air-released, disc-type air brake is mounted to each of the two motors. The dual planetary configuration with separate drive motors permits straight ahead or reverse propel as well as counter rotation steering.

Manual No. 10500

1 - 20

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

COLLECTOR RINGS High voltage collector rings, on bottom of the revolving frame, transfer electric power from the truck frame to the rotating deck. Electric power enters the truck frame just below the propel motor and is transferred by means of collector ring shoes to the collector rings. The shoes are mounted between the cast center pintle hub and the swing rack.

ROTATING DECK The rotating deck consists of revolving frame, center pintle, right and left deck extensions, operator’s cab and the machinery house. Also included are the electrical system components, operating controls, air system, A-frame, along with the hoist, swing and crowd machinery units.

August 2007

1 - 21

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

REVOLVING FRAME The revolving frame is the main structural member of the rotating deck. It is a welded, stress relieved structure with integral lugs for mounting the A-frame, crowd machinery and boom. Provisions are made for mounting deck extensions, operator’s cab, ballast box and swing gearcases. Machined pads on the deck locate hoist drive motor and machinery frames. The revolving frame is connected to the truck frame by the center pintle.

CENTER PINTLE

The center pintle is a large diameter, hollow cylindrical forging and threaded at the bottom. A bronze coated steel core spherical thrust washer between the lower retaining nut with dual lockbars, and the bottom surface of the truck frame provides a wear surface for pintle loads. The top of the center pintle is doweled and bolted to the revolving frame using a clamping collar.

The hollow pintle provides passage for air and grease lines and electrical cables from the revolving frame to the lower works. This is done by means of a swivel and collector ring assembly,.

Manual No. 10500

1 - 22

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DECK EXTENSIONS Right and left side deck extensions are bolted to each side of the revolving frame. They provide a mounting area for the electrical transformers and accessory machinery as well as supporting the machinery house walls.

Deck Extensions and Ballast Box - Plan View

BALLAST BOX The ballast box is an all-welded steel fabrication located at the rear of the main revolving frame. A series of vertical plates in the box form compartments for holding ballast.

MACHINERY HOUSE The machinery house encloses the revolving frame, ballast box and deck extensions. It is constructed of self-supporting steel panels with built-in framing. Removable roof sections are provided over the swing machinery and to the side and rear of the A-frame. The house also provides mounting for the air ventilation and pressurization system. A separate electrical room is located over the ballast box. Platforms and stairs facilitate access to the sides and tops of the house for inspection and maintenance purposes.

August 2007

1 - 23

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

A set of boarding stairs is attached to the machinery house platform - either on the left side of the machine, the right side or both. When lowered, the stairs allow entrance to the machinery house from ground level. To activate the stairs, a chord attached to a lever arm is reachable from the ground. An additional lever is available at the top of the stairs. These stairs must be in their raised and latched position to enable the operator’s controls.

DANGER:

STORED ENERGY! System may be under hydraulic pressure which can cause severe personal injury or death. Shut down pump and relieve system of all pressure before removing components.

The boarding stairs pivot about a pivot shaft attached to the boarding platform. A set of counterweights offsets the weight of the stairs. A self-contained hydraulic system, with an accumulator and cylinder, operates the stairs.

Manual No. 10500

1 - 24

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

A-FRAME An A-frame with seamless tubular alloy steel front legs provides ample space for the retracted dipper handle end. The rear legs are cold weather steel fabricated beams. Both front and rear legs are pin connected to lugs integral with the revolving frame. The A-frame supports the boom via structural strands.

A- Frame and Front End Support Components

August 2007

1 - 25

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST MACHINERY The hoist machinery consists of a motor coupled to two gear reductions which drive the hoist drum. A spring set, air released plate disc type brake is mounted to the motor. A hoist rotary encoder limits hoist travel. The hoist motor is connected to the motor pinion shaft by a gear tooth coupling.

The first reduction gear set is mounted in an oil lubricated, totally enclosed gearcase. The second reduction gears are drip lubricated with open gear lubricant from the automatic lubrication system.

All shafts run on anti-friction bearings. The hoist bull gear is bolted to a spider on the left hand side of the drum.

The hoist drum is manufactured with machined, flame hardened rope grooves. Drum spider stub shafts turn on an anti-friction bearings supported by side frames which are bolted to the rotating deck.

Hoist Machinery - Plan View

Manual No. 10500

1 - 26

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING MACHINERY Two planetary swing gearboxes, each driven by a vertically mounted motor, are mounted on either side of the revolving frame. Dual output shafts from each gearbox are splined to pinions which engage the swing rack.

Swing Machinery Components

Bolt-on mounting permits easy field exchange or replacement of either the planetary gearboxes or the splined pinions. Check the magnetic plug in each gearcase at each scheduled maintenance.

The four pinions result in lower shared tooth loads for longer pinion and rack life. A spring set air released disc brake is mounted on each of the two swing motors.

August 2007

1 - 27

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD MACHINERY The crowd machinery, located at the front center of the revolving frame, consists of motor, brake, drum and gearing. A crowd rotary encoder prevents overtravel of the dipper handle. This is done by setting the limits on the panel view screen. Locating the crowd machinery on the revolving frame, instead of the boom, substantially reduces front end weight resulting in lower swing inertia and reduced required swing effort. The entire machinery unit can be removed from the machine should maintenance or overhaul become necessary.

Crowd Machinery Components

The crowd drum drives the crowd and retract rope system. Rope grooves are machined and flame hardened. The crowd and retract ropes are attached to the drum by ferrule-becket anchors which greatly simplifies rope changes.

A spring set, air released disc type brake is mounted on the electric drive motor.

Manual No. 10500

1 - 28

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

OPERATOR’S CAB The isolated and elevated operator’s cab at the right hand front of the machinery house provides a comfortable, safe and efficient working environment for the operator. Sufficient space is provided for the fully adjustable operator’s seat, a helper’s seat, the standard operator’s display panel, two storage lockers and a small table.

All operating controls are incorporated into the arms of the seat.

The cab is sound and heat insulated with interior walls made of a sound deadening steel-plastic-steel composite.

Electric powered windshield wipers are provided for quiet, dependable operation. A onepiece front window is supplied in a rugged, easy-to-change frame. A forward front window slant with over hanging roof helps keep the window clean. Transparent sun shades are provided in front and side windows.

Visibility through both side and front windows is excellent. The operator has the best view in the industry of the digging face and for truck spotting.

This view is enhanced by the streamlined sides and top surfaces of the boom, unencumbered by crowd machinery or dipper handles on the outside of the boom.

Each air conditioner and pressurizing unit utilizes environmentally friendly 134a refrigerant in the cooling system.

Interior ducting distributes the airflow to best suit the comfort of the operator.

August 2007

1 - 29

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

COMPRESSED AIR SYSTEM The compressed air system consists of a rotary screw type air compressor, air receiver, controls and center pintle air swivel. Hydraulic high pressure hose is used throughout. The air system is used to operate all brakes and lubrication components and to perform various other functions.

AUTOMATIC LUBRICATION SYSTEM The lube system is located in an insulated, double wall, lube room which can be heated for cold weather operation. A one ton (907 kg) monorail-mounted electric chain hoist is provided to be used to raise supplies from the ground onto the left house platform and into the lube room. Lube points on the electric motors, suspension rope pins and some dipper pins are manually accessed. All other lube points are fed from the automatic system or by oil bath.

Manual No. 10500

1 - 30

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

A single line type automatic lubrication system applies open gear lubricant (OGL) and grease via a programmable logic controller (PLC). The system has six lube pumps (four for OGL and two for grease), each feeding individual PLC controlled circuits. Lincoln Powermaster IV (75:1 ) air powered pumps are mounted on two reservoirs; one 100 gallon and one 200 gallon. High pressure hoses with reusable fittings are utilized.

Lubrication Room

The six separately controlled lube circuits provide selective distribution frequency and quantity resulting in reduced lubricant usage and cost.

August 2007

1 - 31

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

FRONT END EQUIPMENT The front end equipment consists of the boom, boom point sheaves, padlock, saddle block, dipper handle, dipper, dipper trip mechanisms, running ropes and boom suspension strands.

SUSPENSION STRANDS The suspension strands are designed to maintain the proper 43 degree boom angle. These are fixed-length strands that support the entire weight of the boom and the load.

Manual No. 10500

1 - 32

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BOOM The boom is a welded steel structure consisting of twin box girders integrally connected at the boom point and in the lower section between the shipper shaft and boom feet. Impact resistant steel is utilized, coupled with 100% penetration and UT quality welds on all main splice joints.

Design optimization has resulted in heavier outside skin plates, minimizing the need for internal diaphragms. This reduction in weld related stress concentrations further enhances structural life.

Open manholes have been incorporated in the boom as a standard feature permitting periodic structural inspection. Integral “ladders” within the upper boom sections permit internal access without lowering the boom.

Boom Assembly

The boom is supported by four pre-stressed suspension (structural) strands attached to equalizer links on the A-frame. These inherent long life structural strands carry the working loads of the front end equipment. When structural fatigue finally does begin, it can start in the outside layer of wires which will be easily detected by visual inspection. Internal cracks in the suspension strands must be checked by x-ray. A boom limit switch with soft setdown prevents boom jacking shock loads.

August 2007

1 - 33

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

RUNNING ROPES Hoist, crowd, retract and dipper trip ropes are all plastic impregnated for increased life and for sheave and drum grooving life enhancement. The double twin hoist ropes are attached to the center of the hoist drum using ferrule-becket anchoring for faster rope change out. Each rope passes over a boom point sheave through the padlock and back over the boom point sheave to the hoist drum. The dual twin hoist rope configuration stabilizes the dipper while digging by attachment to the outer edges of the dipper body.

Ropes - General Arrangement

Crowd and retract ropes are attached to the crowd drum and work as an integral system. As the crowd rope is wound on to the drum, the retract rope is reeled off.

Manual No. 10500

1 - 34

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SADDLE BLOCK The saddle block, positioned between the boom side girders and pivoting on manganese-bronze bushings about the shipper shaft, acts as a guide for the longitudinal movement of the dipper handle. The free floating design of the handle in the saddle block eliminates handle torsion.

DIPPER HANDLE One end of the 34" (0.86m) diameter handle connects to the dipper. The crowd rope half sheave attaches to the other end. A hydraulic adjustable take-up mechanism at the dipper end is used to remove slack from the crowd/retract rope system. The dipper handle moves in and out within the saddle block.

An electrical rate reduction circuit, along with the crowd ropes, absorb digging shock loads encountered when the dipper is crowded into the bank.

August 2007

1 - 35

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DIPPER A general purpose dipper is usually constructed as a casting and plate weldment. The dipper lip and lower front are alloy heat treated castings. The dipper body, back, upper sides and door are made of steel plate. Removable Whistler type tooth adapters and replaceable tooth points are attached to the lip casting to penetrate the bank material.

The door is hinged and latched to the dipper body. A dipper trip mechanism controls the release of the latch bar, allowing the door to swing open. The latch bar holds the door shut during digging.

Spring loaded snubbers dampen the door’s swinging action.

Dipper Assembly

Manual No. 10500

1 - 36

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PADLOCK Padlocks connect the hoist ropes to the outer edges of the dipper while still permitting fore and aft and sideways movement.

DIPPER TRIP The dipper trip is a wire rope activated dipper door trip mechanism driven by an electric motor through gear reduction mounted on the boom near the boom foot.

Dipper Trip - General Arrangement

August 2007

1 - 37

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TYPICAL MACHINE SPECIFICATIONS This specification describes the principal mechanical features of a standard Bucyrus International, Inc. 495HD Acutrol controlled machine. The machine is fully revolving, crawler mounted and equipped to operate from an alternating current power source.

WEIGHTS

Working Weight (w/Dipper) Dipper (64 yd3, 49 m3) Ballast Shipping Weight

(pounds)

(kilograms)

2,606,000 163,000 607,570 1,850,000

1,182,062 73,935 275,589 839,146

Front End Equipment Boom Boom Point Sheaves Boom Point Sheave Diameter Shipper Shaft Sheaves Shipper Shaft Sheave Diameter Dipper Handle Diameter Dipper Handle Wall Thickness

Welded, Impact Resistant Steel Twin Grooved, Flame Hardened 96" 243.84cm Twin Grooved, Flame Hardened 72" 182.88cm 34" 86.36cm 2.5" (nominal) 6.35 cm

Rope Data Hoist Crowd Retract Dipper Trip Boom Suspension

Manual No. 10500

# Ropes

Diameter

Type

2 1 1 1 4

2 3/4" 2 1/2" 2 1/2" 5/8" 3 1/4"

Twin Dual 6X37 Single Dual 6X37 Single Dual 6X37 Single 6X37 Equalized Structural

1 - 38

69.88mm 63.5mm 63.5mm 15.9mm 82.6mm

Constr.

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Typical Dimensions and Working Ranges US

Dipper Capacity (nominal) ............................................. 64 yd3 Dipper Capacities (range) ......................................... 25-80 yd3 Length of Boom ................................................................... 67' Boom Angle ......................................................................... 43o Effective Length of Dipper Handle ................................... 35’10" Overall Length of Dipper Handle ........................................... 47' A: Dumping Height ......................................................... 34’-7" A1: Dumping Height @ Maximum Radius ........................ 28’-2" B: Dumping Radius - Maximum ..................................... 69’-0” C: Cutting Height - Maximum ......................................... 56’-9" D: Cutting Radius - Maximum ...................................... 79’-11” E: Radius of Level Floor ................................................. 55’-4" G: Clearance Height @ Boom Point Sheaves ............... 65’-10" H: Clearance Radius @ Boom Point Sheaves ................ 64’-8" I: Clearance Radius @ Revolving Frame ....................... 29’-7" J: Clearance Under Frame to Ground .......................... 10’-10" K: Height of A-Frame ..................................................... 43’-4" L: Overall Machine Width .............................................. 42’-8" M: Ground Clearance (Lowest point of Truck Frame) .......... 22" N: Operator’s Cab Eye Level ........................................... 28’0"

Metric

49. m3 19.1-61.2 m3 20.4m 43o 10.92 m 14.32 m 10.5 m 8.59 m 21.0 m 17.3 m 24.37 m 16.86 m 20.1 m 19.7 m 9.02 m 3.3 m 13.3 m 13.01 m 0.57 m 8.53 m

D H

BUCYRUS

G C 495HD

K

acutrol

A

N

A1

J mdim495HD

I

E B

August 2007

1 - 39

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

GENERAL ESTIMATED COMPONENT WEIGHTS CAUTION:

These are estimated weights only. Contact your Bucyrus International service representative for the exact weight of components on your specific machine before rigging and lifting.

Quantity

Weight Each (U.S. Pounds)

Lower Works Truck Frame ..................................................... 1 ............... 168,100 Pintle Bushing ................................................... 1 ...................... 280 Lower Rail ....................................................... 12 ..................... 220 Propel Brake Adapter ........................................ 2 ...................... 370 Propel Brake ..................................................... 2 ...................... 650 Propel Brake Hub ............................................. 2 ........................ 60 Propel Motor ..................................................... 2 ................... 4,500 Propel Motor Blower ......................................... 2 ...................... 300 Propel Brake Guard, Welded ............................ 2 ........................ 60 Collector Ring Assembly (Propel) ..................... 1 ...................... 230 Crawler Belt (108 in.) ........................................ 2 ............... 279,500 Crawler Link (108 in.)....................................... 74 .................. 3,600 Crawler Belt (84 in.) .......................................... 2 ............... 240,000 Crawler Link (84 in.) ........................................ 74 .................. 3,100 Crawler Frame Assembly ................................. 2 ............... 124,100 Gearcase, Planetary Propel ............................. 2 ................. 18,100 Drive Tumbler ................................................... 2 ................... 6,930 Drive Tumbler Shaft .......................................... 2 ................... 5,800 Drive Tumbler Bearing ...................................... 2 ................... 1,400 Take-up Tumbler ............................................... 2 ................... 6,400 Take-up Shaft .................................................... 1 ................. 24,500 Take-up Cylinder ............................................... 1 ...................... 100 Take-up Tumbler Hub Cap ................................ 2 ...................... 200 Roller Hub Cap, Lower ..................................... 8 ...................... 300 Roller Shaft, Lower ........................................... 8 ................... 4,200 Roller, Upper Front ........................................... 2 ...................... 750 Roller Shaft, Upper Front .................................. 2 ...................... 460 Roller, Upper ..................................................... 8 ...................... 620 Shaft, Upper Roller ........................................... 8 ...................... 400 Center Pintle Assembly .................................... 1 ................... 9,900 Center Pintle Sleeve ......................................... 1 ................... 7,900 Center Pintle Split Clamp .................................. 1 ...................... 850 Center Pintle Lower Nut .................................... 1 ................... 1,425 Collar, Center Pintle, Upper .............................. 1 ...................... 380 Washer, Thrust, Center Pintle .......................... 1 ...................... 400

Manual No. 10500

1 - 40

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Quantity

Weight Each (U.S. Pounds)

Upper Works Revolving Frame, Weldment ............................ 1 ............... 163,400 A-Frame Front Leg ........................................... 1 ................. 23,000 A-Frame Rear Leg ............................................ 2 ................... 6,700 Dual Winch Assembly, Solid Leg ...................... 1 ................... 3,600 Boom Foot Pin .................................................. 2 ...................... 610 Upper-Center Rail ............................................. 6 ...................... 210 Upper End Rail ................................................. 4 ...................... 140 Planetary Swing Gearcase ............................... 2 ................. 10,600 Swing Brake Adapter ........................................ 2 ...................... 270 Swing Brake ..................................................... 2 ...................... 500 Swing Motor (with or without tach) .................... 1 ................... 3,600 Crowd 2nd Intermediate Shaft .......................... 1 ................... 2,000 Crowd 2nd Intermediate Gear .......................... 1 ................... 2,700 Crowd Motor Shaft Coupling ............................. 1 ...................... 150 Crowd Frame ................................................... 1 ................. 11,500 Crowd Pinion Guard ......................................... 1 ...................... 300 Crowd Gearcase Cover .................................... 1 ................... 2,700 Crowd Gear Guard - Upper .............................. 1 ...................... 170 Crowd Gear Guard - Lower .............................. 1 ...................... 350 Crowd Drum ..................................................... 1 ................. 12,800 Crowd Drum Spur Gear .................................... 1 ................... 5,000 Crowd Pinion, 1st Reduction Shaft ................... 1 ...................... 130 Crowd 1st Intermediate Gear ........................... 1 ................... 1,100 Crowd Brake ..................................................... 1 ...................... 500 Crowd Brake Adapter........................................ 1 ...................... 270 Crowd Motor ..................................................... 1 ................... 4,000 Air Swivel .......................................................... 1 ...................... 150 Swivel Housing ................................................. 1 ...................... 650 Swivel Collector Ring Assembly ....................... 1 ...................... 230 Hoist Planetary Gearcase ................................. 1 ................. 35,500 Hoist Pinion ....................................................... 2 ................... 2,600 Shaft, Pinion ..................................................... 2 ................... 1,700 Roller Bearing ................................................... 2 ...................... 250 Bearing Carrier ................................................. 2 ...................... 500 Hoist Gear Guard .............................................. 1 ................... 4,500 Hoist Top-Front Guard ...................................... 1 ................... 1,300 Hoist Top-Rear Guard ....................................... 1 ...................... 950 Hoist Front-Bottom Guard ................................ 1 ................... 2,000 Hoist Bearing Housing ...................................... 2 ................... 3,000 Hoist Drum ....................................................... 1 ................. 55,000 Spider, Hoist Drum ........................................... 1 ................. 16,000 Hoist Drum Gear .............................................. 1 ................. 11,000 Hoist Frame - R. H. .......................................... 1 ................... 8,600

August 2007

1 - 41

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Quantity

Weight Each (U.S. Pounds)

Oil Cooler, Air-Cooled ...................................... 2 ................... 1,750 Hoist Motor........................................................ 1 ................. 15,000 Hoist Brake ....................................................... 1 ................... 1,800 Hoist Brake Adapter .......................................... 1 ...................... 500 Hoist Brake Hub ................................................ 1 ...................... 210 Hydraulic Crowd Motor Coupling Assembly ...... 1 ...................... 150 Hoist Motor Coupling Guard .............................. 1 ...................... 300 Boarding Stairway ............................................. 1 ................... 1,525 Retractable Ladder ........................................... 1 ................... 1,750 Machinery House Filter Assembly ..................... 2 ................... 1,350 Control Room Filter Assembly .......................... 1 ................... 1,350 Front End Boom (Bare) ..................................................... 1 ............... 148,500 Boom Point Shaft ............................................. 2 ................... 1,100 Boom Point Sheave .......................................... 2 ................... 4,750 Boom Bumper Assembly .................................. 1 ................... 6,630 Saddle Block Assembly (W/O Shaft) ................ 1 ................. 16,000 Shipper Shaft .................................................... 1 ................... 5,000 Crowd / Retract Rope ....................................... 2 ................... 2,100 Hoist Rope .................................................... 1 pair ............... 9,000 Suspension Rope ............................................. 4 ................... 9,500 Pendant Equalizer - R.H. .................................. 1 ................... 2,400 Pendant Equalizer - L.H. ................................... 1 ................... 2,400 Crowd Sheave .................................................. 2 ................... 2,600 Dipper Handle ................................................... 1 ................. 53,700 Handle Weldment ............................................. 1 ................. 43,900 Handle End ....................................................... 1 ................... 5,000 Machined Tube ................................................. 1 ................. 25,800 Retract Rope Take-Up Support ......................... 1 ................... 1,600 Crowd Take-Up Guide ....................................... 1 ................... 2,200 Crowd Take-up Worm Gear Wheel .................. 1 ...................... 650 Crowd Take-up Worm Gear Wheel Housing .... 1 ...................... 450 Crowd Take-Up Screw Rod .............................. 1 ................... 4,550 Crowd Take-Up Sheave .................................... 1 ................... 2,600 Sheave Crowd Cushion Pin ............................. 1 ...................... 250 Take-up Cylinder ............................................... 2 ...................... 150 Take Up Guide .................................................. 1 ...................... 500 Retract Spreader and Front Stop ...................... 1 ................... 2,100

Manual No. 10500

1 - 42

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Quantity

Weight Each (U.S. Pounds)

Dipper Assembly (64yd) ............................................ 1 ............... 163,000 Includes: Dipper Body (w/o Liners) .................................. 1 ................. 91,200 Dipper Body (w/Liners) ..................................... 1 ................. 97,450 Dipper Tooth ..................................................... 9 ................... 1,200 Tooth Adapter .................................................... 9 ...................... 850 Tooth Wear Cap ............................................... 9 ........................ 50 Tooth C-Clamp ................................................. 9 ........................ 70 Tooth Wedge .................................................... 9 ........................ 40 Center Shroud Wedge ...................................... 8 ........................ 20 Center Shroud C-Clamp ................................... 8 ........................ 15 Center Shroud .................................................. 8 ...................... 500 Corner Shroud .................................................. 4 ...................... 300 Pitch Brace Assembly ...................................... 2 ................... 3,025 Snubber Assembly ........................................... 2 ................... 1,800 Pin, Handle ....................................................... 2 ...................... 500 Pin, Pitch Brace ................................................ 4 ...................... 300 Pin, Door .......................................................... 2 ...................... 400 Thrust Washer .................................................. 4 ........................ 40 Dipper Door ...................................................... 1 ................. 23,200 Dipper Door Bumper ........................................ 4 ........................ 10 Latch Lever Pin ................................................. 1 ........................ 40 Latch Bar .......................................................... 1 ................... 1,200 Latch Lever ....................................................... 1 ...................... 500 Padlock, Manganese Bushings, No Lube ......... 1 ................... 5,000 Padlock Pin ....................................................... 2 ...................... 370 Padlock Sheave ................................................ 2 ...................... 650

August 2007

1 - 43

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

1 - 44

August 2007

BI617098

Motor Control Center (MCC1) Mine Signal Switch Air Compressor Motor Control Center (MCC2) Dipper Trip Transformer Lighting Transformer #2

Power Skid Control Cabinet

Auto Lube Pumps and Reservoirs

Auxiliary Transformer Welding Receptacle under deck extention

Load Center #2

Remote Hoist/Swing Cabinet

Swing Hoist Planetary Blower Gearcase

A-Frame Lugs, Rear

Fire Protection Cabinet Swing Gearcase, Left

Hoist Motor

Hoist Blower

Lubrication Room

Center Pintle

Crowd Blower

C L Machine

Crowd Motor

Hoist Drum Shaft

High Voltage Access

Remote Auto Lube Cabinet

Crowd Brake

Hoist Machinery

Hoist Coupling Shaft

Thermocouple ZPCC Cabinet

Swing Brake

Air Dryer

Front of Machine Crowd Drum

Crowd Machinery

Boom Foot Lugs Swing Blower Swing Gearcase Right

Hoist Brake Thermostats Auxillary Constant Transformer Voltage Cabinet Transformer

Constant Voltage Transformer

Welding Receptacle under deck extention Drive Power Transformer #1

A-Frame Lugs, Front Remote Crowd/Swing Cabinet

High Voltage Cabinet Drive Power Transformer #2

Swing Brake Emergency Stop Load and Thermostat Center #1

Lighting Transformer #1

Left Console Operator’s Display

Left Joystick Operator’s Seat Right Joystick

Mine Signal Switch Operator’s Cab Right Console

BUCYRUS

Boarding Stairs, Right

R

C L Rotation

495HD Deck Plan LOT 81, SN: 141233 141233_D.cdr

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

2

Operation Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents GENERAL INFORMATION ............................................................................................................ 5 OPERATION NEAR ELECTRICAL LINES ............................................................................... 5 OPERATOR’S CONTROLS ......................................................................................................... 6 PRIMARY OPERATING CONTROLS ..................................................................................... 7 Operator’s Control Consoles in the Cab ............................................................................. 7

CONTROLS ON THE LEFT CONSOLE ........................................................................... 8 LEFT MASTER SWITCH ............................................................................................. 8 DIPPER TRIP .............................................................................................................. 8 SIGNAL HORN ............................................................................................................. 8 RADIO ......................................................................................................................... 8 HOIST BRAKE ............................................................................................................ 9 CROWD BRAKE ........................................................................................................ 9 SWING BRAKE ........................................................................................................... 9 PROPEL BRAKE ........................................................................................................ 9 Left Control Console .......................................................................................................... 9

CLIMATE CONTROL PANEL ....................................................................................... 9 WINDSHIELD WIPER/WASHER CONTROL PANEL ................................................. 9 CONTROLS ON THE RIGHT CONSOLE ................................................................. 10 RIGHT MASTER SWITCH ......................................................................................... 10 CONTROL STOP PUSHBUTTON ............................................................................ 11 CONTROL RESET PUSHBUTTON .......................................................................... 11 Right Control Console ....................................................................................................... 11

DIG/PROPEL TRANSFER SWITCH ............................................................................... 12 EMERGENCY STOP PUSHBUTTON ....................................................................... 12 MAIN POWER OFF PUSHBUTTON ......................................................................... 12 EARTH CONTINUITY LOCKOUT PUSHBUTTON .................................................... 13 TELEPHONE ............................................................................................................. 13 OPERATOR’S SEAT .................................................................................................................. 14 Operator’s Seat - IsometicView ........................................................................................ 14

OPERATOR’S DISPLAY ............................................................................................................. 16 Operator’s Display Panel .................................................................................................. 16

DISPLAY AREA AND INDICATORS ....................................................................................... 16 DISPLAY SCREENS ............................................................................................................. 17 Title Screen ...................................................................................................................... 17 Main Menu ........................................................................................................................ 18 Main Menu - Info ...............................................................................................................18 Active Alarm ..................................................................................................................... 19 August 2007

2-1

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

New Alarm ........................................................................................................................ 19 Alarms Help ..................................................................................................................... 20 Rope Reeving/Pintle Tightening ........................................................................................ 21 Rope Reeving/Pintle Tightening Help ................................................................................ 22 Calibration Help ................................................................................................................ 23 Fault Counters/Operating Hours ....................................................................................... 24 PLC Menu Screen ............................................................................................................ 24 Typical Bearing Temperature Screen ................................................................................ 25 Operator’s Screen ............................................................................................................. 25

BRAKE INDICATORS ..................................................................................................... 26 TIME/DATE WINDOW ..................................................................................................... 26 CONTROL STATUS INDICATORS .................................................................................. 27 LIMIT SLOWDOWN INDICATORS .................................................................................. 27 DIG/PROPEL INDICATOR .............................................................................................. 27 INFORMATIONAL ICONS ................................................................................................ 28 DELAYED SHUTDOWN INDICATOR ............................................................................. 28 ACTIVE ALARMS INDICATOR ......................................................................................... 28 AIR PRESSURE .............................................................................................................. 28 AUXILIARY CONTROLS ............................................................................................................. 29 REMOTE START CONSOLE ............................................................................................... 29 HOUSE LIGHT CIRCUIT BREAKERS .................................................................................. 30 LIGHTING TRANSFER SWITCH ........................................................................................... 31 LUBRICATION CONTROL PANEL ........................................................................................ 31 WINDSHIELD WIPERS ........................................................................................................ 32 WINDSHIELD WASHER ............................................................................................................. 32 FIRE SUPPRESSION SYSTEM ............................................................................................ 33 PRE-START CHECKS ................................................................................................................ 33 WALKAROUND GROUND LEVEL INSPECTION ........................................................... 34 ON-BOARD INSPECTION .................................................................................................... 36 MACHINE START-UP, OPERATION AND SHUTDOWN ............................................................. 37 START-UP ............................................................................................................................. 37 Start-Up Control Locations ............................................................................................... 37

RESTARTING AFTER AN ELECTRICAL FAULT ................................................................... 39 OPERATION ......................................................................................................................... 40 MACHINERY MOTIONS ........................................................................................................ 41 HOIST MOTION ............................................................................................................... 41 CROWD MOTION ........................................................................................................... 42 PROPEL MOTION ........................................................................................................... 43 Propel - Straight Forward/Reverse ................................................................................... 43

SWING MOTION ............................................................................................................. 44 PROPER SWING MOTION ............................................................................................. 45 STEERING ...................................................................................................................... 46 COUNTER-ROTATION TURNS ...................................................................................... 48

Manual No. 10500

2-2

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

POSITIONING THE MACHINE .................................................................................................... 49 BACK-UP METHOD .............................................................................................................. 49 DRIVE-BY METHOD ............................................................................................................. 50 THE DIG CYCLE ............................................................................................................. 51 Variations on Dipper Penetration ...................................................................................... 52

ENGAGING THE BANK ................................................................................................... 53 SLOPE LIMITATIONS ...................................................................................................... 55 Slope vs. Degrees ............................................................................................................ 55 Rollover and Operation Limits ........................................................................................... 56

EXCAVATED MATERIAL ........................................................................................................ 56 OPERATION CHECKS ......................................................................................................... 57 OPERATING HINTS .............................................................................................................. 58 STOPPING THE MACHINE ................................................................................................... 59 MACHINE SHUTDOWN ........................................................................................................ 59

August 2007

2-3

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

2-4

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

2

Operation

GENERAL INFORMATION This section of the manual will assist in the operation of this machine. It provides the operator with the location and explanation of the controls, instructions for machine operaion and certain maneuvering techniques. Throughout this section and the remainder of the manual, the use of the terms “LEFT, RIGHT, FRONT and REAR” refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.

Safe operation of the machine minimizes production delays and costly damage to equipment.

Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to prevent accidents from occurring and are provided in the interest of all mine personnel. Overall safety depends upon the use of good judgment and the alertness of the entire mining crew. Refer to Section 1 in this manual for specific safety precautions.

OPERATION NEAR ELECTRICAL LINES

DANGER:

HIGH VOLTAGE! The following precautions shall be complied with whenever operating around or near electrical distribution and transmission lines.

Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be taken. For purposes of this manual we are considering the entire machine or its load, in any position, that can reach to within the minimum distance specified by local, state and federal regulations.

Safe operating practices require that you maintain the maximum possible distance from the lines and never violate the minimum clearances.

Before working in the vicinity of power lines, always take the following precautions: •

Always contact the owners of the power lines or the nearest electric utility before beginning work.

•

You and the electrical utility representative must jointly determine what specific precautions must be taken to insure safety.

August 2007

2-5

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

•

It is the responsibility of the user and the electric utility to see that necessary precautions are taken.

•

Consider all lines to be power lines and treat all power lines as energized even though it is known that the power is shut off and the line is visibly grounded.

•

Slow down the operating cycle. Reaction time may be too slow and distances may be misjudged.

•

Caution all ground personnel to stand clear of the machine at all times.

•

Use a signal person to guide the machine into close quarters. The sole responsibility of the signal person is to observe the approach of the machine to the power line. The signal person must be in direct communication with the operator and the operator must pay close attention to the signals.

DANGER:

HIGH VOLTAGE! Death or injury could result should any part of the machine come within the minimum distance of an energized power line specified by local, state and federal regulations.

OPERATOR’S CONTROLS

The operator must become familiar with the machine and its operating controls. The figure depicts the general location of controls on the machine.

The operating controls will be grouped as primary and secondary controls, depending upon their location. The primary controls are the controls located in the operator’s cab and the secondary controls are the controls located in the machinery house.

The descriptions listed should familiarize the operator with each control’s location and functional use.

The terms left, right, forward and reverse indicate directions with the operator seated in the cab and facing forward, and with the boom extending over the take-up axle of the crawlers.

Manual No. 10500

2-6

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PRIMARY OPERATING CONTROLS

Operator’s Control Consoles in the Cab

August 2007

2-7

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CONTROLS ON THE LEFT CONSOLE LEFT MASTER SWITCH The Left Joystick functions as the crowd/horn/dipper trip/propel master switch. It is the vertical handle mounted on the left console of the operator’s seat. The switch will spring return to neutral when released.

During normal operation, pushing the joystick forward will extend the dipper handle and dipper into the bank. Pulling the joystick rearward will retract the dipper handle and dipper toward the machine. The neutral position between the crowd and retract functions is defined by a detent that is easily felt. The rate of motion is controlled by varying the distance the joystick is moved from the neutral (center) position. Full forward or full rearward position provides maximum speed to the handle. Moving the joystick to neutral will cause a braking action slowing the crowding or retracting handle. Reversing the joystick will cause the motion to stop and if the joystick is held in this position, it will change the direction of the motion.

With the propel transfer switch in the PROPEL position, pushing the joystick forward will cause the left crawler to move forward. Pulling the joystick to the rear will cause the left crawler to move in the reverse direction. The crowd/retract motion is locked out electrically when the machine is in the propel mode.

DIPPER TRIP The dipper trip is part of the crowd joystick function. Moving the joystick to the right will activate the dipper trip mechanism which releases the dipper door latch. The dipper trip is operational throughout the entire range of the crowd motion.

SIGNAL HORN Moving the joystick to the left will activate the signal horn. The signal horn is operational throughout the entire movement range of the crowd motion.

RADIO The radio supplied with your machine is an AM/FM Stereo radio with the capability to play cassette tapes in the player incorporated. This is a quality piece of sound equipment and will provide long term operation.

Manual No. 10500

2-8

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST BRAKE A selector switch used to set or release the Hoist Brake.

CROWD BRAKE A selector switch used to set or release the Crowd Brake.

SWING BRAKE A selector switch used to set or release the Swing Brake.

PROPEL BRAKE A selector switch used to set or release the Propel Brake.

Left Control Console

CLIMATE CONTROL PANEL The Climate Control Panel contains a rheostat controller on the top portion of the panel which is used to tailor the temperature of the air delivered to the operator’s cab within the selected mode of operation.

The Mode switch is provided to set the basic mode of operation for the roof mounted air conditioning/ heater unit.

The Blower Speed switch controls the volume of air being moved by the unit.

WINDSHIELD WIPER/WASHER CONTROL PANEL The Windshiel Wiper/Washer Control Panel contains a switch that activates the the wipers and controls the speed of the wipers. A pushbutton activates the Washer system where pressurized fluid is dispensed through spray nozzles mounted around the window.

August 2007

2-9

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CONTROLS ON THE RIGHT CONSOLE

RIGHT MASTER SWITCH The Right Joystick functions as the hoist/swing/propel master switch. It is a joystick mounted on the right console of the operator’s seat. The joystick is used to control the hoist, swing and right crawler motions of the machine. The position of the propel transfer switch will determine whether this switch controls the hoist motion or the crawler motion.

With the propel transfer switch in the dig position, pushing the joystick forward will lower the dipper. Pulling the joystick to the rear will hoist the dipper. The neutral position between the hoist and lower functions is defined by a detent that is easily felt. The speed of moving the dipper is controlled by varying the distance the joystick is moved from the neutral (center) position. The full forward, or full rearward position provides maximum speed to the dipper.

Moving the joystick to neutral will cause a braking action slowing the hoisting or lowering motion. Reversing the joystick will cause the motion to stop and if the joystick is held in this position, it will change the direction of the motion.

NOTE: When the hoist/swing master switch is used in the hoist/lower mode the switch is a spring returned switch. That is, it will return to the neutral position when it is released.

Moving the joystick to the left from the neutral position will cause the machine to swing to the left.

Moving the joystick to the right will cause the machine to rotate to the right. The swing motion is operational throughout the entire movement range of hoisting or lowering the dipper. The swing rate of acceleration is controlled by varying the distance the joystick is moved from the neutral position. Moving the joystick to the neutral position will not stop the swing motion but will allow the machine to coast. To stop or change direction the control joystick is moved past the neutral point in the opposite direction. The rate of deceleration is controlled by varying the distance the joystick is moved from the neutral position in the opposite direction.

With the propel transfer switch in the propel position, pushing the lever forward will cause the right crawler to move forward. Pulling the lever to the rear will cause the right crawler to move in the reverse direction. The hoist motion is locked out electrically when the machine is in the propel mode.

NOTE: When the JOYSTICK is used in the swing mode the switch is a spring returned switch.

That is, it will return to the neutral position when it is released.

Manual No. 10500

2 - 10

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CONTROL STOP PUSHBUTTON The control stop pushbutton is a pushbutton located on the right operator’s console. Normally it is used to de-energize controls after the machine has been safely stopped by placing motion controls in neutral.

Actuation of this pushbutton when motions are running will cause all motions to automatically electrically brake to a stop and, when the motion speed has reached less than 5% speed, set all mechanical brakes. If the motions are already stopped, the brakes will be set and power is removed immediately. A similar switch is located on the front panel of the PLC control cabinet that can be used during testing of the machine.

DANGER:

THE OPERATOR SHOULD NEVER LEAVE THE OPERATOR’S SEAT BEFORE PRESSING THE CONTROL STOP PUSHBUTTON. Setting only the mechanical brakes with individual switches is not a sufficient safeguard to prevent machine damage and/or personnel hazards.

CONTROL RESET PUSHBUTTON CAUTION:

This is not an automatic reset system. All controls must be returned to neutral before the control reset button is pushed.

Right Control Console

The control reset pushbutton is a pushbutton located on the right operator’s console. The reset pushbutton restores control to all motions if no additional faults exist. This pushbutton is inoperative until the main power start control has been actuated.

If a control fault occurs that shuts down a motion, all motions will automatically be shut down together. At this time the operator should set all brakes. If the fault clears, the motion may be reset by pressing this pushbutton. If the fault does not clear, the unfaulted motions can be restarted by pressing this pushbutton to enable these motions to re-position themselves.

August 2007

2 - 11

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DIG/PROPEL TRANSFER SWITCH The Dig/Propel Transfer Switch is used to switch between the two primary operating modes of the machine. The current mode of operation will be indicated on the Operator’s screen on the Operator’s Display.

IMPORTANT: • WHILE IN THE DIG MODE, THE PROPEL CONTROLS ARE DISABLED. • WHILE IN THE PROPEL MODE, THE DIG CONTROLS ARE DISABLED. The recommended procedure to transfer from hoist to propel is to bring all motions to a controlled stop by the operator. Turn the hoist brake switch to the SET position and then press the control stop pushbutton. Turn the transfer switch from DIG to PROPEL. When the indicator on the Operator Display screen indicates that the transfer has been completed, turn the propel brake switch to release.

EMERGENCY STOP PUSHBUTTON The machine stop/emergency stop pushbutton is located on the right operator’s console. It is used to remove power from the machine motions after the motions have been stopped in the normal manner. A second purpose of the pushbutton is to stop the machine under operational emergency conditions. Pushing this button will provide electrical and immediate mechanical braking simultaneously. Therefore, this button should only be used if the operator intends the harshest braking of all motions. If the machine is in motion, power will remain on the motions in order to provide electrical braking for a few seconds. If the machine is in motion or stopped, this button will power the DC bus to approximately zero voltage quickly after the time delay.

CAUTION:

PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY RESULT IN COMPONENT DAMAGE.

A second pushbutton that also provides the functions as described above is located in the remote start console and is labeled “machine stop.”

MAIN POWER OFF PUSHBUTTON The main power off pushbutton is located on the right operator’s console. It is used only to immediately remove power from the drives in case of an electrical emergency involving component failure or fire.

CAUTION:

Manual No. 10500

PUSHING THE “POWER OFF” PUSHBUTTON WHILE IN MOTION WILL IMMEDIATELY SET THE MECHANICAL BRAKES AND REMOVE INCOMING HIGH VOLTAGE FROM THE DRIVES. THIS ACTION MAY RESULT IN COMPONENT DAMAGE. It will also result in the inability to power the DC bus voltage down to a low value. This voltage will decay slowly, taking several minutes.

2 - 12

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

EARTH CONTINUITY LOCKOUT PUSHBUTTON The earth continuity lockout pushbutton is used to trip the breaker that supplies power to the machine.

When the machine is operating, this pushbutton should be used to shutdown the machine only when removal of power to the machine is required.

TELEPHONE A telephone is located at the rear of the right control console. This telephone is connected to other phone stations throughout the machine.

August 2007

2 - 13

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

OPERATOR’S SEAT

Operator’s Seat - IsometicView

The operator’s seat has been selected to provide a maximum of operator comfort along with easy control access for increased productivity. The seat has numerous adjustments allowing it to be tailored to meet the individual needs of each operator.

Weight Adjustment The seat should be adjusted for the operator’s weight by pulling the actuator lever of the automatic weight and height adjuster while the operator is sitting in the seat and the machine is stationary.

Height Adjustment The seat height is adjusted pneumatically by pulling or pressing the adjustment lever as required to obtain the position required. DO NOT operate the compressor unit for more that 1 minute continuously.

Manual No. 10500

2 - 14

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Seat Cushion Angle Adjustment The angle of the seat cushion can be adjusted individually from the back. Lift the handle and exert pressure in the desired direction while seated. Release handle once the required position is achieved.

Seat Depth Adjustment The depth of the seat pan can be individually adjusted. Lift the handle and slide the seat pan forward or backwards to position. Release the handle when the desired position is obtained.

Armrest Adjustment The armrests can be adjusted to fit the individual needs of each operator or folded up and placed out of the way.

To adjust the armrest height; loosen the manual friction knobs on the outboard side of the armrest allowing the armrests to pivot. Move the armrest to any desired position within it’s range and retighten when desired.

To raise the arm rests; lift at front and stow vertically.

Headrest Adjustment The headrest can easily be adjusted by lifting, or tilting, headrest to the desired position.

Lumbar Support The curvature of the backrest can be adjusted pneumatically by pressing the switches on the lower left rear of the backrest.

Backrest Adjustment The backrest is adjusted by lifting the lever and then releasing once the desired position is obtained.

August 2007

2 - 15

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

OPERATOR’S DISPLAY The Operator’s Display is a CTR panel used to provide the operator with an interface to the machine and it’s functional areas. From this informational display the operator can make inputs that effect machine operation, monitor systems and make system adjustments. Through this display terminal the operator will receive pertinent fault data to identify potential problems and prevent machine damage.

Operator’s Display Panel

The display panel is mounted on an articulated arm assembly protruding from the seat base on the right side of the operator. The articulated arm allows individual operators to locate the screen in any desired position. The monitor screen can be rotated along the horizontal and vertical axis’.

DISPLAY AREA AND INDICATORS The display area of the monitor screen is the large area in the center of the screen. This area is “touch sensitive.” All information will be displayed on this area in either a text format or in the form of visual icons. The buttons and icons that appear on the screen will respond to touching the screen in the appropriate area of the icon.

Manual No. 10500

2 - 16

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

These icons and buttons will react by activating the screen, switch activation or display information relevant to the icon. The switches and buttons will be covered in the following pages under the screen topic in which they appear.

The indicators on the lower portion of the screen area are indicators and sensors which indicate functionality of the operator display and it’s interface with the machine’s PLC controller. They have no effect on machine operational use.

All the machine controls can be found on the Operator’s Display Panel touch sensitive screen or the left and right Control Consoles of the operator’s seat.

DISPLAY SCREENS The Title Screen display appears when the machine is initially started.

Title Screen

The information provided in the central area of the screen is machine specific and lists the machine serial number, the customer name and a listing of important documents and drawings associated with the machine.

The 2 buttons available, if touched, will cause the display to refresh with the information of the desired screen.

August 2007

2 - 17

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Main Menu

The Main Menu screen will provide the operator with a choice of 16 buttons to select. Touching the screen in any of these button areas will cause the display to change to the requested option. Many of these screens will be displayed in the following pages. Several screens have an INFO button which will provide more detailed information concerning the functionality of listed buttons and switches.

Main Menu - Info

The Main Menu Information screen provides information about the various display screen options available through the Main Menu screen.

Manual No. 10500

2 - 18

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Active Alarm

The Active Alarm screen will provide a list of all active alarms and faults that have been initiated on the machine and have not been RESET. Once an alarm or fault has been sensed, these messages will remain visible and WILL NOT be removed from this screen until it is RESET.

New Alarm

The New Alarm screen appears automatically any time a machine sensor detects a newly occurring fault or warning message. This screen has the ability to list up to 10 of the new fault messages that have occurred. If more than 10 new fault messages are present a message will appear below the white text box indicating that more messages are present.

August 2007

2 - 19

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

NOTE: It is important to remember that messages will appear in this screen that are no longer active alarm messages. All messages will appear since the time of the last reset.

Alarms Help

The Alarms Help screen can be reached from any of the alarm message screens at any time. This screen will provide clarifying information related to the alarm system on your machine.

Manual No. 10500

2 - 20

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Rope Reeving/Pintle Tightening

The Rope Reeving/Pintle tightening screen is selected in order to make adjustments to the center pintle or change any of the main machine wire ropes. This screen will become active in the pintle tightening mode. If rope reeving is the desired intent, a selection must be made at the buttons in the lower left of the display area.

NOTE: Before switching between different modes of operation the Disable Selected Mode button should be pressed.

Switches for the activation/release of the hoist, crowd and swing brakes are provided, along with condition indicators displayed below the brake switches. This screen assists in the correct wrapping of the ropes on drums and allows full control of drum movements.

August 2007

2 - 21

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Rope Reeving/Pintle Tightening Help

This screen will provide clarifying information on the reeving of ropes and pintle tightening.

Calibration The Calibration screen is used to set the various limits required to control the movements of the machine.

Manual No. 10500

2 - 22

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

On this screen can be found switches for the hoist, crowd and swing brakes along with status indicators for each.

The limit settings can be found on the left side of the display area.

The white text box near the bottom of the display area displays the current positions of the components.

Calibration Help

This screen will provide clarifying information on the calibration process.

August 2007

2 - 23

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Fault Counters/Operating Hours

The Fault Counter/Operating Hours screen provides the operator with information on the number of faults that have occurred since last RESET. It also provides the total operating hours.

PLC Menu Screen

This screen will active further screens which are used to monitor various racks within the PLC cabinets.

Manual No. 10500

2 - 24

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Typical Bearing Temperature Screen

Operator’s Screen

The Operator’s Screen is the primary operational information tool to be visible to the machine operator during daily use of this machine. The controls available on this screen will provide the operator with the information needed to view “at a glance” the status of items required for digging and make changes in control settings.

August 2007

2 - 25

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BRAKE INDICATORS The 4 rectangular areas in the upper left portion of the operator’s screen provide DISPLAY ONLY information on the motion brakes. The HOIST, CROWD, SWING and the PROPEL brakes are separately identified at this location.

NOTE: The hoist, CROWD AND SWING brakes ARE not to be used as a braking device, except as a holding brake or with an electrical fault or in an emergency. The primary function of the brake is to prevent motor rotation while the particular function is not in use.

1.

SET - This will indicate a condition where the brake for that system is fully set and functional as a braking device to prevent movement of that system.

2.

SETTING - This message indicates that the brake is in a transition period between the RELEASED and the SET positions. During this period the brake is not functional and care should be exercised to not rely on the brake at this time.

3.

RELEASED - This message is an indication that the brake is fully released for the system in question.

4.

RELEASING - This is an indication that the brake is in a transition phase from the Set position and has not yet achieved the fully RELEASED position.

NOTE: While in transition from one setting to another (ie: during the RELEASING and SETTING periods, the button will be displayed in yellow. While fully SET or fully RELEASED the button will be displayed in grey.

NOTE: Unlike the other brakes on the machine, the propel brakes are intended as operational brakes and are used in the operation of the machine

TIME/DATE WINDOW

The Time/Date window, locate in the lower left corner of the screen will provide the current local time and date information to the operator at all times. In addition, the total operating hours on the machine will also be displayed.

Manual No. 10500

2 - 26

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CONTROL STATUS INDICATORS

The Control Status indicator buttons provide an immediate visual notification of which control systems are functional at that moment. When a control system is active it will be illuminated in green. If a control indicator is grey the system control for that function is currently disabled.

The Dig/Propel switch will have an effect on the status indicators and controls by automatically disabling the propel controls when the machine is in the Dig Mode of operation. Likewise the Hoist, Crowd and Swing controls are automatically disabled when the machine is in the Propel Mode.

It is important to remember that when a brake system is SET the controls for that motion will be disabled.

LIMIT SLOWDOWN INDICATORS

The Limit Slowdown indicators are provided on the operator’s screen to provide the operator with an indication that he is reaching the limits of either the Hoist or the Crowd ropes. These indicators, normally grey, will illuminate yellow as the motion extends into the limit area and the machine has signaled a slowdown condition.

The operator will notice that the reaction of the machine will actually slow down in an effort to prevent damage to the machine by exceeding limits.

The actual settings for these limits is made on the Calibration screen.

DIG/PROPEL INDICATOR

This icon will indicate the current operating mode of the machine by an illumination of the active control in red. To activate the other operating mode, use the Dig-Propel Transfer switch on the operator’s console.

August 2007

2 - 27

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

INFORMATIONAL ICONS The below listed icons are for informational display during the operational use of the machine.

These icons will normally be displayed in grey unless the message within the icon is active, and the icon will illuminate yellow.

POWER OFF - Get information from ELECTRICAL. SYSTEM ON - Get information from ELECTRICAL. MASTER SWITCH NEUTRAL - Get information from ELECTRICAL. BOOM JACK LIMIT - This message indicates that the boom is being jacked upward by the crowd motion into the bank. Power is removed from the crowd controls during this event. Pressure must be relieved from the crowd system for controls to return to normal.

FANS OFF - Get information from ELECTRICAL. LADDER DOWN - This icon displays a message indicating that the boarding ladder is NOT currently stowed in it’s topmost position.

DELAYED SHUTDOWN INDICATOR The Delayed Shutdown indicator will normally appear as a grey button near the right side of the screen. This indicator will illuminate red when a delayed shutdown fault has occurred and the machine is now in the delay process.

This is a direct indication to the operator that the machine is about to automatically shut down and he must make preparations.

When this illuminates the operator should stop any swing motion and safely place the dipper on the ground in preparation to lose control in one or more machine systems.

ACTIVE ALARMS INDICATOR The Active Alarms indicator will illuminate red, from grey, whenever there exists a condition in which an active alarm is being signaled from a machine sensor. This indicator will remain red at any time that any active alarm condition exists.

AIR PRESSURE The air pressure gauge is located on the right portion of the Operator Display.

It indicates the regulated air pressure available in the air system.

Manual No. 10500

2 - 28

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

AUXILIARY CONTROLS

REMOTE START CONSOLE The remote start panel is located on the right side of the machine just inside the machinery house door. The panel contains the following switches and indicator lights used to initially start the machine: Phase Sequence Light This green indicator light, when lit, indicates that incoming power sequence is correct. If the light is OFF, have electrical maintenance change the trail cable phase sequence.

Drive Cabinets Temperature Light This green indicator light, when lit, indicates that the drive electronic cabinets are at the correct operating temperature. Too low or too high cabinet temperatures will not allow the machine to start.

PLC Power On Light This green indicator light, when lit, indicates that PLC and drive control power is on. This light should be lit about 20 seconds after the UPS mg set is started.

System Ready Light This green indicator light, when lit, indicates the system is ready to start. When the system run pushbutton is pressed and the system successfully started, this light will go out.

Auxiliary Ground Fault Light This green indicator light, when lit, indicates that no auxiliary power ground fault exists. If the light is OFF, alert an electrician as soon as possible.

August 2007

2 - 29

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Incomplete Sequence Light This red indicator light, when lit, indicates the automatic start-up sequence did not complete in a preset time period. Have an electrician troubleshoot the sequence. If this indicator does not light up, the start-up sequence is progressing properly and machine start-up can continue.

System Run Pushbutton This pushbutton will energize the drive system when pressed if the system ready light is on.

Air Compressor Start/Stop Pushbuttons The air compressor start and stop pushbuttons are used to control the auxiliary air compressor.

The stop pushbutton is only used for complete machine shutdown or when maintenance is being performed on the air compressor.

HOUSE LIGHT CIRCUIT BREAKERS The house light circuit breakers are located on the right side wall of the machinery house next to the remote start console. A main light circuit breaker is located on the auxiliary control cabinet. The breakers protect the lights from over-current loads.

Manual No. 10500

2 - 30

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LIGHTING TRANSFER SWITCH

The lighting transfer switch is located on the right side wall of the machinery house near the lighting control center. This switch is used to transfer power for lighting from on machine source to off machine source.

LUBRICATION CONTROL PANEL The top row on this panel consists of a group of indicating lights. A red light indicating that the system has a fault and a green light indicating that power for the system is provided for each independent lubricating system (A, B & C). Isolating switches are used to provide power to each system and a means of isolating each system from electrical power. They are also used to reset lubrication faults. These switches are normally on. Manual lube buttons are also provided.

August 2007

2 - 31

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

WINDSHIELD WIPERS There are two electrically operated windshield wipers on the front window of the cab: one for the lower portion of the window and one for the upper portion of the window.

Check the wiper blades to make sure they swing freely across the window without contacting the window frame. Reposition the pantograph arm on the wiper motor shaft if necessary to prevent contact with the window frame.

Frequently check the condition of the wiper blades and replace if damaged.

WINDSHIELD WASHER An optional electric operated windshield washer unit supplies a cleaning agent to the windshield through spray nozzles when activated. When operating in warm climates, water may be used as the agent. In areas where freezing temperatures are encountered, a suitable commercial windshield washer solvent with anti-freezing characteristics is recommended.

Manual No. 10500

2 - 32

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

FIRE SUPPRESSION SYSTEM Fires on surface mining equipment typically involve faults in electrical equipment, or the combustion of flammable fluids. The time between the onset of the fire and its detection is critical. Early detection and suppression of a fire minimizes hazards to personnel, equipment damage / downtime and loss of production.

PRE-START CHECKS Before starting, inspect the machine to ensure it is ready to be put into operation. Failure to make such a routine check could result in unnecessary downtime. For example: an undetected oil leak could result in a dry gearcase, eventually leading to excessive gear wear or destruction, seized bearings or other mechanical problems. Broken strands in the hoist ropes, crowd rope, retract rope or structural strands could, if undetected, result in serious injury or damage to the machine or haulage unit. A few minutes spent inspecting the machine often results in considerable savings in time and machine efficiency. Section 4 of this manual contains reproducible checklists to assist in record keeping and ensure that adequate inspection standards are met.

August 2007

2 - 33

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

WALKAROUND GROUND LEVEL INSPECTION Check the following areas daily during a general walkaround inspection: 1.

Check the areas under and around the crawlers for signs of oil leaks. If single droplets are noticed, leakage is minimal. Determine the point of leakage and make a note of it on the log sheet. If pooling of oil is noticed, determine the source and take corrective action immediately.

Determine if loose hardware, a defective gasket, a combination of both, or a similar problem is responsible. Tighten hardware or replace defective gaskets.

2.

Inspect the crawler belts for missing links or lock pins, excessive belt sag, cracked shoes or other deterioration. Check the oil level in the propel planetary gearcase. Add oil as required.

3.

Check the swing rack and pinion guards for rocks, dirt and other debris that will interfere with the operation of the machine. Inspect the swing rack gear and rollers for the proper lubricant film.

DANGER:

HIGH VOLTAGE! THE MACHINE TRAIL CABLE CARRIES A LETHAL VOLTAGE. Handle the cable in an approved manner with appropriate rubber gloves and insulated hooks or tongs.

Manual No. 10500

2 - 34

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

4.

Visually inspect the trail cable for cuts, abrasions and other damage.

5.

Visually inspect exterior of machinery house for damage or evidence of internal leakage.

6.

Inspect the dipper trip mechanism, rope, latch bar and associated hardware for damage, adjustment and wear.

7.

Inspect the dipper door, hardware and bumpers for damage and excessive wear.

8.

Inspect fulcrum attachment points, take up cylinders and spacers and dipper handle for damage, excessive wear and evidence of adequate lubrication.

9.

Inspect boom bumper for security and damage.

10.

Inspect the dipper and tooth adapters for tightness and excessive wear.

11.

Inspect padlocks for damage, wear and evidence of adequate lubrication.

12.

Check both the running ropes and the boom structural strands for broken strands and loose sockets.

August 2007

2 - 35

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

ON-BOARD INSPECTION Check the following areas daily on board the machine: 1.

Visually inspect the swing, crowd and hoist gearcases for oil levels and leaks. Repair or service as required.

2.

Visually inspect all machinery for loose bolts, nuts, clamps or unusual deterioration. Repair as required.

3.

Visually inspect the open gears of the swing, crowd and hoist machinery for proper lubricant film and evidence of adequate lubrication from the automatic lubricant dispensing system.

4.

Visually inspect hoist and crowd ropes for wear, lubrication and evidence of birdcaging near the drum attachment beckets.

5.

Check the oil level in the air compressor. Add oil if required.

6.

Check lubricant supply level in the air system lubricator and lube system lubricators.

7.

Inspect the automatic lubrication central pumping stations for any signs of malfunctioning.

Check the lubricant supply and refill tanks if required.

8.

Visually inspect swing, crowd and hoist brake assemblies for damage, wear and evidence of an overheated condition.

9.

Check the operator’s cab for cleanliness and visual condition of controls and location of special equipment that may be required by the mine site. Check all operating controls for freedom of movement. Controls should move freely without binding.

10.

Clean windows of operator’s cab.

11.

Inspect all walkways and stairways to ensure there are no obstructions or fluids creating a safety hazard.

12.

Ensure ladder(s), steps and/or man basket are raised and properly stowed.

13.

Perform the following manual lubrication points: Crowd Cushion Sheave .............. OGL - 1 Fitting Padlock Pins ............................... OGL - 6 Fittings Dipper Pins ................................. OGL - 2 Fittings Dipper Trip Rope Guide Roller .... OGL - 1 Fitting Latch Lever Sleeve ..................... OGL - 1 Fitting Structural Strand Pins ................. OGL - 4 Fittings Hoist Rope Roller Bushings ....... MPG - 4 Fittings

NOTE: Detailed information on the proper servicing of these components can be found in Sections 3 and 4 of this manual.

Manual No. 10500

2 - 36

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MACHINE START-UP, OPERATION AND SHUTDOWN START-UP Whether starting the machine for the first time, or starting after the machine has been in service for some time, the procedures are essentially the same.

1.

Perform all pre-start checks listed earlier in this section of the manual.

2.

Raise the boarding stair, making sure it is secured in the raised position. The limit switch at the top of the stair will not close and the controls will not energize if the stair is not in the fullyraised position.

Start-Up Control Locations

3.

In the operator’s cab check that all brake switches are in the SET position and that the control joysticks are in the neutral position. Then go to the electrical room at the rear of the machinery house.

4.

At the AC control cabinet verify that the uninterruptable breaker is in the ON position. At the motor control cabinet, verify that all breakers are in the ON position.

August 2007

2 - 37

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5.

At the remote starting console in the machinery house, use the following sequence to start the machine: a.

Verify that the green AUXILIARY GROUND FAULT light is lit.

CAUTION:

b.

IF THE AUXILIARY GROUND FAULT LIGHT IS OFF, ALERT AN ELECTRICIAN AS SOON AS POSSIBLE. The machine may be operated with one fault but a second fault could cause damage to the machine and/or become a safety hazard. The fault should be cleared as soon as possible.

Verify that the green PHASE SEQUENCE light is lit. This indicates that the incoming power sequence is correct. If not, the light will be out and the machine will not start.

Electrical maintenance personnel must correct the problem.

NOTE: This PHASE SEQUENCE light also indicates auxiliary power phase unbalance, phase loss or under-voltage. Any of these faults occurring while the machine is running will produce an alarm. In the event of such an alarm an electrician should be notified, however the machine may be operated.

6.

c.

Verify that the PLC and drive cabinets green temperature lights are lit. If the cabinet temperature is too low or too high, the machine cannot be started.

d.

Press the UNINTERRUPTABLE POWER SUPPLY on pushbutton. A second start pushbutton is located on the UPS control cabinet.

e.

Verify that the green PLC POWER ON light is lit. This light should be on about 20 seconds after the UPS motor is started.

f.

Turn the AIR COMPRESSOR RUN switch to the run position or press the start pushbutton.

g.

Verify that the green SYSTEM READY light is lit.

h.

Press the SYSTEM RUN pushbutton. When this button is pressed, the system ready light will go out and the drive system will automatically power up.

i.

Verify that the red INCOMPLETE SEQUENCE light is out. If lit, call the electrician to troubleshoot the sequence.

In the operator’s cab, verify that the air pressure displayed on the operator’s display is correct.

The machine cannot be operated until the air pressure is at the specified rating.

Manual No. 10500

2 - 38

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

7.

Verify that the brake switches are in the set position, the joysticks are in the neutral position and the air pressure is at the correct pressure. Sound the signal horn and be sure all personnel are clear of machine.

8.

Turn the propel transfer switch to the DIG position. When the Operator Display lights indicate that the process is complete, press the control reset pushbutton to activate the controls.

9.

Turn the hoist, crowd, swing and propel brake switches to their RELEASED position.

10.

Briefly actuate swing, crowd, hoist and propel controls to make sure each motion is operational.

RESTARTING AFTER AN ELECTRICAL FAULT To restart the machine after the electrical control system has gone into a fault condition, proceed as follows: NOTE: Before any or all motions can be reset, the following conditions must be met: a.

No operator’s monitor special screens should be activated.

b.

For hoist/propel motion the hoist/propel transfer switch is in the position called for by the operator’s mode selector switch.

c.

The master switch for the motion being reset must be in the neutral position.

d.

The motion mechanical brake selector switch must be in the released position.

1.

For hoist or crowd travel limit faults, the motion will first slow down and then will stop, but the controls will remain active. Reversing the master switch will remove the fault and allow continued operation.

2.

For a boom jacking fault, the motion will stop but the controls will remain active. Reversing the crowd master switch will remove the fault and allow continued operation.

3.

If the boarding ladder is pulled down while the machine is in operation, an alarm message will be sent to the operator and swing and propel motions will be shut down. The hoist and crowd motions will remain active.

Once the ladder is back in position, the motions may be restarted by pressing the control reset pushbutton.

4.

For most other faults, the machine will be shut down and the brakes set. In these situations, the controls cannot be reset until the fault has been corrected by an electrician.

August 2007

2 - 39

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

OPERATION Efficient operation is essentially the result of understanding and applying the basic techniques related to each machine motion, to achieve fast, smooth and safe load cycles. The interrelated coordination of the hoist, swing and crowd motions results in efficient machine operation.

Each motion is described in the following paragraphs. The operator should thoroughly learn each motion, its purpose and how this knowledge can be applied in becoming a better operator.

When learning to handle the controls, be sure that all personnel are clear of the machine and that there is ample clearance with no danger spots around the machine, such as culverts, ditches, embankments and that the machine is not too close to the digging face or overhanging ledge and large rocks.

Use the Operator Display panel, in the operator’s cab, to assist in the operation of the machine.

The monitor allows a large number of messages to be sent to the operator from all portions of the control system. These messages fit into four basic categories: 1.

Normal routine operational messages.

2.

Alarm only.

3.

Delayed shutdown messages.

4.

Immediate faults and shutdowns.

This monitor also allows the setting of certain operating parameters for the machine. Refer to the topic earlier in this section for detailed descriptions of the Operator Display monitor screens and how they relate to the proper operation of the machine.

Manual No. 10500

2 - 40

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MACHINERY MOTIONS HOIST MOTION Hoist motion is controlled by the operator’s right joystick. Set the propel transfer switch in the DIG mode. The crawlers should be positioned so that the digging is done over the front of the crawlers.

Move the joystick between the hoist and lower until a “feel” is developed for the height, depth range and speed at which the dipper moves. Practice the hoist function until movement can be stopped smoothly.

CAUTION:

August 2007

This joystick also controls the swing motion through left and right motions.

2 - 41

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD MOTION Crowd motion is controlled by the operator’s left joystick. Move the joystick to crowd and retract the dipper handle until a “feel” is developed for the limits and speed of the motion.

CAUTION:

This joystick also controls the signal horn and dipper trip.

Practice the crowd and retract functions until the movement can be stopped smoothly. Combine the crowd and hoist functions and practice until smooth coordinated motions and subsequent machine effectiveness are achieved.

Manual No. 10500

2 - 42

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PROPEL MOTION Propel motion is controlled by placing the propel transfer switch in the propel mode and actuating the hoist master switch control and/or crowd master switch control. To propel in a straight forward direction, push forward on both the hoist and crowd master switches at the same time. The speed is increased as the levers are displaced farther from neutral. To propel straight in reverse, pull equally both joysticks to the rear.

NOTE: The control stop pushbutton must be pressed before the propel transfer switch can be activated.

DANGER:

THE HOIST BRAKE MUST BE SET WHENEVER IN THE PROPEL MODE.

Propel - Straight Forward/Reverse

August 2007

2 - 43

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING MOTION Swing motion is controlled by the operator’s right joystick. To swing in either direction, move the joystick lever in the direction of swing. Practice swinging in each direction until a “feel” is developed for start-up and stopping.

NOTE: The joy stick also controls the hoisting and lowering of the dipper through forward and backward motions.

DANGER:

Each motion - hoist or swing - is fully operational throughout the complete movement of the other motion.

NOTE: When this joystick is used for propelling the machine, the hoist and swing motions are electrically locked out.

Manual No. 10500

2 - 44

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PROPER SWING MOTION Proper swing motion means smooth control and an efficient swing cycle. The swing motion is begun toward the haulage unit when the dipper is filled and is clear of the bank.

DANGER:

EXTENSIVE DAMAGE TO THE DIPPER HANDLE AND DIPPER CAN OCCUR IF THE MACHINE IS ROTATED BEFORE THE DIPPER CLEARS THE BANK.

The swing motion begins with acceleration to an optimum point at which the excavator is brought to a stop over the haulage unit. Maximum efficiency and minimum swing machinery wear are direct results of mastering the swing motion.

NOTE: Improper swing motion results in erratic control and an inefficient swing cycle.

DANGER:

August 2007

THE DIPPER SHOULD NEVER BE POSITIONED OVER PERSONNEL, TRAIL CABLES, RELATED ELECTRICAL EQUIPMENT OR OTHER EQUIPMENT. When the dipper is loaded, accidental tripping of the dipper door could result in death or serious injury to personnel and extensive damage to equipment. Empty dippers may contain small fragments of material that can be extremely dangerous when dropped from a considerable height. On long moves open the door on an empty dipper and lower the dipper to a point that permits moving without striking the ground.

2 - 45

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Time is required to accelerate any motion from zero to working speed and also to decelerate from working speed back to zero. THE TIME EXPENDED FOR ACCELERATING AND DECELERATING THE SWING REPRESENTS THE MAJOR PART OF THE ENTIRE DIG CYCLE. Therefore, the swing arcs must be kept to a minimum to obtain maximum operating efficiency. As an example: assuming that a 90° swing results in 100 percent of the maximum output, increasing the swing arc to 180° reduces output to 70 percent, while decreasing the swing arc to 45° increased the output to 126 percent. Therefore, a swing arc of 90° or less should usually be used.

Haul units should be positioned so their center line is approximately under or not more than slightly outside the swing path of the boom point. This substantially reduces the amount of dipper maneuvering required of the operator when positioning the dipper for dumping. Positioning of the haulage unit inside or outside the boom point makes it necessary to retract or crowd the dipper handle and dipper, which breaks the operator’s natural rhythm.

A clean, level pit floor must be maintained. A good operator will always clean the floor before moving into the bank. A clean and level floor grade is a requisite to safe and stable machine operation and reduces damage to crawler links and related components.

DANGER:

“SWEEPING” SHOULD NEVER BE ATTEMPTED WITH THE MACHINE. Sweeping consists of lowering the dipper to the ground and using the swing motion of the machine to move the dipper from side-to-side and “sweep” the pit floor. THE DIPPER, DIPPER HANDLE AND BOOM STRUCTURES CAN BE DAMAGED BY SWEEPING. A bulldozer or loader should be used to help the machine operator maintain a clean pit floor in conjunction with the shovel.

STEERING

To make a gradual forward right turn, move the LEFT joystick (crowd) forward and leave the right joystick (hoist) in neutral.

To make a gradual forward left turn, move the RIGHT joystick (hoist) forward and leave the left joystick (crowd) in neutral.

Manual No. 10500

2 - 46

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Whenever possible, gradual turns should be made in short increments of 15° to 20° maximum.

Propel straight for a short distance (usually 1/2 the length of the crawler belts) to clear the crawler belts of stone and other debris; then make another 15° to 20° turn. Continue until the turn is completed.

NOTE: When steering in soft material such as sand, clay, etc., increments of less than 15° to 20° should be used to minimize material build up on the crawler belt roller path.

August 2007

2 - 47

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

COUNTER-ROTATION TURNS Although possible, a single sharp turn should be avoided to minimize material build up on the crawler belt roller path. This results in high loading of the crawler belt and associated propel components.

To make a sharp right turn, move the LEFT joystick forward and pull the RIGHT joystick to the rear.

To make a sharp left turn, move the RIGHT joystick forward and pull the LEFT joystick to the rear.

CAUTION:

When using the counter-rotation method for turning, have a helper insure that the trail cable does not get fouled and/or torn from the machine.

NOTE: The ability of the machine to turn sharply is dependent on the surface on which the machine is setting. A soft surface will cause the crawlers to dig-in and machine to bogdown.

CAUTION:

The propel brakes are released when either joystick is moved from neutral. The propel brakes are set when both joysticks are returned to neutral.

When moving the machine in a straight line, propel forward, which is in the direction of the take-up axle to reduce strain on the crawler belts and propel mechanism. When not possible and propelling to the rear, make sure the trail cable is clear of the machine and follow the signals given by the helper. The machine should be rotated in a position to allow the operator to face the direction of travel.

NOTE: Turning when propelling to the rear requires that the master control be positioned in a direction opposite the actual direction in which the turn takes place.

The machine should be moved close to the bank in short and frequent moves to maintain digging efficiency. Movement should occur between the loading of haul units.

Manual No. 10500

2 - 48

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

POSITIONING THE MACHINE There are two basic methods for positioning the machine at the working face of the bank: the “back-up method” and the “drive-by method”. Both methods are acceptable and effective.

BACK-UP METHOD When using the back-up method, position the machine at the bank with the front of the machine facing the digging face. The haul units are spotted on both sides of the machine. The bank can be excavated until a 180° circular area of material has been removed from the bank. Once the material is removed, a 90° or greater swing will be required in order to load the haul units, requiring the machine to be moved.

To reposition the machine, propel to the rear, away from the bank, at an approximate 45° angle to the bank. When the machine is centered in-line with the untouched edge of the previous excavation, propel straight toward the bank and position the machine for further digging.

The back-up method will minimize the swing arc and reduce moving time, produce less bank toe area clean up and simplify handling of the trail cable, cable standard and trail cable boat.

August 2007

2 - 49

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DRIVE-BY METHOD NOTE: If mine conditions or equipment prevent the use of the following procedures, use the “Back-up Method” instead.

Position the machine crawlers parallel to the bank with the outer set of crawler tracks directly in line with the bank toe.

The haul units must approach the machine from the front, making a turn away from the machine as the unit’s front wheel approaches the outside crawler. Haul units then stop in a position to allow backing toward the point of the bank for loading.

During the load cycle, swing arc is to one side only and should not exceed 90°. The cycle time from one full haul unit to the next empty unit should not exceed the cycle time between successive dipper loads to each unit.

During the load cycle, the swing arc should not exceed 90°. The time between finishing one truck to the first digging cycle of the next should not exceed that of any cycle during a load.

Manual No. 10500

2 - 50

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

THE DIG CYCLE

Crowd motion forces the dipper lip into the bank at the start of the digging cycle. It is the crowd thrust which enables the dipper lip and front opening to get into a column of material of sufficient cross section to fill the dipper rapidly.

There is a direct relationship between crowd depth of bank penetration and the distance the dipper must rise in the bank to fill the dipper. The deeper the “bite” the quicker the dipper will be filled, providing the hoist force is sufficient to cut the column of material. Do not attempt to lift the entire bank with each pass. As soon as the dipper is full, retract it from the bank and swing to the truck.

Crowd penetration should be rapid just at the arc of entry and rise as the dipper enters the bank.

This will permit as much digging as possible near the base of the bank. This is of particular advantage when digging loose or blasted material. The greater the hoist force and crowd thrust, the faster the dipper filling time of the dig cycle. The crowd thrust should be maintained to hold the dipper in the bank while it is being hoisted. An added benefit of proper crowd thrust and hoist force is that the opposing vertical resistance of the bank material tends to have a “ramming” effect in the dipper front opening, minimizing voids and producing larger dipper

It is important that the full cutting surface of the dipper contact the bank on each pass. A full face cut combined with deep bank penetration will result in a full dipper for the least amount of hoist. A partial cut, even with deep bank penetration, requires a greater rise and tends to leave voids in the dipper, requiring additional passes to fill the haulage unit.

August 2007

2 - 51

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Shallow bank penetration of the arc of entry and rise is ineffective and inefficient. A shaving cut dribbles material into the dipper resulting in voids and making additional passes necessary while accelerating dipper lip wear.

Digging should take place under the boom point for maximum shovel effectiveness. If necessary, the machine should be moved closer to the bank face, rather than extending the dipper handle.

Reaching for material results in a partially filled dipper and excessive crowd and retract time. Use caution not to damage the boom point sheaves when operating close to the high wall.

Variations on Dipper Penetration

Manual No. 10500

2 - 52

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Overcrowding with the dipper lowered can result in lifting the boom. This jacking action can result in damaged components. Overcrowding the dipper in the bank slows up the dipper loading process, thereby reducing machine efficiency.

ENGAGING THE BANK

To make maximum use of the hoist rope pull, the dipper rise should be as close to vertical as possible.

The dipper should enter the bank approximately under and behind the boom point. The actual cut should start a few degrees behind an imaginary vertical line from the front of the boom point sheaves. Proper bank engagement results in maximum hoisting force in line with the cut. When the dipper is too far forward, bank penetration will be minimal and the hoist and crowd forces will oppose each other rather than working together.

Dipper capacity rating is the struck measure cubic yard capacity. When digging, a load greater or less than the rated capacity may be obtained, depending on the type of material. An efficient operation can be measured by the number of dipper loads required to load a haulage unit. When the dipper capacity is efficiently sized to the truck capacity, not less than three or more than five dippers full should be required to load a unit. Other factors such as improper sizing of haulage units to dipper, improper material fragmentation, etc., also must be considered.

August 2007

2 - 53

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

In all types of digging the skilled operator must carefully control the desired depth of cut and control the hoist power requirements. Often, digging situations are encountered which require hoist and crowd motions to maneuver around oversize or lodged obstructions in the bank, rather than attempting to lift the entire bank.

DANGER:

MAINTAIN A DIGGING FACE WHICH AVOIDS ANY MAJOR SLIDES WHICH COULD CAUSE AN ACCIDENT. Examine the digging face for large boulders, large rocks, or frozen material which could slide and cause an accident. Avoid overhanging material.

Do not repeatedly stall the dipper in the bank, nor maintain a stall condition. The life expectancy of the hoist machinery and hoist ropes is directly related to the operator’s skill in avoiding stalling. Whenever stall conditions are encountered, back off on the hoist motion, retract the dipper, or do both. Avoid stall conditions at all times.

DANGER:

DO NOT SUSPEND A LOADED OR EMPTY DIPPER IN THE AIR WITH THE BRAKES SET FOR LONG TIME PERIODS. Lower the dipper to the ground if the machine is to be idle or unattended for any length of time. Failure to comply can result in personal injury or death of anyone beneath the dipper.

For most efficient production, the dipper should be loaded from the most remote point while waiting for a truck. When the truck is positioned, excavating should begin close to the haulage unit, progressively working away from the unit.

This technique saves time by allowing smooth, short dig cycles and eliminates excessive swing, crowd and retract motions.

Manual No. 10500

2 - 54

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SLOPE LIMITATIONS While it is strongly recommended that the machine dig on level ground for the greatest possible productivity and the longest component life, limited operation on slopes up to 8% is, however; acceptable with only minimal adverse effects.

NOTE: It is important to remember the difference between Slope Percent and Degrees!

Slope vs. Degrees

August 2007

2 - 55

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Rollover and Operation Limits

EXCAVATED MATERIAL It is important that the operator not only know the controls but recognize other aspects of the mining operation. Chief among these is the type of material to be excavated. It plays a great part in the overall efficiency of the machine.

Materials can be roughly divided into four categories.

1.

EASY DIGGING - This category includes all loose, free-flowing materials, such as sand and gravel deposits, stock pile materials such as finely crushed stone, ore fines, coal fines and any other similar materials. The dipper will usually obtain a heaped load.

2.

MEDIUM DIGGING - This category includes only materials which can be excavated from their natural beds without blasting and which break up in bulk with some voids. Such material includes clay, dry earth, clay-gravel mixtures, gravel with some boulders, certain types of ores and coal. The dipper will usually obtain a full load, with filling augmented by the material’s natural tendency to break apart when it encounters the dipper lip and teeth.

Manual No. 10500

2 - 56

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

3.

HARD DIGGING - Included in this category are materials that require blasting, resulting in good fragmentation, but leaving large chunks which develop voids. Limestone, gypsum shale, cemented gravel, wet earth, clay and certain types of ore and overburden all fall within this category. The dipper will average less than a full load because of the resistance of the material against flow and voids due to blocky material

4.

VERY HARD DIGGING - This category includes all materials that require heavy blasting and give irregular fragmentation. Taconite, granite, laminar shale, certain types of limestone and conglomerate overburden fall into this category. The dipper will average considerably less than a full load, because of the large chunks and interlocking action of the material which block fill.

OPERATION CHECKS During machine operation there are several things to consider relative to safe, efficient machine operation.

1.

Check the motors for unusual noise, loss of power or failure to respond to controls.

2.

Check hoist, crowd, swing and propel machinery for unusual sounds and overheating of bearings.

3.

Avoid slack hoist ropes which could allow the ropes to become crossed on the drum, or skip a groove.

4.

Check the air gauge frequently and investigate immediately if there is a drop in air pressure.

Correct all air leaks.

5.

When propelling, check the engagement of the drive tumblers on the crawler belt links and adjust the belts to correct any improper alignment.

6.

When operating auxiliary functions, such as steering, note any tendency of the controls to jam or hang up. Check and correct any problems at the earliest opportunity.

August 2007

2 - 57

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

OPERATING HINTS The following hints are reminders of the do’s and don’ts related to excavator operation: • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Engage the bank properly.

Load with the successive pass technique.

Maintain a clean pit floor.

Use proper hoist control.

Make effective use of the hoist pull.

Use proper crowd control.

Force the dipper lip into the bank at the arc of entry.

Crowd the dipper into the bank for deep penetration.

Make full face cuts for faster loading cycles.

Dig under the boom point.

Make smooth, safe swing cycles.

Keep swing arcs within 90°.

“Spot” the haulage units properly.

Keep the working faces free of projections.

Propel forward whenever possible rather than backward.

Move up to the bank frequently.

Dig over the take-up axle end of the crawlers whenever possible.

Make gradual turns when propelling.

Do not suspend a loaded dipper for an extended time.

Do not operate too close to material.

Do not operate with missing dipper teeth.

Do not stall hoist or crowd motions.

Do not reach for material.

Do not reach for haulage units.

Do not overcrowd and jack the boom or machine.

Do not make partial face cuts.

Do not make shallow bank penetration.

Do not make erratic swings.

Do not swing until dipper is clear of the bank.

Do not swing loaded or unloaded dippers over personnel or equipment.

Do not “sweep” pit floor.

Do not make sharp turns when propelling.

Do not make long inefficient moves.

Do not exceed swing arc of 90°.

Do not spot haulage units inside or outside the boom point swing arc.

Maintain adequate clearance between digging face and point sheaves.

Do not allow the dipper to contact the crawler belts.

Manual No. 10500

2 - 58

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

STOPPING THE MACHINE 1.

Return Hoist and Crowd joysticks to their center positions and set all brake switches.

2.

After all motions are stopped and brakes are set, press the CONTROL STOP pushbutton.

This action will remove power to the control units and set the brakes. The controls will become inoperative.

3.

To stop the machine completely and remove power from the drives, press the MACHINE STOP Pushbutton on the right operator’s console.

MACHINE SHUTDOWN When shutting down the machine at the end of a shift proceed as follows: 1.

Park the machine on firm ground in a position where it cannot be damaged by a slide, falling rocks or flooding. In cold climates, be sure the crawler belts will not freeze into the ground.

2.

Place the dipper firmly on the ground.

3.

Make sure Hoist and Crowd joysticks are in their center positions.

4.

Make sure all brake switches are in their SET positions.

5.

Press the CONTROL STOP pushbutton. All primary controls should be de-energized.

6.

To de-energize the DC bus, press the MACHINE STOP pushbutton on the remote start console or the MACHINE STOP/EMERGENCY STOP pushbutton on the operator’s console.

7.

Place the air compressor switch on the remote start console in the STOP position.

8.

Close all windows in the cab and lock all cab doors.

August 2007

2 - 59

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

2 - 60

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

3

Lubrication Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents LUBRICATION PRINCIPLES ......................................................................................................... 3 GREASING MAIN A.C. DRIVE MOTORS ...................................................................................... 4 1. TYPE OF GREASE ....................................................................................................... 4 2. INITIAL COMMISSIONING .............................................................................................. 4 3. MAINTENANCE ............................................................................................................. 4 4. REGREASING INTERVALS ........................................................................................... 5 LUBRICANT SELECTION ............................................................................................................. 6 OIL FILL CAPACITIES ................................................................................................................... 7 TYPES OF LUBRICANTS AND CAPACITIES ................................................................... 7 QUANTITIES FOR FIRST FILL OF LUBRICANTS ............................................................ 7 AUTOMATIC LUBRICATION SYSTEM .......................................................................................... 8 LUBE ROOM................................................................................................................................. 9 Lubrication Room Details ...................................................................................................................... 9

AUTO LUBE CONTROL PANEL ......................................................................... 10 LOWER WORKS LUBRICATION ................................................................................... 11 Lube System A2 - Lower Works OGL Piping ....................................................................................... 11 Lube System A2 - Lower Works OGL Manifold .................................................................................... 12 Lube System C2 - Lower Works Grease Piping ................................................................................... 13

PROPEL MACHINERY LUBRICATION ............................................................................ 14 Roller Axle Positioning for Proper Lubrication ...................................................................................... 14

LUBRICANT REPLACEMENT/SAMPLING .......................................................... 15 LUBRICANT CHANGE CYCLE ................................................................ 15 REVOLVING FRAME LUBRICATION ............................................................................... 16 HOIST MACHINERY LUBRICATION ................................................................................ 17 HOIST GEARCASE OIL COOLER .................................................................................. 18 CROWD MACHINERY LUBRICATION ............................................................................ 21 SWING MACHINERY LUBRICATION .............................................................................. 22 Swing Machinery Components ............................................................................................................. 22

AIR COMPRESSOR LUBRICATION ............................................................................... 23 CROWD ROPE TAKE-UP MECHANISM LUBRICATION ............................................... 23 FRONT END LUBRICATION ........................................................................................... 24 LINCOLN TYPE SL-1 LUBRICANT INJECTORS ............................................................ 25 LUBRICANT INJECTOR OPERATION ................................................................ 26 INJECTOR ADVANTAGES................................................................................... 27

August 2007

3-1

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

ADDITIONAL LUBRICATION BENCHMARKS: EGL - ENCLOSED GEARCASE LUBRICANT (495H) ...................................................... (insert) MPG - MULTIPURPOSE GREASE ................................................................................... (insert) OGL - OPEN GEAR LUBRICANT ..................................................................................... (insert) CERTIFIED LISTING FOR OGL, MPG AND EGL LUBRICANTS ...................................... (insert)

HYDRAULIC SCHEMATICS .................................................................................................(insert)

Manual No. 10500

3-2

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LUBRICANT SELECTION The selection of the proper lubricants for use on this machine is critical to its reliability. Improperly lubricated bearings, gears, couplings and other precision parts quickly fail. For this reason, lubricants selected in accordance with the “American Standards Testing Material” (ASTM) standards are recommended. These standards were compiled in cooperation with major petroleum suppliers to ensure the consumer of an exact supply to specific requirements, regardless of source.

We recommend you advise your petroleum supplier of the following information to assist him in selecting the proper product for each application of this machine.

Final acceptance of all lubricants supplied to this standard will be based upon their satisfactory performance in the intended application and does not relieve the supplier of performance responsibility for brand name products.

Operation of this machine in extreme temperatures (below -20°F/-29°C or above 110°F/44°C) requires special lubrication. Note the temperature ranges on the following lubricant specification sheets. Contact your local supplier, your Bucyrus representative, or the Service Department of you local Bucyrus International office for recommendations if you require additional information or advice.

•

STORE LUBRICATION DRUMS ON THEIR SIDE, WITH THE OPENING TOWARD THE TOP.

•

STORE ALL LUBRICANTS IN TIGHTLY COVERED CONTAINERS!

•

WIPE OFF COVERS AND SURROUNDING AREA BEFORE OPENING!

•

FILTER ALL OIL BEFORE ADDING IT TO THE SYSTEM!

•

USE ONLY CLEAN and PROPER LUBRICANTS!

•

DO NOT MIX TYPES or BRANDS of LUBRICANTS!

Even the best lubricants are less useful in preventing wear if they become contaminated by dirt or water due to careless handling or storage.

Manual No. 10500

3-6

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

3

Lubrication LUBRICATION PRINCIPLES The proper lubrication of this machine is vital to its successful, continued operation. Application of the CORRECT lubricant in the CORRECT amount at the CORRECT place as part of a PROVEN maintenance program is required to keep the machine operating at a level of productivity that will make your mining operation profitable. Proper lubrication will provide better component service life with a reduction of repairs and downtime. When not properly lubricated, moving parts wear quicker and fail sooner.

The primary wear items of this machine are lubricated by an automatic system that dispenses lube to selected points at pre-selected, timed intervals during machine operation. This system is covered in more detail further on in this section. It is important to the operation of this automatic lube system that you become familiar with it and understand its operation in order to properly maintain and service it, thus keeping it operable. It is also necessary that you inspect on a regular basis the points for automatic lubricant application to insure the system is performing its job adequately.

Some components, due to their location and function, can not be readily covered by the automatic lube system. You should become familiar with these points so you can service them properly at the intervals listed. A listing of the parts covered by the automatic lubrication system is included later in this section. The standard lubrication fittings used for manual service are the hydraulic type, push-on fittings having 1/8 inch or 1/4 inch NPT threads.

Bushings and bearings operating in a highly contaminated atmosphere (dust, grit, etc.) should be lubricated until clean grease seeps out around the journal or seal, or comes out the purge fitting, if one is provided.

Overfilling an anti-friction bearing can cause it to run excessively warm. After lubricating anti-friction bearings (those that are sealed such as in electric motors must use electric motor grease) remove the pressure fitting, or the relief plug when provided, allowing the bearing to purge itself of any excess lube during the first 10-15 minutes of operation. Replace the fitting or plug after that time.

Grease in a bearing generally deteriorates gradually, not suddenly. Only a small amount needs to be added to it at regular intervals to maintain the proper lubricant level. Adding a small quantity of grease to the bearing every 600 operating hours, unless otherwise specified, is adequate.

Open gears and pinions require a constant coating of high grade lubricant which is specified for operation. Inspect all open gear sets at least once daily (every 24 hours) to ensure they are coated with OGL. CAUTION:

August 2007

Contact with or ingestion of petroleum products can be harmful.

Automatic lubrication systems operate under pressure. Before opening any lube supply line, relieve the system and that line in particular, of any residual pressure.

3-3

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

GREASING MAIN A.C. DRIVE MOTORS Main drive motors are shipped from the factory with the bearings packed with grease. A lubrication information plate is mounted on each motor with greasing instructions and the correct quantity or grease to be added. Main drive motors for Bucyrus International machines have their inlet tube filled with grease and include nameplates attached to the motor indicating “grease inlet” and “grease drain”.

An improper greasing procedure will cause premature bearing failure. Mixing of non-compatible lubricants will result in lubricant breakdown and bearing failure. Proper lubrication is important for all aspects of bearing life.

NOTE:

This information covers main drive motors manufactured by Siemens, Norwood, Ohio.

It does not apply to NMA style motors manufactured by Siemens Germany.

1. TYPE OF GREASE NOTE:

Motors are shipped with Mobil SHC 100 NLGI #2 grease installed in the bearings. This grease has a lithium complex soap thickener and a synthetic base fluid having a base oil viscosity of 40 cSt @ 40C. Caution:

Do not mix greases with different thickeners since the greases may not mix properly and bearing failure may result.

2. INITIAL COMMISSIONING Prior to initial start-up, the bearings should be greased. The normal maintenance regreasing procedure, item 3, should be used except the quantities should be doubled.

3. MAINTENANCE This procedure should be used for regular maintenance regreasing. Refer to the following table, item 4, and/or lubrication information plate on each motor for regreasing intervals and type and quantity of grease to be used. a.

Stop the motor and lockout the starter.

b.

Remove and thoroughly clean the grease inlet fitting or plug.

c.

Remove the drain plug and clean out any hardened grease.

d.

Determine the correct amount of grease required for the bearings.

Manual No. 10500

3-4

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

NOTE:

The drive end bearing and the non-drive end bearings require different quantities of grease.

e.

Slowly pump the correct amount of grease into the grease inlet.

f.

Reinstall the inlet plug that was removed.

g.

Clear the lockout switch and start the motor.

h.

Allow the motor to run at least for one (1) hour to vent the bearing housing and to allow the expulsion of any excess grease from the drain opening before reinstalling the drain plug. (If it is not practical to run the motor for one hour and then stop the motor, it is acceptable to reinstall the drain plug without damage to the bearings or seals.)

i.

Stop the motor and lock out the starter. Reinstall the drain plug.

j.

The motor is now ready to be put back in service.

4. REGREASING INTERVALS The regreasing interval can be found in the following table. Follow either the recommended operating hours, or the time interval, which ever comes first.

Drive End Grease Amount Grams (oz.)

Non-Drive End Grease Amount Grams (oz.)

3000 operating hours or every 6 months

88 (3.1)

140 (5.0)

Propel motor

3000 operating or every 6 months

54 (1.9)

94 (3.3)

Crowd motor

3000 operating or every 6 months

54 (1.9)

94 (3.3)

Swing motor

1500 operating or every 4 months

54 (1.9)

80 (2.8)

Motor Hoist motor

Regreasing Interval

NOTES: 1.

It is critical that the drain pipe not be allowed to become plugged with caked or contaminated grease. If it does, then the pipe must be cleared.

2.

A common mistake is over-lubrication of bearings. When grease is added without removing the drain plug, the excess grease can be forced into and through the grease seals leading to grease leakage along the shaft (out of the motor or into the motor and possibly onto the motor windings). Proper lubrication is desired, but some under-lubrication is less harmful than over-lubrication.

3.

Bucyrus part number 59100651 is a 14 ounce cartridge of Mobilith SHC100 grease.

August 2007

3-5

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

OIL FILL CAPACITIES

TYPES OF LUBRICANTS AND CAPACITIES Description

Type

Gallons

All open gearing, bushings & dipper handle

OGL

275

Most, anti-friction bearings

MPG

137

Crowd, enclosed gearing - 1st. reduction

EGL

7

Crowd, enclosed gearing - 2nd. reduction

EGL

10

Propel, final drive bearings

MPG

27

Propel, planetary 2-cases

EGL

140

Swing, planetary 2-cases (Flender)

EGL

172

Hoist, planetary case (Flender) w/cooler

EGL

115

OGL bulk lube tank

OGL

200

Grease bulk lube tank

MPG

100

QUANTITIES FOR FIRST FILL OF LUBRICANTS Gallons

Drums

Type

Description

475

8.6

OGL

Open Gear Lubricant

264

4.8

MPG

Multi-Purpose Grease w/EP Additives

444

8.1

EGL

320

NOTE: 1 drum = 55 gallons = 208 liters

August 2007

3-7

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

AUTOMATIC LUBRICATION SYSTEM THE AUTOMATIC LUBRICATION SYSTEM IS NOT DESIGNED TO PROVIDE INITIAL COVERAGE. New parts installed or those cleaned during maintenance procedures must be fully lubricated before commencing machine operation. Anti-friction bearings and bushings must be hand packed or thoroughly coated with the correct lubricant. Open gearing and moving contact surfaces must be completely covered with their lubricant. Do not permit the lack of lubricant at start-up to cause you to redo a repair job!

NOTE: The greatest amount of wear to be experienced by any moving part will take place during the first few cycles, or operating hours. A lack of proper lubrication can destroy a new part at a dramatically increased rate over the normal wear patterns experienced.

Enclosed gearcases must have their recommended lubricant level maintained at the prescribed level. Check the lubricant level at the oil level plug or with the dipstick at least once weekly (every 150 hours). Inspect them daily (every 24 hours) for leaks. Change the oil in the gearcase at their recommended intervals while flushing each case with a light lube oil before adding the new gear oil.

ALWAYS STORE THE USED OIL IN A SAFE CONTAINER UNTIL PROPERLY DISPOSED. DO NOT POLLUTE THE ENVIRONMENT! Bucyrus International recommends that scheduled oil samplings from the enclosed gearcases and air compressor crankcase on this machine be taken and tested by an authorized, reputable lab to determine the contamination level of the sump oil. These samples should be obtained and tested every 30 operating days (600 hours). They should be taken when the oil is at its normal operating temperature and is well mixed in the case, so the samples are representative of actual conditions.

This diagnostic maintenance procedure will permit you to determine the condition of internal components within the operating gearcases. Increases in the presence of certain metallic types can be analyzed with the Bucyrus International Service personnel to determine the best time to change the oil, thus obtaining its best service life. This will simultaneously allow you to monitor the condition of the components and address situations in their infancy instead of after a catastrophic breakdown. This program will pay you dividends in the long run.

If a sample diagnostic system is undertaken, it is imperative that adequate records be maintained of the maintenance and component history of the items in question. Without these records, there will be no adequate data by which to compare any changes or occurrences and make realistic determinations.

Wire Rope Lubrication dislodges with the movement of one strand against another. Moisture can then enter the stranding and cause deterioration of the wire rope. The areas where the greatest deflection occurs are most susceptible to this contamination and early failure. On pendants, it is at or near the sockets. On other wire rope applications, such as the hoist rope, it is at the sheaves or lagging. To increase the service life of any wire rope, apply the proper wire rope lubricant (WRL) to the areas of its greatest deflection at periodic intervals.

Lubricant Service Life is adversely affected by unusually dusty or dirty environments and atmospheres where extreme high humidity or temperatures exist. It shall, therefore, be the responsibility of the owner/operator of this machine to determine the most effective lubricant and lubrication interval for all the components according to the environmental conditions that prevail.

Manual No. 10500

3-8

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LUBE ROOM The lubrication room is located at the left front corner of the machinery house. The lube room can be accessed from the walkways external to the machinery house. The lube room contains the pumps, tanks, transducers and the basic components associated with the automatic lubrication system of the machine.

Lubrication Room Details

(Looking toward the rear of the machine.)

August 2007

3-9

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

AUTO LUBE CONTROL PANEL The Automatic Lubrication Control Panel is mounted on the right hand wall of the lubrication room.

The panel provides the switches and override functions required to activate, reset and override the automatic functions, POWER ON -

Indicates the autolube system is energized.

LUBE FAULT -

A light that, when lit, indicates that a fault is present in that system. Reset the fault by turning the affected system off and then on.

MANUAL LUBE - A pushbutton that will disperse (on command) 1 measured quantity of lubricant to the injectors on that system.

ON /OFF -

Manual No. 10500

Energizes the system for normal operation.

3 - 10

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LOWER WORKS LUBRICATION Although this machine does not spend very much time being propelled between digging sites, there are considerable forces exerted on the lower works of the machine. The severe loads and oscillations created during the constant cycles of the digging process tend to squeeze the lubricant out of bushings, creating a circumstance for wear if proper lubrication habits are neglected.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

-

Take Up Axle, left Upper Roller, front left Upper Roller, 2nd from front left Upper Roller, center left Center Pintle Bushing, right Upper Roller, center right Upper Roller, 2nd from front right Upper Roller, front right Take Up Axle, right Lower Roller Axle, front right Lower Roller Axle, 2nd from front left Lower Roller Axle, 2nd from front left Lower Roller Axle, front left Upper Roller, rear left Lower Roller Axle, rear left Upper Roller, 2nd from rear left Lower Roller Axle, 2nd from rear left Center Pintle Bushing, left Upper Roller, rear right Lower Roller Axle, rear right Upper Roller 2nd from rear right Lower Roller Axle, 2nd from rear right

Lube System A2 - Lower Works OGL Piping

With the high possibility of operation while submersed in water the applied lubricant should have properties which allow for protection under theses circumstances.

When propelling over any long distances the machine should be lubricated at least every 1500 feet of travel, or every ½ hour. Bearings and bushings should be carefully watched and force lubricated until they run cool if evidence of heat build-up is apparent.

Under extremely harsh conditions such as propelling up a hill, frequent turns, or through deep water and mud the lubrication frequency should be increased.

August 2007

3 - 11

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Lube System A2 - Lower Works OGL Manifold

Manual No. 10500

3 - 12

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Lube System C2 - Lower Works Grease Piping

August 2007

3 - 13

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PROPEL MACHINERY LUBRICATION Propel planetary gearcases should be checked every 48 hours. Inspect the lubricant level with the machine on level ground and add the required amount of the recommended lubricant if necessary.

If water has accumulated within the gearcases, remove the drain plug and drain into a container for waste removal, then refill with clean lubricant.

When radical changes in temperature, or at the recommendation of a testing facility, make it necessary to change the lubricant within a gearcase, it is advised to drain the box immediately after propelling the machine. This will allow for a more thorough removal of contaminants and foreign material due to the elevated temperature and suspension of particles within the lubricant.

The center pintle is lubed through 2 ports to the bushing in system A2 and through 1 port to the thrust washer in system B1. The tumbler bearings are lubed through system C2.

Roller Axle Positioning for Proper Lubrication

For all machinery motions - Hoist, Crowd, Swing & Propel - the gearcase lubricant should be first changed after approx. 500 machine operating hours.

The lubricant should then be changed every 6,000 hours or 12 months thereafter, whichever comes first. Flush the gearcase prior to refilling with new oil.

Manual No. 10500

3 - 14

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LUBRICANT REPLACEMENT/SAMPLING The recommended mineral oils should have additives that improve corrosion protection and aging resistance, as well as reduce wear in the mixed friction field. Polyalphaolefin oils (oils on the basis of synthetic hydrocarbons) as well as bio-oils (oils on the basis of synthetic ester) which satisfy the demands specified for industrial type gear oils according to DIN 51517, part 3, are also permitted.

Designation to DIN 51517 part 3 : .................CLP 220 ISO viscosity to DIN 51519 : .........................ISO - VG 220 Kinematic viscosity at 40° C : .......................min. 199 mm2/s (cSt) max. 242 mm2/s (cSt) FZG test A /8,3/90 to DIN 51354, pg. 2 : ........min. breakdown load stage 12 The lubricant is to be selected from a proven, stable, and reliable lubricant vendor that meets the above listed specification.

It is strongly suggested that the gearcase lubricant be part of a routine spectrometric oil analysis program to forecast impending problems and thereby reduce the possibility of catastrophic failure.

This analysis should take place every 250 propel hours and monitor the elements listed in the following table, at a minimum: Element

Normal

Excessive

Critical

Iron

<400

400-700

>700

Copper

<25

25-60

>60

Chromium

<5

5-15

>15

Silicon

<40

40-60

>60

NOTES: 1. All values are Parts per Million.

2. Particle count may be higher during the initial run-in period.

3. The oil should be changed when any element value exceeds normal levels.

4. Maintain an analysis record using the gearcase serial number and machine operating hours.

LUBRICANT CHANGE CYCLE To fill the propel gearcase, remove the inboard plug at the center of the gearcase. Remove the oil breather at the top of the gearcase and fill the gearcase with oil until oil flows from the unplugged port. Replace the removed plug. Oil capacity is approx. 70 US Gallons (265 liters)

August 2007

3 - 15

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

REVOLVING FRAME LUBRICATION Always keep the swing rack and roller path coated liberally with the proper lubricant and check daily. In the event of severe accumulations, remove accumulated material and re-lubricate the area before placing the machine back into service.

Although the machinery contained within the house is not exposed to the extreme conditions of some other machine components, the loading and stresses exerted on this equipment are severe.

Longevity of these components is largely dependent upon proper lubrication.

Spray valves are mounted at the same height on both sides of the pinion. The spray valves receive air from the brake lines and lube from system B1.

Manual No. 10500

3 - 16

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST MACHINERY LUBRICATION The hoist machinery drive is comprised of 2 stages of gear reduction. The first stage gear reduction is an enclosed system running submersed in lubricant. The gearcase housing is equipped with lubricant level check plugs on the right side of the case. A filter breather is provided to allow for air entry to equalize pressure differentials created by the warming and cooling of the gearcase, allows moisture to escape and prevents contaminants from entering.

The second stage of gear reduction is operating as a semi-enclosed system lubricated by OGL. The drum shaft bearings are grease lubricated by System “C-1” along with the intermediate shaft of the hoist gearing. The motor pinion shaft bearings are splash lubricated from the 1st stage gearcase.

August 2007

3 - 17

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST GEARCASE OIL COOLER Located under the deck of the revolving frame, directly below the hoist gearcase and motor, is the hoist gearcase oil cooler. The oil cooler is a dual unit assembly provided to reduce heat generated by motion of the hoist gearcase.

The motor and two cooler units are mounted on welded supports specifically fabricated for this purpose.

Oil is drawn from the gearcase sump through a 1st stage filter. The oil is then pumped via the pump motor (through a tee) to one of two forced-air oil coolers mounted side by side. Leaving the cooler, the two lines rejoin and the oil is forced through a 2nd stage filter before being returned to the gearcase sump.

Oil pressure in the cooling system is monitored via pressure and vacuum transducers to ensure a constant flow of hoist gearcase oil through the cooling circuit.

Manual No. 10500

3 - 18

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Should the coolers require any service involving removal or replacement, use the following procedure for removal.

1.

Drain any fluid from the cooler, oil pump and any lines between the cooler and the hoist gearcase.

2.

Disconnect the fluid lines at the oil pump and oil filter.

3.

Support the cooler and support beam assembly with a jack (or several jacks as necessary) beneath the base of the cooler being removed.

DANGER

DO NOT PROCEED UNTIL THE COOLER AND SUPPORT ASSEMBLY IS FULLY SUPPORTED. The weight of each of the coolers is approximately 800 Lbs.

4.

With supports and cooler fully supported, remove the .75 inch capscrews (16 places) that fasten the four vertical posts to the supports of the revolving frame.

5.

Carefully lower the cooler and support assembly down and out from beneath the revolving frame.

The cooler, cooler motor and/or oil pump can now be repaired or replaced.

August 2007

3 - 19

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

The cooler pump and pump gearcase can be serviced without removal of the cooler or support structure.

The 1st stage filter is located in the line between the hoist gearcase sump and the pump motor.

Access to this filter is gained by first closing the valve between the sump and filter, and then removing the six cap screws at the end of the filter cartridge assembly. Remember to open the valve in the line prior to restarting the cooling circuit.

The 2nd stage filter assembly is in the output line at the rear of the cooler assembly, and is located directly behind the hoist planetary gearcase above the deck. The filter cartridge can be replaced by removing the screws and cover at the top of the filter canister.

NOTE

A clogged filter switch is present at the 2nd stage filter and is monitored by the control system to ensure constant flow though the hoist gearcase cooling circuit.

Manual No. 10500

3 - 20

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD MACHINERY LUBRICATION The crowd machinery includes 2 gearcases. The crowd first and second stages of gear reduction are totally enclosed systems submerged in gear lubricant. The gearcase is provided with it’s own level plug to check for adequate lubrication, and a filter breather. The third stage of gear reduction, the crowd drum gear, is lubricated by OGL from system “B-1”. The bearings of the crowd drum, along with the shafts of the crowd reduction system are lubricated by grease from system “C-1”

August 2007

3 - 21

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING MACHINERY LUBRICATION The swing machinery is primarily composed of an enclosed planetary gearcase on either side of the machine’s swing rack. The gearcases are self contained units with their own individual pump, filtering system and lubricant reservoir. Lubricant levels should be checked at least every 48 hours with a visual inspection for leakage at the start of each shift.

Swing Machinery Components

Manual No. 10500

3 - 22

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

A filter breather is provided on each planetary gearcase to allow for air entry to equalize pressure differentials created by the warming and cooling of the gearcase, to allow moisture to escape and to prevent contaminants from entering.

The swing pinions and lower swing shaft bearings are lubricated with open gear lubricant from System “B-1”.

AIR COMPRESSOR LUBRICATION The air compressor supplied with the machine has very specific lubrication needs. For the details of servicing this equipment you should refer to the manufacturer’s instructions and the specific lubricant recommendations made later within this section.

CROWD ROPE TAKE-UP MECHANISM LUBRICATION When repairing and reassembling the take-up mechanism, fully coat all contact surfaces with Molykote before assembly.

This includes the screw rod, take-up guide, worm gear housing, worm gear wheel, worm shaft, shaft bushings and shaft thrustwashers. Refer to CROWD ROPE TAKE-UP MECHANISM in Section 5 - SERVICE PROCEDURES in this manual for the proper assembly procedures.

With the mechanism fully assembled, pump grease into the worm shaft housing at the base of the worm shaft. Approximately 1.5 gallons of grease are required.

August 2007

3 - 23

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

FRONT END LUBRICATION The front end equipment is exposed to the most extreme working environment of any part of the machine. The proper amount of lubrication and its quality is imperative to achieving a substantial service life from these components. Daily inspection and monitoring of the lubrication system will result in both parts durability and the reduction of machine downtime.

Boom Foot Pins:

Although not under constant movement during the operation of the machine, the boom point feet are subjected to high loads and oscillations in a variety of directions. Virtually all movement of the front end equipment will exert a load on the pins. OGL is introduced from lube system “A-1” to reduce wear.

Saddle Block:

The saddle block bears the brunt of movement from the dipper, dipper handle, attached equipment and any material being moved. The saddle block lube points need to be checked at least before each shift to avoid dry spots and accumulations of foreign material. The saddle block lube to the handle is received from lube system B-2. The crowd sheaves and shipper shaft bushings lube is received from lube system A-1.

Sheaves:

Both fixed and rotating front end sheaves are subjected to loads introduced by the ropes as they move the larger components of the machine. The sheave bearings on the boom point, the crowd sheaves and the connection points of the structural strands are lubricated by lube system “A-1”.

Wire Ropes:

Running and structural wire ropes have very specific requirements for lubrication in order to survive the difficult conditions they are forced to operate within. Without proper lubrication and maintenance the expected life of costly wire ropes will be seriously degraded. Refer to Section 9 ENGINEERING DATA for general care and maintenance of wire ropes.

Suspension Ropes: The suspension ropes support the boom as well as the rest of the front end equipment. These ropes are under constant tension but also sustain additional loads during machine operation. Lubricate the suspension rope sockets approx. every 3 months or 1250 hours of machine operation.

Manual No. 10500

3 - 24

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LINCOLN TYPE SL-1 LUBRICANT INJECTORS These pressure-operating, spring-reset, series-installed injectors are supplied in banks mounted on manifolds or individually. Each injector expels a maximum of .08 cu. inch of lubricant from its outlet port each cycle. Dual outlet ports on each injector permit the injectors to be piped in series for increased lube supply to a common point. The quantity of lube to each point on this machine has been carefully designed by our engineers for proper coverage. Each injector output can be adjusted; however Bucyrus recommends that injectors initially be set and used at their maximum setting.

NOTE:

MAXIMUM Operating Pressure: RECOMMENDED Operating Pressure: MINIMUM Operating Pressure: MAXIMUM Recharge Pressure: CAUTION:

3,500 2,500 1,850 600

PSI PSI PSI PSI

STORED ENERGY! Contact with or ingestion of petroleum products can be harmful. Automatic lubrication systems operate under pressure.

Before opening any lube supply line, relieve the system and that line in particular, of any residual pressure.

To set an injector for maximum output: 1.

2.

3.

4.

Loosen locknut.

Turn adjusting nut until there is a small gap at the top of the stem.

Orient the adjusting nut so that the opening is toward the front of the injector.

Tighten the locknut.

To reduce an injector’s output: 1.

2.

3.

Loosen locknut.

Turn adjusting nut clockwise (CW) until desired discharge rate is obtained. This forces the stem into the body, retarding the stem’s movement.

Set the locknut.

CAUTION: Do not turn adjusting nut down (clockwise) more than 5 full turns from the maximum discharge setting. Check output flow from injector at this time to ensure it is still operating.

If not, back off adjusting nut until injector does consistently operate. Inspect the adjusted injector for operation over 3 or 4 cycles after returning machine to work to make sure it is functioning.

August 2007

3 - 25

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LUBRICANT INJECTOR OPERATION

STAGE 1:

The injector piston is in its normal or reset position. The discharge chamber is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant, the slide valve is about to open the passage leading to the piston.

STAGE 2:

STAGE 3:

When the slide valve uncovers the passage, lubricant is admitted to the top of the piston, forcing the piston down. The piston forces lubricant from the discharge chamber through the outlet port to the bearing.

As the piston completes its stroke, it pushes the slide valve past the passage, cutting off further admission of lubricant to the passage. The piston and slide valve remain in this position until lubricant pressure in the supply line is vented (relieved) at the pump.

STAGE 4:

NOTE:

Manual No. 10500

After the pressure is relieved, the compressed spring moves the slide valve to the closed position. This opens the port from the measuring chamber and permits the lubricant to be transferred from the top of the piston to the discharge chamber.

The injectors may be mounted individually, or grouped in a manifold at one location.

3 - 26

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

INJECTOR ADVANTAGES

August 2007

3 - 27

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

3 - 28

August 2007

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT Applicable to Models 495BII, 495HF, 495HR and 495HD Electric Mining Shovels.

(September 1, 2005)

SCOPE: This specification covers the requirements for “Enclosed Gearcase Lubricant” used on models 495BII, 495HF, 495HR and 495HD Electric Mining Shovels.

The materials furnished under this specification are intended to lubricate spur, helical and spiral bevel gears as well as anti-friction bearings at the interior of enclosed planetary and non-planetary type gearcases (Hoist, Swing, Crowd and Propel).

This specification covers “Enclosed Gearcase Lubricants” that may be applied in service at temperatures ranging from –50ºC (-58ºF) to the highest ambient temperature conditions.

GUIDELINES FOR SELECTING AN APPROVED LUBRICANT: Step #1 Using Table 1, determine the recommended oil type (Mineral or Synthetic) based upon the anticipated ambient temperature range.

AMBIENT TEMPERATURE RANGE: Ambient Temperature: The ambient temperature is defined as the air temperature in the immediate vicinity of the gearcase. a. Use atmospheric temperature for gearcases located outside of the machinery house (Swing, Crowd and Propel Gearcases). b. Use machinery house temperature for gearcases located inside of the machinery house (Hoist Gearcase) for some machines are equipped with machinery house heaters. c. If the ambient starting temperature approaches the lubricant pour point, external heaters may be required to facilitate starting and insure proper lubrication. Use oil temperature for gearcases having oil immersion heaters.

Page 1 of 4

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT Applicable to Models 495BII, 495HF, 495HR and 495HD Electric Mining Shovels.

(September 1, 2005)

Table 1 Ambient Temperature Range 14°F to 100°F (-10°C to 37°C) Less than 14°F to 120°F (Less than -10°C to 50°C)

ISO Viscosity Grade / Oil Type ISO VG 320 / Mineral or Synthetic (poly-α-olefin) Oil ISO VG 320 / Synthetic (poly-α-olefin) Oil

Under normal circumstances, an ISO VG 320 oil viscosity is required for all Gearcases (Hoist, Swing, Crowd and Propel). For cold weather applications, an ISO VG 220 oil viscosity may be used for the Propel Gearcases to help ensure that the lubricant pour point remains below that of the ambient starting temperature. The pour point and flash point of individual brand name gear oils must be observed. Refer to the oil manufacturers technical data sheets for these properties.

Step #2 Select an approved lubricant for the Hoist, Swing, Crowd and Propel Gearcases from the Approved Lubricant Tables 2 & 3.

APPROVED LUBRICANTS: Lubricants that have been approved for use by the Gearcase manufacturers are listed in the Approved Lubricant Tables 2 & 3. The use of non-approved lubricants may invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/regulatory requirements.

Page 2 of 4

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT Applicable to Models 495BII, 495HF, 495HR and 495HD Electric Mining Shovels.

(September 1, 2005)

Table 2 Approved Mineral Oil Lubricants (ISO VG 320) Manufacturer BEL-RAY BP CASTROL

CHEVRON ESSO FUCHS LE (Lubrication Engineers) MOBIL PETRO CANADA SHELL TEXACO WHITMORE

• •

Product Description Bel-Ray 100 Gear Oil 90 Energol GR-XF 320 Alpha SP 320 Alpha MAX 320 Optigear BM 320 Tribol 1100/320 Chevron Ultra Gear Lube 320 Gear Compound EP 320 Spartan EP 320 (Only Product Originating from Europe) Renolin CLP 320 Plus Almasol 605 Mobilgear XMP 320 Ultima EP 320 Omala F 320 Auriga EP 320 Meropa 320 Meropa WM 320 Paragon 320

Shaded lubricants are approved for use in the Planetary Hoist, Swing and Propel Gearcases as well as the Non-Planetary type Crowd Gearcase.

Non-shaded lubricants are approved for use only in the Planetary Propel and NonPlanetary type Crowd Gearcase.

Page 3 of 4

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT Applicable to Models 495BII, 495HF, 495HR and 495HD Electric Mining Shovels.

(September 1, 2005)

Table 3 Approved Synthetic (Poly-α-olefin) Oil Lubricants (ISO VG 320)

Manufacturer BEL-RAY BP

CASTROL

CHEVRON FUCHS MOBIL PETRO CANADA SHELL TEXACO WHITMORE

• •

Product Description Synth. Gear Oil 6692 Enersyn EP-XF 320 Enersyn HTX 320 Optigear Synth. A 320 Optigear Synth. X 320 Alphasyn EP 320 Alphasyn T 320 Tribol 1510/320 Tribol 1710/320 Tegra Synth. Gear Lube 320 Renolin Unisyn CLP 320 Mobil SHC 632 Mobilgear SHC XMP 320 Ultima Synth. EP 320 Traxon E Synth. 80W-140 Omala HD 320 Pinnacle EP 320 Decathlon F 320

Shaded lubricants are approved for use in the Planetary Hoist, Swing and Propel Gearcases as well as the Non-Planetary type Crowd Gearcase.

Non-shaded lubricants are approved for use only in the Planetary Propel and NonPlanetary type Crowd Gearcase.

SPECIFICATION REVISIONS: This specification is subject to change without notice. Please refer to the Bucyrus International, Inc. web site www.bucyrus.com for the latest specification.

Page 4 of 4

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) SCOPE: 1. This specification covers “Multi-Purpose Grease”.

2. Materials furnished under this specification are primarily intended to lubricate heavy duty ball, roller, and plain bearings.

3. The material furnished under this specification must be dispensable through the distribution lines of a centralized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors or metering blocks.

4. The particular grade or consistency selected must perform within the specific temperature range in which it is utilized.

PHYSICAL CHARACTERISTICS: 1. Heat Resistance - Shall be thermally stable, should not flow or harden in service.

2. Retention - Shall not exhibit high leakage.

3. Stability - Shall work continuously with a minimum change in consistency.

4. Water Resistance - Shall withstand water washout or leaching.

5. Reversibility - Shall be stable with repeated heating and cooling.

6. Pressure Separation - Shall resist oil-soap separation.

7. Extreme Pressure - Shall withstand heavy shock loading.

8. Compatibility – a. Low temperature greases shall be compatible with mineral oil base greases. b. Grease must be compatible with oil seal lip materials (Nitriles, Viton), and all centralized lubrication system components (i.e. gaskets, o-rings, vent valves, etc.). Reference ASTM D 4289-03.

9. Compounding – a. Suitable for producing the extreme pressure characteristics (without inert fillers) required for heavy duty ball, roller, and plain bearing lubrication.

Page 1 of 5

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) b. Base fluid is to be mineral or synthetics which are compatible with mineral base. c. Thickener types are to be of the following varieties: Aluminum, Lithium, or Calcium.

Page 2 of 5

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) MINIMUM PERFORMANCE REQUIREMENTS: PROPERTY Ambient Temperature (See Note #1) NLGI Consistency # Dropping Point °C(°F) Minimum Timken O.K. load-lbs(kgf) Minimum Shell Four Ball EP Load wear index (LWI) kg Minimum Load Weld kg Minimum Shell Four Ball Wear Wear Scar mm Maximum 40KG for 1 hour @ 75°C @ 1200 RPM Copper Strip Corrosion 24 Hrs @ 100°C (212°F) Rust Test Viscosity of Base Fluid Minimum Motormatic Grease Worker Mechanical Stability 10,000 strokes, Maximum change Roll Stability Test Maximum change in 2 hours Wheel Bearing Test 6 hours @ 104°C(220°F) Maximum loss Water Washout Test Loss @ 38°C(100°F), Maximum Loss @ 80°C(175°F), Maximum

REFERENCE

REQUIREMENT -1°C to +43°C -18°C to +27°C Less than -12°C (+30°F to +110°F) (0°F to +80°F) (Less than +10°F) ASTM D-217 2 1 1, 0, 00 (See Note #2) ASTM D-2265 177(350) 177(350) 177(350) ASTM D-2509

50(23)

50(23)

50(23)

ASTM D-2596

65

65

65

ASTM D-2596

400

400

400

ASTM D-2266

0.6

0.6

0.6

2e

2e

Pass 220cSt @ 40°C

Pass 130cSt @ 40°C

ASTM D-4048

2e

ASTM D-1743 Pass ASTM D-445 460cSt @ 40°C

ASTM D-217A

10%

10%

10%

ASTM D-1831

15%

15%

15%

ASTM D-1263

10%

10%

10% (NLGI #1 Only)

ASTM D-1264

5%

5%

5% (NLGI #1 Only)

15%

15%

15% (NLGI #1 Only)

Page 3 of 5

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) PROPERTY REFERENCE REQUIREMENT Pressure Oil Separation The Lubrication Engineers U.S. Steel test method - Cake Manual (United States Steel). penetration not less than 25% of grease penetration.

Grease Mobility The Lubrication Engineers U.S. Steel method - not less than 0.10 Manual (United States Steel). grams flow per second at the lowest anticipated ambient temperature.

(Testing temperature not less than -34°C/-30°F).

Pumpability, The Lubrication Engineers To vent from 1800 psi (127 kgf/cm^2) Lincoln Ventmeter Manual (United States Steel). to less than or equal to 600 psi (42 kgf/cm^2) within 30 seconds at the lowest anticipated ambient temperature (Testing temperature not less than -25°C/-13°F).

Lubricating Solids (Molybdenum Disulfide, Less than or equal to 5% Graphite, Etc.) % by Weight Lubricating Solids (Molybdenum Disulfide, 10 Microns Graphite, Etc.) Particle Size, (Microns, max.)

NOTES: 1. Ambient Temperature - The ambient temperature shall be the temperature at the point of lubricant application.

2. Low Temperature Grease - For extended use in low temperature (-12°C to -46°C / +10°F to -50°F) areas, this product should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing.

This product should meet the Mobility and Pump-ability criteria for the lowest anticipated ambient temperature. In order to minimize compatibility problems, it is desirable that the thickener and additive system be compatible with the additional grades that are suitable for the other ambient temperatures.

Page 4 of 5

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) CERTIFIED LUBRICANTS: Lubricants certified by their manufacturers as complying with this specification will be listed on the “Certified Lubricants Listing for Multi-Purpose Grease” (see the Bucyrus International, Inc. web site www.bucyrus.com for the latest listing). The use of non-certified lubricants may invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements.

Lubricant manufacturers seeking to certify their products should contact the following for direction: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000 SPECIFICATION REVISIONS: This specification is subject to change without notice. Please contact the following for the latest specification: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000

Page 5 of 5

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) SCOPE: 1. This specification covers “Open Gear Lubricant”.

2. Materials furnished under this specification are primarily intended to lubricate open gears, but may also be used to lubricate racks, bushings, rails, rollers, dipper handles and propel mechanism components.

3. The material furnished under this specification must be dispensable through the distribution lines of a centralized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors, metering blocks, or spray nozzles.

4. This specification covers open gear lubricants that may be applied in service at temperatures ranging from -50°C (-58°F) to the highest ambient temperature conditions. The particular grade or consistency selected must perform within the specific temperature range in which it is utilized.

PHYSICAL CHARACTERISTICS: 1. Materials furnished under this specification may be asphaltic (bitumen) compounds, or blends of a thickener and mineral oils and/or synthetic fluids. They may be in the form of viscous fluids, semi-fluid greases or pastes.

2. Materials furnished under this specification are produced with highly fortified blends of viscous fluids combined with additives to form stable, long lasting, high load carrying, wear resistant films that lubricate under mixed film and boundary conditions.

3. Open gear lubricants supplied under this specification must have excellent adhesive and cohesive qualities, must not chip or throw off, and must provide sufficient film thickness and scuffing resistance to prevent metal to metal contact between applications under all operating conditions.

4. Various grades or consistencies of open gear lubricants may be required to provide proper lubrication and application properties over a wide range of ambient temperatures. The consistency of the lubricant as applied must be appropriate for the method of application, and the in-service consistency shall be appropriate for the lubricant to meet or exceed the minimum performance requirements listed in the "MINIMUM PERFORMANCE REQUIREMENTS" section.

Page 1 of 4

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) 5. Viscosity, a fluid's resistance to flow, is the principal physical characteristic of a fluid in terms of its ability to produce a lubricating film between two interfacing surfaces.

All lubricating fluids possess a natural viscosity that may be altered (enhanced) by additives such as resins or polymers. Some "viscosity enhancers" are shear sensitive, which could result in insufficient protection of the lubricated components under high load, elevated temperatures and/or high shear conditions. The viscosity of the fluids utilized in the open gear lubricants shall be sufficient under operating conditions for the product to meet or exceed the performance requirements listed in the "MINIMUM PERFORMANCE REQUIREMENTS" section.

6. Open gear lubricants supplied under this specification must be specifically formulated to protect surfaces, reduce wear, and provide satisfactory service life under all anticipated operating conditions.

7. Open gear lubricants supplied under this specification must have excellent water tolerance and rust preventive qualities, as well as minimal dripping qualities for operation over wide temperature ranges.

8. Should the material furnished under this specification contain a diluent to improve dispensability, special care must be exercised to ensure its compatibility with all centralized lubrication system components, i.e., gaskets, o-rings, vent valves, etc., and oil seal lip materials (Nitriles, Viton). Reference ASTM D 4289-03.

9. For extended use in low temperature areas, open gear lubricants supplied under this specification should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing. In order to minimize compatibility problems, it is desirable that the thickener and additive system be compatible with the additional grades that are suitable for the other ambient temperatures.

Page 2 of 4

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) MINIMUM PERFORMANCE REQUIREMENTS: PROPERTY REFERENCE REQUIREMENT Flash point of product as applied, minimum (base product with diluent) ASTM D92 / ISO 2592 Ambient Temperature (See Note #1) -50°C(-58°F) to +10°C(50°F) 61°C (142°F) Above +10°C(50°F) 80°C (176°F) Flash point of base fluid(s), minimum ASTM D92 / ISO 2592 140°C (284°F) Rust protection ASTM D 1743 Pass Copper strip corrosion maximum rating ASTM D 4048 2e 24hr. @ 100°C (212°F) Four ball EP test weld point, minimum kgf ASTM D 2596 800 (base product without diluent) Load wear index (LWI), minimum ASTM D 2596 120 (base product without diluent) Four ball wear test 60 minutes @ 40 kgf.

ASTM D 2266 0.7 Maximum scar, mm (base product without diluent) Adhesive properties Must adhere to surfaces at the lowest anticipated ambient temperature.

Pumpability, Lincoln Ventmeter To vent from 1800 psi (127 kgf/cm^2) to less than or equal to 600 psi (42 kgf/cm^2) within 30 seconds at the lowest anticipated ambient temperature (Testing temperature not less than -25°C/-13°F).

Minimum Base Fluid Viscosity Ambient Temperature ASTM D 445 (See Note #1) °C (°F) -50 to +10 (-58 to +50) 680 cSt at 40°C -20 to +40 (-4 to +104) 1860 cSt at 40°C +10 to +50 (+50 to +122) 3600 cSt at 40°C Lubricating Solids (Molybdenum Disulfide, Graphite, Etc.) 15 Microns Particle Size, (Microns, max.)

NOTE: 1. Ambient Temperature - The ambient temperature shall be the temperature at the point of lubricant application.

Page 3 of 4

BI617098

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) CERTIFIED LUBRICANTS: Lubricants certified by their manufacturers as complying with this specification will be listed on the “Certified Lubricants Listing for Open Gear Lubricant” (see the Bucyrus International, Inc. web site www.bucyrus.com for the latest listing). The use of non-certified lubricants may invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements.

Lubricant manufacturers seeking to certify their products should contact the following for direction: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000 SPECIFICATION REVISIONS: This specification is subject to change without notice. Please contact the following for the latest specification: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000

Page 4 of 4

BI617098

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

SCOPE: Materials furnished under the specifications for “OGL–Open Gear Lubricant (SD4713)”, “MPG-Multi Purpose Grease (SD4711)” and “Dragline Enclosed Gearcase Lubricant” (SD4721 Part A) are intended for use on Bucyrus International, Inc. mining machinery (Electric Mining Shovels, Draglines and Rotary Blasthole Drills).

Lubricants certified by their manufacturers as complying with these Bucyrus International, Inc. specifications are listed in the tables below.

LUBRICANT SELECTION: Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements.

Each lubricant listed in the tables below has a unique operating temperature range. It is the responsibility of the lubricant manufacturer to recommend the appropriate products based upon the applicable Bucyrus lubricant specification (SD4711, SD4713 and SD4721 Part A) and the anticipated ambient temperature range for each application.

CERTIFIED LUBRICANT LISTING FOR “OGL–OPEN GEAR LUBRICANT (SD4713)” Manufacturer Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Castrol Castrol Castrol Castrol Chemtool Inc. Chemtool Inc. Chemtool Inc. Haycock Petroleum

Product Description Molylube SF 100 Sub-Arctic 77070 Molylube SF 100 Arctic 77020 Molylube SF 100 Light 76990 Molylube SF 100 Medium 77010 Molylube SF 100 Heavy 77000 Molylube Unee NS 70550 Molylube Unee 70600 Molylube Unee 70540 Molylube SD-1 70620 Molylube Gear TAC Light 68990 Molylube Gear TAC Regular 68940 Molylube Gear TAC Medium 68950 Molub-Alloy 936 SF Light Molub-Alloy 936 SF Medium Molub-Alloy 936 SF Heavy Molub-Alloy 936 SF Heavy A Alpha OGL-680 Alpha OGL-1860 Alpha OGL-3600 Shovel Lube OGL 1.5 Ultra

Page 1 of 6

PDF created with pdfFactory trial version www.pdffactory.com

BI617098

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

Imperial Oil / Esso Imperial Oil / Esso Lubritene Lubritene Lubritene Lubritene Petro-Canada Petro-Canada Petro-Canada Petron Petron Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Shell Shell Shell Stewart Lubricants & Service Co. (SLS) Talcor Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co.

Dynagear Heavy Dynagear Extra Lubrene Multi Serv OGL Lubrene Multi Serv OGL-H Lubrene OGL-e Lubrene Bio Serv OGL Vulcan Synthetic All Season Vulcan Synthetic 2200 Vulcan Heavy Petrotac EP Premium 30-B Petrotac EP Premium 10-B Silver Streak Quickvent All Season (#196ALL) Silver Streak Quickvent Arctic (#196ARC) Silver Streak BGL 100 Silver Streak BGL 200 Silver Streak BGL 300 Malleus Grease GL 3500 Malleus OGM Heavy Malleus OGM Extra Heavy SLS BI OGL Heavy OGP V Axiom Multiservice Mining Lubricant – Arctic / SurStik 800 – Arctic Axiom Multiservice Mining Lubricant – Medium / SurStik 800 – Medium Axiom Multiservice Mining Lubricant – Heavy / SurStik 800 – Heavy

CERTIFIED LUBRICANT LISTING FOR “MPG-MULTI-PURPOSE GREASE (SD4711)” Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel

Manufacturer Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray

Product Description Molylube AC 1000 40890 Molylube AC 1000 40900 Molylube AC 1000 40922 Molylube LC135 67800 Molylube LC135 67810 Molylube LC135 67820 Molylube LC135 67832 Molylube LC133 67840 Molylube LC133 67850 Molylube LC133 67860 Molylube LC133 67872 Molylube LC131 27660 Molylube LC131 27670 Molylube LC131 27680 Molylube LC131 27692

Page 2 of 6

PDF created with pdfFactory trial version www.pdffactory.com

BI617098

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Castrol Castrol Castrol Castrol Chemtool Inc. Chemtool Inc. Chemtool Inc. Chemtool Inc. Chemtool Inc. Exxon Exxon Haycock Petroleum Haycock Petroleum Imperial Oil Imperial Oil Lubrication Engineers Lubrication Engineers Lubrication Engineers Lubrication Engineers Lubritene Lubritene Lubritene Lubritene Lubritene Lubritene Lubritene Lubritene Lubritene Petro-Canada Petro-Canada Petro-Canada Petro-Canada Petro-Canada Petro-Canada Petron Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Shell Shell Shell Shell

Molylube 126 EP 23200 Molylube 126 EP 23220 Molylube 126 EP 23242 Termalene EP 72400 Termalene EP 72420 Molub-Alloy 4086-0 Molub-Alloy 4086/460-1 Molub-Alloy 777-1 ES Molub-Alloy 777-2 ES CSC 174 MGD CSC MP1-220 CSC MP1 CSC MP0 CSC MP00 Ronex Extra Duty 2 Ronex Extra Duty Moly 2 / Mobilgrease XHP 462 Moly Calcuplex M5 NLGI #1 Calcuplex M5 NLGI #2 Epic EP Moly Unirex EP 1 Moly Almagard Vari-Purpose 3750 Almagard Vari-Purpose 3751 Almagard Vari-Purpose 3752 Almaplex Ultra-Synthetic 1299 Lubrene Li 500 EP 2 Lubrene LiM 500 EP 2 Lubrene AXM 1000 EP 1 Lubrene AXM 1000 EP 2 Lubrene AXM 500 EP 1 Lubrene AXM 500 EP 2 Lubrene LXCa 700 EP 2 Lubrene Li 900 WP EP 2 Lubrene EMV-2 Supreme Arctic Supreme EP1 Supreme EP2 Precision XL 3 Moly EP1 Precision XL 3 Moly EP2 Precision XL 5 Moly EP0 Petro-Plate M5/800 NLGI #1 Moly Ultra 800 EP #1 (#221) Moly Ultra Red EP #1 (#229) Moly Supreme #1 (#238) Moly EP Synthetic Blend #1 (#274) Albida Grease HDX2 Albida Grease MDX 1 Albida Grease MDX 2 Alvania Grease SDX2

Page 3 of 6

PDF created with pdfFactory trial version www.pdffactory.com

BI617098

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

Shell Shell Shell Shell Shell Talcor Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co.

Albida SLC 460 Limona LX1 Limona LX2 Albida HLS00 Albida HLS2 Super HD 2-M5 Omnilith 500 Extreme Pressure Grease EP 0 Omnilith 500 Extreme Pressure Grease EP 1 Omnilith 500 Extreme Pressure Grease EP 2 Omnilith 500 M Extreme Pressure Grease EP 0 Omnilith 500 M Extreme Pressure Grease EP 1 Omnilith 500 M Extreme Pressure Grease EP 2 Caliber 3M Extreme Pressure Grease EP 00 Caliber 3M Extreme Pressure Grease EP 0 Caliber 3M Extreme Pressure Grease EP 1 Caliber 3M Extreme Pressure Grease EP 2 Caliber 5M Extreme Pressure Grease EP 00 Caliber 5M Extreme Pressure Grease EP 0 Caliber 5M Extreme Pressure Grease EP 1 Caliber 5M Extreme Pressure Grease EP 2

Page 4 of 6

PDF created with pdfFactory trial version www.pdffactory.com

BI617098

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

CERTIFIED LUBRICANT LISTING FOR “DRAGLINE ENCLOSED GEARCASE LUBRICANT (SD4721 Part A)” Mineral Oils Manufacturer Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Exxon / Esso Exxon / Esso Lubritene Lubritene Lubritene Mobil Mobil Mobil Mobil Petro-Canada Petro-Canada Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Shell Shell Shell Shell Talcor Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co.

Product Description 100 Gear Oil 140 (ISO VG 460) 100 Gear Oil 250 (ISO VG 1000) 100 Gear Oil 350 (ISO VG 1500) 100 Gear Oil 460 SBF (ISO VG 460) 100 Gear Oil 1000 SBF (ISO VG 1000) 100 Gear Oil 1500 SBF (ISO VG 1500) Spartan EP 460 (ISO VG 460) Spartan EP 1000 (ISO VG 1000) Lubrene Syn 1500 (ISO VG 1500) Lubrene Super Series Gear Oil 1500 (ISO VG 1500) Lubrene Super Series Gear Oil 1000 (ISO VG 1000) Mobilgear 600XP 460 (ISO VG 460) Mobilgear 634 (ISO VG 460) Mobilgear XMP 460 (ISO VG 460) Mobilgear 639 (ISO VG 1000) Ultima 460 (ISO VG 460) Ultima 1000 (ISO VG 1000) #209A Universal Gear Lube (ISO VG 460) #209A Universal Gear Lube (ISO VG 1000) #294 Supreme Gear Lube (ISO VG 460) #294A Supreme Gear Lube No Tack (ISO VG 460) Omala 460 (ISO VG 460) Omala 1000 (ISO VG 1000) Omala 1500 (ISO VG 1500) SP Plus Gear Oil (ISO VG 1500) Gear Oil EP (ISO VG 1000) Paragon Heavy Duty Enclosed Gear Oil (ISO VG 460) Paragon Heavy Duty Enclosed Gear Oil (ISO VG 1000) Paragon Heavy Duty Enclosed Gear Oil (ISO VG 1500) Paragon Gold High Performance Gear Oil (ISO VG 1000)

Synthetic (PAO) Oils Manufacturer Bel Ray Bel Ray Lubrication Engineers Lubrication Engineers Mobil

Product Description Synthetic Gear Oil 460 (ISO VG 460) Synthetic Gear Oil 1000 (ISO VG 1000) 9846 Synolec Gear Lubricant (ISO VG 460) 9899 Synolec Gear Lubricant (ISO VG 1000) Mobil SHC 634 (ISO VG 460)

Page 5 of 6

PDF created with pdfFactory trial version www.pdffactory.com

BI617098

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

Mobil Mobil Mobil Mobil Mobil Schaeffer Mfg. Schaeffer Mfg. Shell Shell Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co.

Mobilgear SHC XMP 460 (ISO VG 460) Mobilgear SHC 460 (ISO VG 460) Mobil SHC 639 (ISO VG 1000) Mobilgear SHC 1000 (ISO VG 1000) Mobilgear SHC 1500 (ISO VG 1500) #167 Pure Synthetic Gear Lube (ISO VG 460) #167 Pure Synthetic Gear Lube (ISO VG 1000) Omala HD 460 (ISO VG 460) Omala HD 1000 (ISO VG 1000) GF 365 Synthetic Gear Fluid (ISO VG 460) GF 365 Synthetic Gear Fluid (ISO VG 1000) Decathlon HD Series Synthetic Enclosed Gear Oil (ISO VG 460) Decathlon HD Series Synthetic Enclosed Gear Oil (ISO VG 1000)

LUBRICANT CERTIFICATION PROCESS: Lubricant manufacturers seeking to certify their products should contact the following for direction: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000

REVISIONS: This listing is subject to change without notice. Please refer to the Bucyrus International, Inc. web site www.bucyrus.com for the latest listing.

Page 6 of 6

PDF created with pdfFactory trial version www.pdffactory.com

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500 Aug. 2007

Schematic No. 1

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500 Aug. 2007

Schematic No. 2

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

4

Preventive Maintenance Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents INTRODUCTION ........................................................................................................................... 3 ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM ......................................... 5 SCHEDULED PREVENTIVE MAINTENANCE PROGRAM ............................................... 5 GENERAL SAFETY CONSIDERATIONS .......................................................................... 6 MAINTENANCE DURING MACHINE OPERATION ........................................................................ 6 MAINTENANCE PRECAUTIONS .................................................................................................. 7 PREVENTIVE MAINTENANCE FOR LUBRICATION..................................................................... 8 LUBRICANT CLEANLINESS ............................................................................................. 9 FREQUENCY OF INSPECTION AND MAINTENANCE ............................................................... 10 MAINTENANCE SCHEDULES .................................................................................................... 10 MAINTENANCE INSPECTION ......................................................................................... 11 EVERY 100 HOURS, OR WEEKLY ................................................................................ 15 100 HOURS, OR WEEKLY (CONT.) ............................................................................... 16 EVERY 500 HOURS, OR MONTHLY .............................................................................. 17 EVERY 1250 HOURS, OR QUARTERLY ....................................................................... 21 EVERY 2500 HOURS, OR SEMI-ANNUALLY .................................................................. 25 EVERY 5000 HOURS, OR ANNUALLY ........................................................................... 29 MAJOR COMPONENT LOCATIONS .......................................................................................... 32 Machine Nomenclature ........................................................................................................................ 32 Lower Works and Crawlers .................................................................................................................. 33 Crawler Assembly ................................................................................................................................ 34 Crawler Link Assembly ........................................................................................................................ 35 Propel Machinery ................................................................................................................................. 36 Roller Circle Section View .................................................................................................................... 37 Roller Circle Assembly ........................................................................................................................ 38 Collector Rings - Auxiliary .................................................................................................................... 39 Collector Rings - High Voltage ............................................................................................................. 39 Center Pintle Assembly ....................................................................................................................... 40 Revolving Deck Frame & Extensions ................................................................................................... 41 Hoist Machinery ................................................................................................................................... 42 Swing Machinery .................................................................................................................................. 43 Crowd Machinery .................................................................................................................................. 44 Lubrication Reservoirs ......................................................................................................................... 45 Operators Cab ..................................................................................................................................... 46 Boarding Stairway ................................................................................................................................ 47 Machinery House Walkways & Platforms ............................................................................................. 48 Front End Equipment ........................................................................................................................... 49 Boom Support Ropes .......................................................................................................................... 50 Dipper Assembly ................................................................................................................................. 51

August 2007

4-1

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

4-2

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

4

Preventive Maintenance This section of the manual describes those aspects of preventive maintenance such as inspection, adjustment and routine repetitive tasks of the Model 495HD Electric Mining Shovel. Information related to lubrication techniques, frequency and service points is also partially included. Further detailed information can be found in Sections 3 and 5 of this manual.

At the end of this section are reproducible maintenance schedules that may assist in record keeping and maintenance scheduling.

INTRODUCTION A Preventive Maintenance Program is a systematic series of operations performed periodically on equipment to prevent breakdowns.

Any breakdown WILL reduce productivity and increase overhead expense. Machinery is only new at one point in time. From that moment, the machinery begins to deteriorate through use and aging.

A well organized maintenance program will avoid unexpected high-cost breakdowns and will increase component life.

A systematic approach to the program should be followed and detailed records of all findings kept, to detect potential problem areas. Valuable time and effort can be saved if defects are corrected before they lead to a major breakdown. The records should be reviewed often and kept on file for future reference.

Personnel involved in the program should go through an established training program, to know WHAT to check and HOW to rectify any potential problem area. When personnel are able to do routine maintenance and normal repairs efficiently, downtime is reduced and machine productivity increased. Also, to keep the machine in good running condition, the necessary parts, tools and current information should be kept on hand.

Equipment maintenance is a science and its practice an art. This art can be divided into 6 types of operations - they are: Inspection is probably the most important operation. Careful observation is required of all parts of the equipment. Slight abnormalities may not interfere with the equipment performance BUT those that are a deviation from the normal should be discovered early. When inspecting, notice placement, state of cleanliness, color, etc. of part(s). Examples: discoloration indicates overheating; all guards, bolts in place and good housekeeping.

August 2007

4-3

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Cleaning and keeping clean is essential for good operation. Periodic cleaning should be more frequent on exposed parts than those which are contained within cabinets. Parts, connections and joints should be free of dust, corrosion and other foreign matter.

A Feeling operation is used more often to check guarded rotating machinery for vibration due to worn parts, lack of lubrication, overheating, etc. Feeling operation on electrical items should be performed as soon as possible AFTER power has been removed and the circuit grounded.

Feeling of excessive heat may indicate an overloaded condition and should be corrected.

A Tightening operation should be done on all connections that have worked loose due to vibration, etc. Loose parts are a definite hazard because they may fall out of place and damage nearby components. The importance of firm mounting and tight connections cannot be overemphasized. Always replace missing or broken bolts with proper size and use the correct tools.

Adjusting should be done when inspection indicates that it is required to maintain normal operating conditions. Specific adjustment is contained in the “Mechanical Adjustment Section” of this manual, the electrical manual or the component manufacturer’s manual.

Lubrication refers primarily to the application of CORRECT LUBRICANT in the CORRECT AMOUNT to bearings and other rotating parts. It also means the application of a light oil to door hinges or other sliding surfaces. Use only clean and proper lubricant.

Planned maintenance, common sense, and good judgment are less costly and more effective than panic maintenance. Action taken on recommendations made on the following suggested inspection Check Lists by your maintenance department should reduce repair and maintenance costs and increase production.

Replacing worn components with genuine Bucyrus parts on a scheduled basis will avoid costly down-times and emergency repairs. The cost of parts is small when compared to unscheduled breakdowns that result in excessive overtime man-hours and lost machine production.

Whenever a problem is indicated, the inspector should briefly explain it on the maintenance report (a suggested form is at the end of this section) along with his signature. Then, an authorized person should briefly explain a solution to the problem. Finally, CORRECT THE PROBLEM.

Manual No. 10500

4-4

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM •

Preventive Maintenance Program.

•

Well Trained and Motivated Work Force.

•

Effective Communications.

•

Proper Equipment Selection and Procurement.

•

Meaningful Documentation.

•

Cooperation with the Operations / Maintenance Department.

•

Warehouse Support.

•

Good Shop Facilities.

SCHEDULED PREVENTIVE MAINTENANCE PROGRAM Economically maintaining the productivity and performance of a Bucyrus mining shovel requires maintenance and inspection activities in a scheduled manner. Manpower requirements and performance of needed maintenance during scheduled downtime dictates a system which recognizes the recommended inspection interval. For example, dipper and crawler assemblies are exposed to severe service and should be inspected every maintenance period, while other components can be reasonably expected to operate twice this interval before inspection. By staggering the inspection or servicing of these items, labor time and work-force size is balanced.

Maintenance and component inspection should be performed simultaneously during scheduled downtime. History of machine maintenance practices has shown that parts replacement and component rebuild in advance of destructive failure yields the lowest operating costs. Keeping good records is vital to support any preventive maintenance program. Early “change-out” reduces unscheduled downtime and prevents secondary damage. Record keeping should be an “easy to use” format and contain enough detail to isolate the function. For instance, shovel rope and dipper teeth wear will often directly relate to tons of material loaded, rather than machine operating hours.

However, power transmission shafting and bearing wear rates correspond closer to operating hours. Since basic machine life extends over thousands of operating hours, maintenance records can be utilized to forecast budgets for maintenance expenditures. This makes records a very valuable planning tool for mine management.

Use the Bucyrus maintenance program that is outlined here to formulate a schedule suited to your work force and mining environment. Over a period of time, additional inspection or planned work may supplement the activities described in this manual.

August 2007

4-5

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

GENERAL SAFETY CONSIDERATIONS The importance of overall safety in the maintenance of a mobile machine should always be emphasized; excavating operations may involve a variety of hazardous conditions. Many critical components are subject to wear and other deterioration which limits their useful life; thus making them expendable. When new, all such parts have a built in reserve strength against unknown factors and reasonable loss of durability from gradual wear. If however; inspection and adjustment are neglected, these parts eventually reach a condition where they become a potential problem.

Similarly, failure to replace various mechanisms to ensure proper performance of the machine could constitute a problem. Study this manual carefully to avoid unsafe conditions. Review the manual periodically to refresh your knowledge of these procedures. Supervisors, operators and maintenance men should continuously follow safe practices.

MAINTENANCE DURING MACHINE OPERATION Safety requirements dictate that all machines in active service be inspected at regular intervals for proper adjustment of operating mechanisms, excessive wear of components, system cleanliness and any other defects. Deficiencies during machine operation should be carefully investigated. It should be determined if a safety problem exists. Maintenance is vital to safe operation! It should be performed systematically by competent personnel.

From an economic standpoint, it is advisable to perform as much of the upkeep as can be safely accomplished while the machine is running. Obviously, there are some maintenance procedures, such as gear tooth inspections and replacement which require machine shut down. However; many support duties can be effectively handled at shift change when the machine is still activated.

Automatic lubrication systems function throughout the operational cycles of the machine. These systems release pre-measured lubricant which extends the wear life of the machinery units. Other parts of the machine may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the operator’s hands at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.

CAUTION:

Manual No. 10500

A repair or maintenance job is not complete until all guards, plates and other safety devices have been replaced before the equipment is restored to operation.

4-6

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MAINTENANCE PRECAUTIONS The operator must be sure that the machine equipment is in a safe position before repairs or adjustments are made. The machine should not be endangered by falling rock or a possibly yielding support surface. Before beginning repair or adjustment, the operator shall: 1.

2.

3.

4.

Set the dipper on the ground.

Set all brakes.

De-energize control functions.

Do whatever else is necessary to prevent accidental movement of the machine.

DANGER:

HIGH VOLTAGE! IF POWER IS ESSENTIAL TO THE REPAIR, SUCH AS FOR TESTING, IT SHOULD ONLY BE ENERGIZED WHEN ALL PERSONNEL ARE CLEAR OF ELECTRICAL AND MECHANICAL HAZARDS. The power should only be energized during the testing period and not when repair work is actually being done.

Prior to undertaking any work, maintenance personnel should notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the starting controls should be locked in the OFF position and tagged. The lock and tag should be removed only by the maintenance people who installed them, or other authorized personnel. During all phases of maintenance, use extreme caution when working near electrical equipment. Never work near exposed, energized high voltage connections.

Approved protective equipment such as gloves and insulated hooks or tongs should always be used when high voltage electrical cables are handled.

DANGER:

Only qualified electricians are permitted to directly maintain electrical equipment such as motors, transformers and switches.

While performing maintenance, the awkward positions assumed and the handling of heavy parts often increases the possibility of injuries. As a precautionary measure, use mechanical handling equipment whenever possible. The mining foreman can facilitate safer and easier maintenance work by providing blocking materials. Service crews should have a fundamental knowledge of lifting practices so their knees and legs are used rather than their backs.

DANGER:

August 2007

Many of the components comprising the machine are heavy, bulky items. EXTREME CAUTION SHOULD BE USED WHEN LIFTING THESE ITEMS. PERSONNEL SHOULD BE CERTAIN OF THE WEIGHTS OF COMPONENTS BEFORE ATTEMPTING TO LIFT THEM, EITHER MANUALLY OR WITH A LIFTING DEVICE. ALL APPLICABLE SAFETY RULES MUST BE FOLLOWED WHEN USING A CRANE OR OTHER LIFTING DEVICE. Be aware of the load rating, lifting height and swing radius of the lifting device before lifting a load. Failure to follow all applicable safety rules when performing maintenance could result in serious injury, or death.

4-7

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PREVENTIVE MAINTENANCE FOR LUBRICATION Lubrication may well be the most important portion of a preventative maintenance program. Do not allow anything to interfere with the lubrication of the machine. Experience will dictate how to adjust the amount of lubricant to use at each servicing. However; the extra effort will result in a smooth running machine with less wear and breakdowns.

It is difficult to predict how much lubricant should be applied to a particular bearing. It varies with how hard the machine is being worked, how much the bearing has previously worn and the grade of lubricant being used. Watch all the bearings closely until you are sure the lubricant added at one servicing is enough to last until the next.

Most wearing parts require that lubricant be applied regularly in small quantities as with the automatic lubrication system instead of large amounts applied occasionally. Make regular inspections of the machine and watch for signs of improper lubrication such as the accumulation of excess lubricant or discolored lubricant. Ensure that the lubricant has not come from a broken or disconnected line or lubricant pipe. Normally excess lubricant pumped into a plain bearing is not used. However, certain bearings in locations which may collect dirt (such as the lower works and dipper padlocks) should have extra lubricant added to purge all of the old lubricant which may have collected abrasive dirt.

New bushings sometimes overheat because they are too tight to allow normal distribution of lubricant.

Old bushings may overheat because they are so worn that lubricant will not stay in until the next time of servicing. In the case of the new bushing, it may be necessary to give it more frequent lubrication until it is worked in. It may be necessary to do the same for the old bushing, until it can be replaced. It is much better to lose a little time on a shift to give some extra lubricant to a point which needs it rather than trying to run it to the end of the shift.

The most common cause of overheating an anti-friction bearing is churning of the lubricant. This happens when the bearing is packed excessively full. If lubricant leaks out of an anti-friction bearing, it is almost a sure sign that too much lubricant was added to the bearing. Continue to lubricate it as often as before, but use less lubricant.

Section 3 of this manual will provide more detailed and specific information on lubricants and their usage.

Manual No. 10500

4-8

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LUBRICANT CLEANLINESS Even the best lubricant is a useless wear preventative if it has become contaminated by careless handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep it clean. It is the responsibility of the person performing the machine lubrication to be sure that no dirt gets into the lubricant.

Follow these points of good lubrication practice: •

Keep all oil and other lubricants in tightly covered containers.

•

Wipe off covers before opening containers.

•

Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off with a clean lintfree cloth before using.

•

Wipe off each fitting before attaching the lubricant gun.

•

Wipe off oil filler caps or covers and the surrounding area before removing them.

Refer to the topic “Lubricant Benchmarks” in Section 3 of this manual for an explanation of each type of lubricant required for servicing this machine. Make sure the lubricant was not dirty or of improper viscosity. When the machine is operated for more than one shift each day, all crews must cooperate on checking lubrication. This is to ensure that no lubrication point will be missed or over-lubricated. It is usually best to do this at the beginning of each shift. Reproducible service schedules are provided for recording service information.

NOTE: Lubrication instructions provided by any vendor for a vendor supplied item have priority over Bucyrus lubrication intervals and procedures.

CAUTION:

August 2007

When it is not possible to work on the machine with a safety harness, use a “cherry picker” or “man basket” when inspecting or servicing elevated areas. A slip or fall can result in severe personal injury or death.

4-9

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

FREQUENCY OF INSPECTION AND MAINTENANCE The suggested maintenance schedule is developed on a planned usage of 5,000 operating hours per year. This is a planned reference only. The actual conditions within the mine site, operator’s abilities and habits, along with the quality of components and consumables will ultimately drive the inspection schedule used on the machine.

Care should be take to properly evaluate the maintenance approach during the initial period after machine commissioning.

MAINTENANCE SCHEDULES The following maintenance schedule is based on a typical machine. Certain features or configurations may be different on a specific machine. This maintenance schedule is intended to outline the intervals for the various repetitive maintenance requirements. For any assistance, refer to the appropriate section in this Maintenance and Operation Manual, or contact the Bucyrus International service representative.

NOTE: This maintenance schedule is not to be substituted for the Maintenance Section of this manual.

Manual No. 10500

4 - 10

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MAINTENANCE INSPECTION CHECK POINTS

DAILY 1.

Check the areas under and around the crawlers for signs of oil leaks. If single droplets are noticed, leakage is minimal.

Determine the point of leakage and make a note of it on the log sheet. If pooling of oil is noticed, determine the source and take remedial action immediately.

Determine if loose hardware, a defective gasket, a combination of both, or a similar problem is responsible. Tighten hardware or replace defective gaskets.

2.

Inspect the crawler belts for missing links or pins, excessive belt sag, cracked shoes or other deterioration.

3.

Check the swing rack, pinions and pinion guards for rocks, dirt and other debris that will interfere with the operation of the machine. Inspect the swing rack gear and rollers for the proper lubricant film.

4.

Inspect propel motor couplings for debris, adequate lubrication and evidence of damage. Apply MPG as required.

5.

Visually inspect exterior of machinery house for damage or evidence of internal leakage.

6.

Inspect the dipper trip mechanism, rope, latch bar and associated hardware for damage, adjustment and wear.

August 2007

4 - 11

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DAILY CHECK POINTS (CONT.)

7.

Inspect the dipper door, hardware and bumpers for damage and excessive wear.

8.

Inspect crowd and retract rope attachment points, take up cylinders and spacers and dipper handle for damage, excessive wear and evidence of adequate lubrication.

9.

Inspect boom bumper for security and damage.

10.

Inspect the dipper for cracks deformations and teeth adapters for security and excessive wear.

11.

Inspect padlocks for damage, wear and evidence of adequate lubrication.

12.

Check both the running ropes and the boom structural strands for broken strands, loose sockets or any additional visual indications that would indicate a loss of structural integrity.

13.

Visually inspect the swing, crowd and hoist gearcases for oil levels and leaks.

Repair or service as required.

14.

Visually inspect all machinery for loose bolts, nuts, clamps or unusual conditions. Repair as required.

15.

Visually inspect the open gears of the swing, crowd and hoist machinery for proper lubricant film and evidence of adequate lubrication from the automatic lubricant dispensing system.

Manual No. 10500

4 - 12

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DAILY CHECK POINTS (CONT.)

16.

Visually inspect hoist and crowd ropes for wear, lubrication and evidence of birdcaging near the drum attachment beckets.

17.

Check the oil level in the air compressor.

Add ASCL if required.

18.

Check lubricant supply level in the air system lubricator and lube system lubricators.

19.

Inspect the automatic lubrication central pumping stations for any signs of malfunctioning. Check the lubricant supply and refill tanks if required with OGL or MPG.

20.

Visually inspect swing brake assemblies for damage, wear and evidence of an overheated condition.

21.

Visually inspect the crowd brake assembly for damage, wear and evidence of an overheated condition.

22.

Visually inspect the hoist brake assembly for damage, wear and evidence of an overheated condition.

August 2007

4 - 13

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DAILY CHECK POINTS (CONT.)

23.

Check the operator’s cab for cleanliness and visual condition of controls. Check location of special equipment that may be required by the mine site. Check all operating controls for freedom of movement. Controls should move freely without binding.

24.

Clean windows of operator’s cab.

25.

Inspect all walkways and stairways to ensure there are no obstructions, damage or fluids creating a safety hazard.

26.

Ensure ladder(s) and steps are raised, properly stowed and latched.

27.

Visually inspect the trail cable for cuts, abrasions and other damage.

DANGER:

HIGH VOLTAGE! The machine trail cable carries a lethal voltage. Handle the cable in an approved manner with appropriate rubber gloves and insulated hooks or tongs.

28.

At the cable reel, if equipped, check the hydraulic fluid reservoir for proper fluid level. Add fluid if required.

29.

Check the cable reel hydraulic system for leaks. Tighten, repair or replace components as necessary.

Manual No. 10500

4 - 14

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MAINTENANCE INSPECTION CHECK POINTS

EVERY 100 HOURS, OR WEEKLY (WHICHEVER OCCURS FIRST) 1.

Hoist Drum Gear Pinion - Clean off lubricant and inspect tooth condition of the gear.

2.

Hoist Drum Bearing Lube - Check operation of auto lube system for bearings and open gears.

3.

Hoist Automatic Lubrication System Check lube valves for bypassing in valves and injectors.

4.

Crowd Lube System - Check operation of injectors, condition and connection of all hoses, cycle each injector to ensure proper lubricant delivery.

5.

Gearcase fluid level - Check fluid level, sample fluids for testing (viscosity and contamination).

6.

Gearcase Breathers - Clean, verify condition and security. Check both crowd and hoist gearcases.

7.

Lower Rail Lubrication - Verify proper function of the automatic lubrication system.

August 2007

4 - 15

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

100 HOURS, OR WEEKLY (CONT.)

8.

House Rollers/Rails - Verify roller axle lube and lube of roller flange and surfaces.

9.

Automatic Lube System - Check all lube lines for damage and replace as required.

10.

Automatic Lube System - Check each lube injector for proper operation and adequate dispensing of lubricant.

11.

Boarding Stairs and/or Boarding Ladders - Check all components including safety chains and gates, mounting bolts, hydraulic line and fittings, cylinder pin, arm pins and pin retainers, Replace any worn or damaged components.

Lubricate the arm pins and cylinder pins.

Check the lock pin and lubricate as necessary.

Manual No. 10500

4 - 16

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MAINTENANCE INSPECTION CHECK POINTS

EVERY 500 HOURS, OR MONTHLY (WHICHEVER OCCURS FIRST) 1.

Hoist Brake - Check proper operation, lining wear and adjustment. Refer to section 6 in this manual ~ Brakes and Couplings, for adjustment procedure.

2.

Crowd Gearcase Lube - Check both gearcases for leaks, lubricant level and condition of gearcase breather. Clean or repair as needed.

3.

Crowd Brake - Check operation, linings for excessive wear, quick release operation and solenoid valve operation.

4.

Crowd Auto Lube System - Inspect lube injectors, fittings and hoses. Verify correct operation of the system.

5.

Swing Transmissions - Sealed units.

Operate machine while listening for unusual noises and vibrations. Contact Bucyrus International if problems are encountered.

6.

Swing Gear Lubricants - Check levels and correct as required.

7.

Swing Brake - Check for proper operation, lining wear, proper release and solenoid operation.

8.

Air System Controls - Inspect all air gauges, regulators, filters and oil-to-air line lubricators.

9.

Air System Lines - Inspect all tubing, hoses and fittings for damage and leaks.

Repair all leaks.

August 2007

4 - 17

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

500 HOURS, OR MONTHLY (CONT.)

10.

Lube Lines - Inspect all lines and fittings.

Repair all leaks and damaged hoses.

11.

Auto Lube Control Panel - Lube Reservoirs Check lubricant levels and re-service. Repair all leaks and clean up spillage.

12.

Boom Structure - Inspect entire boom structure (man basket recommended) for damage, cracks - repair immediately.

13.

Boom Foot Pins - Inspect boom foot pins, clearance keepers and retainers for damage - repair or replace as required.

14.

Boom Ladders/Handrails - Inspect for damage and repair immediately.

15.

Front and Rear Legs - Inspect visually for cracks and indications of stress.

16.

Suspension Cables - Check for broken wires. If 10% of outer layer of wires are broken replace suspension cable.

17.

Dipper Corner and Center Shrouds Check for tightness, repair as required.

18.

Dipper Tooth Points - Teeth should be tight to adapters or dipper lips. Rebuild or repair as required.

Manual No. 10500

4 - 18

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

500 HOURS, OR MOTHLY (CONT.)

19.

Dipper Lip, Front - Completely check front structure for wear, rebuild as required. Inspect for cracks and pay special attention to weld joint areas, repair immediately.

20.

Dipper Back Structure - Inspect for cracks/damage, repair immediately.

21.

Dipper Door - Check for bushing and pin wear. Rebuild as required. Check the door structure for cracks/damage, repair immediately.

22.

Latch Bar/Mechanism - Inspect latch bar for wear, rebuild as required. Adjust mechanism for proper operation.

23.

Latch Bar Dutchman/Keeper - Rebuild as required, replace after 3 rebuilds.

24.

Dipper Door Snubbers - Inspect the linkage, pins, bushings, replace as required. Adjust if door swings too freely or does not close completely.

25.

Dipper Heel Band - Inspect and record wear to assure proper rebuild timing.

26.

Dipper - Inspect and record internal wear to plans. Adjust rebuild timing.

Refer to Bucyrus International for relining recommendations.

27.

Dipper Connecting Bushings/Pins Inspect all connecting bushings and pins, replace as necessary.

28.

Dipper Pitch Brace - Adjustable (If present) - Check for missing or loose bolts. Tighten or replace as required.

August 2007

4 - 19

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

500 HOURS, OR MONTHLY (CONT.)

29.

Crowd Rope - Inspect the ropes, replace badly worn, frayed or damaged ropes.

30.

Retract Rope - Inspect the ropes, replace badly worn, frayed or damaged ropes.

31.

Dipper Trip Rope - Inspect the ropes, replace badly worn, frayed or damaged ropes.

32.

Hoist Drum Lagging Grooves - Inspect for damage and excessive wear.

33.

Upper Rail Clamps - Tighten clamps and verify the integrity of the rail end chocks.

34.

Propel Planetary Gearcases - Pull bottom plug and collect a 1/2 gallon sample. Inspect the sample for metal particles.

35.

Boarding Stairs and/or Boarding Ladders - Check all components including safety chain and gate, mounting bolts, hydraulic line and fittings, cylinder pin, arm pins and pin retainers. Replace any worn or damaged components. Lubricate the arm pins and cylinder pins. Check the lock pin and lubricate as necessary.

Manual No. 10500

4 - 20

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MAINTENANCE INSPECTION CHECK POINTS

EVERY 1250 HOURS, OR QUARTERLY (WHICHEVER OCCURS FIRST) 1.

Crawler Links - Adjust the tension as required.

2.

Take-Up Tumbler - Check condition of thrust plate, dirt shield and bushing.

3.

Lower Rollers/Bogie - Check condition for cracks, unusual wear, O.D. of rollers, bushing wear, seal leakage and proper lubrication.

4.

Crawler Links - Check drive tumbler O.D. and the link pins for wear and/or an out of pitch condition.

5.

Gearcases - Check all covers and plugs for leakage - seal as required.

6.

Propel Brake Assembly - Verify proper brake operation. Replace worn friction linings as required. Check air cylinder piston travel and adjustment of springs.

7.

Roller Circle Rollers - Verify roller integrity, replace broken or cracked rollers.

8.

Center Pintle - Verify the proper adjustment of the pintle locking nut and the security of locking bars. Clean spent grease from under lower nut.

9.

Center Pintle Lube - Verify correct spherical washer and truck frame bushing lubrication.

August 2007

4 - 21

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

1250 HOURS, OR QUARTERLY (CONT.)

10.

Warning/Safety Placards - Replace all missing safety and warning signs.

11.

Left Hoist Drum Spider - Inspect the spider for cracks, fit to drum and bolt tension.

12.

Hoist Drum Assembly Bearings - Inspect the bearings, retainers and seals for damage and correct as needed.

13.

Hoist Motor Coupling - Inspect the coupling, replace as required.

14.

Hoist Motor - Inspect mounting bolts for security, blower duct work for damage and security.

15.

Hoist Brake Air System - Check operation of solenoid valve, release and set operations, hoses, fittings and quick release valve.

16.

Crowd Machinery Frame - Inspect for loose bolts or chock blocks, worn mount pins and cracks. Repair as required.

17.

Crowd Drum Bearing Journals - Inspect the retainer, bearing retainer bolts, seals and condition of bearings.

Bearing Cap Mounting Bolts - Check for tightness.

18.

Crowd 1st Gear Reduction - Inspect the gear and pinion teeth for the proper wear pattern, excessive wear and alignment.

Correct as required.

Manual No. 10500

4 - 22

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

1250 HOURS OR QUARTERLY (CONT.)

19.

Crowd 2nd Gear Reduction - Inspect gear/pinion teeth for the proper wear pattern, excessive wear and alignment.

Correct as required.

20.

Crowd 3rd Gear Reduction - Inspect gear/pinion teeth for the proper wear pattern, excessive wear and alignment.

Correct as required.

21.

Crowd Machinery Bearings - Inspect the bearings, retainers and seals. Retighten the retainer bolts.

22.

Crowd Motor Coupling - Check for lubrication and wear.

23.

Air Compressor - Change the crankcase oil, clean the intake filter and refill antifreezer with required agent.

24.

Compressor V Belts - Check belt tension, adjust as required. Maintain belt/ pulley alignment.

25.

Compressor Intercooler - Inspect intercooler tubing, replace as required.

26.

Center Spindle - Inspect the upper end for leaking or broken fittings. Check lube and air swivel for worn spindle housing seal and/or bypassing. Repair immediately as required.

27.

Lube Pressure Switches - Verify that all pressure transducers operate properly as per machine requirements.

August 2007

4 - 23

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

1250 HOURS OR QUARTERLY (CONT.)

28.

Boom Bumpers - Inspect and repair as required.

29.

Boom Point Machinery - Inspect both sheaves and bearings for damage, repair as required.

30.

A-Frame Legs - Check mounting pins and retainers, replace worn parts.

31.

Suspension Links - Inspect links for worn pins, cracks, replace as required.

32.

Boom Suspension Rope Sockets Inspect and lubricate the sockets at each end of the rope.

33.

Dipper Teeth Adapters - If used, check fit of adapters to lip. Must be tight fitting, repair as required.

34.

Padlock Connection - Check clearance in the dipper padlock bearing, replace worn parts as required. Check padlock link-to-bucket pin for wear.

34.

Hoist Ropes - Inspect Ropes, replace badly worn, frayed or damaged ropes.

Manual No. 10500

4 - 24

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MAINTENANCE INSPECTION CHECK POINTS

EVERY 2500 HOURS, OR SEMIANNUALLY (WHICHEVER OCCURS FIRST) 1.

Crawler Link Pin Clearance - Check, record average link pin clearance as per Section 5 of this manual.

2.

Crawler Frames - Inspect crawler frames for cracks in the wear plates and bottom plates of the crawlers. Also inspect connection of crawler frames to truck frame for loose and/or missing hardware.

3.

Lower Rollers/Axles - Check for wear, cracks and condition of the axle retainers.

4.

Upper Rollers - Check condition of retainer collars/pins, excessive wear and evidence of proper lubrication.

5.

Propel Gearcases - Verify mounting bolt tension with torque wrench.

6.

Propel Motor Coupling - Open coupling - inspect coupling gear teeth for wear, re-lubricate.

7.

Drive tumbler - Check for presence of lube in relief fitting.

Important:

8.

Lube must be present! If fresh lube is not present, attempt to purge the lube through. If still no lube, remove the tumbler and shaft to investigate the problem.

Open door on crawler frame and inspect final drive bearing retainer.

August 2007

4 - 25

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

2500 HOURS OR SEMI-ANNUALLY (CONT.)

9.

Propel Motor Bearing Lube – Relubricate.

10.

Propel Blower Mounts - Verify security and condition of blower motor.

11.

Truck Frame - Visually inspect internal structure for cracks and damage. Repair as required.

12.

Lower Rail Clamps - Verify all clamps are tight.

13.

House Roller Frame - Verify all frame splice plate bolts and roller pin bolts are tight.

14.

Propel Blower - Check blower ducts and connections and clean fan.

15.

Hoist Machinery Pedestals - Check the connection between hoist gearcase and revolving frame.

16.

Center Pintle Upper Box - Remove the cover and verify condition of all lube and air lines through the center of rotation.

17

Center Pintle Air Swivel - Check test port for signs of air or lube leakage.

18.

Walkways/Ladders/Stairs, Hand Rails/ Skid Protection - Repair all damaged sections. Repair or replace all damaged hand rails, toe plates and skid protection.

Manual No. 10500

4 - 26

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

2500 HOURS OR SEMI-ANNUALLY (CONT.)

19.

Hoist Drum Lagging Bolts - Check all bolts for tension and retainers. Hoist Drum Gear Bolts - Check bolts for tension and retainers on left and right sides.

20.

Crowd Bearing Case Bolts - Check the tightness of all bolts.

21.

Crowd Drum Lagging - Inspect condition of rope grooves and anchors for excessive wear and distortion.

22.

Crowd Auto Lube System - Check all valves and injectors for by-passing.

23.

Crowd Gears/Pinions - Photograph all crowd machinery gears/pinions for future comparison. Ensure all teeth are clean for photo. Record date and machine hours.

24.

Swing Air System - Inspect all air lines and fittings for leaks. Repair as required.

25.

Swing Motor Mounting - Inspect and tighten all swing motor mounting bolts.

26.

Air System Pressure Switches - Verify correct function and setting of switches and regulator.

27.

Air Control Panel - Inspect all valves electrically and manually for proper operation. Repair/replace as required.

August 2007

4 - 27

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

2500 HOURS OR SEMI-ANNUALLY (CONT.)

28.

Lube Pump Stations - Verify that all pumps and controls are operating properly, repair as required.

29.

Boom Point Machinery - Check all bearings, adjustments, retainers and seals - repair or replace as required.

30.

Suspension Sockets - Check for worn pins, lug ends. If wear exceeds 0.250 inches replace bridge pendant.

Manual No. 10500

4 - 28

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MAINTENANCE INSPECTION CHECK POINTS

EVERY 5000 HOURS, OR ANNUALLY (WHICHEVER OCCURS FIRST) 1.

Crawler Frame Propel Gearcases Check for leaks, cracks - repair as required.

2.

Crawler Frame Case Wear Bar - Check condition of wear plates - replace as required.

3.

Crawler Frame Case Upper Wear Bar Check condition of wear plates - replace as required.

4.

Crawler Frame Underside - Check for wear, cracks, damage.

5.

Propel motors - Verify motor coupling clearance and alignment using a dial indicator. (refer to manufacturer’s information)

6.

Propel Gearcase - Pull the bottom plug and collect a 1/2 gallon of lubricant.

Inspect the sample for metal particles.

7.

Final Drive Shaft Bearing - Lube must be present! If fresh lube is not present, investigate the problem.

6.

Swing Rack - Verify then tension of the rack-to-truck frame mounting bolts and the rack to joint assembly bolts.

7.

Roller Circle and Rails - Check for wear.

Replace rails and roller when wear exceeds 1/2".

8.

Center Pintle Bushing - Check the truck frame bushing and replace if required.

August 2007

4 - 29

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5000 HOURS, OR ANNUALLY (CONT.)

9.

Center Pintle Upper Nut - Verify lock bars and retaining dowels are in place. Check that nut is flush with the top of the pintle - if not, investigate the problem.

10.

Revolving Frame - Thoroughly inspect the revolving frame integrity. Repair damage from cracks and wear. (Includes ballast box weld joint and swing gearcase support welds.)

11.

Revolving Frame Extensions - Check the extension bolts for security and retension as required.

12.

Machinery House - Repair all damaged sections, panels, doors and latches.

13.

House Filtration - Clean the filter units, inspect the blowers and fan blades closely. Repair or replace damaged and worn parts.

14.

Hoist Motor Pinion Shaft - Inspect bearings, retainers, seals for damage and correct as needed. Inspect oil passages for obstructions.

15.

Hoist Drum Gear Cover - Clean out excessive OGL.

16.

Hoist Brake Mounts - Inspect mounting bracket bolts for damage and alignment.

17.

Crowd Motor - Inspect mounts, chocks, coupling and blower for damage or wear.

Correct as required.

Manual No. 10500

4 - 30

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5000 HOURS, OR ANNUALLY (CONT.)

18.

Crowd Brake Mounting - Inspect mounting bracket for security and damage.

19.

Check the torque on the taper lock pin retainers on crowd module-to-deck mounts. Lubricate with spray lube.

20.

Swing Brake Mounting - Inspect mount brackets and check the tightness on all mounting bolts.

21.

Lube System - Check all valves, injectors and pumps for proper operation and damage. Repair as required.

August 2007

4 - 31

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MAJOR COMPONENT LOCATIONS

Crowd Half Crowd Rope Sheave Adjusting Mechanism Suspension Strands

Electrical Control Room Filter House Filters

Crowd Rope Hydraulic Adjusting Unit Equalizers A-Frame Air Conditioner Operator’s Dipper Trip Cab Machinery

Machinery House Electrical Control Room

Boom Point Sheaves Boom

BUCYRUS

Saddle Block Dipper Handle Retract Rope

Shipper Shaft

495HD ac utrol

Boom Bumper

Crawler Assembly

Take-Up Cylinders Hoist Ropes Pitch Brace

Crowd Dipper Machinery Trip Swing Rack Rope

Padlocks Dipper

Dipper Door Boarding Stair

141233nm

Machine Nomenclature

Manual No. 10500

4 - 32

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Lower Works and Crawlers

August 2007

4 - 33

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Crawler Assembly

Manual No. 10500

4 - 34

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Crawler Link Assembly

August 2007

4 - 35

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Propel Machinery

Manual No. 10500

4 - 36

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Roller Circle Section View

August 2007

4 - 37

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Roller Circle Assembly

Manual No. 10500

4 - 38

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Collector Rings - Auxiliary

Collector Rings - High Voltage

August 2007

4 - 39

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Center Pintle Assembly

Manual No. 10500

4 - 40

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Revolving Deck Frame & Extensions

August 2007

4 - 41

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Hoist Machinery

Manual No. 10500

4 - 42

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Swing Machinery

August 2007

4 - 43

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Crowd Machinery

Manual No. 10500

4 - 44

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Lubrication Reservoirs

August 2007

4 - 45

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Operators Cab

Manual No. 10500

4 - 46

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Boarding Stairway

August 2007

4 - 47

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Machinery House Walkways & Platforms

Manual No. 10500

4 - 48

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Front End Equipment

August 2007

4 - 49

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Boom Support Ropes

Manual No. 10500

4 - 50

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Dipper Assembly

August 2007

4 - 51

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

4 - 52

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

5

Service Procedures Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents LOWER WORKS ......................................................................................................................... 5 PROPEL MACHINERY ............................................................................................................ 5 CRAWLER FRAMES AND TRUCK FRAME ........................................................................... 6 CRAWLER BELTS ............................................................................................................ 8 Crawler Link Assembly ...................................................................................................... 8

BELT ADJUSTMENT ................................................................................................... 8 Crawler Belt Tension Adjustment ....................................................................................... 9

BELT REPLACEMENT .............................................................................................. 11 Crawler Belt Support ......................................................................................................... 12

CRAWLER LINKS ........................................................................................................... 13 Crawler Links ~Section View ............................................................................................ 13

TAKE-UP TUMBLER & AXLE .................................................................................... 14 TUMBLER REPAIR ................................................................................................... 15 UPPER ROLLERS .......................................................................................................... 16 UPPER ROLLER REPAIR ........................................................................................ 17 LOWER ROLLERS ........................................................................................................ 18 LOWER ROLLER REPAIR ....................................................................................... 18 DRIVE TUMBLER ............................................................................................................ 20 TUMBLER REPAIR ................................................................................................... 20 TUMBLER REBUILD ................................................................................................. 21 Drive Tumbler Rebuild ...................................................................................................... 24

TUMBLER DRIVE SHAFT ............................................................................................... 25 SHAFT REPAIR ......................................................................................................... 26 PROPEL MOTOR ................................................................................................................. 28 PROPEL PLANETARY GEARCASE ..................................................................................... 29 SWING RACK ....................................................................................................................... 31 ROLLER CIRCLE ................................................................................................................. 32 Roller Circle Assembly ..................................................................................................... 33

ROLLER CIRCLE REPAIR ............................................................................................. 33 Roller Circle ~Section View .............................................................................................. 34 Roller Circle and Rails ...................................................................................................... 35 Roller Circle ~Exploded View ............................................................................................ 36

SWING RACK DUST CURTAINS .......................................................................................... 37 CENTER PINTLE .................................................................................................................. 38 CENTER PINTLE ADJUSTMENT .................................................................................... 39 Center Pintle ~Section View ............................................................................................. 40

CENTER PINTLE REPAIR .............................................................................................. 41 COLLECTOR RINGS ............................................................................................................ 43 COLLECTOR RING INSPECTION .................................................................................. 44 COLLECTOR RING REPAIR .......................................................................................... 44 SWING MACHINERY ............................................................................................................. 45 August 2007

5-1

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING BLOWER ........................................................................................................... 46 SWING MOTOR .............................................................................................................. 46 SWING MOTOR REMOVAL ...................................................................................... 47 SWING MOTOR INSTALLATION ............................................................................... 47 SWING PLANETARY GEARCASE .................................................................................. 47 Swing Planetary Gearcase - Primary Assemblies ............................................................. 48

GEARCASE INSPECTION ........................................................................................ 49 SWING SHAFTS AND PINIONS ...................................................................................... 50 Swing Shaft, Dual Output - Section View .......................................................................... 50

SWING PINION REMOVAL ........................................................................................ 50 Swing Shaft and Pinion ~Exploded View ........................................................................... 51

SWING PINION INSTALLATION ...................................................................................... 52 SWING SHAFT REMOVAL .............................................................................................. 52 SWING SHAFT INSTALLATION ................................................................................. 53 Section A-A ...................................................................................................................... 53 Proximity Switch Clamp Collar .......................................................................................... 53

HOIST MACHINERY .............................................................................................................. 55 Hoist Machinery Assembly ............................................................................................... 55 Hoist Machinery - Plan View ............................................................................................. 56

HOIST MOTOR ............................................................................................................... 57 Hoist Motor Mounting - Plan View ..................................................................................... 57

HOIST GEARCASE ASSEMBLY ..................................................................................... 58 Hoist Drive Gearcase ....................................................................................................... 58

HOIST GEARCASE INSTALLATION .......................................................................... 59 Installation of the Hoist Gearcase .................................................................................... 59

HOIST GEARCASE REPAIR ........................................................................................... 60 MOTOR COUPLING SHAFT ........................................................................................... 61 Guard over Coupling Shaft ................................................................................................ 61 Coupling Alignment Reference .......................................................................................... 62

HOIST DRUM ASSEMBLY ............................................................................................... 62 Hoist Drum Assembly ...................................................................................................... 62 Hoist Drum Bearing Assembly .......................................................................................... 64

HOIST GEAR REPLACEMENT ................................................................................. 65 BEARING REPLACEMENT ....................................................................................... 66 HOIST MOUNTING BOLTS ............................................................................................. 67 HOIST LIMIT SWITCH ..................................................................................................... 68 HOIST MOTOR ............................................................................................................... 69 CROWD MACHINERY .......................................................................................................... 71 Crowd Gearcase ............................................................................................................... 72

GEARCASE REPAIR ...................................................................................................... 73 Crowd Motor Pinion ~Exploded View ................................................................................. 74 Crowd 1st Reduction ~Exploded View ............................................................................... 75 Crowd 2nd Reduction ~Exploded View .............................................................................. 76

CROWD MOTOR ................................................................................................................. 77 CROWD GEAR AND DRUM ........................................................................................... 79 CROWD DRUM REPAIR ................................................................................................ 80

Manual No. 10500

5-2

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MACHINERY HOUSE ............................................................................................................ 82 WALKWAYS, STAIRWAYS AND HANDRAILS ................................................................. 83 BOARDING STAIRS .............................................................................................................. 84 FRONT END EQUIPMENT ......................................................................................................... 86 BOOM ASSEMBLY ................................................................................................................ 86 BOOM REPAIR ............................................................................................................... 87 BOOM LIMIT SWITCH ........................................................................................................... 87 LIMIT SWITCH INSPECTION .......................................................................................... 89 LIMIT SWITCH ADJUSTMENT ........................................................................................ 89 BOOM POINT SHEAVES ...................................................................................................... 90 BOOM POINT SHEAVE REMOVAL AND DISASSEMBLY ............................................... 91 BOOM POINT SHEAVE REASSEMBLY AND INSTALLATION ........................................ 93 BOOM BUMPER ................................................................................................................... 94 SADDLE BLOCK .................................................................................................................. 95 Saddle Block Bushing Arrangement ................................................................................. 95

SADDLE BLOCK REPAIR .............................................................................................. 95 SADDLE BLOCK REMOVAL .......................................................................................... 96 Saddle Block Sheave ....................................................................................................... 97

DIPPER HANDLE ................................................................................................................. 99 DIPPER HANDLE REMOVAL ........................................................................................ 100 CROWD ROPE TAKE-UP MECHANISM ...................................................................... 102 CROWD ROPE TAKE-UP MECHANISM DISASSEMBLY ...................................... 103 CROWD ROPE TAKE-UP MECHANISM ASSEMBLY ............................................ 104 RETRACT ROPE TAKE-UP MECHANISM ................................................................... 106 SPREADER REPAIR .................................................................................................... 108 DIPPER ASSEMBLY ........................................................................................................... 110 Dipper Door Latch Bar and Lever .................................................................................... 111 Latch Bar Assembly ....................................................................................................... 112 Latch Bar Bumpers ........................................................................................................ 113

DIPPER DOOR BUMPERS .......................................................................................... 114 Dipper Door Bumper Adjustment .................................................................................... 114

DIPPER DOOR SNUBBERS ........................................................................................ 115 DIPPER PADLOCK ...................................................................................................... 117 Adjustable Pitch Brace ................................................................................................... 119

DIPPER TRIP ASSEMBLY .................................................................................................. 120 A-FRAME............................................................................................................................. 121 AUXILIARY WINCH .............................................................................................................. 124 HOIST ROPE SUPPORT ROLLER ................................................................................... 125 BOOM STRUCTURAL STRANDS ...................................................................................... 126 WIRE ROPES ..................................................................................................................... 127 WIRE ROPE INSPECTION ........................................................................................... 128 CROWD ROPE TAKE-UP HYDRAULIC UNIT ................................................................... 129 Hydraulic Schematic ~Crowd Screw Hydraulic Unit ......................................................... 130

August 2007

5-3

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST ROPE REEVING/REPLACEMENT ................................................................... 131 Shim for Hoist Rope Socket .......................................................................................... 134

CROWD ROPE REEVING/REPLACEMENT ................................................................ 135 Crowd Rope Reeving ....................................................................................................... 136 CROWD ROPE TERMINATION DETAILS ...................................................................... 137

RETRACT ROPE REEVING/REPLACEMENT ................................................................... 138 Retract Rope Reeving ..................................................................................................... 139

CROWD ROPE TIGHTENING ...................................................................................... 141 RETRACT ROPE TIGHTENING ................................................................................... 142 DIPPER TRIP ROPE REEVING/REPLACEMENT ........................................................ 143 HOIST AND CROWD LIMIT SYSTEMS .............................................................................. 144 SETTING ROPE LIMITS ................................................................................................ 145 CROWD STOP END LIMIT ..................................................................................... 145 RETRACT SLOWDOWN/STOP LIMITS................................................................. 146 HOIST SLOWDOWN/STOP LIMITS ....................................................................... 147 CROWD SLOWDOWN/STOP LIMITS ................................................................... 148

Manual No. 10500

5-4

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

5

Service Procedures LOWER WORKS PROPEL MACHINERY The propel machinery consists of two self-contained separate units consisting of the frame, motor, power transmission equipment and the belt assembly. A planetary gearcase drives the drive tumbler of the crawler. The belt is driven by the drive tumbler and is kept aligned by a series of upper and lower rollers. A disc-type brake is mounted to each motor. A common blower supplies air to both motors. Each motor is independently controlled allowing for sharper turns. Controlled from the operator’s cab, the electrical propel mechanisms allow for repositioning the machine. The propel machinery should be inspected on a daily basis.

August 2007

5-5

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CRAWLER FRAMES AND TRUCK FRAME Once a month inspect the crawler frames and truck frame for cracks and structural defects. Pay particular attention to the weld between the crawler frames and the truck frame along with the internal diaphragms in the front corners of the truck frame.

DANGER:

Manual No. 10500

HIGH VOLTAGE! DO NOT ATTEMPT TO ENTER THE TRUCK FRAME COMPARTMENTS WITHOUT FIRST DISCONNECTING AND LOCKING OUT ALL ELECTRICAL POWER TO THE MACHINE BY DEENERGIZING THE TRAIL CABLE. Failure to do so could result in electrocution or serious injury.

5-6

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Every six months disconnect and lock out power to the machine and inspect the inside of the truck frame for cracks. Pay particular attention to the center pintle area of the truck frame.

Check the hardware connecting the front of the crawlers to the truck frame. Refer to the view below.

Check the center pintle through access covers in the bottom and top of the main frame. A qualified electrician should inspect the propel and high voltage collector rings.

If cracks or other defects are found, contact the Bucyrus International Service Department before attempting any repair. Questions concerning repair welding of the crawler frames and truck frame should be referred to the Bucyrus International Service Department for a specific solution.

August 2007

5-7

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CRAWLER BELTS The crawler belts and individual links should be inspected frequently to minimize wear and prevent unexpected breakdowns.

Crawler Link Assembly

Check the links for cracks, worn lugs, elongated link pin bores or other damage. For optional bushed crawler links, check for bushing wear. Links with broken or severely worn drive lugs can cause the belts to ride off the rollers or tumblers and should be replaced as soon as practical.

Bent, broken or badly worn link pins should be replaced before any further damage is done.

BELT ADJUSTMENT When properly adjusted, the crawler belts will sag approximately 1 to 1-1/2 inches at the center points between the upper rollers. The belts need adjusting if any of the following conditions exists: 1.

The amount of sag is greater than 1 to 1-1/2 inches.

2.

When propelling forward: a.

Excessive peaking occurs as the links leave the drive tumbler.

- or -

b.

3.

Links are forced away from the tumbler at the top and are being driven by the ends of the drive tumbler lugs.

When propelling in reverse, excessive link buckling occurs between the raised drive tumbler and the nearest lower roller.

Manual No. 10500

5-8

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Crawler Belt Tension Adjustment

CAUTION:

The crawler belts should not be allowed to become so loose that excessive crawler belt buckling occurs. A link, link pin or roller can be damaged if the lower roller travels over a buckled belt.

If the action of the crawler belt system is smooth and quiet while propelling forward or in reverse, the system is working correctly. If the crawler belt looks jerky and is noisy it should be adjusted.

Adjustment of the crawler belts is accomplished at the take-up tumbler end of the belts. The takeup tumblers are bushing-mounted on a single forged axle which extends through elongated guides in the side frames. Shims placed ahead of, or behind, the axle guides the axle’s position to obtain the desired belt tension.

1.

Propel the machine forward on firm level ground a distance sufficient to remove the slack at the bottom of both crawler belts. All belt slack should now be on the top side of the crawler frame. The links on the bottom side of the crawler frame should be taut.

2.

Remove the shim retainer from the crawler frame.

3.

Securely attach a 150-ton jack to the take-up axle on one side of the machine and move the axle forward minimally to allow clearance.

4.

Remove several shims from in front of the axle.

5.

With the jack and support, push on the axle until the crawler belt is properly tensioned. The sum total of sag at the points between the upper rollers, the upper roller and take-up tumbler, and the upper roller and drive tumbler should be 4 to 6 inches.

6.

Insert sufficient shims behind the axle to hold the adjustment. Several different thickness shims are provided.

August 2007

5-9

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

5 - 10

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

7.

Release pressure from the jack and install the remaining shims in front of the axle. Install the shim retainer.

CAUTION:

THE AXLE MUST BE SHIMMED TIGHT, BOTH FORE AND AFT, USING ALL SHIMS ORIGINALLY PROVIDED WITH THE MACHINE TO PREVENT AXLE MOVEMENT. Failure to do so allows axle movement during machine operation which can lead to crawler frame damage and expensive repair procedures.

8.

Move the jack to the other side of the machine and repeat the procedure on that side. Be sure the shims are the same thickness as installed on the opposite side.

9.

When both crawler belts have been correctly adjusted, remove the jack and clear all tools and equipment from the crawler belt area.

10.

Check the performance of the crawler belts by propelling the machine forward on a relatively flat surface.

11.

When correct tension can no longer be achieved by moving spacers to the front of the axle, a link must be removed from the belt on each side of the machine. Following this link removal and re-pinning of the links, adjust the belt tension as previously described.

BELT REPLACEMENT NOTE: For this operation the machine will need to be positioned where adequate space is available for assembly of a complete replacement belt in front of the machine, and enough room to propel the machine forward this same distance.

Belt replacement is not frequently required. However, to replace a belt propel the machine to flat, firm, level ground.

1.

Remove tension from the existing belt by removing the tensioning shims from behind the take-up axle. Use a jack to relieve tension for shim removal. Remove link pins.

2.

Remove the pin from a link in front of the take-up roller, but below the centerline of the roller.

3.

Assemble the new belt to the lower end of the existing belt laying under the machine. Position the links and insert the link pins directly on to the end of the old belt.

4.

When assembled, the new belt must be in a straight line forward of the machine and attached to the old belt.

NOTE: Due to the elevated drive tumbler design of this machine, tension must be applied at all times to the end of the belt being removed. Use a bulldozer, road grader or other vehicle.

August 2007

5 - 11

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5.

Position a vehicle, of adequate size and strength to straddle and drag the old belt assembly over the newly assembled belt. Move the vehicle along the belt until it is close enough to attach it to the top end of the old belt on the machine.

DANGER:

DO NOT PROCEED UNTIL COMMUNICATION IS AVAILABLE. Positive communication between machine operator and the vehicle operator is critical. The vehicles MUST move in the same direction and at the same speed while the belt is pulled into position. IF VEHICLE SPEED AND DIRECTION ARE NOT THE SAME, THE MACHINE MAY OVERRIDE THE TOW VEHICLE CAUSING SEVERE VEHICLE DAMAGE AND POSSIBLE INJURY OR DEATH!

6.

Attach chains or strapping to the free end of the belt on the machine and to the towing vehicle.

7.

Apply tension to the belt end by pulling forward with the pulling vehicle.

8.

Carefully propel the machines slowly to move the machine off the old belt and onto the new belt. Be sure to maintain tension on the old belt.

The new belt will have to remain under tension from the tow vehicle until completely repositioned and the two ends are able to be rejoined.

9.

Once the two ends of the new belt are positioned, stop the propel motion and shut down the machine. Remove the link pins between the new and old sections of the belt and pull away the old section of belt.

10.

Using a crane, or other suitable lifting device, lift and drag the lower free end of the new belt into position on the take-up tumbler and rollers and install the pin and keepers.

Crawler Belt Support

11.

Adjust belt tension as described elsewhere in this manual.

Manual No. 10500

5 - 12

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CRAWLER LINKS To replace a crawler link: 1.

Propel the machine to position the defective link in an accessible position.

2.

Remove tension from the belt by removing the tensioning shims from behind the take-up axle. Use a jack to relieve the tension behind the take-up axle. Remove the tensioning shims from behind the take-up axle. Release the jack to remove tension in the crawler belt.

3.

Attach a lifting device to the belt link.

4.

Remove the locks and pins from the link assembly and remove the link. Use the lifting device to remove the link

Crawler Links ~Section View

5.

Position the replacement link and insert new link pins after applying a liberal coating of MolyKote Type G.

6.

Adjust belt tension as described elsewhere in this manual.

August 2007

5 - 13

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TAKE-UP TUMBLER & AXLE Inspect the take-up tumbler for cracks and damage that can impair normal tracking of the crawlerRemove the take-up tumbler hub caps every three months. Also make sure the cap is filled with lubricant. At the same time, check the tumbler clamp collars, to make sure they are secured on the take-up axle. Tighten the clamp collar bolts if loose.

Every six months, relieve weight of the machine at the take-up axle, remove the take-up tumbler hub cap and tumbler clamp collar and check the take-up tumbler bushing for bore elongation and wear.

Manual No. 10500

5 - 14

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TUMBLER REPAIR If bushing replacement is needed, the tumbler must be removed from the machine. To accomplish this: 1.

Place blocking in front of the crawler belt which requires repair. Propel the machine onto the blocks so that the take-up tumbler will be out of contact with the ground once the belt is removed.

2.

Separate the crawler belt as described elsewhere in this manual. Separation of the belt should take place at a point near the take-up tumbler. Set the links laid back out of the way.

3.

Remove the take-up tumbler hub cap and the tumbler clamp collar. Remove the O-Ring from the hub cap.

4.

Attach a suitable lifting device to the tumbler and slide the tumbler from the axle.

5.

The tumbler bushings are press-fit into the tumbler and must be removed with appropriate tooling,

NOTE: Bushings that have an interference fit can be difficult, if not impossible to replace. The use of liquid nitrogen will, in most cases, allow sufficient size reduction for the installation of interference fit bushing. It is advisable to work quickly and efficiently as heat will transfer quickly.

DANGER:

COMPONENTS THAT HAVE BEEN CRYOGENICALLY TREATED TO REDUCE THEIR TEMPERATURES ARE EXTREMELY DANGEROUS TO HANDLE. ALWAYS WEAR APPROPRIATE EYE PROTECTION AND GLOVES TO AVOID ANY POSSIBLE SKIN CONTACT WITH FROZEN COMPONENTS.

6.

After the bushing is removed, check the tumbler bushing bore for defects. Remove any burrs. Check the bore for out-of-round condition. Replace or rebuild the tumbler if bore is outof-round. Check take-up axle for wear.

7.

Inspect the dirt seal and thrust plate on the take-up axle. Replace the thrust plate if it is badly worn. Replace the dirt seal if it is worn or damaged.

8.

Install new bushings in the take-up tumbler after adequate temperature reduction. Apply light lubrication into the bushing bore.

9.

Lubricate the bushing bore and the axle mating surface. Use a hoist and slide the take-up tumbler onto the axle. Install the tumbler clamp and hub cap. Be sure to install a replacement hub cap O-Ring.

10.

Join the crawler belt links and adjust belt tension as described elsewhere. Thoroughly lubricate the take-up tumbler bushings.

11.

Propel the machine carefully and remove the installed blocking. The hub cap should be 100% full.

August 2007

5 - 15

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

UPPER ROLLERS Inspect the upper rollers for cracks and damage that can impair normal tracking of the crawler belts.

Every six months remove the upper roller collar and check the roller bushing for bore elongation and wear. Replace the bushing if badly worn.

Manual No. 10500

5 - 16

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

UPPER ROLLER REPAIR If bushing replacement is necessary, the upper roller must be removed from the machine. To remove the roller: 1.

Relieve crawler belt tension as described elsewhere in this manual.

2.

Raise the belt with a suitable lifting device until it clears the upper portion of the roller. Block the belt in the raised position.

3.

Remove the nut and bolt securing the roller collar and remove the collar. Slide the roller from the shaft.

4.

Remove the bushing from the roller. Check the roller bore and the shaft for damage and elongation. Remove any burrs with a file. Check the roller bore for an out-of-round condition and replace the roller if the bore is out-of-round. Check the roller shaft for wear.

NOTE: Bushings that have an interference fit can be difficult, if not impossible to replace in the field locations of this equipment. The use of liquid nitrogen will, in most cases, allow sufficient size reduction for the installation of interference fit bushing. It is advisable to work quickly and efficiently as heat will transfer quickly due to the material utilized in bushing construction.

DANGER:

COMPONENTS THAT HAVE BEEN CRYOGENICALLY TREATED TO REDUCE THEIR TEMPERATURES ARE EXTREMELY DANGEROUS TO HANDLE. ALWAYS WEAR APPROPRIATE EYE PROTECTION AND GLOVES TO AVOID ANY POSSIBLE SKIN CONTACT WITH FROZEN COMPONENTS.

5.

Install new bushing into the roller bore. Make sure bushing is flush with, or slightly below the surface of the roller. Ensure the groove in bushing is facing to the outside when the roller is mounted to crawler frame.

6.

Lubricate the bushing bore and the shaft mating surface. Slide the roller onto the shaft and secure with the collar, capscrew and nut.

7.

Lower the belt until it contacts the upper rollers. Adjust belt tension as described elsewhere.

August 2007

5 - 17

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LOWER ROLLERS Inspect the lower roller for cracks and damage that can impair normal tracking of the crawler belts.

Every six months remove the roller hub cap and clamp collar and check the roller bushings for bore elongation and wear. Replace bushings if badly worn.

LOWER ROLLER REPAIR The most common problem encountered is bushing wear. However, the rollers can develop cracks and wear. If cracks in the rollers do occur, they can be gouged out and rewelded. Contact the Bucyrus International Service Department for specific instructions concerning the repair welding of these structures.

If bushing replacement is necessary the roller must be removed from the machine. To replace a bushing: 1.

For accessibility to the lower rollers propel the machine over a hole just large enough to disconnect the crawler belt, lower the links and remove the roller.

2.

Relieve crawler belt tension as described elsewhere.

Manual No. 10500

5 - 18

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CAUTION:

Always consider the overall stability of the machine. Unstable or uneven terrain may lead to catastrophic results.

3.

Remove the lower roller hub cap and clamp collar. Remove the O-Ring from the hub cap.

4.

Attach a suitable lifting device to the roller and slide the roller from the shaft.

5.

Remove the press-fit bushings from the rollers.

6.

After removing the bushings, check the roller bushing bore and the shaft for defects. Remove any burrs with a file. Check the bore for out-of-round condition. Replace the roller if the bore is found to be out-of-round. Check roller shaft for wear.

7.

Inspect the rubber face seal and thrust washer. Replace the thrust washer if it is badly worn.

Replace the seal if it is worn or damaged.

NOTE: Bushings that have an interference fit can be difficult, if not impossible to replace. The use of liquid nitrogen will, in most cases, allow sufficient size reduction for the installation of interference fit bushing. It is advisable to work quickly and efficiently as heat will transfer quickly.

DANGER:

COMPONENTS THAT HAVE BEEN CRYOGENICALLY TREATED TO REDUCE THEIR TEMPERATURES ARE EXTREMELY DANGEROUS TO HANDLE. ALWAYS WEAR APPROPRIATE EYE PROTECTION AND GLOVES TO AVOID ANY POSSIBLE SKIN CONTACT WITH FROZEN COMPONENTS.

8.

Install new bushings in the roller after adequate temperature reduction and apply light lubrication in the bushing bore

9.

Lubricate the bushing bore and the shaft mating surface. Slide the roller onto the shaft.

Install the clamp collar and hub cap. Be sure the replacement hub cap O-Ring is in place.

10.

Adjust belt tension as described elsewhere.

11.

Thoroughly lubricate the lower roller bushing. The hub cap should be 100% full.

August 2007

5 - 19

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DRIVE TUMBLER Inspect the drive tumbler for cracked or broken lugs, lug wear, and other defects which can impair tumbler function and belt tracking. Check the tumbler retainer bolts and tighten if loose. Replace worn or damaged seal or bearing. Check inner bearing retainer by opening inspection hole in crawler frame. LUBE MUST BE PRESENT!

TUMBLER REPAIR The drive tumbler is splined to the drive shaft and is held securely to the shaft with a retaining plate.

If repair of the tumbler is deemed necessary, consult with the Bucyrus International Service Department for repair instructions.

To replace the drive tumbler: 1.

Relieve crawler belt tension and separate the belt as described earlier. Separation of the belt should take place at a point near the drive tumbler. Lay the links back out of the way.

2.

Remove the bolts securing the retaining plate to the drive shaft and remove the plate and shims. Remove the O-Ring from the plate.

3.

Attach a suitable lifting device to the drive tumbler and slide the tumbler from the drive shaft.

4.

Inspect the bearing and duo-cone seal on the drive shaft for defects and damage. Remove any burrs from the splines of the shaft.

5.

Examine the exposed end of the drive shaft for defects and damage.

Remove any burrs from the splines of the shaft.

6.

If the duo-cone seal was removed, reinstall it as per the Duo-Cone Seal Installation Procedure found in the Engineering Data section of this manual.

7.

Lightly lubricate the tumbler bore and the splines of the drive shaft with MolyKote Type G.

8.

Slide the new tumbler on to the shaft. Install the retaining plate and shim to obtain a gap of 0.002 to 0.005 inches and tighten the bolts to specification. Install a new O-Ring onto the retaining plate prior to installation.

9.

Join the crawler belt links and adjust belt tension as previously described.

Manual No. 10500

5 - 20

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TUMBLER REBUILD 1.

The crawler system on this machine is designed to accommodate a limited amount of component wear in the drive tumbler/link system.

NOTE: Dimensions "A" and "B" indicate the gaps between the drive tumbler teeth and the drive lug on two crawler links. These gaps are measured at the end of a span of 3 links at the rear of the crawler. Refer to the figures in DRIVE TUMBLER REBUILD for a representation of these dimensions.

Figure 1 - New Links & Tumbler - 24.38 Pitch

2.

The tumbler/link engagement results in clearances “A” and “B” as shown in figure 1 above.

The sum of dimensions “A” and “B” is typically 4.08 inches (A+B=4.08 in.)

As link pin wear occurs, clearance “B” will decrease unit it becomes zero, (as in figure 2) and dimension “A” will decrease accordingly.

August 2007

5 - 21

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Figure 2 - Worn Links & New Tumbler - 25.50 Pitch

Eventually both dimensions “A” and “B” will become zero as depicted in Figure 3 below.

Figure 3 - Worn Links & New Tumbler - 27.00 Pitch

When both gaps are zero, a component rebuild or replacement is necessary to avoid link distress and/or breakage.

NOTE: Wear of the individual tumbler lugs will actually increase dimensions “A” and “B”.

3.

Inspections of the tumbler/crawler engagement should consist of actual “A” + “B” measurements. If the sum of these two dimensions approaches zero, refer to the following rebuild procedures.

Manual No. 10500

5 - 22

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

NOTE: A new drive tumbler O.D. is 45.75 inches. If your drive tumbler is worn to an O.D. of 43.75 inches or less, rebuilding the O.D. should be considered. Dimension “A” + “B” will increase by 1.23 inches for each 1.00 inch the O.D. of the tumbler is increased.

Drive Tumbler Rebuild

August 2007

5 - 23

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TUMBLER DRIVE SHAFT For inspection of the bearings and other components of the drive tumbler shaft, removal of the shaft is necessary. The tumbler drive shaft can be removed without disturbing the propel planetary gearcase.

Manual No. 10500

5 - 24

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SHAFT REPAIR To disassemble the drive tumbler shaft proceed as follows: 1.

Remove the drive tumbler as described elsewhere.

2.

Remove the socket head screws securing the bearing retainer. Remove the retainer. Separate the duo-cone seal from the retainer.

3.

Install an eyebolt in one of the tumbler retainer plate screw holes and attach a “come-a-long” to the eyebolt.

4.

As the shaft is removed and the bearing clears the crawler frame, support the shaft with an additional sling in the area of the bearing retainer nut. The sling should be installed prior to the shaft exiting the guide bushing. Monitor this through the inspection hole in the top of the crawler frame.

5.

Remove the lockplate capscrews, lockplate, and bearing nut from the shaft. Remove the flat head screws securing the seal retainer to the bearing. Remove the seal retainer and bearing spacer from the shaft. Separate the oil seal from the retainer.

6.

The bearing has an interference fit of .0052 to .0084 to the shaft. The shaft is machined with two grooves under the bearing for hydraulic assist in bearing removal. Each groove is connected to an individual lube port at the end of the shaft.

CAUTION:

When using hydraulic assist for bearing removal, take precautions to prevent grease spray as the bearing is removed.

7.

Through the inspection hole, remove the shaft guide bushing retainer capscrews, the retainer and guide bushing.

8.

Clean and inspect all parts. Repair or replace all worn or damaged parts.

9.

Reassemble in reverse order of disassembly. a.

Heat the bearing in an oil bath to 250° F.

b.

Install the bearing on the shaft tightly against the shaft shoulder while ensuring holes for mounting seal retainer are facing away from the shaft shoulder.

c.

Install bearing spacer and retaining nut.

August 2007

5 - 25

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

d.

Allow bearing to cool.

e.

Install oil seal and retainer on bearing with seal lip facing toward the bearing. Install nut lockplate and lockplate capscrews.

f.

The nut may have to be backed-off slightly to install lockplate.

g.

Reinstall the guide bushing and retainer in the crawler frame. Coat the bushing with lubricant prior to installing shaft to help protect the shaft splines.

h.

All splined surfaces should be re-coated with MolyKote Type G or other suitable antiseize compound.

i.

To prevent damage to the planetary gearcase when installing the drive tumbler shaft, bolt and nut must be installed in the center hole of cover. This will prevent movement of the sun shafts.

j.

When installation is complete, the bolt and nut should be switched with plug.

k.

Reinstall shaft assembly into crawler frame. Shaft may have to be rotated slightly to align splines of shaft and planetary unit.

l.

When the bearing is tight against shoulder in crawler frame bore, install bearing retainer and duo-cone seal.

m.

Install the drive tumbler as described earlier.

n.

Thoroughly lubricate the bearing. Refer to Section 3 ~ LUBRICATION.

Manual No. 10500

5 - 26

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PROPEL MOTOR At least once a month check the hardware of the motor coupling for tightness. Tighten if necessary.

Check the couplings for evidence of lubricant leakage. If leakage from a coupling is noticed, the coupling should be disassembled and repaired. Refer to Section 6 ~ BRAKES AND COUPLINGS for coupling repair.

However, to add lubricant: 1.

2.

3.

Remove the pipe plugs from the sleeves.

Orient the grease holes horizontally.

Fill the coupling until grease just overflows through the grease holes.

The couplings normally will not require lubricant. To add lubricant, remove the pipe plugs from the sleeves and fill the coupling until an overflow condition exists with the grease holes in the horizontal position. Reinstall plugs firmly after lubricating couplings.

The level of lubricant in the gearcase should be checked weekly and lubricant added as required.

The daily inspection should also include checking for leaking seals or gaskets.

DANGER:

HIGH VOLTAGE! Press the MAIN POWER OFF button and tag it to avoid inadvertent energizing before attempting to disconnect the propel motor leads. A voltage hazard is present and could cause electrocution or serious injury. DO NOT ATTEMPT TO DISCONNECT ANY WIRES UNTIL THE AUXILIARY POWER HAS BEEN DISCONNECTED AND THE MAIN POWER IS OFF.

Frequently check the electrical connection of the propel motor and blower motor for tightness.

Tighten the connection hardware if necessary.

August 2007

5 - 27

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PROPEL PLANETARY GEARCASE The propel planetary gearcase assembly includes three reductions. To minimize down time, it is recommended that the gearcase be replaced as a complete unit, if a problem should develop within the case. If the case is to be disassembled, it should be taken to a maintenance shop for repairs. To remove the gearcase, proceed as follows: 1.

Position the machine on level ground and swing the revolving frame so the boom foot is slightly beyond the center of the propel motor. This will allow for vertical pickup of motor.

2.

Have the power to the motor disconnected and tagged by a qualified electrician.

Manual No. 10500

5 - 28

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

3.

Remove all lube lines and drain the gearcase.

4.

Remove the propel motor blower ducts.

5.

Remove coupling guard cover and the coupling bolts. Remove the motor mounting bolts and lift the motor and brake from the truck frame.

6.

Secure a crane and rigging to the planetary gearcase and remove the bolts mounting the gearcase to the crawler frame. Match-mark the gearcase to the crawler frame so that the input shaft will be at the correct angle to align with the motor shaft at reassembly.

7.

Slide the gearcase out of the crawler frame. Remove the O-Ring and retainer from the output end of the gearcase.

Reinstall in reverse order, noting the following: a.

Re-coat all splined surfaces with MolyKote Type G or other suitable anti-seize compound.

b.

To prevent damage to the gearcase, before assembling the drive tumbler shaft into the gearcase spline, the hex bolt and nut must be installed at location “X” and the Allen head screw plug installed at location “Y”. After assembly, install the pipe plug at location “X” and the bolt and nut at location “Y”. This will prevent movement of the sun shafts.

(Refer to the image on the previous page.)

c.

To prevent damage to the splines, coat the guide bushing with lube prior to installing the drive shaft into the crawler frame.

d.

Insure that the breather and adapter are installed in the tapped hold at the top of the gearcase and that the screw plug is installed in the forward hole approx. 40o below horizontal.

e.

Lubricate and tighten gearcase mounting bolts to 4,100 Ft.Lb. (Machine lots 11 and up) A hardened steel washer is used with each bolt. Once properly tightened, lockwire bolts.

f.

When installing the motor coupling, align per instructions in Section 6 - BRAKES AND COUPLINGS in this manual.

g.

Fill the gearcase to the oil fill plug with approximately 70 gallons of ISO-VG 220 oil.

h.

FOR LUBRICANT REPLACEMENT, Refer to Section 3 - LUBRICATION in this manual.

August 2007

5 - 29

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING RACK Make sure all teeth carry a protective coating of lubricant to reduce wear. Inspect the swing rack weekly for broken teeth and unusual wear patterns. Every six months, disconnect power, remove access covers and inspect the weld between swing rack and truck frame. Also, clean and inspect swing rack teeth for pitting, abrasion, spalling and galling.

If during inspection a broken tooth is noted, shut down the machine immediately and do not operate the machine until the tooth has been repaired. Due to the specific materials and processes involved in the manufacture of this component, contact your Bucyrus International Service representative for an appropriate repair procedure.

CAUTION:

Manual No. 10500

DO NOT OPERATE THE MACHINE WITH ONE OR MORE BROKEN TEETH IN THE SWING RACK. This could result in additional damage to the swing rack, swing pinions and swing machinery units.

5 - 30

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

ROLLER CIRCLE DANGER:

HIGH VOLTAGE! EXTREME CARE MUST BE EXERCISED AT ALL TIMES WHEN PERFORMING MAINTENANCE IN THE CENTER PINTLE AREA. High voltage can cause serious or fatal injury.

Installation, operation and servicing of components should be performed only by qualified personnel. ALWAYS DISCONNECT THE ELECTRICAL POWER BEFORE ACCESSING THE CENTER PINTLE AREA.

Inspect the rollers and rails of the roller circle monthly for severe pitting or spalling. This will usually be an indication of non-uniform loading. Small incipient pitting is not unusual and is not harmful. If rollers are damaged to the extent that they retard the swing function, they should be replaced as soon as possible. The diameter of the replacement roller must be matched to the worn good rollers. Consult the Bucyrus International Service Department for the correct procedure.

NOTE: The machine can operate in an emergency with a few rollers missing - however the missing rollers must not be adjacent to each other and must be equally-spaced around the roller circle. The remaining rollers will be subjected to increased loading, resulting in a shorter roller life.

Inspect the inner and outer roller frame sections and the rollers weekly for broken bolts. Normally the inside flange of the rollers contacts the inside edge of the lower rail. If they do not, a cracking or popping noise may be heard as the machine swings. This noise is caused by the rollers aligning themselves with the rails. Excessive popping requires a close inspection of the roller frame. Also, check the lubricant being used. Consult the Bucyrus International Service Department if noise is excessive.

Check both the upper and lower rails to see that they are properly chocked and secured to the swing rack and the revolving frame. Check the rail clamp bolts and retighten as required. Also check the rail surfaces for pitting and spalling.

August 2007

5 - 31

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Roller Circle Assembly

ROLLER CIRCLE REPAIR To replace a roller, roller pin, frame or rail: 1.

Swing the machine until maximum access is available to the defective component. Defective rollers should not be between upper and lower rails.

2.

Remove the splice plate bolts from each end of an outer frame section.

3.

Remove the nuts securing the roller pins to the outer frame section and remove the frame section.

4.

Remove the bolts from the roller pin and remove the defective roller with its pin.

If a lower rail segment must be replaced: 1.

Remove both inner and outer frame splice joints.

2.

Remove the chocks, clamp bar, and hardware securing the rail to the rack.

3.

Install a new rail segment. If required, install shims as needed to remove any spacing between rail segments.

Manual No. 10500

5 - 32

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

If an upper rail segment must be replaced: 1.

Remove a frame and roller section.

2.

Swing the machine until the upper rail is over the gap.

3.

Remove the rail segment and install a new segment.

NOTES: •

Before replacing a new roller, contact Bucyrus International for the procedure required to size the new roller to the old roller.

•

Install a new roller, roller pin or frame section as needed reversing the steps necessary for removal of the component.

•

Be sure to lubricate the roller pins and bushings and the roller when installing them.

Roller Circle ~Section VIEW

August 2007

5 - 33

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Roller Circle and Rails

Manual No. 10500

5 - 34

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Roller Circle ~Exploded VIEW

August 2007

5 - 35

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING RACK DUST CURTAINS During regular maintenance intervals insure that all dust curtains are in place and in good shape.

Also be sure all brackets and hardware are in place and tight.

Manual No. 10500

5 - 36

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CENTER PINTLE DANGER: HIGH VOLTAGE! EXTREME CARE MUST BE EXERCISED AT ALL TIMES WHEN PERFORMING MAINTENANCE IN THE CENTER PINTLE AREA. High voltage can cause serious or fatal injury.

Installation, operation and servicing of components should be performed only by qualified personnel.

ALWAYS DISCONNECT the electrical power BEFORE accessing the center pintle area.

1.

To inspect for worn thrust washers, rails, or rollers proceed as follows: a.

Every 3 months, check the amount of lift of the revolving frame at the rear of the machine. Engage the dipper in the bank at near maximum reach and apply hoist power.

b.

Measure the distance between the upper and lower roller rails at the rear of the machine.

c.

Subtract from this measurement the measured distance at the rear between the upper and the lower roller rails with the dipper on the ground.

d.

If the difference in measurement is greater than 1/2 inch, the pintle lower nut must be adjusted to limit the amount of lift to between 3/16 and 1/4 inch. Refer to the Adjustment procedure.

August 2007

5 - 37

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

2.

The thrust washer, rails, or rollers may be worn sufficiently to require replacement rather than adjustment. If necessary, replace a worn thrust washer per the center pintle repair procedure and replace a worn roller and/or rail per the applicable repair procedure.

3.

Clearance for free rotation of the revolving frame must be provided between the truck frame bushing and the sleeve. Such clearance, however, cannot be excessive or premature wear of the truck frame bushing or sleeve will occur.

To determine this clearance, proceed as follows: DANGER:

HIGH VOLTAGE! EXTREME CARE MUST BE EXERCISED AT ALL TIMES WHEN PERFORMING MAINTENANCE IN THE CENTER PINTLE AREA OF ELECTRICAL ENERGY. High voltage can cause serious or fatal injury. Installation, operation and servicing of components should be performed only by qualified personnel.

ALWAYS DISCONNECT the electrical power BEFORE ACCESSING the center pintle area.

a.

Disconnect the power to the machine. Enter the truck frame through the bottom access opening.

b.

Remove the cover from the top of the truck frame and gain access to the space between the pintle and the rollers. Insert a feeler gauge between the sleeve and the bushing of the truck frame. Any measurement over 0.250" diametral clearance is considered excessive and replacement of the bushing and/or sleeve is necessary.

CENTER PINTLE ADJUSTMENT To secure a loose center pintle sleeve which may be due to a worn thrust washer, roller, or rail, tighten the pintle lower nut as follows: 1.

Enter the bottom compartment of the truck frame, which will give access to the pintle lower nut adjusting pin.

2.

Cut the lock wires and remove the capscrews attaching the lock bars to the lower nut. Remove the lock bars.

3.

Pull down on the pin handle and rotate it 90° so that the pin can be moved into one of the slots in the lower pintle nut.

4.

To calculate the required rotation of the center pintle to keep lift at the rear rails within the allowable range of 0.18" to 0.25", use the following formula:

Manual No. 10500

5 - 38

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

R = (M-.25)576° M = Measured lift at rear rails R = Rotation, in degrees, required at center pintle Example: If measured lift is .625", then R = (.625-.25)576° = 216° The actual adjustments must be made in 90° increments to allow reinstallation of the nut-lock bars. After determining the required rotation, select the degree of turn closest to 90°, 180°, 270°, or 360°. In the above example 216° is closest to 180°. When there is a choice of selecting a higher or lower degree of turn from the formula’s result, always use the lower degree turn to prevent over-tightening of the pintle nut.

5.

Install the lock bars and capscrews. Secure the capscrews with lock wire.

6.

Disengage the adjusting pin. Make sure the pin handle is turned parallel to the pin and locked in the slot on the pin to prevent the pin from accidentally re-engaging the pintle lower nut.

7.

Apply power to the machine and check the lift as described in Inspection.

August 2007

5 - 39

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Center Pintle ~Section View

Manual No. 10500

5 - 40

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CENTER PINTLE REPAIR Remove the center pintle sleeve and thrust washer through the bottom of the truck frame as follows: 1.

Propel the machine over a pit of sufficient depth to allow the center pintle sleeve to clear the truck frame.

2.

Disconnect electrical power to the machine.

DANGER:

HIGH VOLTAGE! EXTREME CARE MUST BE EXERCISED AT ALL TIMES WHEN PERFORMING MAINTENANCE IN THE CENTER PINTLE AREA OF ELECTRICAL ENERGY. High voltage can cause serious or fatal injury. Installation, operation and servicing of components should be performed only by qualified personnel. ALWAYS DISCONNECT the electrical power BEFORE ACCESSING the center pintle area.

3.

Remove the coupling cover, the coupling, and shaft spacer. Disconnect, plug and tag all lube and air lines.

4.

Remove protector and cover. Disconnect and tag electric leads.

5.

Remove shoes, spacers and insulators from the housing.

6.

Remove the control collector rings from the swivel shaft. Remove the swivel assembly retainer and remove the retainer with swivel assembly attached. Remove the collector ring support and remove the support and collector rings as a unit.

7.

Secure the swivel support at the top so that when it is removed it will not fall. Remove the access cover from the bottom of the truck frame and enter truck frame. Disconnect and tag the air and lube lines and the electrical cables and tie them out of the way.

8.

Remove the swivel support base from the truck frame and lower the swivel support with base out of the truck frame.

9.

Remove the lock bars, lower nut, and thrust washer from the lower end of the pintle sleeve

10.

Install the lifting lug, supplied with the machine, to the top of the pintle and connect the auxiliary winch to the lifting lug.

CAUTION:

11.

Be sure to apply a load to the center pintle lifting lug sufficient to lift the center pintle - before proceeding.

Remove the bolts, lockwashers and dowels that fasten the upper nut to the revolving frame.

Remove the upper lock bars and their hardware. Remove the hardware joining the upper nut then remove the upper nut from the pintle sleeve.

August 2007

5 - 41

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

12.

Using the auxiliary winch, lower the sleeve into the pit. Replace a worn or damaged sleeve with a new one. Check the pintle sleeve bushing for wear or damage. Replace if required.

Check the truck frame around the pintle structure for cracks. If the pintle structure area needs repair, contact the Bucyrus International Service Department for instructions.

Center pintle sleeve installation is the reverse of disassembly.

DANGER:

HIGH VOLTAGE! Be sure the electrical lines are correctly connected and all connections are tight. Also make sure that the air and lube lines are connected to the correct outlets in the swivel assembly and that the connections do not leak.

Manual No. 10500

5 - 42

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

COLLECTOR RINGS There are three sets of collector rings on the machine. High voltage collector rings, on bottom of the revolving frame, transfer electric power from the truck frame to the rotating deck. Electric power enters the truck frame just below the propel motor and is transferred by means of collector ring shoes to the collector rings. The shoes are mounted between the cast center pintle hub and the swing rack.

The low voltage collector rings transfer power for the propel motors. The propel collector rings provide control to the propel motors and power for the propel blower motor.

August 2007

5 - 43

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

COLLECTOR RING INSPECTION Inspect the collector rings and shoes frequently for grease and contaminant accumulations on the rings, shoes, insulators and incoming wires.

Clean the collector rings and related parts with an approved solvent regularly to prevent high potential grounds. Make sure each shoe bears firmly against the collector ring. The shoes are springloaded to maintain constant contact.

CAUTION:

Solvents may be toxic or flammable. Adequate ventilation must be provided to minimize fire and health hazards caused by using solvents for cleaning. Use away from sparks, heat or flame to prevent fire or explosion. Follow the manufacturer’s instructions.

Check the insulators for cracks or chipping and replace promptly if damaged. Verify that the screws securing the rings to the insulators do not protrude beyond the countersunk holes of the rings.

CAUTION:

A cracked or chipped insulator or an excessive amount of contaminants may cause an electrical fault. This could result in death or serious injury.

COLLECTOR RING REPAIR Repair of the collector rings involves replacement of damaged insulators or defective shoes. The collector ring life expectancy exceeds the life expectancy of the machine. However, to replace the insulators or shoes: 1.

Disconnect electrical power to the machine.

DANGER:

HIGH VOLTAGE! Do not access the collector rings unless power to the machine has been disconnected and locked-out. Only authorized personnel should service the collector rings.

2.

Remove the attaching hardware securing the insulator or shoe to the mounting. Access to the shoes mounted to the truck frame is obtained by entering the truck frame through the bottom access opening.

3.

Install new insulators or shoes. Make sure all electrical leads are securely attached to the shoes and collector rings.

CAUTION:

Manual No. 10500

Do not attempt to inspect the underside of the revolving frame until power to the machine is disconnected.

5 - 44

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING MACHINERY

The swing machinery is mounted on both the left and right sides of the rotating deck. The machinery consists of a pair of 505 horsepower electric motors mounted vertically atop a planetary gearcase.

The planetary gearcases possess individual motor driven lubrication pumps to provide positive lubrication to the critical bearing surfaces of the gearcase. The motors are force cooled by blowers mounted to their sides. The motors drive the planetary gear systems through a single input coupling on each side.

August 2007

5 - 45

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Each gearcase transmits the torque to a pair of pinion shafts that drive sets of pinions on each side of the machine (2 per side). These pinions mesh with the swing rack of the machine and, in turn, provide rotational movement for the swing cycle. Mounted on top of the swing motors are springset, pneumatically-released disc brake assemblies to prevent undesired movement.

The swing machinery should be inspected daily for proper lubricant level within the planetary gearcases. If lubricant level is found to be low it must be serviced prior to machine operation. The area of the mesh between the rack and pinions must be looked at with a critical eye. Proper lubrication, damage and the presence of foreign material are some of the items to look for in this area.

SWING BLOWER The blower assembly is mounted to the top of the swing motor. The blower is normally replaced as a complete assembly.

DANGER:

BEFORE ATTEMPTING TO DISCONNECT ANY POWER LEADS, PRESS THE MAIN POWER OFF BUTTON AND TAG IT TO AVOID INADVERTENT ENERGIZING OF THE ELECTRICAL CIRCUIT. Electrocution or serious injury may occur if appropriate safety measures are not followed.

Electrical connections should only be handled by trained electrical personnel.

SWING MOTOR Inspection, lubrication and maintenance instructions for the swing motor can be found in the motor’s manufacturer’s manual. Replacement of the motor is covered below.

DANGER:

Manual No. 10500

BEFORE ATTEMPTING TO DISCONNECT ANY POWER LEADS, PRESS THE MAIN POWER OFF BUTTON AND TAG IT TO AVOID INADVERTENT ENERGIZING OF THE ELECTRICAL CIRCUIT. Electrocution or serious injury may occur if appropriate safety measures are not followed.

Electrical connections should only be handled by trained electrical personnel.

5 - 46

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING MOTOR REMOVAL NOTE: Removal of the appropriate roof panel is required for the removal/replacement of either the left or right swing motor. Complete instructions for the removal and replacement of the motor coupling hub and swing brake hub may be found in Section 6, at the rear of this manual.

1.

Have a qualified electrician tag and remove the electrical leads to the motor.

2.

Remove the swing motor blower and duct assembly.

3.

Remove the swing brake and it’s mounting hardware from the motor.

4.

Remove the bolts securing the motor drive coupling halves together as per the instructions in the Section 6 of this manual .

5.

Attach a lifting device to the motor and remove slack from sling.

6.

Remove the bolts securing the motor to the planetary gearcase housing.

7.

Remove the motor from the planetary gearcase and store in a dry location if to be reinstalled.

SWING MOTOR INSTALLATION Installation of the swing motor is the reverse operation of the removal procedure covered above with the following exception: IMPORTANT: Alignment of the motor coupling is critical to the longevity of the bearings within the motor and the planetary gearcase. Check and adjust the coupling alignment in accordance with the instructions found in section 6 of this manual.

SWING PLANETARY GEARCASE The planetary gearcases are self-contained, segregated units designed to provide extended service under adverse conditions.

With regular oil changes, inspections and normal preventative maintenance, these gearcases should operate continuously for 25,000 hours before requiring a “Level 1” rebuild (replacement of all bearing and seals) and 40,000 hours between major overhauls.

August 2007

5 - 47

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Swing Planetary Gearcase - Primary Assemblies

Manual No. 10500

5 - 48

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

GEARCASE INSPECTION 1.

Check the magnetic plug weekly for evidence of excessive metallic deposits indicating unusual wear of the internal components of the gearcase.

NOTES: • The magnetic plug equipped on this gearcase provides an internal check valve to prevent lubricant loss when the plug is removed.

• Normal wear within the gearcase will provide a metallic deposit that appears like “silver paint” when the substance is rubbed between the fingers. This is a collection of tiny metal particles that are produced by normal friction within the internal components of the gearcase. The amount may seem excessive during the initial break-in of the machine, but will reduce in short order.

• Abnormal wear within the gearcase will be evidenced by a “gritty” crumb type of material being found on the plug. If the material gathered is not smooth a problem may be surfacing. When a gear tooth or bearing begins to erode and “make metal”, this process will only increase in severity until a point when severe and costly damage will result.

2.

Check the oil each time the magnetic plug is inspected, refill or change lubricant as needed.

August 2007

5 - 49

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING SHAFTS AND PINIONS NOTE: Removal of the swing shaft pinions can be accomplished at nearly any location on a mine site. Removal of the swing shaft assemblies will require heavier hoist and more detailed tooling capabilities.

Swing Shaft, Dual Output - Section View

SWING PINION REMOVAL 1.

Remove lockwire and loosen the 5 - 1 Inch capscrews on the swing pinion retainer. Ensure to only remove 3 of the 5 capscrews at this time.

Manual No. 10500

5 - 50

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

2

Place appropriate blocking, capable of supporting 600 lbs., under the pinion in such a manner to allow access to the remaining pinion retention bolts and the removal of the retainer. Remove the remaining bolts, retainer and shim pack.

3.

Use a suitable puller to remove the pinion. (Weight: 524 Lbs.) Lower the pinion to the ground and repair/replace as required.

Swing Shaft and Pinion ~Exploded View

August 2007

5 - 51

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING PINION INSTALLATION Installation of the pinion is the reverse of disassembly with the exception of shim pack determination.

This will be covered in the following topic.

SWING SHAFT REMOVAL NOTES: •

Removal of the swing shaft will require the prior removal of: •

An appropriate section of the machinery house roof panel.

•

Swing motor and Brake assembly.

•

Planetary gearcase.

•

Remove the swing shaft through the TOP of the revolving frame structure when removing the shaft without the bearing. (The bearing fits on the tapered portion of the shaft.)

•

Remove the swing shaft from the BOTTOM of the gearcase support if removing the shaft, bearing and carrier as an assembly.

DANGER:

1.

BE EXTREMELY CAUTIOUS WHEN REMOVING THE SHAFT ASSEMBLY THROUGH THE BOTTOM. AFTER LOOSENING THE BEARING CARRIER BOLTS THE SHAFT IS UNSUPPORTED AND MAY FALL.

Remove the appropriate machinery house roof panel.

DANGER:

BEFORE ATTEMPTING TO DISCONNECT ANY POWER LEADS, PRESS AND TAG THE MAIN POWER OFF BUTTON. This will avoid inadvertent energizing of the electrical circuit. Electrocution or serious injury may occur if appropriate safety measures are not followed. Electrical connections should only be handled by trained electrical personnel.

2.

Remove the swing motor and planetary gearcase from the swing to be removed. Refer to the proper procedures in this section of the manual.

3.

Remove the swing shaft bushing retainer at the top of the shaft and its capscrews. Remove the bushing.

4.

Remove the proximity switch clamp collar from the swing shaft just above the bearing assembly. Refer to the figure on the following page.

5.

Remove the swing shaft pinion. Refer to the instructions in the previous section of this manual.

6.

Remove the spacer between the lower bearing retainer and the swing shaft.

Manual No. 10500

5 - 52

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

7.

Attach a crane to a 2 inch lifting eye threaded into the top of the shaft.

NOTE: Remove any slack from lifting device, but do not apply excessive force in an upward direction at this time.

8.

Use a hydraulic hand pump, placed on blocking, to apply pressure attempting to force the shaft through the interference fit of the bearing.

NOTES: •

If shaft does not move, increase viscosity of hydraulic fluid and increase force to a maximum of 10,000 PSI applied pressure.

•

In the event that the shaft will still not move additional force can be applied with the hydraulic ram or a jacking device of up to 50 ton. If this additional force is required to loosen the shaft, the bearing must be discarded.

9.

Once the shaft has been released it may be lifted clear of the machinery house and stored or transported for repair.

10.

Inspect the bushing at the top of the shaft and all lower seals within the swing shaft housing.

Replace as required.

SWING SHAFT INSTALLATION 1.

Assemble seals and retainer at the top of the bearing, the bearing and the O-Rings in the gearcase support in preparation for the shaft.

2.

Apply a thin coating of MolyKote lubricant to the splined sections and the tapered section of the swing shaft prior to assembly.

3.

Lower the swing shaft into the lower seal and bearing assembly. Install the bottom bearing retainer and seal from beneath.

Section A-A Proximity Switch Clamp Collar

4.

Tighten the lower retainer retention bolts to 110 Ft.Lb. and lockwire in place.

5.

Install the proximity switch clamp collar and hardware as shown in the figure.

6.

Install the shaft bushing, retainer and hardware at the top of the shaft.

7.

Install the spacer, the pinion and the pinion retainer on the bottom of the shaft. Support all parts and install 2 capscrews. Tighten to 20 Ft.Lb. August 2007

5 - 53

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

8.

Through the 3 remaining holes in the retainer, obtain a measurement of the distance between the bottom of the shaft and the bottom of the pinion retainer. Average this measurement.

9.

Measure the thickness of the retainer at 3 places and average this measurement.

10.

Subtract the averaged plate measurement from the averaged overall dimension. Subtract .08 Inch from this dimension. This results in the required shimpack thickness for use beneath the shaft assembly and will allow for proper advance of the tapered bearing on the tapered shaft.

11.

Support the pinion gear and remove the retainer and capscrews.

12.

Install a shimpack equal to the final dimension calculated above, the retainer and capscrews

13.

Using a criss-cross pattern, tighten the 5 capscrews in stages of 50 Ft.Lb. each to a final torque value of 480 Ft.Lb.

IMPORTANT:

14.

This staged tightening procedure is critical to allow for proper seating of the tapered portion of the shaft within the bearing surface. A sharp rise in torque value will indicate proper seating of the bearing to the shaft.

After the final torque value is reached lockwire the capscrews in place.

Manual No. 10500

5 - 54

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST MACHINERY

Hoist Machinery Assembly

The Hoist Machinery consists of: • A Large Diameter Hoist Drum, • Integral Single-Helical Hoist Gear, • Dual-Output Planetary Gearcase, • Hoist Motor and Brake Assembly.

Frequently check the hoist machinery for loose or missing hardware. At least once a month, check the hardware on the hoist motor, shaft, couplings and Right and Left Pedestals for tightness. Retighten or replace any loose or missing hardware.

Every 12 months remove the upper hoist gear guard inspection covers and the gearcase inspection covers and inspect the gear and pinions for pitting, abrasion, scratching, spalling, galling and/or other tooth wear. Check the gearcase for evidence of lubricant leakage. Replace any defective seals.

August 2007

5 - 55

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Hoist Machinery - Plan View

Manual No. 10500

5 - 56

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST MOTOR Inspection, lubrication and maintenance instructions for the hoist motor are described in the manufacturer's manual for the motor. If removal of the hoist motor is required, use the following procedure: 1.

Position the machine so that the dipper lip and front are flat on the ground.

2.

Remove the appropriate roof panels above the hoist motor.

DANGER:

3.

HIGH VOLTAGE! BEFORE DISCONNECTING THE CABLES TO THE HOIST MOTOR, PRESS AND TAG THE MAIN POWER OFF BUTTON. Failure to comply may result in injury or death.

Disconnect the leads to the hoist blower motor and to the hoist motor. Remove the piping to the hoist brake.

Hoist Motor Mounting - Plan View

4.

Remove the 4 - 2.0 Inch nuts that fasten the motor to its mounting pads on the deck.

5.

Remove the 7 - .5 Inch capscrews that fasten the coupling guard to the deck and remove the coupling guard. Separate and remove the coupling from the motor end of the motor coupling shaft.

August 2007

5 - 57

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

6.

Using a suitable crane, lift the motor and brake assembly through the house roof and away from the machine.

7.

Save and identify the motor shims for later reuse.

Installation of the hoist motor is the reverse procedure.

NOTES: • If replacing the original motor with a new motor, remove the alignment chocks and wedges from the motor mount, reinstall after setting and aligning the new motor.

• Align the coupling using the procedure in Section 6 - BRAKES AND COUPLINGS, in this manual.

• The hoist motor is fastened to its mounting pads using 2.0 inch Nuts and Bolts with Torque Nuts. To tighten use the Torque Nut tightening procedure at the end of this section of the manual.

HOIST GEARCASE ASSEMBLY The hoist gearcase is a split-power, planetary gearcase. Power is transferred from the hoist motor through a single input shaft to dual helical output pinions mated to the main hoist gear. Three pins fasten the gearcase to the left hoist pedestal. The gearcase utilizes an oil circulating system to lubricate internal gearcase components and to maintain cooling.

Hoist Drive Gearcase Manual No. 10500

5 - 58

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST GEARCASE INSTALLATION

Installation of the Hoist Gearcase

The Hoist Gearcase can be removed or replaced without removing the hoist motor or the hoist gear. To remove the gearcase: 1.

Position the machine so that the dipper lip and front are flat on the ground.

2.

Apply sufficient force on the crowd to “jack” the boom enough to unwind the suspension strands. Set the crowd brake.

3.

Remove the appropriate roof panels above the hoist gearcase.

4.

Remove the left-upper-rear A-Frame leg pin. Swing the A-Frame leg to the rear of the machine.

DANGER:

August 2007

BEFORE PERFORMING ANY MAJOR MAINTENANCE ON THE HOIST MACHINERY, PRESS AND TAG THE MAIN POWER OFF BUTTON. Failure to comply may result in injury or death.

5 - 59

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5.

Remove the upper-rear section of the hoist gear guard. Use blocking to prevent accidental movement of the hoist drum.

6.

Pull the gearcase bearing drain hoses up from the deck and tie back out of the way.

7.

Drain the oil from the gearcase. Remove the oil pump-to-radiator hose and the radiator-tomanifold hose.

8.

Remove the 7 - .5 Inch capscrews that fasten the coupling guard to the deck and remove the coupling guard. Separate and remove the couplings from both ends of the motor coupling shaft and remove the shaft. (Shaft weight is approx. 1,325 Lbs.)

9.

Using a suitable crane, support the gearcase using the 4 lifting lugs at the top of the gearcase.

Apply enough lift to just support the weight of the gearcase. (Gearcase weight is approx.

27,000 Lbs.)

10.

Remove the cotter pins and the T-Head pins from the 3 mounting pins that attach the gearcase to the hoist pedestal.

NOTE: The gearcase is attached to the deck at the bottom of the gearcase with 1 long pin on the forward side and 2 unique short pins on the rear side. Mark the short pins to ensure correct re-installation.

Forward Pin (long) ............... 509 Lbs. Rear Pin Outer (short) ......... 191 Lbs. Rear Pin Inner (short) .......... 168 Lbs. 11.

With the gearcase supported, it may be necessary to use a come-along or other suitable pulling device to pull the gearcase slightly toward the rear of the machine, in order to disengage it from the hoist gear.

12.

Once the gearcase will clear all obstructions, lift it through the house roof and away from the machine.

The hoist gearcase can be reinstalled using the reverse procedure.

NOTES: • Verify that the planetary output pinion-to-drum gear alignment has the proper backlash and contact patterns.

•

Install the motor coupling shaft and check the alignment. Refer to Section 6 ~ BRAKES AND COUPLINGS, in this manual.

•

Re-install the gearcase drain lines into the openings in the deck.

•

Re-install the oil cooling hoses.

•

Insure that the gearcase is filled with the proper type and amount of oil.

HOIST GEARCASE REPAIR

Manual No. 10500

5 - 60

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Repair of the hoist gearcase is best completed with the gearcase removed from the machine and in a shop environment. Basic “Level-1” repair involves replacement of seals and O-Rings in the pinion shaft area.

MOTOR COUPLING SHAFT Power is transferred from the hoist motor to the gearcase through a motor coupling shaft with 2 couplings. Using the inspection doors on the coupling guard, check the couplings for evidence of lubricant leakage. Under normal circumstances, a coupling will operate for 3 to 5 years before service is required. However, if leakage from a coupling is noticed, the coupling should be disassembled and repaired.

Guard over Coupling Shaft August 2007

5 - 61

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

When reinstalling the coupling shaft, it is recommended to use a laser alignment procedure. Refer to Section 6 ~BRAKES AND COUPLINGS.

Coupling Alignment Reference

HOIST DRUM ASSEMBLY The hoist drum shaft uses a single-helical hoist gear fastened to a large-diameter drum with the hoist spider and rotates on double-row, tapered roller bearings.

Hoist Drum Assembly

Manual No. 10500

5 - 62

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Removal of the hoist drum shaft will require lowering and supporting the boom. To remove the hoist drum shaft: 1.

Position the machine so that the dipper lip and front are flat on the ground.

DANGER:

BEFORE PERFORMING ANY MAJOR MAINTENANCE ON THE HOIST MACHINERY, PRESS AND TAG THE MAIN POWER OFF BUTTON. Failure to comply may result in injury or death.

2.

Remove the hoist ropes.

3.

Remove the A-Frame ladders and platforms.

4.

Remove the two machinery house fan/filter assemblies.

5.

Remove the A-Frame shrouds.

6.

Remove the center front roof panel, the 6 center roof panels and the 3 left roof panels over the left deck extension. Save all indicated items for re-use.

NOTE: To remove the center roof panel, cut the welds between the channels on the front wall panels and the center roof panel ~ both sides. The rubber sheets can remain attached to the roof panel. All front wall panels can remain in place, however the upper left and upper center wall panels can be removed, with their hardware, and saved for later reuse.

7.

Remove 4 center roof crossbeams, 2 left roof crossbeams and 4 center roof fore/aft truss beams.

8.

Using the crowd machinery (or a separate crane) support the weight of the boom to unload the A-Frame and main suspension strands.

9.

Remove the upper A-Frame pins from the rear A-Frame legs. (Will require a cherry picker.)

10.

Rotate the rear A-Frame legs back toward the rear of the machine and secure to the control room roof.

11.

Using the crowd machinery (or a separate crane) lower the boom until the front A-Frame legs are pulled forward so that they are at an 80o to 85o angle to the top of the revolving frame. Set the crowd brake and block the boom in position. Install a safety cable to prevent the front AFrame from being inadvertently over center.

August 2007

5 - 63

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Hoist Drum Bearing Assembly

12.

Remove the drain lines from the bearing housings. Disconnect and remove the lube lines from the hoist bearing housings and the gear guard.

13.

Disconnect the hoist limit switch wiring. Remove the hoist limit switch assembly from the drum shaft.

14.

Remove both the front and rear sections of the upper hoist gear guard. Each guard section weighs approx. 1,110 Lbs.

15.

Use a crane to support the hoist drum shaft assembly. approx. 70,000 Lbs.

16.

Remove the 3 - 1 Inch capscrews from each of the 4 pins that attach the bearing housings to the hoist pedestals. Remove the 4 pins by pushing from inside the pedestals. Note that each pin weighs approx. 240 Lbs.

17.

The drum assembly can now be lifted from the machine.

Installation is the reverse procedure.

Manual No. 10500

5 - 64

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST GEAR REPLACEMENT The hoist gear can be reversed on the hoist spider to provide more useful life. To reverse or replace the hoist gear, the hoist drum shaft must be removed from the machine. Remove the drum assembly using the above procedure.

1.

Once removed, support the hoist drum assembly on cribbing in a vertical position, with the gear end down and the cribbing supporting the hoist gear only. Insure that the bearing housing on the gear end of the shaft or the stub shaft is not resting on the ground. This may require cribbing approx. 30 inches in height.

2.

If replacing the hoist gear with a new one, insure that the new gear is resting flat on cribbing just as the old one (approx. 30 inches above the ground). If reversing the existing gear, provide suitable cribbing (approx. 30 inches in height) to rest the hoist drum and spider assembly while turning the hoist gear.

3.

Support the old drum and spider assembly with a crane. Do not attach the crane support to the hoist gear.

4.

Remove the 36 - 1.75 Inch body-fit bolts that fasten the hoist gear to the spider.

5.

Lift the drum and spider assembly away from the hoist gear.

6.

Place the drum and spider assembly onto the new hoist gear (resting on cribbing).

NOTE: If reversing the existing hoist gear, set the drum and spider assembly on cribbing, turn over the existing gear with an additional crane, then set the drum and spider assembly on the gear. The hoist gear weighs approx. 12,000 Lbs. 7.

Install the 36 body-fit bolts and tighten.

8.

The drum shaft can now be reinstalled in the machine using the above procedure.

August 2007

5 - 65

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BEARING REPLACEMENT To remove or replace the hoist drum shaft bearings, it is best to remove the drum shaft assembly from the machine. Use the above procedure, then proceed as follows:

1.

Insure that the drum shaft assembly is resting horizontally on cribbing.

2.

Remove the 6 - 1 Inch rod assemblies that fasten each of the outer retainers to the each of the bearing housings.

3.

Mark then remove each outer retainer. Each retainer weighs approx. 230 Lbs.

NOTE: These parts are not interchangeable. Inspect the O-Ring on the inside of each retainer.

Replace if required.

4.

Pull the bearing housings (3,000 Lbs. each) from the bearings.

5.

Remove the 6 - 1.5 Inch capscrews that fasten each drum shaft end plate to the shaft.

6.

Mark then remove each end plate (approx. 170 Lbs. each). Tag and save the shim packs for later reuse.

7.

Use a bearing puller to pull each bearing from the shaft. Each bearing weighs approx. 420 Lbs.

8.

Inspect the bearings, the spacer and seal remaining on the shaft ends, and the O-Ring on each seal. Repair or replace any parts as needed.

Reassembly is the reverse of disassembly.

NOTE: The bearings are assembled with an interference fit. Preheat the bearings in an oil bath to ease assembly.

Manual No. 10500

5 - 66

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST MOUNTING BOLTS Use the following view to identify the correct installation of the mounting bolts for the hoist machinery.

For tightening, refer to TORQUE NUT INSTALLATION in Section 9 - Engineering Data in this manual.

August 2007

5 - 67

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST LIMIT SWITCH The hoist limit switch is used to prevent the padlocks on the dipper from being pulled into the boom point sheaves. The switch electrically cuts the reference signal. It is mechanically connected to the hoist drum shaft. It is composed of a gear reducer, an input shaft connected to the hoist stub shaft and an optical encoder. Setting the hoist limit switch is a function of the Operator’s Display in the operator’s cab. The procedure is detailed in Section 2 of this manual.

Manual No. 10500

5 - 68

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST MOTOR Inspection, lubrication and maintenance instructions for the hoist motor are described in the motor’s manufacturer’s manual. If removal of the hoist motor is necessary, follow the instruction below: NOTE: Removal of the appropriate roof panel is necessary to facilitate this procedure.

1.

Place the dipper on the ground.

DANGER:

BEFORE ATTEMPTING TO DISCONNECT ANY POWER LEADS, PRESS THE MAIN POWER OFF BUTTON AND TAG IT TO AVOID INADVERTENT ENERGIZING OF THE ELECTRICAL CIRCUIT. Electrocution or serious injury may occur if appropriate safety measures are not followed.

Electrical connections should only be handled by trained electrical personnel.

2.

Disconnect and identify the electrical leads to the hoist blower motor and the hoist motor.

3.

Remove the hoist blower motor and duct as a unit from the hoist motor.

4.

Remove the brake from the motor.

August 2007

5 - 69

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CAUTION:

RELEASE THE HOIST BRAKE TO REMOVE ALL TENSION FROM THE HOIST DRUM BEFORE REMOVING THE BRAKE.

5.

Separate the coupling on the gearcase end of the motor.

6.

For repair of original motor: remove the two chocks and wedges located on the side of the motor towards the hoist drum. For replacement of original motor with a new motor: remove the four chocks and wedges located on both the front and rear sides.

7.

Remove the motor mounting hardware. Attach the crane to the motor and lift it from the machine. Wire shims together, if used, and identify their location for future use.

8.

Install the motor by reversing the steps used to remove it. For installation of a new motor, mount and align the motor coupling per instructions in Section 6.

9.

Re-install four chocks and wedges on both sides of the motor.

10.

For re-installation of the original motor: position the motor and provide the specified end clearance at the coupling. Re-install the two chocks and taper wedge on the hoist drum side of the motor.

Manual No. 10500

5 - 70

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD MACHINERY The Crowd Machinery is located on the deck at the front of the machine, forward of the center of rotation. This machine consists of the crowd drum assembly for take-up of the crowd and retract ropes, a gearcase, motor and brake.

Weekly, check both the crowd gearcases for lubrication leaks at all cover and case junctions and at the bearing retainers. Replace seals or rings if lubrication leaks are excessive. Replace sealant as required.

Weekly, check the electrical connection of the crowd motor and blower motor for tightness. Tighten the connection hardware if necessary.

August 2007

5 - 71

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Crowd Gearcase

Every six months remove the inspection covers of the gearcases and inspect the gears and pinions for pitting, abrasion, scratching, galling, spalling and other abnormal tooth wear.

Check the crowd machinery attachment pins for movement under load. Tight attachment pins minimizes wear on the pins and pin holes. Check every 100 hours.

Weekly, remove the pipe plugs in the first reduction gearcase and the second reduction gearcase and check the lubricant level. The first reduction gearcase lubricant level plug is located at the rear of the gearcase cover to the rear of the first reduction pinion.

Manual No. 10500

5 - 72

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

The second reduction lubricant level plug is located on the inboard side of the second reduction portion of the gearcase. Maintain the lubricant level at the bottom of the pipe plug opening. When lubricant sample tests make it necessary, drain the gearcase immediately after operation, flush out the gearcase and refill with the recommended lubricant. Refer to Section 3 for the correct lubricant.

GEARCASE REPAIR Repair of the crowd reduction gears is basically a matter of component replacement. Use the following procedures to disassemble the crowd machinery whether the crowd is on the machine or separated from the revolving frame.

NOTE: Removal of the appropriate roof panel is necessary to facilitate this procedure.

1.

Remove the crowd ropes and retract ropes from the crowd drum. Refer to the instructions in the FRONT END EQUIPMENT in this manual.

2.

Disconnect any lubrication lines attached to the crowd gearcases and covers. Drain the lubricant from the gearcase.

3.

Disconnect the electrical leads to the crowd motor and the blower motor. Identify the leads to ensure correct installation.

DANGER:

BEFORE ATTEMPTING TO DISCONNECT ANY POWER LEADS, PRESS THE MAIN POWER OFF BUTTON AND TAG IT TO AVOID INADVERTENT ENERGIZING OF THE ELECTRICAL CIRCUIT. Electrocution or serious injury may occur if appropriate safety measures are not followed.

Electrical connections should only be handled by trained electrical personnel.

4.

Remove the motor coupling guard and separate the coupling.

5.

Remove the motor shaft outboard end cover and the inboard bearing retainer. Remove the two first intermediate shaft end covers. Remove the second intermediate shaft end cover and the inboard bearing retainer. Remove the bolts that secure the second intermediate shaft left side bearing cover and inner retainer.

August 2007

5 - 73

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Crowd Motor Pinion ~Exploded View

6.

Attach a crane to the gearcase cover and remove the bolts securing the cover to the gearcase.

Remove the bearing cap rods, nuts and washers.

NOTE: When removing torque nuts, refer to the proper removal procedure in Section 9 Engineering Data 7.

Lift and remove the cover from the gearcase. Remove the cover seal from the gearcase.

8.

Attach a crane to the motor shaft and lift the shaft assembly from the gearcase. Remove the first and second intermediate shafts in the same manner.

Manual No. 10500

5 - 74

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Crowd 1st Reduction ~Exploded View

9.

Dismantle the shafts as required. a.

For any shafts that are dismantled, inspect the bearings for pitting, scoring and other defects. Replace damaged bearings.

b.

Check the oil seals for cuts, abrasions and other damage to the sealing surface. Replace as necessary.

c.

Install new O-Rings and gaskets where required.

d.

Some bearings and spacers are interference fit and must be preheated in an oil bath prior to installation on the shafts.

August 2007

5 - 75

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Crowd 2nd Reduction ~Exploded View

For reassembly: 1.

Install the shafts in the gearcase, using the crane to lift the shaft units.

2.

Be sure the flanges of the gearcase and gearcase cover are clean. Install the seal in the groove in the gearcase. Apply a continuous bead of LOCKTITE #515 to the gearcase flange halfway between the bolt pattern and the inside of the flange. Install the gearcase cover securing it with the necessary hardware.

3.

Pre-load the second intermediate bearing cap against rear hook of frame with a 1-1/2" by 4" GR5 capscrew. Apply LocTite and tighten to 1,700 Ft.Lb.

4.

Install the rods and their associated hardware into the bearing caps. and hand tighten.

NOTE: The bearing caps and rods are assembled with torque nuts. Refer to Section 9 ~ ENGINEERING DATA for tightening.

Manual No. 10500

5 - 76

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5.

Tighten the torque nuts on the rods using the proper procedure.

4.

Install the retainer hardware. Install and secure the shaft end covers. Be careful not to pinch the O-Rings.

5.

Attach the lubrication lines and lubricate the bearings. Fill the gearcases with oil to level with the bottom of the oil filler opening. Attach the electrical leads to the motor and the blower motor.

6.

Install the crowd and retract ropes on the drum. Refer to FRONT END EQUIPMENT in this manual.

CROWD MOTOR Inspection, lubrication and maintenance instructions for the crowd motor are described in the motor manufacturer’s manual. If removal of the crowd motor is necessary, follow the instructions below.

NOTE. Removal of the appropriate roof panel is necessary to facilitate this procedure.

Crowd the dipper outward and place the dipper on the ground.

DANGER:

BEFORE ATTEMPTING TO DISCONNECT ANY POWER LEADS, PRESS THE MAIN POWER OFF BUTTON AND TAG IT TO AVOID INADVERTENT ENERGIZING OF THE ELECTRICAL CIRCUIT. Electrocution or serious injury may occur if appropriate safety measures are not followed.

Electrical connections should only be handled by trained electrical personnel.

1.

Disconnect and identify the electrical leads to the crowd blower motor and the crowd motor.

2.

Remove the blower motor and duct as a unit from the crowd motor.

3.

Remove the brake from the motor.

August 2007

5 - 77

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

4.

Remove the motor coupling guard and separate the coupling.

5.

For repair of the original motor, remove the two chocks and wedges located on the side of the motor towards the boom.

6.

For replacement of the original motor or motor pinion, remove the four chocks and wedges located on both the front and rear side. Also remove the two chocks at the brake end of the motor.

7.

Remove the bolts securing the crowd motor to the crowd machinery frame. Use a crane to lift the motor from the frame.

8.

For reinstallation of the original motor and pinion, position the motor against the two in-place chocks and wedges. Reinstall the two chocks and wedges on the boom side of the motor. Re check coupling alignment.

9.

For replacement of the original motor with a new motor refer to Section 6 ~ BRAKES AND COUPLINGS. Align the motor coupling per the instructions in Section 6. Install the four chocks and wedges on both sides of the motor.

Manual No. 10500

5 - 78

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD GEAR AND DRUM Inspect the drum gear-to-drum mounting hardware for loose or missing nuts and bolts. These bolts and nuts were tightened at the factory using Turn-of-the-Nut torque method. Loose bolts and nuts should not be re-tightened but replaced with new bolts and nuts. Tighten the new bolts and nuts using the Turn-of-the-Nut method per Section 9 ~ ENGINEERING DATA.

Check the drum for cracks. Check the drum grooves for rough edges and other defects which would damage the crowd and retract ropes. Check the retract rope for any damage. Inspect the drum gear teeth for pitting, abrasions, spalling, galling and other damage.

August 2007

5 - 79

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD DRUM REPAIR If repair of the crowd drum is needed: 1.

Remove the crowd ropes and retract ropes from the drum. Refer to the FRONT END EQUIPMENT in this manual.

2.

Remove the gear guard from the drum gear.

3.

Disconnect the lubrication lines at the shaft end covers. Remove the end covers.

4.

Remove the bolted-on crowd frame lower front cross tie.

5.

Attach a crane to the drum and apply enough force to support the weight of the drum.

6.

Remove the Pre-Load screws. Then loosen the torque nuts on the bearing caps. Refer to the procedures in Section 9 - ENGINEERING DATA.

7.

Remove the torque nuts and washers securing the bearing caps then remove the bearing caps. The drum can then be lowered to the ground.

8.

Cut the lock wire and remove the retainer bolts from each end of the shaft.

Remove the bearing retainers. Remove the shim pack, bearings, bearing spacer and labyrinth seals and wire together for future use.

7.

If necessary, remove the hardware securing the drum gear to the drum and remove the gear. Consult the Bucyrus Service Department for repair procedures for the drum and gear.

8.

Inspect the bearings for pitting, scoring, scratches and other defects. Replace defective bearings.

Manual No. 10500

5 - 80

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

To reassemble the crowd drum: 1.

If removed, reinstall the drum gear using new bolts and nuts.

2.

Tighten the nuts to 1120 Ft.Lb. (lubed threads, 100% proof load) or tighten the nuts to 224 Ft.Lb. followed by 1/3 turn of the nut (dry threads).

3.

Let the joint set for 24 hours then loosen and retighten. When re-tightening use LocTite #277 on nuts.

4.

The bearings and spacers are interference fit and must be preheated in an oil bath prior to installation.

5.

Attach a crane to the drum unit and position it in the frame.

6.

Install the bearing caps and rod bolts and hardware. Pre-load the bearing caps against the front hook using 3/4" x 7-1/2" GR8 bolts and lockwashers. Lubricate threads and tighten to 385 Ft.Lb.

7.

Secure the rods in place with special torque nuts. Refer to the proper torque nut tightening procedures in Section 9 - ENGINEERING DATA.

August 2007

5 - 81

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MACHINERY HOUSE The machinery house has separate structural members consisting of front and rear main truss and interconnecting beams. These form the permanent house structure.

Roof panels are individually fastened to the interconnecting beams. Any panel can be removed separately to provide access to a machinery house unit. All roof panels are secured with hold down bolts on retainer bands. Vinyl tape weather stripping is installed between the retainer band and roof panel.

Shroud covers around the A-frame legs have vinyl tape between the leg and shroud. Shroud support joints are sealed with rubber cement or silicone caulking.

All mating surfaces of the machinery house wall panels are sealed with rubber cement or silicone caulking to ensure weather tight seal.

Frequently inspect all house panels and structural members for cracking. Include a close examination of all roof structures. Examine all struts, beams and braces used to reinforce the machinery house.

Always restore defective structural members to their original state by repair welding.

Periodically observe the hinges and closure mechanisms on all doors and windows to ensure they will remain closed during machine operation. Verify the sealing of the leg closures of the A-frame.

Tighten all loose bolts and replace all missing hardware. The absence or looseness of these fasteners can result in excessive vibration and wear of house components. Individually, these faults can be considered minor, but taken collectively, they represent a major exposure of the electrical and mechanical elements of the house to dust and water.

Check the condition of the house paint. Paint is not impervious to deterioration. A well-painted machine is less susceptible to rust, corrosion and progressive failure.

Be sure the pressurization system is functioning properly to keep the house well-ventilated at a pressure higher than atmospheric pressure.

Manual No. 10500

5 - 82

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

WALKWAYS, STAIRWAYS AND HANDRAILS Inspect all walkways, platforms, stairways and handrails on the machine daily. Maintenance personnel should do the inspecting. Should a structural member become damaged, repair or replacement may be necessary. Replace nuts and bolts where required or repair weld to restructure individual access members such as steps and railings.

Eliminate accumulations of wiping rags, oil and grease, dust and dirt and mislaid maintenance tools. They can create a safety hazard. Keep new and used wiping rags in barrel containers rather than draped or tied to railings. Clean off oil and grease in the primary walking and working areas to prevent workers from slipping. Maintain a tool bench and rack for the storage of all tools used in the machine upkeep. Do not let tools lie scattered upon walkways and stairways.

August 2007

5 - 83

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BOARDING STAIRS A set of boarding stairs is attached to the machinery house platform - either on the left side of the machine, the right side or both. When lowered, the stairs allow entrance to the machinery house from ground level. To activate the stairs, a chord attached to a lever arm is reachable from the ground. An additional lever is available at the top of the stairs. These stairs must be in their raised and latched position to enable the operator’s controls.

DANGER:

STORED ENERGY! System may be under hydraulic pressure which can cause severe personal injury or death. Shut down pump and relieve system of all pressure before removing components.

The boarding stairs pivot about a pivot shaft attached to the boarding platform. A set of counterweights offsets the weight of the stairs. A self-contained hydraulic system, with an accumulator and cylinder, operates the stairs.

Manual No. 10500

5 - 84

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

A bumper assembly attached to the latch assembly on the machinery house wall stops the stairs when raised to the upper position. Another bumper is attached to the counterweights to prevent the stairs from lowering too far. Ensure that all bumpers are in place and have not deteriorated.

Both actuating levers are attached to a set of wire ropes that are in turn connected through sheaves to the latch assembly on the right wall of the machinery house.

Generally very little maintenance is required for the stairs. However, ensure that the flanged bearings on the pivot shaft are lubricated and also that the limit switches in the lever assembly and beneath the platform are in place and in good working order. The tension in the wire ropes should be adjusted so that approx. 15-25 lbs. of force on either lever will operate the stairs. To modify this tension, adjust the springs in the latch assembly by loosening or tightening the spring U-bolts.

August 2007

5 - 85

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

FRONT END EQUIPMENT BOOM ASSEMBLY Maintenance of the front end equipment requires at minimum a weekly visual check for cracks or other damage to the boom structure. It will include checking the ladders and the boom point platform. Also, check for signs of wear and cracks on the sheaves. Replace, if necessary. There should always be a sign of fresh grease on both sheave bearing areas. Visually check sheave bearing retainer bolts.

Unusual problems should be referred to the Bucyrus International Service Department for solutions.

Inspect the boom foot lugs for any signs of cracking. Also check to see that the boom foot pins are being properly lubricated.

Manual No. 10500

5 - 86

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BOOM REPAIR Repair of the boom is normally limited to very minimal additional damage sustained following the failure of an attached component. If any structural damage should be encountered on the boom assembly contact Bucyrus International’s Service Department immediately.

DANGER:

DUE TO THE HIGH LOAD CARRYING POSTURE OF THE BOOM ASSEMBLY, ANY QUESTIONABLE DAMAGE MAY SERIOUSLY ENDANGER HUMAN LIFE AND IT MUST BE INVESTIGATED BY QUALIFIED PERSONNEL BEFORE CONTINUED SERVICE CAN BE UNDERTAKEN.

BOOM LIMIT SWITCH

The boom limit switch is used to prevent the boom from being pushed backward towards the machine by the action of the dipper being forced into a bank.

An actuator bar is suspended between the boom and a sensor assembly located in the lube room. The sensor detects movement of the boom should the actuator be forced back into it’s sensing field.

A support bracket is welded onto the lower left hand side of the boom. This bracket supports one end of the actuator bar. Should engagement of the dipper into a bank result in motion of the boom, the actuator bar is pushed backwards. As the bar moves backwards, it trips the Boom Limit Trip Sensor.

August 2007

5 - 87

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

The limit switch assembly is mounted to the inside wall of the lube room. The actuator rod is passed through the front wall of the lube room. Once mounted, two bars are welded onto the actuator. One limits the forward range of motion of the actuator bar, while the second acts as a trip for the Boom Limit Switch sensor.

When viewed looking out from the lube room, the boom bracket that holds the actuator arm aligns it with the proper location of the Boom Limit Switch sensor in the Lube Room. To the boom bracket, two supports have been welded on top of which are mounted Oiltite bearings. The rotation of the bearings provide the actuator bar a limited freedom of motion.

Should the boom be forced backwards, sufficient motion of the actuator bar is allowed to provide tripping of the sensor.

The distance from the sensor to the trip bar that has been welded to the actuator is adjustable. The sensor should be set to a distance no more than 0.31 inches from the sensor bar as it passes through the sensor field.

Manual No. 10500

5 - 88

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LIMIT SWITCH INSPECTION A verification of the switch’s adjustment can easily be made during the operation of the machine at shift change. With the dipper on the ground, raise the boom by extending the crowd action of the dipper handle until the boom begins to raise. There should be no power allowed to the crowd machinery after the boom point has moved about 5.25 inches.

LIMIT SWITCH ADJUSTMENT 1.

Set the dipper on the ground ensuring that the boom remains tight against the suspension ropes.

2.

Adjust the push rod with set screw so that the switch roller is fully extended and there is a .125" (+0, -.03125") gap between the switch roller and the push rod. If the boom point is raised approximately 0°-30' (about 5.25"), the push rod will actuate the switch roller and cut off power.

August 2007

5 - 89

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BOOM POINT SHEAVES This machine uses 2 Boom Point Sheave assemblies to redirect the hoist ropes from the dipper padlock to the hoist drum. Check the boom point sheaves monthly for unusual wear. Check that the sheave bearings are receiving proper lubrication and that the lube lines are not damaged or crimped. For detailed sheave inspection procedure refer to the topic near the end of this manual.

Boom Point Sheave Assembly (2 Places)

Manual No. 10500

5 - 90

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BOOM POINT SHEAVE REMOVAL AND DISASSEMBLY Use the following procedures to remove ONE Boom Point Sheave assembly: 1.

Position the machine in a clear and level area.

2.

It is not necessary to lower the boom when removing the boom point sheaves. However, lift the hoist ropes with a suitable crane, and set them at the center of the boom away from the sheave assemblies.

CAUTION:

CAUTION:

THE HOIST ROPES MUST BE SECURED TO THE BOOM FOR SAFETY UNTIL THE REPAIR IS COMPLETED. USE BLOCKING BETWEEN THE ROPES AND THE BOOM STRUCTURE TO PREVENT ANY DAMAGE OCCURRING TO THE ROPES. ADEQUATE PRECAUTIONS MUST BE TAKEN TO ENSURE THE SAFETY OF THE PERSONNEL WHEN EQUIPMENT IS REMOVED AND REPLACED. USE EXTREME CAUTION AND USE PROPER SAFETY DEVICES WHEN WORKING AT THE BOOM POINT.

3.

Disconnect and plug the lubrication lines to the sheave pins.

4.

Use a suitable crane and provide just enough lift to the boom point sheave to be removed to carry its weight. The approximate weight is 7,000 Lbs. DO NOT APPLY TOO MUCH FORCE WITH THE LIFTING DEVICE.

5.

Remove the sheave clamp collar from each end of the boom point shaft.

6.

Ensure that the sheave assembly is supported with a sufficient sling or chain and loosen the four 1.5 inch capscrews that retain the bearing caps on the shaft to be removed.

7.

With the shaft assembly secured, remove the capscrews and bearing caps.

8.

Lift the sheave assembly away from the boom point and set on the ground.

NOTE: When lifting the sheave assembly, locate the key at the bottom of the outboard end of the shaft and retain for reinstallation.

CAUTION:

THE SHAFT KEY MAY FALL WHEN THE SHAFT IS LIFTED!

To disassemble the boom point sheave: 1.

Remove the spacer from the shaft.

2.

Remove the bearing retainer, bearing clamp and associated hardware from both sides of the sheave.

August 2007

5 - 91

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

3.

Use caution and remove the O-Ring and seal from each retainer and also the O-Ring from the bearing clamp.

4.

Remove the sheave and bearing from the sleeve. Separate the bearing from the sheave.

5.

Remove the sleeve from the shaft.

6.

Inspect and then repair all damaged or worn parts.

Manual No. 10500

5 - 92

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BOOM POINT SHEAVE REASSEMBLY AND INSTALLATION 1.

Apply a thin coat of Molycote G to the shaft. Install the sleeve onto the shaft. Install the bearing and sheave onto the sleeve.

2.

Assemble the O-Ring to each bearing clamp then install the bearing clamps. Tighten the .75 Inch socket head capscrews.

3.

Assemble the seal and O-Ring to each bearing retainer then install the bearing retainers.

Tighten the .75 Inch capscrews and lockwire in place.

4.

Slide the spacer onto the end of the shaft opposite the keyway.

To reinstall the boom point sheave assembly: 1.

Insert the shaft key into the proper slot in the boom point structure.

2.

Using a suitable crane, lift the sheave assembly into place at the boom point.

NOTE: The sheave assembly must be oriented with the spacer near the end of the shaft toward the center of the boom, and also the key slot on the shaft must be at the bottom and toward the outside of the boom. Ensure that the ends of the shaft in the bearing cap area are coated with Molycote G. 3.

With the shaft in place, attach the bearing caps and capscrews.

4.

Apply retaining compound (SD 4522F) to the 1.5 inch boom point hub cap capscrews, insert, and tighten to 1460 Ft.Lb.

5.

Slide the shaft toward the center of the boom as far as possible. Attach the clamp collar on that end and tighten its capscrews.

6.

Slide the shaft as far as possible toward the outside of the boom. Attach the clamp collar on that end and tighten its capscrews.

7.

Re-connect all lube lines.

8.

Using a crane lift and set the hoist ropes back onto the sheaves. DO NOT CROSS THE HOIST ROPES. If required, refer to the proper reeving instructions in this section of the manual.

August 2007

5 - 93

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BOOM BUMPER Regularly check the condition of the boom bumper and make repairs as required. Inspections should be conducted at minimum of once per operating shift. Additional inspections may be required.

Operator’s style will affect bumper life. Repair of the boom bumpers consists or replacing common hardware and cushion material.

Manual No. 10500

5 - 94

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SADDLE BLOCK The saddle block should be inspected daily for signs of excessive wear. Make certain that it is being adequately lubricated and that the injectors are functioning properly. Also check the condition of the shipper shaft sheaves for signs of unusual wear. The lubrication lines which run up the boom should be checked for any signs of damage or crimping which could impede the flow of lubricant to the saddle block.

Saddle Block Bushing Arrangement

SADDLE BLOCK REPAIR The saddle block liners should be replaced when the 0.50 inch chamfer has been worn off the inner bushings, or when the measured distance from one side of the handle to the lining is 0.12 inch or less - with the handle pushed to the same side of the liner. Measure the liners at 4 equally-spaced points about its circumference. It may be possible to remove the liner capscrews and rotate the liner for additional wear. Replace the liners as follows: 1.

Remove the dipper handle per the procedures in Dipper Handle Removal.

2.

Secure the rear liner with a crane and remove the liner mounting bolts. Remove the liner from the saddle block.

NOTE: The liner was installed with Loctite. It may be necessary to heat the saddle block or to cut and discard the liner in order to remove it.

3.

When installing new rear liners, uniformly coat the mating surfaces of liner O.D. and saddle block I.D. with Loctite (R) 680 immediately before installation. Use Loctite 227 on the liner bolts.

4.

Replace the front liners using the same procedures as above.

August 2007

5 - 95

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SADDLE BLOCK REMOVAL For any work to be done on the saddle block other than replacement of liners, the saddle block must be removed from the machine. Remove the saddle block as follows: 1.

Remove the crowd and retract ropes as described under Crowd & Retract Rope Removal.

2.

Remove the dipper handle as described under Dipper Handle Removal.

3.

Two cranes are required to remove the saddle block. One crane is used to support and remove the saddle block. The other crane is used to remove the shipper shaft.

4.

Separate and plug the lube lines to the saddle block.

5.

With a crane supporting the saddle block, remove the shipper shaft clamp collars and slide the shipper shaft to either side to remove it from the saddle block and boom. Lower the saddle block to the ground.

6.

Check the shipper shaft bushings in the boom and replace if required. Consult Bucyrus Service Department prior to starting repair.

Manual No. 10500

5 - 96

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Saddle Block Sheave

7.

Inspect and replace any worn sheave bearings and seals or saddle block bushings.

Bearing retainer shimming instructions: a.

Install the spacer and the bearing on the saddle block. Install the seals and the seal retainers. Press the bearing tight against the spacer.

NOTE: Do not install the saddle block retainer. b.

Install the bearing retainer. Tighten just until snug, the socket head cap screws that hold the bearing retainer in place.

c.

Keeping the bearing tight against the spacer, measure the depth along the outer edge of the bearing retainer using the depth micrometer as shown. Remove the bearing retainer and measure the retainer thickness.

d.

Subtract the measured retainer thickness from the measured depth to calculate the gap and assemble the shim with the thickness equal to the gap thickness -0.002 to 0.005.

August 2007

5 - 97

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

e.

Re-install the bearing retainer and snug-tighten the cap screws. All cap screws require retaining compound Loctite 277. Tighten in a sequence 180° apart in 3 steps adding 1/3 torque value each time.

NOTE: All cap screws should be tightened to 146 Ft. Lb. 8.

Reinstall the saddle block in the boom. Reconnect the lube lines. Reinstall the dipper handle.

Reeve the crowd and retract ropes on to the machine.

Manual No. 10500

5 - 98

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DIPPER HANDLE

The dipper handle assembly should be checked regularly for bending or any structural cracks. If any cracks or bending are noticed, remove the handle and repair as required For instructions and/or assistance, please refer to Bucyrus International’s Service Department.

Check the handle for proper lubrication in the area that passes through the saddle block. Ensure that the automatic lubrication system is working properly.

Check the condition of the retract rope take-up mechanism and the crowd rope screw rod adjustment mechanism.

Ensure that all components are present and all hardware is tight.

August 2007

5 - 99

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DIPPER HANDLE REMOVAL 1.

Crowd the handle out until the saddle block is a slight distance from the crowd cushion. (This is to prevent undo tension on the worm gear housing capscrews.) Lower the dipper to the ground, resting it with the heel on the ground. Set all machine brakes, but do not lock out the power.

2.

Remove the crowd and retract ropes. Refer to the proper instructions in the rope removal and replacement section of this manual.

3.

Support the crowd screw half-sheave assembly with a crane, both at the half-sheave and at the take-up guide. (Weight is approx. 10,500 Lbs.) Be sure not to damage the bellows. Note the location of the lifting lug on the top of the take-up guide housing.

4.

Remove the 28 - .75 inch capscrews, on the half-sheave end of the handle, that attach the worm gear housing and take-up guide to the handle. Do not remove the 7 capscrews toward the inside of the worm gear housing, nor the 12 nuts and capscrews holding the cushion in place, at this time.

NOTE: The 7 capscrews toward the inside of the worm gear housing attach the housing to the take-up guide. These screws must remain in place when removing the crowd rope take-up mechanism as a unit.

5.

The crowd rope adjusting mechanism consists of the crowd half-sheave, screw rod, bellows, worm gear housing and crowd cushion. With the capscrews mentioned above removed, carefully slide the take-up mechanism out of the handle then lift it away from the handle and rest it on cribbing.

6.

Secure a crane to the dipper handle, between the saddle block and the dipper. Insure that the crane will support the free end of the handle. Apply additional rigging to prevent the crane cable from sliding away from the dipper end of the handle. Support the saddle block to prevent it from rotating in either direction once the handle has been removed.

CAUTION:

THE SADDLE BLOCK MAY ROTATE SUDDENLY ONCE THE HANDLE IS REMOVED. Be sure the saddle block is supported to prevent its rotation once the handle has been removed.

CAUTION:

The rigging from the crane must be securely fastened with additional rigging to prevent the crane cable from sliding away from the dipper end of the handle, and also to support the free end of the handle once it is removed from the saddle block.

Manual No. 10500

5 - 100

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

7.

While supporting the dipper handle with a crane, SLOWLY propel the machine in a straight line to the rear. The dipper handle will slide from the saddle block.

CAUTION:

8.

THE DIPPER HANDLE WILL FALL ONCE REMOVED FROM THE SADDLE BLOCK IF IT IS NOT FULLY SUPPORTED.

Set the free end of the dipper handle on blocking and perform the required maintenance.

While the handle is on the ground, the crowd half-sheave (previously removed) and retract take-up mechanism should be inspected and repaired if required.

Dipper handle installation is the reverse of removal. Note the following: •

Carefully align the free end of the dipper handle and the saddle block before propelling the machine forward.

•

The crowd rope screw adjusting mechanism should be completely pre-assembled AND THOROUGHLY LUBRICATED before installing into the end of the dipper handle.

•

BE SURE THAT THE WORM GEAR HOUSING AND CROWD HALF-SHEAVE ARE PERFECTLY LEVEL WITH THE DIPPER-TO-HANDLE PINS AND ALSO WITH THE RETRACT ROPE SPREADER AND TAKE-UP MECHANISM.

•

Install the crowd and retract ropes using the proper procedures in this section of the manual.

August 2007

5 - 101

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD ROPE TAKE-UP MECHANISM

Manual No. 10500

5 - 102

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD ROPE TAKE-UP MECHANISM DISASSEMBLY With the take-up mechanism off the machine, set it in a vertical position with the take-up guide up and the clevis end of the screw rod down, then proceed as follows to disassemble it: 1.

Remove the 12 - .5 inch capscrews that fasten the crowd cushion to the forward side of the take-up guide. Then remove the crowd cushion.

2.

Remove the crowd rope roller supports from the half-sheave.

3.

Remove the sheave pin lock plate and remove the pin. Slide the half-sheave out from the screw rod clevis.

4.

Insert an 8.00” long, 0.50” bolt or threaded rod into the end of the worm shaft opposite the drive end.

5.

Remove the anti-rotation bracket from the worm shaft. Remove the worm shaft cover at the bottom of the worm gear housing. Remove the thrustwasher bushing from the shaft.

6.

Turn the worm shaft counter-clockwise to remove it from the worm gear housing. Remove the remaining thrust washer bushing.

7.

Remove the stop plate from the square end of the screw rod.

8.

Remove the 7 - .75 inch capscrews that attach the worm gear bushing to the take-up guide. Remove the take-up guide..

9.

Remove the larger bushing from inside the bore of the take-up guide.

August 2007

5 - 103

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

10.

Turn the worm gear wheel to remove it from the screw rod.

11.

Loosen the clamps on the bellows.

Remove the worm gear housing from the bellows and screw rod.

12.

Carefully remove the bellows from the screw rod.

13.

Remove the smaller bushings from inside the worm gear housing and the worm shaft cover.

Inspect all parts for wear or cracking.

Check for evidence of the proper amount of lubricant on all moving parts.

Repair or replace any defective parts as required.

CROWD ROPE TAKE-UP MECHANISM ASSEMBLY Before beginning to assemble the take up mechanism, fully cover all rubbing and contact surfaces with Molykote. During assembly, grease all rubbing and contact surfaces liberally. Assemble in the following order: 1.

Position the screw rod so it is vertical and with its square end on top.

2.

Slide the bellows onto the square end of the screw rod, down to the clevis end of the rod.

3.

Shrink the worm shaft bushing and install it into the right-hand worm shaft bore at the bottom of the housing.

4.

Shrink the opposite worm shaft bushing into the worm shaft cover.

Manual No. 10500

5 - 104

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5.

Slide the worm gear housing onto the screw rod until it mates with the bellows.

6.

Slide the worm gear wheel onto the screw rod and spin it onto the threaded portion of the screw rod.

7.

Slide the worm gear bushing onto the screw rod.

8.

Slide the crowd take-up guide onto the screw rod. Note the orientation of the lifting lug on the take-up guide.

9.

Position the worm gear housing so that the worm shaft housing is opposite to the lifting lug on the take-up guide. Check that the bolt holes on the housing and crowd take-up guide are aligned for the capscrews.

10.

Bolt the screw rod stop plate to the end of the screw rod using the 4 - .75 inch capscrews.

Tighten the clamps on the bellows.

11.

Install an 8.00” long, 0.50” bolt or threaded rod into the end of the worm shaft, opposite the drive end, for assembly purposes.

12.

Slide one thrust washer bushing onto the end of the worm shaft, opposite the drive end.

13.

Insert the worm shaft into its housing. Spin the worm shaft clockwise until it is fully inserted.

14.

Install the remaining thrust washer bushing on the drive end of the worm shaft. Slide the cover onto the worm shaft and bolt it to the housing using 6 - .38 inch capscrews. Assemble the anti-rotation bracket. Remove the bolt or threaded rod from the end of the worm shaft that was used for assembly.

August 2007

5 - 105

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

15.

Insert the pin bushing into the crowd half-sheave and assemble the half-sheave to the screw rod with the half-sheave pin. Attach the pin locking plate and 2 - 1 inch capscrews.

16.

Install the roller support plates to the half-sheave. Leave the rollers off until the crowd rope has been installed.

17.

Pump grease into the worm shaft housing until the grease comes out from the lube relief valve. This will require about 1.5 gallons.

18.

Attach the crowd cushion halves to the take-up guide.

RETRACT ROPE TAKE-UP MECHANISM

The retract rope take-up mechanism is attached to the dipper handle at the dipper end and provides the ability to remove slack from, and apply the proper tensioning to, the retract rope.

Manual No. 10500

5 - 106

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

To repair the retract mechanism: 1.

Lower the dipper so that the front of the dipper is flat on the ground.

2.

Remove the shim guard bolts and rotate shim guard out of the way.

3.

Unload retract rope using hydraulic jacks to remove shims as follows: CAUTION:

Oil within the needle valves is under high pressure. STAY CLEAR OF TAKE-UP NUT, SHIMS AND CYLINDERS WHEN OPERATING NEEDLE VALVE, AS THESE ITEMS COULD MOVE UNEXPECTEDLY AND CAUSE SERIOUS INJURY.

a.

Clean and grease the sliding area on the take-up nut, support and screw.

b.

Make sure the right needle valves are open and the left needle valves are closed.

c.

Extend the cylinders by injecting hydraulic fluid into the coupler located on the left side of the dipper handle above the left needle valve.

d.

Remove the desired amount of shims from the cylinder side of the take-up nut and store them on the opposite side of the nut.

e.

Slowly open the left needle valve.

CAUTION:

f.

Stay clear of the take-up nut. The weight of the rope may jerk the takeup nut when the needle valve is opened.

Close the right needle valve.

August 2007

5 - 107

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

4.

Release the pressure from the hydraulic jacks.

5.

Repair or replace any damaged parts.

6.

Retighten the retract rope per the procedure in RETRACT ROPE TIGHTENING later in this section of the manual.

SPREADER REPAIR NOTE: The following procedures involve burning and rewelding the spreader. Contact Bucyrus International service department for the proper weld specifications for this item.

1.

Lower the dipper to the ground.

Manual No. 10500

5 - 108

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

2.

Back-off the retract rope as far as possible. Refer to removal step 3 of RETRACT TAKE-UP MECHANISM.

3.

Remove the retract rope retainer bolts and retainers. Lift the retract rope out of the spreader grooves.

4.

Carefully burn out the weld joining the cylinder guard support to one-half of the spreader only.

The cylinder guard support can remain attached to the other half of the spreader.

5.

Burn off the upper and lower splice plates from one-half of the spreader. The splice plates can remain attached to the other half of the spreader.

6.

Attach a crane to one side of the spreader. Remove the anchor bolt attaching that side.

7.

Lift the spreader from the handle.

8.

Attach a crane to the remaining side of the spreader, remove its anchor bolt and lift it from the handle.

9.

Repair or replace any damaged parts.

10.

Reinstall each half of the spreader and their anchor bolts, but do not tighten the anchor bolts.

11.

Be sure the spreader assembly is aligned to the handle so that one side is aligned with the other side and each side is an equal distance from the handle.

12.

Contact Bucyrus International service department for the proper weld specifications for the spreader.

13.

Tighten the anchor bolts, then tighten the retract rope using the procedure in RETRACT ROPE TIGHTENING later in this section of the manual.

August 2007

5 - 109

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DIPPER ASSEMBLY The dipper should be inspected before the start of each shift. The side and front surfaces provide critical reinforcement for the dipper. Consequently, they should be checked regularly for cracks and component wear. When wear spots develop in the side and front surfaces, the metal contour can be restored by building up the affected area. Contact the Bucyrus International Service Department for a specified welding repair solution.

NOTE: Do not apply hard-surfacing to steel side and front surfaces. This could promote the development of cracks. Where wear is excessive, mild steel plates can be welded in place and hard-surfacing applied to these additional plates with excellent results.

All lubrication points should be inspected and lubricated each shift. The dipper should also be checked for missing or broken teeth or missing wedges. These items if missing or broken must be replaced before digging is started.

Manual No. 10500

5 - 110

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Check the latch bar and the latch bar keeper insert, if applicable, for wear and replace if required. Check latch bar and latch lever for proper adjustment. The latch bar should be adjusted so that it enters the latch keeper pocket between 3/4 and 1 inch as shown in Section View A.

Dipper Door Latch Bar and Lever

August 2007

5 - 111

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Latch Bar Assembly

Manual No. 10500

5 - 112

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Latch Bar Bumpers

August 2007

5 - 113

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DIPPER DOOR BUMPERS 1.

Position the door to the rear (toward boom) as far as possible in order to obtain the maximum possible gap between the door and the dipper body with the latch bar engaged.

2.

Measure and record the gaps on both sides of the dipper between the bumper housing and the rear face of the dipper body.

3.

Assemble the bumpers so that they extend out of the housings equal to or slightly less than the gaps recorded in step 2. Use the shims as necessary to achieve this dimension.

4.

Save the excess shims for use in future adjustments.

5.

Check and re-adjust the bumpers after one week of operation.

Dipper Door Bumper Adjustment

Manual No. 10500

5 - 114

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DIPPER DOOR SNUBBERS The dipper door snubbers provide tension on the dipper door to prevent excessive speed and movement of the dipper door during closing. Check the door snubber periodically for proper tension.

CAUTION:

August 2007

STORED ENERGY! The snubber pads are under compression. Care must be taken when removing the adjusting nut in order to avoid injury.

5 - 115

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SNUBBER ADJUSTMENT These adjustment procedures apply to the following snubber assemblies using urethane snubber pads: E016896-01 &- 02, E017485-01 & -02, E017992-01 & -02, E019671-01 & -02, E020438-01 & -02, E020930-01 & -02, E020940-01 & -02 (Refer to the Parts Book for the proper part numbers).

CAUTION:

DO NOT use these procedures for snubber assemblies that use belleville washers.

To adjust the dipper door snubbers: 1.

Using a torque wrench, tighten both snubber adjusting nuts to 650 Ft. Lb. (Approximately 30,000 Lbs. bolt tension). Both snubbers must be adjusted EQUALLY!

2.

Observe the door closing during the machine dig cycles. Further tighten or loosen the adjusting nut to allow the dipper door to gently contact the dipper body.

3.

Repeat the above steps as necessary to minimize dipper-to-door contact.

4.

After all adjustments are complete, rotate the adjusting nut just enough to reinstall the adjusting nut cover. Record the final torque for future snubber adjustments.

5.

After two full days of operation (40 hours), re-tighten snubbers to the final torque setting.

6.

Periodically check snubbers and re-tighten to the final torque setting as needed (usually 2 months or more).

Manual No. 10500

5 - 116

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DIPPER PADLOCK The padlock should be checked every shift to see that all pin retaining bolts are not loose or missing.

All lubrication points should be lubricated every shift. Daily check excessive movement at the pin joints which indicate bushing wear. Replace worn bushings and pins. Check for cracking in the frames and links and make repairs when required.

August 2007

5 - 117

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

To Repair the Dipper Padlock: 1.

Place the dipper on the ground. Remove enough tension from the hoist ropes to remove the weight from the dipper lug pin, but not allowing enough slack to permit the weight of the padlock to rest on the pin.

2.

Remove T-bolts retaining the lug pin. Remove lug pin with suitable lifting device.

3.

Using hoist ropes, lift the padlock from the dipper padlock lug and lower padlock to the ground.

Remove thrust washers and dowels from the lug.

4.

Remove T-bolt retaining the link pin. Strike the link pin foot with enough force to expose enough of the link pin head to secure to a suitable lifting device. Remove link pin from padlock frame.

5.

Remove bushings from the link and from lower padlock frame. The bushings have an interference fit.

6.

Support the padlock sleeve. Remove T-bolts retaining the padlock sheave pin. Remove sheave pin with a suitable lifting device.

7.

Using a suitable lifting device, remove the padlock sheave from padlock frame. Remove the thrust washers and dowels from the sheave.

8.

Remove the hoist rope from padlock frame. Remove the sheave pin bushings from padlock sheave and frame. The bushings have an interference fit. See Bushing Fits Tabulation on figure.

9.

Clean and inspect all parts. Repair or replace all damaged or worn parts.

10.

Reassemble in reverse of disassembly. Be sure all the dowels are flush with, or below, the surface of the thrust washers.

CAUTION:

Manual No. 10500

The upper and lower pins of the padlock appear to be identical. These items are identical in size only! The material of construction and part numbers are different. Ensure they are placed in the proper location during assembly.

5 - 118

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DIPPER PITCH BRACE, ADJUSTABLE

Adjustable Pitch Brace

August 2007

5 - 119

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DIPPER TRIP ASSEMBLY The dipper trip can be disassembled in place on the machine or removed as a complete unit. In either case, the disassembly procedure is the same.

1.

Remove the drum guard and trip rope from the drum.

2.

Open the gear and pinion guard.

3.

Remove the drum retainer and drum.

4.

Remove the bearing retainer and spacer on the drum side. Then remove the cover and bearing retainer at the other end of this shaft.

Manual No. 10500

5 - 120

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5.

Support the gear and slide the shaft from the gear and base on the drum side of the base.

Remove the gear, bearings, spacers and seals.

6.

Repair or replace all worn or damaged parts and reassemble in reverse order of disassembly.

Lubricate the bearings.

7.

If the pinion was removed from the motor, when it is reinstalled, the motor shaft should be recessed inside of the pinion 1/16 inch.

A-FRAME Periodically inspect the A-frame for signs of cracking or other damage. This check should include the mounting lugs and pins, the ladders and platforms, the equalizer links holding the boom structural strands and the leg shrouds on the machinery house roof. Make certain there are good seals around the leg shrouds.

If any repair welding is required, contact the Bucyrus International Service Department for a specialized repair process. For any other unusual problems consult the Bucyrus International Service Department.

Carefully inspect the mounting lugs and pins for cracks or other signs of wear or deterioration.

Lubricate these areas occasionally to prevent rusting. Check the leg shrouds both from the inside August 2007

5 - 121

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

and on the top of the machinery house to see that a tight seal is maintained and there are no leaks.

If there are any signs of leaking, re-seal around the shrouds with a suitable caulking compound.

Make certain the ladders are securely mounted in good condition. Repair any cracks as soon as they are noticed.

Manual No. 10500

5 - 122

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Check the condition of the platforms to see that they are secure and safe. At the same time inspect the equalizer links and connections of the boom structural strands.

DANGER:

STORED ENERGY! Removal of equalizer pins requires the attached items to have proper support to release the load. Failure to comply could result in death, severe personal injury, or damage to the machine.

Under normal circumstances the A-Frame of the machine will most likely not be removed until disassembly of the machine is required. Please contact the Bucyrus International Service Representative should any unusual circumstances arise.

August 2007

5 - 123

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

AUXILIARY WINCH The auxiliary winch is attached to the hoist ropes to raise and lower the ropes during hoist machinery maintenance and change-out of hoist ropes.

The winch can be single or double arrangement. The double arrangement is shown. The winch consists of a drum and rope mounted to an electric gear motor.

Manual No. 10500

5 - 124

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST ROPE SUPPORT ROLLER The hoist rope support rollers are used to guide the hoist ropes as they leave the hoist drum and exit the machinery house.

The rollers should be inspected daily for wear. The roller bushings should be lubricated once every shift. Repair of the rope rollers will consist mainly of replacement of worn bushing and/or rollers.

August 2007

5 - 125

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BOOM STRUCTURAL STRANDS Periodic inspection of the outer layer of wires immediately adjacent to the sockets should be made.

If 30% of outer strands are broken, the strand must be replaced.

Additional, detailed information can be found under topic of Wire Rope Care and Maintenance found later within this section.

Manual No. 10500

5 - 126

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

WIRE ROPES In designing excavating machinery, careful study of the size and operating speed of all sheaves and drums is conducted to determine the proper wire rope for each application. Continual contact with many machines in the field and repeated consultation with leading rope manufacturers permits the selection of the most satisfactory rope for each machine. To maintain the machine at its highest level of efficiency, purchase new ropes which conform to Bucyrus International specifications, and thereby obtain the wire rope best suited for the particular application. Here are a few pointers relative to the proper inspection, lubrication and replacement of wire ropes on the machine.

August 2007

5 - 127

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

WIRE ROPE INSPECTION 1.

It is the operator’s responsibility to maintain drums and sheaves in good condition. Use ropes of proper size and construction. Examine ropes for signs of deterioration or damage in service, replace them when necessary.

2.

It is customary to work the running ropes almost to destruction in order to reduce the machine operating cost and downtime for replacement. When loading trucks, hoppers and the like, which would be damaged by a falling dipper, ropes should be inspected for signs of deterioration.

3.

Outer wires of the hoist ropes may be damaged or broken by falling rocks, by chafing over sharp rocks in the bank and by the presence of stones in sheave grooves. Rope life may be prolonged if broken wires are trimmed so that they do not cross over and cause additional damage to adjacent unbroken wires.

4.

The operator should always observe safety precautions.

5.

For more information refer to the WIRE ROPE CARE AND MAINTENANCE in Section 9 ~ ENGINEERING DATA.

Manual No. 10500

5 - 128

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD ROPE TAKE-UP HYDRAULIC UNIT DANGER:

August 2007

STORED ENERGY! System may be under hydraulic pressure which can cause severe personal injury or death. Shut down pump and relieve system of all pressure before removing components.

5 - 129

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

This hydraulic unit is used to apply torque to the worm shaft at the end of the dipper handle when adjusting the tension in the crowd rope. It is located on the machinery house roof, near the center of the machine just behind the operator's cab.

The hydraulic unit is a self-contained unit, including a reservoir of hydraulic fluid, a stationary pump and electric drive motor, and a removable hydraulic motor (with handles) connected to the pump through a length of hydraulic hoses. To operate the unit, withdraw the hydraulic motor from its storage on the unit and install the motor on the dipper handle. Refer to the instructions in CROWD ROPE ADJUSTMENT, in this section of the manual, for the proper procedures. Press the start pump button on the control panel then use the hand held pendant station to control the pump.

Be sure the reservoir is filled with hydraulic fluid. Check for leaks in the piping. Replace the filter cartridge when indicated.

Hydraulic Schematic ~Crowd Screw Hydraulic Unit

Manual No. 10500

5 - 130

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST ROPE REEVING/REPLACEMENT

NOTE: The procedure outlined in this manual assumes that the old hoist ropes are not broken or severely frayed, that the machine is equipped with an auxiliary rope winch and that all of the tools and supplies specified are on hand. THE HOIST ROPE MUST BE KEPT UNDER COMPLETE CONTROL AT ALL TIMES. CAUTION:

AVOID ANY METHODS WHICH ALLOW THE ROPE TO BECOME UNCONTROLLED AT ANY TIME DURING THE REEVING OPERATION. Death, serious injury, or damage to the machine will result should a rope become uncontrolled.

To replace the hoist ropes: 1.

The machine should be in a clear, flat area with sufficient room in front of the machine to work. All applicable safety regulations should be followed. Only personnel directly connected with replacing the ropes should be allowed on or near the machine.

DANGER:

2.

The condition of the ropes may make it necessary to modify the procedures outlined, especially if the rope is broken or severely damaged. Be sure to always follow safety precautions when burning or climbing. Always keep the ropes under complete control.

Lower the dipper to the ground. Position the dipper so that the padlocks are directly beneath point sheaves. The hoist ropes will be vertical and the heel of the dipper will be on theground.

August 2007

5 - 131

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

3.

Position a person in the machinery house in a position to observe the hoist drum and ropes.

Slowly rotate the drum in a lowering direction until all of the rope is spooled off of the drum and the rope sockets are in the bottom rear quadrant of the hoist drum.

CAUTION:

Throughout this operation drum or rope positions must be communicated to the operator. Make sure that a system of signals is worked out in advance and that the line of communication is unbroken.

NOTE: Each hoist rope is a continuous length of rope.

•

The “LEAD ROPE” is the portion of rope from the hoist drum, over the outer groove of the point sheaves, and down to the back of the padlock. The socket on the hoist drum for this rope “LEADS” the socket for the “FOLLOW” rope.

•

The “FOLLOW ROPE” is the portion of rope from the front of the padlock, over the inner groove of the point sheaves, and back to the hoist drum.

4.

Attach an auxiliary winch line to each follow rope becket. Remove the keeper that attaches the follow ropes to the hoist drum.

5.

Pull the ferrules out of the becket receivers. Lower the auxiliary winch line until the hoist rope can be tied off. Tie-off the follow ropes.

6.

Carefully rotate the drum 180° in the LOWER direction to unwrap the remainder of the lead ropes from the drum.

7.

With the lead rope sockets in the lower rear quadrant of the drum, stop the drum.

8.

Attach the auxiliary winch line to each lead rope becket. Remove the lead rope keeper. Payout the winch line until the lead rope can be tied off then tie it off.

Manual No. 10500

5 - 132

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

9.

Attach the follow ropes to the winch line.

10.

Attach a sling to the follow rope near the front of the padlock. Attach this sling to a ground vehicle.

11.

Slowly and carefully pay-out the auxiliary winch while pulling the hoist rope away from the front of the machine with the ground vehicle. Lower the hoist ropes until the winch line can be disconnected.

NOTE: The ground vehicle is required to pull the weight of the hoist ropes over the boom point sheaves, and also help bend the ropes through the padlock sheaves.

12.

Rotate the hoist drum in the lower direction until the lead rope keeper in is the lower rear quadrant.

13.

Attach a winch and lower the lead ropes in the same manner as that used for the follow ropes. When the ends of the lead ropes approach the padlocks, one rope must be removed from the winch line, the remaining lead rope lowered through the padlock, and then removed from the winch rope.

To install a new pair of hoist ropes: 1.

Place the new hoist ropes approximately 10 feet in from of the dipper. If the ropes are on reels, they should be located so that the ropes unreel from the bottom of the reel.

DANGER:

ROPE END(S) WILL FORCEFULLY UNCOIL WHEN SHIPPING CONSTRAINTS ARE REMOVED.

2.

Be sure a winch line runs through each padlock.

3.

Attach a winch line to one end of each new rope, making them the new lead ropes.

4.

Hoist the winch until the lead ropes have cleared the padlock. Attach the free end of each hoist rope to the winch line that its lead end is attached to.

5.

Pull both ropes over the point sheave, being careful to keep the lead rope (rear rope in padlock) on the outside groove of the point sheave.

6.

Continue pulling the ropes into the machinery house. When the ends of the ropes reach a August 2007

5 - 133

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

point where the follow rope can be tied off, stop pulling, detach the follow rope from the winch line and tie it off.

7.

Pull the lead ropes until they are in a position to be placed in their becket resolvers. Place the lead rope ferrules in the resolvers, install the lead rope keeper and detach the winch line.

8.

Slowly rotate the drum 180° in the HOIST direction so that the follow ropes can be attached.

9.

Hoist the winch attached to the follow ropes until the ropes can be attached to the drum.

10.

Place the follow rope ferrules in the resolvers, install the lead rope keeper and detach the winch line.

11.

Slowly rotate the drum in the hoist direction until the hoist ropes are tight. Make sure the ropes stay in the proper grooves.

12.

Hoist the dipper approximately 1 foot off of the ground.

Check to make sure the dipper hangs straight. If not, place shims between the ferrule and the ferrule socket on either the lead or the follow ropes on the side that the dipper hangs lower. If necessary, locally manufactured shims may be placed under both ferrules.

13.

Hoist and lower the dipper several times to seat the ropes.

Make sure the dipper hangs straight. If not, shim as above.

Reset the hoist and crowd limit switches.

Shim for Hoist Rope Socket

NOTE: The above steps are used to remove and replace 1 pair of hoist ropes. When replacing a single hoist rope, be sure to check the alignment of the dipper and shim the old rope if required to level the dipper.

Manual No. 10500

5 - 134

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD ROPE REEVING/REPLACEMENT NOTE: To use the procedure below the old crowd rope must not be broken or severely frayed, the new crowd rope should be wound on a shipping reel with one ferrule button-end in and one ferrule button-end out, and all tools and equipment specified must be on hand.

DANGER:

AVOID ANY METHODS WHICH ALLOW THE ROPE TO FALL UNCONTROLLED. An uncontrolled rope could cause death or serious injury.

NOTE: Should it be necessary to replace both the crowd and retract ropes, THE CROWD ROPE SHOULD BE REPLACED FIRST. The crowd rope has ferrules swaged onto the ends of the rope to the drum. These ferrules limit the amount of rope on the crowd drum in relationship to the handle position. Failure to install the crowd rope first may cause the ropes to “out of time” and cause operating difficulties. Replacing both ropes simultaneously should not be attempted.

To replace the crowd rope: 1.

Check the new rope for the correct length. Measure to inner ends of ferrule buttons.

2.

The machine should be in a clear flat area with sufficient room to allow all of the steps in the procedure to be carried out. All applicable safety regulations should be followed. Only personnel directly connected with replacing the rope should be allowed on or near the machine.

CAUTION:

The condition of the rope may make it necessary to modify the procedure described here, especially if the rope is broken or severely damaged.

Be sure to always follow all safety precautions when burning. Always maintain complete control over the rope and over any burned sections of rope.

3.

Crowd and lower the dipper simultaneously until the rear stop of the dipper handle contacts the saddle block and the dipper heel is resting on the ground as shown.

4.

Set all brakes, shut the machine down and tag and lock all controls.

5.

Back-off the retract take-up adjustment to its complete limit.

6.

While using an auxiliary line to control the becketed end of the retract rope, remove the clamp and disconnect retract rope from left side of the crowd drum.

7.

Use an auxiliary line to pull the ferrule button-end of the retract rope sufficiently to permit the removal of the ferrule button from the ferrule socket on the right side of the crowd drum.

8.

Secure both ends of the retract rope away from the crowd drum.

August 2007

5 - 135

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

9.

Remove locks and tags from the controls and, using the crowd motor, rotate crowd drum in the retract direction to unwind the crowd rope from the drum. When the crowd rope ferrule buttons are in position for easy removal from the sockets, stop rotating the crowd drum. Set the brakes and replace the tags and locks to the controls.

Crowd Rope Reeving

10.

Remove the crowd rope ferrule buttons from the ferrule sockets and allow the rope ends to hang vertically from the saddle block sheaves. Inspect the drum grooves for sharp edges and grind them as necessary.

11.

Position the reel of new crowd rope under the saddle block and in-line with the left saddle block sheave.

DANGER:

ROPE END(S) WILL FORCEFULLY UNCOIL IN RELEASE OF ENERGY WHEN SHIPPING RESTRAINTS ARE REMOVED.

If the old crowd rope IS NOT broken, attach the end of the new crowd rope to the end of the old crowd rope at the left side. Secure the end of the old crowd rope on the right side to a ground vehicle.

- OR If the old crowd rope IS broken and has to be removed in sections: a. b.

12.

Inspect rope grooves and repair/weld as required.

Reeve an auxiliary line up to and over the inner groove of the right side saddle block sheave, around the crowd cushion sheave, back over the inner groove of the left saddle block sheave, and down to the new reel of rope. Attach the auxiliary line to the becket loop of the new rope and the other end of the line to a ground vehicle as shown.

With the ground vehicle, pull the new crowd rope onto the machine until an equal amount of crowd rope hangs from each saddle block sheave. Secure the crowd rope and disconnect

Manual No. 10500

5 - 136

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

the auxiliary line.

NOTE: Liberally lubricate the grooves of the crowd drum to help prevent damage to the new crowd rope as it is pulled into position on the crowd drum.

CROWD ROPE TERMINATION DETAILS

13.

Bring the auxiliary line over the top of the crowd drum, through the crowd rope socket, around the rear of the drum and forward from the bottom of the drum to the corresponding end of the new crowd rope. Connect the auxiliary line to the corresponding end of the crowd rope. Release the corresponding end of the crowd rope from (step 12) securing means, and with the ground vehicle still attached to the other end of the auxiliary line, pull the crowd rope onto the rope ferrule socket on the drum. Secure the crowd ferrule button into the drum ferrule socket.

Release the auxiliary line from the crowd rope.

14.

Connect the other end of the crowd rope to the other corresponding crowd drum ferrule socket in the same way as described in step 13.

15.

Remove the locks and tags from the controls and using the crowd motor, rewind new crowd rope onto the crowd drum by rotating the drum in the crowd direction. Make sure rope is seating properly in drum grooves and the inner grooves of the saddle block sheaves. Stop rotating drum when the crowd rope is tight. Set brakes and replace the tags and locks to the controls.

NOTE: The construction stretch may be out of the crowd rope when it becomes necessary to adjust the rope for about the third time. Therefore; after the third rope adjustment after replacement, back off the adjustment by one 0.50 inch shim after obtaining a tight rope by pressurizing the cylinders and thus prevent working with an overly tight rope.

16.

With the ferrule button-end of the retract rope controlled by an auxiliary line to start with, reinstall the retract rope to the crowd drum by following steps 11 through 17 of the Retract Rope Reeving Procedure.

August 2007

5 - 137

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

RETRACT ROPE REEVING/REPLACEMENT NOTE: To use the procedure below the old retract rope must not be broken or severely frayed, the new retract rope should be wound on a shipping reel, and all tools and equipment specified must be on hand.

DANGER:

AVOID ANY METHODS WHICH ALLOW THE ROPE TO FALL UNCONTROLLED. An uncontrolled rope could cause death or serious injury.

NOTE: Should it be necessary to replace both the crowd and retract ropes, THE CROWD ROPE SHOULD BE REPLACED FIRST. The crowd rope has ferrules swaged onto the ends of the rope to the drum. These ferrules limit the amount of rope on the crowd drum in relationship to the handle position. Failure to install the crowd rope first may cause the ropes to be “out of time” and cause operating difficulties. Replacing both ropes simultaneously should not be attempted.

To replace the retract rope: 1.

The machine should be in a clear, flat area with sufficient room to allow all of the steps in the procedure to be carried out. All applicable safety regulations should be followed. Only personnel directly connected with replacing the rope should be allowed on or near the machine.

CAUTION:

The condition of the rope may make it necessary to modify the procedure described here, especially if the rope is broken or severely damaged.

Be sure to always follow safety precautions when burning. Always maintain complete control over the rope and any burned section of rope.

2.

Crowd and lower the dipper simultaneously until the rear stop of the dipper handle engages the saddle block and the dipper is resting on the ground. The dipper heel should be on the ground.

3.

Back off the retract take-up adjustment to its complete limit. Remove the rope retaining bolts on the take-up nut and the rope retainers on the front spreader.

4.

Remove the retract rope from the drum.

5.

Remove the old retract rope from the machine.

6.

Position the reel of new retract rope directly under the saddle block.

DANGER:

Manual No. 10500

ROPE END(S) WILL FORCEFULLY UNCOIL IN RELEASE OF ENERGY WHEN SHIPPING RESTRAINTS ARE REMOVED.

5 - 138

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

7.

Reeve an auxiliary line under then over the crowd drum, up and over the outer groove of the saddle block sheave, through the rope guide on the front stop and around the retract take-up nut. Reeve it through the rope guide on the front stop on the opposite side of the handle, over the outer groove of the other shipper shaft sheave, down and over then under the crowd drum and secure the other end of the auxiliary line to the ground vehicle.

Retract Rope Reeving

NOTE: Liberally lubricate the grooves of the crowd drum and the take-up nut to help prevent damage to the new retract rope as it is pulled onto the machine.

8.

With the ground vehicle, pull the new rope onto the machine until an equal amount of the retract rope is on each side of the machine. Disconnect the auxiliary line from the retract rope.

9.

Reeve the auxiliary line, still attached to the ground vehicle, under the crowd drum up through the rope socket, down under then over the drum and secure it to the retract rope becket loop. With the ground vehicle, pull the retract rope onto the drum and into the rope socket.

Seat the becket within the drum receptacle,

10.

Install the other end of the retract rope in the crowd drum in the same way.

August 2007

5 - 139

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

11.

Be sure the retract rope is seated in the outer groove of the shipper shaft sheaves and the rope grooves of the front stops. Re-install the take-up nut rope retaining bolts and front stop rope retainers.

12.

Take up any slack in the retract rope with the retract take-up mechanism.

NOTE: The constructional stretch may be out of the crowd ropes when it becomes necessary to adjust ropes for about the third time. After the third adjustment, back-off the take-up mechanism 1/2 inch after tightening to prevent working with overtight ropes.

13.

Re-index the crowd limit switch.

Manual No. 10500

5 - 140

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD ROPE TIGHTENING NOTE: The constructional stretch may be out of the crowd rope when it becomes necessary to adjust the rope for about the third time. Therefore, after the third rope adjustment or after replacement, back off the take-up mechanism 1/2 inch after obtaining a tight rope to prevent working with an overly tight rope.

NOTE: Do not overtighten the ropes. The ropes are properly adjusted when a very slight curvature is noticeable on the retract rope (a 3 to 5 inch sag) with a tight crowd rope.

1.

Hoist the dipper until the dipper handle is near horizontal. Retract the handle until the crowd half-sheave is within reach of the hydraulic unit on the machinery house roof, behind the operator’s cab. (With the hoist ropes supporting the dipper and the handle just retracted, any slack that exists should be in the crowd rope.)

2.

Remove the anti-rotation bracket that locks the crowd screw worm shaft from the worm gear housing at the rear of the dipper handle.

3.

Retrieve the hydraulic motor from the hydraulic unit on the machinery house roof. Insure that the special adapter (part no. B008078-01) and a standard 1.12 inch impact socket are on the drive end of the motor.

4.

Install the motor onto the worm shaft as shown in the figure. Use 4 - .62 inch capscrews to attach the motor to the motor bracket.

August 2007

5 - 141

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5.

Using the hand-held pendant on the hydraulic unit, extend the crowd screw rod until the crowd rope is tight. Back off the crowd screw rod 1/2 inch to allow for proper slack in the rope.

6.

Remove the hydraulic motor from the bracket on the worm gear housing and place it in its holder on the hydraulic unit.

7.

Replace the anti-rotation bracket on the worm shaft.

RETRACT ROPE TIGHTENING NOTE: The constructional stretch may be out of the retract rope when it becomes necessary to adjust the rope for about the third time. Therefore, after the third rope adjustment or after replacement, back off the adjustment by one .5 inch shim after obtaining a tight rope by pressurizing the cylinders to prevent working with an overly tight rope.

NOTE: Do not overtighten the ropes. The ropes are properly adjusted when a very slight curvature is noticeable on the retract rope (a 3 to 5 inch sag) with a tight crowd rope.

With the dipper resting on the ground, rotate the crowd drum in such a way as to tighten the crowd rope and provide slack in the retract rope. Retighten the retract rope as follows: 1.

Open the shim guard.

2.

Clean up and grease the sliding areas on the take-up nut, support and screw.

3.

Be sure that the right needle valve is open and the left needle valve is closed.

4.

Extend the cylinders by injecting hydraulic fluid into the left fitting.

Manual No. 10500

5 - 142

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5.

Shim the take-up nut at the desired position.

CAUTION:

6.

Slowly open the left needle valve to release the pressure on the cylinders.

CAUTION:

7.

The take-up nut must be shimmed tight, both fore and aft, using all shims originally provided with machine.

Oil within the needle valves is under high pressure. STAY CLEAR OF TAKE-UP NUT, SHIMS AND CYLINDERS WHEN OPERATING NEEDLE VALVE, AS THESE ITEMS COULD MOVE UNEXPECTEDLY AND CAUSE SERIOUS INJURY.

Close and secure the shim guard.

DIPPER TRIP ROPE REEVING/REPLACEMENT 1.

Use steps one and two from Hoist Rope Reeving. In this procedure the on-board auxiliary winch is not used.

2.

Trip and lock the DTB breaker in the MCC cabinet.

3.

Crowd the dipper handle to unwind the trip rope from the reel. Lower the dipper to the ground and retract it slightly to get some slack in the trip rope. Remove worn rope from dipper door.

August 2007

5 - 143

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

4.

Open the drum guard on the dipper trip and remove the rope and wedge from the drum.

Attach a work line to the trip rope. Pull the trip rope over and off of the trip rope guide sheave and lower to ground. The work rope will remain on the guide sheave and will be used to pull the new trip rope on.

NOTE: Do not use new trip rope which is longer than specified. Increasing length adds layers of rope on the drum which decreases trip torque.

5.

Reeve one end of the new trip rope under the guide roller, around the latch lever sheave and secure it to the rope socket with the rope socket wedge on the dipper door.

6.

Attach the other end of the new trip rope to the work line still in place on the guide sheave.

With the work line, pull the trip rope onto the guide sheave and up to the dipper trip. Secure the trip rope to the drum with the rope wedge. Close the drum guard.

7.

Remove the lock that was previously placed on the DTB breaker in the MCC cabinet and reset the breaker.

HOIST AND CROWD LIMIT SYSTEMS All Bucyrus International mining shovels incorporate a PLC-based limit position system that permits the setting of the Hoist/Lower and Crowd/Retract operational limits. Hoist and crowd encoders send digital signals to the PLC relative to the hoist crowd motor positions. The setup of the hoist and crowd limits is accomplished through the operator’s display terminal by following the instructions provided here in this manual along with those on the operator’s display. When encoder calibration and hoist/crowd positional limits have been properly set the system will prevent the dipper handle from hitting its end stops and will prevent the padlocks from being pulled into the boom point sheaves.

Hoist/Crowd encoder calibration provides the limit system a reference point for tracking both the hoist and crowd positions. Performing the encoder calibration sets all the hoist and crowd limits to their previously set values in order that the actual limits do not require reset after initial commissioning.

Manual No. 10500

5 - 144

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SETTING ROPE LIMITS CROWD STOP END LIMIT

1.

Position the handle near its crowd end stop using hoist and crowd. Raise dipper to the maximum point, just touching boom point sheaves.

2.

Extend the handle to its desired crowd endstop.

3.

Press “ACCEPT”. This calibrates the rope lengths and setting limits. This is required only after changing ropes or adjusting the retract rope.

The slowdown limits reduce speed to 15% of maximum.

August 2007

5 - 145

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

RETRACT SLOWDOWN/STOP LIMITS

1.

Retract the handle until the retract stops are approximately 1.5 feet from the front end of the saddle block. Press “ACCEPT”.

2.

Next, position the handle with the retract stops approximately 6 inches from the saddle block.

Press “ACCEPT” to accept limit.

Manual No. 10500

5 - 146

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST SLOWDOWN/STOP LIMITS

1.

Position the dipper so that the padlocks are approximately 1 foot from the boom point sheaves.

Press “ACCEPT” to accept limit.

2.

Next, lower dipper until the padlocks are 3 feet from the boom point sheaves. Press “ACCEPT” to accept limit.

August 2007

5 - 147

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD SLOWDOWN/STOP LIMITS

1.

Position the handle approximately 1 foot from rear end of the saddle block. Press “ACCEPT” to accept the limit.

2.

Next, retract the handle until crowd stops are approximately 2 feet from the saddle block.

Press “ACCEPT” to accept the limit.

Manual No. 10500

5 - 148

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

6

Brakes and Couplings Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents BRAKES ....................................................................................................................................... 3 Machine Motion Brakes ..................................................................................................... 3

DISC BRAKE OPERATION .................................................................................................... 4 MAINTENANCE ....................................................................................................................... 4 SWING BRAKE ....................................................................................................................... 5 Swing Brake Tachometer ................................................................................................... 5 Swing Brake Friction Disc Inspection ................................................................................ 6

SWING BRAKE INSTALLATION ........................................................................................ 7 Swing Brake Assembly ..................................................................................................... 7

SWING BRAKE BURNISHING .......................................................................................... 8 CROWD BRAKE .................................................................................................................. 10 Crowd Brake Assembly .................................................................................................... 10 Crowd Brake Tachometer ................................................................................................. 11

HOIST BRAKE ...................................................................................................................... 13 HOIST BRAKE ADJUSTMENT ........................................................................................ 14 Hoist Brake Friction Plate Inspection ............................................................................... 14

HOIST BRAKE INSTALLATION ....................................................................................... 16 PROPEL BRAKE .................................................................................................................. 16 PROPEL BRAKE ADJUSTMENT .................................................................................... 17 Propel Brake Assembly ................................................................................................... 18

SPRING REPLACEMENT-ALL BRAKES .............................................................................. 19 FRICTION DISC INSPECTION AND REPLACEMENT - ALL BRAKES ................................. 21 Friction Disc Inspection .................................................................................................... 21

O-RING REPLACEMENT - ALL BRAKES ............................................................................. 23 GRID COUPLINGS ................................................................................................................ 24 LUBRICATION ................................................................................................................. 24 COUPLING DISASSEMBLY AND GRID REMOVAL ........................................................ 25 GRID COUPLING INSTALLATION ................................................................................... 25 GRID COUPLING ALIGNMENT ....................................................................................... 28 Grid Coupling Data ........................................................................................................... 28

GEAR COUPLINGS .............................................................................................................. 29 INSTALLATION ................................................................................................................ 29 GEAR COUPLING ALIGNMENT ...................................................................................... 31 Gear Coupling Data .......................................................................................................... 31

HOIST COUPLING SHAFT ALIGNMENT ......................................................................... 32

August 2007

6-1

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

6-2

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

6

Brakes and Couplings BRAKES This machine uses spring-set, air-released disc brakes on the HOIST, CROWD, PROPEL and SWING motions.

In the event of a power failure or loss of air pressure, the brakes will automatically set to stop the machinery motion. Pressure switches located near each brake control valve monitor air pressure at the brakes. The brakes cannot be released for operation until the air pressure reaches the operating pressure.

Each brake is fitted with a proximity sensor to monitor lining wear and a limit switch to monitor the brake set or released position. When the lining wear limit is reached, it is announced on the operator’s display terminal. The brake position is announced in the operator’s control screen.

Machine Motion Brakes

August 2007

6-3

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DISC BRAKE OPERATION When air is exhausted, the spring force “clamps” the rotor between the friction discs or the mounting flange and pressure plate. To disengage the brake, air enters through the end plate into the diaphragm cavity. As air pressure increases, the end plate moves away from the stationary spring housing.

The pressure plate is bolted to the end plate and travels in the same direction, compressing the springs and releasing the brake.

DANGER:

PRIOR TO INSTALLATION OR MAINTENANCE ON A BRAKE, MAKE SURE THAT MACHINE OR MACHINERY IS BLOCKED TO PREVENT MOVEMENT. Failure to do so could result in serious personal injury or machine damage.

CAUTION:

Protective means must be used to prevent oil or grease from coming into contact with the disc(s) or the friction discs. Oil or grease will significantly reduce the torque capacity of the brake and decrease its ability to hold the machinery in a safe position. DO NOT RISK INJURY!

CAUTION:

DO NOT OPERATE THE MACHINE WITHOUT ALL BRAKE GUARDS INSTALLED.

MAINTENANCE •

No lubrication is required.

•

Replace friction disc(s) when worn to the step on the friction disc O.D.

Manual No. 10500

6-4

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING BRAKE

Swing Brake Tachometer

August 2007

6-5

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Swing Brake Friction Disc Inspection

Manual No. 10500

6-6

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING BRAKE INSTALLATION The tachometer, furnished with the electric motor, must be installed before installing the swing brake assembly. Install the tachometer and the torque arm as shown in the illustration “Swing Brake Tachometer,” preceding.

NOTE: Tachometer will only be installed on one of the two swing motors. Due to mechanical coupling the 2 swing motors and gearcases will operate at identical speeds.

1.

Install the drive hub and keyway on the motor. Refer to “Pinion and Hub Installation” in Section 9 ~ENGINEERING DATA.

2.

Install motor shaft nut and secure to shaft with lockwasher by bending tabs over flats.

Swing Brake Assembly

3.

Install brake adapter onto the motor and secure with hardware. Use care to align the access slots in the adapter for future tachometer inspections.

August 2007

6-7

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

4.

Lightly coat the splines of the drive hub with a teflon grease allowing only a thin film of lubricant to remain on the splines. Excess grease will be thrown outward by centrifugal force and have a degrading effect on the brake.

5.

Using a lifting device and the holes provided in the outer portion of the drive ring, place the brake assembly onto the drive hub and lower while aligning the splines in the drive hub with those in the brake disc.

6.

Apply 46-60 PSI compressed air to the brake to release it.

NOTE: The brake will be fully released once air pressure exceeds 46 PSI on a properly functioning brake. However air pressure in excess of 125 PSI could damage the internal seals of the piston.

7.

Install shims, as required, to achieve a gap of 0.015 - 0.030 inch between the pressure plate and the friction surface of the brake disc.

CAUTION:

A minimum of 46 PSI must remain applied to the brake while this dimension is determined. The brake must remain fully disengaged!

8.

Release the air pressure from the brake piston to relax the internal springs.

9.

Tighten the brake housing for final installation.

10.

Apply air pressure as in step 6. Verify that the proper gap remains between the pressure plate and friction surface of the disc.

11.

Install safety guard around the brake assembly.

12.

If previously removed, install the micro-switches and brackets for the wear and release indicators.

SWING BRAKE BURNISHING The swing brake on this machine is a “single disc assembly” consisting of a ductile iron disc to which multiple metallic lining segments are riveted. The burnishing-in procedure for a new or relined disc brake initiates a controlled wear process to develop the maximum contact area between braking surfaces. The burnish-in process will also start the formation of an oxide layer on the surface of the linings to stabilize and to establish the coefficient of friction.

Manual No. 10500

6-8

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Prior to beginning the burnishing procedure check and record the brake pressure plate temperature with a hand held temperature measuring device. Between each stop, continue monitoring the pressure plate temperature. Do not allow the pressure plate temperature to exceed 300° Fahrenheit (149°C).

NOTE: Check the temperature of each brake on the machine. If the temperature exceeds 300°F (149°C) stop the burnishing procedure and allow the brakes to cool to 200°F (93°C). If overheated or malfunctioning brakes are found, check if the brake is releasing properly. It is normal for a small amount of disc particles to be ejected from the brake and for sparking to occur during this operation. Large amounts of either situation may indicate overheating or improper release and should always be corrected prior to continuing.

BURNISH-IN PROCEDURE (DIPPER EMPTY) # of Stops at Speed

Time Between Stops

4 stops/1/4 speed

1 minute minimum

8 stops/1/2 speed

2 minutes minimum

Perform one additional full load, 3/4-speed stop with the dipper handle in the horizontal position and the hoist rope vertical on the swing motion. This will ensure that the brakes are functional. Record the swing stopping times and angles. Forward these recorded readings to the Bucyrus International service department.

August 2007

6-9

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CROWD BRAKE

Crowd Brake Assembly

Manual No. 10500

6 - 10

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Crowd Brake Tachometer

Installation of the tachometer, furnished with the electric motor, is required before beginning to install the crowd brake assembly. Install the tachometer and the torque arm in relation to the image provided.

August 2007

6 - 11

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

1.

Install the drive hub and keyway on the motor. Refer to “Pinion and Hub Installation” in Section 9 ~ENGINEERING DATA.

2.

Install the motor shaft nut and secure to the shaft with the lockwasher by bending the tabs over the flats.

3.

Install the brake adapter onto the motor and secure with hardware. Use care to align the access slots in the adapter for future tachometer inspections.

4.

Lightly coat the splines of the drive hub with a teflon grease allowing only a thin film of lubricant to remain on the splines. Excess grease will be thrown outward by centrifugal force and have a degrading effect on the brake.

5.

Using a lifting device and the holes provided in the outer portion of the drive ring, place the brake assembly onto the drive hub and lower while aligning the splines in the drive hub with those in the brake disc.

6.

Apply 46-60 PSI compressed air to the brake to release it.

NOTE: The brake will be fully released once air pressure exceeds 46 PSI on a properly functioning brake. However, air pressure in excess of 125 PSI could damage the internal seals of the piston.

7.

Install shims, as required, to achieve a gap of 0.015 - 0.030 inch between the pressure plate and the friction surface of the brake disc.

CAUTION:

A minimum of 46 PSI must remain applied to the brake while this dimension is determined. The brake must remain fully disengaged!

8.

Release the air pressure from the brake piston to relax the internal springs.

9.

Tighten the brake housing for final installation.

10.

Apply air pressure as in step 6. Verify that the proper gap remains between the pressure plate and friction surface of the disc.

11.

Install safety guard around the brake assembly.

Manual No. 10500

6 - 12

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST BRAKE

August 2007

6 - 13

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST BRAKE ADJUSTMENT The hoist brake is equipped with 2 adjustment shims to compensate for lining wear. This brake should be checked daily for lining wear and proper piston travel. If out of adjustment it will not be able to support a fully loaded dipper.

To inspect for excessive disc wear use a micrometer as shown in the image below. The reading must be taken from the same location with the brake engaged and released.

NOTE: The brake will be fully released once air pressure exceeds 60 PSI on a properly functioning brake. However, air pressure in excess of 125 PSI could damage the internal seals of the piston.

Due to the tapered surface of the pressure plate, care must be taken to duplicate the position and process as closely as possible. Friction disc adjustment must be performed when the total wear reaches .400 inch.

View - A Hoist Brake Friction Plate Inspection

NOTE: Adjustment shims are split for ease of removal and installation. DO NOT DISCARD shims after removal during brake adjustment. These shims will be required when reassembling brake following a friction disc replacement.

1.

When wear has reached 0.400 inch, remove the outer cylinder nuts and a single shim from the stack.

Manual No. 10500

6 - 14

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

2.

Reinstall the nuts and tighten to a maximum of 120 Ft.Lb. CAUTION:

3.

Tighten the stud nuts as per the instructions on the brake drive ring to a maximum of 120 Ft.Lb. Excessive or improper tightness can cause the drive ring to become deformed and seriously reduce the effectiveness and life of the brake assembly.

Re-check to total cylinder movement. If total movement is greater than .270 inch, place the unit back into service.

If the brake has already had a single shim removed, a second adjustment is possible. If the brake movement is greater than 0.400 inch the second shim may be removed using the same steps as for the first shim.

NOTES:

• When removing the second shim, the friction discs and center plates should be removed and inspected. Use care during disassembly to keep track of the order in which the components were removed.

• If the wear is unequal between the inner and outer friction discs they should be reversed during reinstallation (Place the inner disc to the outside and the outer disc to the side nearest the motor).

• Always be certain the machined step on the disc (near the center) is facing the motor during installation.

• Replace the brake piston and nuts. Tighten to a maximum of 120 Ft.Lb. as above and check total piston movement. If the movement is greater than 0.270 inch the brake can be returned to service.

August 2007

6 - 15

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST BRAKE INSTALLATION The tachometer, furnished with the electric motor, must be installed before installing the brake assembly.

1.

Install the drive hub and keyway on the motor. Refer to “Pinion and Hub Installation” in Section 9 ~ENGINEERING DATA.

2.

Install motor shaft nut and secure to shaft with loctite.

3.

Install brake adapter onto the motor and secure with hardware. Use care to align the access slots in the adapter for future tachometer inspections.

4.

Lubricate the hub and friction disc splines with a light coat of teflon grease or anti-seize compound.

5.

Install the friction discs and center plates onto the shaft adapter in the required order before sliding on the brake assembly. Tighten the drive ring hardware and install the brake guard.

PROPEL BRAKE The brake friction discs should be inspected monthly by removing the air hole guard and measuring the distance between the pressure plate and the cylinder. The measurement should be taken with the brake engaged and again with the brake disengaged. If the difference between the two measurements is 0.31 inch or greater, the brake must be adjusted or the friction discs replaced.

Manual No. 10500

6 - 16

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PROPEL BRAKE ADJUSTMENT The brake is equipped with three 0.094 inch thick shims located between the drive ring and the cylinder. Before removing a shim, check the friction disc assembly for unequal wear. If the discs are wearing unequally (inside vs. outside), additional brake life can be achieved by reversing the disc assemblies. With two shims out, allowable piston travel before friction disc replacement is 0.31 inch. When piston travel reaches 0.31 inch, remove one shim as follows: CAUTION:

NEVER ALLOW THE BRAKE TO OPERATE WITH PISTON TRAVEL OF LESS THAN 0.220 inch. Removal of shims prior to normal wear adjustment requirements will not increase brake holding capacity.

Premature shim removal will reduce running clearances, causing premature wear and heat damage to linings and brake.

CAUTION:

THE THIRD SHIM MUST NEVER BE REMOVED FOR ADJUSTMENT PURPOSES AS DAMAGE CAN OCCUR TO PRESSURE AND WEAR PLATES.

1.

With the machine parked on flat level surface, with dipper heel resting on the ground, remove the tach cover, the tach, the tach supports and the brake guard.

2.

Apply 43-60 PSI air pressure to the brake to release it. Back-off on the cylinder stud nuts 0.06 inch.

NOTE: The brake will be fully released once air pressure exceeds 43 PSI on a properly functioning brake. However, air pressure in excess of 125 PSI could damage the internal seals of the piston.

3.

Spread one shim at the split line and remove it from brake. For ease of removal, the shims are split radially. Take care not to bend or spring the shim when removing. Save shims for reuse when new replacement friction discs are installed.

NOTE: For ease of removal, shims are split radially.

4.

Retighten the cylinder stud nuts in criss-cross to 90-100 Ft.Lb. and check piston travel. Depressurize brake.

CAUTION:

5.

Do not overtighten the stud nuts as this will cause drive ring distortion and lead to excessive wear on brake disc and mating surfaces.

Reinstall the brake guard, the tach supports, the tach and the tach cover.

August 2007

6 - 17

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Propel Brake Assembly

Manual No. 10500

6 - 18

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SPRING REPLACEMENT-ALL BRAKES To replace the brake springs, disassemble the brake as follows: 1.

Follow steps one through five of the Replacement of Friction Discs procedure.

2.

Remove the cylinder stud nuts.

NOTE: It is recommended that the piston cylinder, pressure plate and drive ring be marked so that the same studs pass through the same bolt holes at reassembly.

Remove the piston with cylinder and pressure plate as a complete assembly from the studs and place on a clean level working area.

3.

Slowly open the temporary shut-off valve and release pressure from the piston with cylinder and pressure plate assembly.

CAUTION:

4.

The brake springs are under compression. Care must be taken when removing piston bolts in order to avoid injury.

Remove all piston bolts except for four located at 90° from one another.

NOTE: Reinstall one piston bolt to the right of each of the four remaining piston bolts, turning each of the reinstalled piston bolts two turns. These bolts act as a safety stop during the removal of the four remaining piston bolts 90° from each other.

5.

Carefully loosen each of the four remaining piston bolts two turns each in a pattern 180° opposite each other until all four piston bolts have been loosened two turns. Repeat loosening each of the four piston bolts in the above manner until the brake spring compression has been fully released at all four remaining piston bolts.

CAUTION:

Tap the piston to make sure it has not bound against the cylinder. Care must be taken when loosening piston bolts so that the piston does not bind against the cylinder.

6.

Remove the four remaining piston bolts and the safety stop bolts and lift the cylinder with piston off the pressure plate and brake springs.

7.

Remove all brake springs and insulating washers.

NOTE: The springs are equipped with insulated fiber washers. Be sure the washers are in place at reassembly.

August 2007

6 - 19

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

8.

Place new insulating washers, then new springs into the counterbores of the pressure plate.

Reposition the cylinder with piston onto the springs taking care that each spring end properly seats into each counterbore of the brake cylinder.

9.

Using piston bolts, assemble the cylinder with piston to the pressure plate and springs by reversing step 4 above. Tighten all piston bolts to 200-220 Ft.Lb. in a pattern 180° apart.

10.

Close the temporary shut-off valve. Reconnect the auxiliary air line to the temporary shut-off valve and follow steps four and five of the Replacement of Friction Discs procedure.

11.

Slide the pressurized piston with cylinder and pressure plate assembly onto the cylinder studs. (When applicable, make sure cylinder shimming is in place between the cylinder and drive ring.) Secure the assembly in place with the stud nuts. Tighten the nuts in a diametrical pattern to 90-100 Ft.Lb. CAUTION:

Do not overtighten the stud nuts as this will cause drive ring distortion leading to excessive wear on brake disc and mating surfaces.

NOTE: Observe the temporary regulator pressure gauge. If the pressure has dropped, the piston O-Rings may need replacement.

12.

Open the temporary shut-off valve and release the brake pressure. Remove the temporary regulator with gauge and the shut-off valve from the brake inlet and reconnect the brake air line to the brake inlet.

13.

Reinstall the brake guard, the tach supports, the tach and the tach cover.

Manual No. 10500

6 - 20

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

FRICTION DISC INSPECTION AND REPLACEMENT - ALL BRAKES The friction disc will require replacement when excessively worn or when contaminated by grease, oil or other foreign materials.

Check for a worn disc by using a depth micrometer as depicted in the image below. The reading must be taken from the same location with the brake engaged and released. Due to the tapered surface of the pressure plate, care must be taken to duplicate the position and process as closely as possible.

Friction Disc Inspection

The disc will be considered excessively worn when the difference between the 2 readings approaches 0.200 inch.

CAUTION:

August 2007

Major damage will occur to the components of the brake assembly if the friction disc is not replaced when wear approaches 0.200 inch. The result of “pushing” will result in metal-to-metal contact that will cause extremely expensive repairs and a seriously degraded braking system.

6 - 21

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

CAUTION:

Do not remove the socket head cap screws near the bore of the piston as this will release the spring pressure within the brake assembly and make re-assembly much more difficult.

1.

Remove the tach cover, the tach, the tach supports, and the brake guard as required.

2.

Release air pressure and remove the airline from the inlet to the piston.

3.

Install a ball, or gate, type valve into the fitting where the airline was removed. This valve will be used to capture pressure within the piston during removal.

4.

Reconnect the air source and pressurize the piston to a minimum of 30 PSI as needed to disengage the brake. Close the valve, and then remove the airlines. At this point the brake is disengaged and not connected to an air source.

NOTE: The cylinder, piston and pressure plate may be removed as a single unit.

5.

Remove the outer cylinder stud nuts at this time and the lift the entire brake assembly off the top of the studs as a unit. Once removed from the motor the pressure may be removed from the cylinder.

6.

Slide the friction disc up and off of the hub adapter splines and free it from the assembly.

7.

Clean the area where the friction disc resides and coat the splines with fresh teflon lubricant lightly.

8.

Install the replacement friction disc ensuring that the machined step, near the center, is facing downward - toward the motor.

9.

Carefully align the splines between the hub and the disc and allow the new disc to rest.

10.

Reinstall the piston and pressure plate onto the top of the friction disc and align the pneumatic fitting, access holes and studs accordingly. Pressurize the piston once more to minimum pressure allowing complete disengagement of the components.

11.

Replace the stud nuts and tighten to value that does not exceed 90 - 100 Ft-Lbs. CAUTION:

12.

Tighten the stud nuts as per the instructions on the brake drive ring.

Excessive, or improper, torque application can cause the drive ring to become deformed and seriously reduce the effectiveness and life of the brake assembly.

Ensure airline and micro-switches are properly reconnected.

Manual No. 10500

6 - 22

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

O-RING REPLACEMENT - ALL BRAKES With machine parked on flat level surface, with dipper heel resting on the ground, the O-rings may be replaced by disassembling the brake as follows: 1.

Remove the tach cover, the tach, the tach supports, and the brake guard as required.

2.

Release air pressure to the brake. Disconnect the airline to the brake inlet. Install a temporary pressure regulator with gauge and a closed shutoff valve to the brake inlet.

NOTE: The pressure regulator with gauge should be located between the brake and the shutoff valve.

3.

Remove the piston bolts attaching the piston to the pressure plate and remove the piston.

CAUTION: Do not remove cylinder stud nuts securing cylinder to pressure plate as this will release the brake springs and make reassembly difficult.

NOTE: It is recommended that piston and cylinder be marked so that the piston bolts pass through the same piston and pressure plate bolt holes at reassembly.

4.

Inspect O-rings for cleanliness, wear, deterioration, or cracks. Clean each as required and replace old or damaged O-rings.

5.

Lubricate O-rings and groove generously before assembly. Install O-rings in grooves as they would lay naturally. Do not nick, pinch, or twist O-rings.

NOTE: It is a good practice to coat the inner surfaces of the piston and cylinder with a teflon type lubricant. This coating of lubricant acts as a final filter to remove air system dust particles which could damage O-rings.

6.

Reassemble piston to pressure plate with piston bolts. Torque the bolts in a pattern 180° apart to 200-220 Ft-Lbs.

7.

Connect an auxiliary air line with a quick disconnect to the closed shutoff valve (installed in step one of this procedure) and follow step four of the Replacement of Friction Discs procedure.

8.

Close the temporary shutoff valve and disconnect the auxiliary airline. Observe the temporary regulator pressure gauge. If no pressure drop is observed, which would indicate an air leak in the brake assembly, release the brake pressure by opening the temporary shutoff valve.

9.

Remove the temporary regulator with gauge and the shutoff valve from the brake inlet.

Reconnect the brake airline to the brake inlet.

10.

Reinstall the brake guard, the tach supports, the tach, and the tach cover.

August 2007

6 - 23

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

COUPLINGS GRID COUPLINGS These instructions apply to Tapered Grid Couplings. They are designed to operate in either the horizontal or vertical position without modification.

However, for vertical applications, the match mark shown above, must be up. The performance and life of the couplings depend largely upon how they are installed and serviced.

Carefully follow these instructions for optimum performance and troublefree service.

All coupling parts have identifying part numbers. When ordering parts, always SPECIFY SIZE and TYPE. Cover halves have 1/8 NPT lube holes. Use a standard grease gun and lube fitting.

LUBRICATION Adequate lubrication is essential for proper operation of the coupling. Refer to the table for the amount of lubricant required. It is recommended that the coupling be checked once a year and lubricant added if required. For extreme or unusual operating conditions, check more frequently.

Grid couplings initially lubricated with LTG will not require re-lubrication until the connected equipment is stopped for servicing.

Manual No. 10500

6 - 24

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

COUPLING DISASSEMBLY AND GRID REMOVAL DANGER:

STORED ENERGY! Once grid is removed, machinery is free to rotate and brake will no longer hold. Equipment must be blocked prior to doing any maintenance to prevent unwanted movement. Death, serious injury, or damage to the machine can result from failure to take proper measures to prevent movement due to release of energy.

Whenever it is necessary to disconnect the coupling, remove the cover halves and grid. A round rod or screwdriver that will conveniently fit into the open loop ends of the grid is required.

Begin at the open end of the grid section and insert the rod or screwdriver into the loop ends. Use the teeth adjacent to each loop as a fulcrum and pry the grid out radially in even, gradual stages, proceeding alternately from side to side.

GRID COUPLING INSTALLATION Only standard mechanics tools, wrenches, a straight edge and feeler gauges are required for installation. For instructions on mounting to a drive motor, refer to the appropriate motor shaft installation instructions in this manual.

1.

Mount Seals and Hubs

Clean all parts. Heat hubs in an oven or use suitable dry heat. DO NOT rest gear teeth on container bottom or apply flame directly to gear teeth. DO NOT heat hubs over 275oF (135oC) for mounting.

Lightly coat seals with grease and place them on shafts BEFORE mounting hubs. Mount hubs on their respective shafts so the hub face is flush with the end of its shaft.

August 2007

6 - 25

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

2.

Gap and Angular Alignment

Use a spacer bar equal in thickness to the gap specified. Insert the bar, as shown here, to the same depth at 90 o intervals and measure clearance between bar and hub face with feelers. The difference in minimum and maximum measurements must not exceed the ANGULAR limit specified.

NOTE:

The motor shaft must be at the mid-point of its end play when measuring the gap.

3.

Offset Alignment

Align hubs so that a straight edge rests squarely (or within the limit specified) on both hubs as shown here. Check at 90 o intervals with feelers. The clearance must not exceed the OFFSET limit specified. Tighten all foundation bolts and repeat Steps 2 and 3. Realign coupling if necessary.

NOTE: Use a dial indicator for more accurate alignment.

4.

Insert Grids

Pack gap and grooves with specified lubricant before inserting grids. Install grid segments so that all cut ends extend in the same direction; this will assure correct grid contact with non-rotating pin in cover halves. Spread grid segments slightly to pass over the coupling teeth and seat with a soft mallet.

Manual No. 10500

6 - 26

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5.

Pack with Grease and Assemble Covers

Pack the spaces between and around the grid with as much lubricant as possible and wipe off excess flush with top of grid. Position seals on hubs to line up with grooves in cover. Position gaskets on flange of lower cover half and assemble covers so that the match marks are on the same side as shown above. If shafts are not level (horizontal) or coupling is to be used vertically, assembly cover halves with the lug and match mark up, or on the high side.

Secure covers halves with fasteners and tighten to torque specified in the coupling data table. MAKE SURE LUBE PLUGS ARE INSTALLED BEFORE OPERATING! 6.

Periodic Lubrication

Remove both lube plugs and insert a lube fitting. Fill with recommended lubricant until an excess appears at hole opposite; then insert plug. Lubricate couplings at least once ever year. Lubricate more frequently when exposed to excessive-moisture, extreme temperatures, rapid reversing or shock loads or excessive misalignment. It is not necessary to re-lube couplings filled with Long Term Grease (LTG) until disassembled for service to attached components.

August 2007

6 - 27

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

GRID COUPLING ALIGNMENT

Grid Coupling Data

Coupling

Crowd

*Part No.

C113194-01

Type

Grid

Motor Frame

812

# Bolts

4

Dia. (inch)

0.5

Torque (in.lb.)

650

Torque (Ft.Lb.)

54

Max. Parallel Offset (in.)

0.022

Max. Angular Limit (in.)

0.04

Min. End Gap Limit (in.)

0.556

Grease Wt. (Lbs.)

1.6

NOTES: • •

Bolts are NOT Standard Fasteners. Values indicated are for clean, dry threads. * Use Parts Book to Verify Part Number.

WARNING: DO NOT SUBSTITUTE STANDARD FASTENERS FOR COUPLING BOLTS.

Manual No. 10500

6 - 28

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

GEAR COUPLINGS INSTALLATION

1.

Clean all parts. Heat hubs in an oven or use suitable dry heat. DO NOT rest gear teeth on container bottom or apply a flame directly to gear teeth. DO NOT heat hubs over 275oF (135oC) for mounting. Refer to motor shaft installation for hubs mounted on drive motors.

Pack sleeve teeth with grease and lightly coat seals with grease BEFORE assembly. DO NOT DAMAGE THE SEALS. Use a dial indicator to align dynamically balanced couplings and assembly parts with mating match marks aligned. Mount the indicator on one hub and take readings for the OFFSET check on the O.D. of the other hub. The difference between the minimum and maximum readings DIVIDED by two should not exceed the values in the table. For ANGULAR check, take readings on either face of other hub. The difference between the minimum and maximum readings should not exceed the values in the gear coupling data table.

2.

Mount the flanged sleeves, seal and hubs. Place the flanged sleeves WITH the seal rings on the shafts before mounting the hubs.

CAUTION:

August 2007

DO NOT DAMAGE THE SEALS. Mount the hubs on their respective shafts, as shown, so that each hub is flush with its shaft end. Position the equipment in approximate alignment with the approximate gap specified in the table.

6 - 29

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

3.

Gap and Angular Alignment - Use a spacer bar equal in thickness to gap specified in Table. Insert bar, as shown, to same depth at 90o intervals and measure clearance between bar and hub face with feelers. The difference in minimum and maximum measurements should NOT exceed the ANGULAR limit specified in the table.

4.

5.

Clamp a dial indicator to the rigid hub as shown and rotate the rigid hub one complete turn. The total indicator reading DIVIDED by two must not exceed the OFFSET limit specified. Tighten all foundation bolts and repeat Steps 3 and 4. Realign coupling if necessary. Grease the hub teeth.

Insert gasket, DO NOT DAMAGE the GASKET, between flanges. Position flanged covers with lube holes at 90o and draw flanged cover into position. Use bolts, nuts and lockwashers furnished with couplings.

IMPORTANT: Tighten the flange bolts and nuts to the torque specified in the table.

6.

CAUTION:

Manual No. 10500

For TYPE G couplings, fill with recommended grease until excess appears at the open hole; then insert plug.

For TYPE GV couplings, proceed as outlined above.

IN ADDITION, when flex hub is on TOP, vent by inserting a .010 thick SMOOTH feeler gauge between seal and hub. Fill until excess appears at feeler. Repeat at 90o intervals.

Make certain all plugs are inserted after lubricating.

6 - 30

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

GEAR COUPLING ALIGNMENT

Gear Coupling Data

Coupling *Part No.

Hoist

Swing

Propel

C116929-01 C111720-01 C112435-01

Type

Gear

Gear

Gear

Motor Frame

820

812

812

# Bolts

14

8

8

Dia. (inch)

0.875

0.625

0.75

Torque (in.lb.)

3000

1500

1800

Torque (Ft.Lb.)

250

125

150

Max. Parallel Offset (in.)

0.003

0.119

0.003

Max. Angular Limit

0.024

1.5°

0.018

Min. End Gap Limit (in.)

0.344

0.19

0.25

1.6

0.54

0.6

Grease Wt. (Lbs.) NOTES: • •

Bolts are NOT Standard Fasteners. Values indicated are for clean, dry threads. * Use Parts Book to Verify Part Number.

WARNING: DO NOT SUBSTITUTE STANDARD FASTENERS FOR COUPLING BOLTS.

August 2007

6 - 31

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HOIST COUPLING SHAFT ALIGNMENT To perform the hoist shaft alignment procedure, the center shaft must be removed and the coupling hubs must be properly installed on the hoist motor and gearbox. All steps to be performed using a laser alignment process.

1.

Check center gap between the coupling parting face on the motor and gearbox. Measure at four places 90 degrees apart, approximately at the bolt circle centerline of the rigid coupling.

Average of the four measurements is to be 37.88 inches, +0.00/-0.12.

2.

Check angular alignment. Max TIR = 0.005”

3.

Check parallel offset alignment. Max TIR = 0.005”

Manual No. 10500

6 - 32

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

7

Compressed Air System Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents AIR COMPRESSOR ..................................................................................................................... 3 Air Compressor Installation ......................................................................................................... 4

LUBRICATION ................................................................................................................... 5 FLUID LEVEL CHECK ....................................................................................................... 5 FLUID FILTER ................................................................................................................... 5 FLUID CHANGE ................................................................................................................ 5 V-BELT TENSION .............................................................................................................. 5 V-BELT REMOVAL AND REPLACEMENT ......................................................................... 6 PRESSURE SWITCH ....................................................................................................... 7 LOCKOUT VALVES ...................................................................................................................... 8 Lockout Valve Locations ............................................................................................................. 8 Lube Room Lockout Valves ........................................................................................................ 9

SAFETY WARNINGS ............................................................................................................ 10

SCHEMATIC, AIR .............................................................................................................. (insert)

August 2007

7-1

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

7-2

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

7

Compressed Air System AIR COMPRESSOR This machine uses a single-stage, positive-displacement rotary compressor which utilizes intermeshing helical rotors to effect the compression action. Both the rotors are supported by largecapacity, anti-friction bearings which are located outside the compression chamber.

The compressor is mounted in a welded frame assembly on the left side of the machine within the machinery house.

The air inlet port is located on top of the compressor near the driveshaft end. The discharge port is near the bottom on the opposite end of the compressor.

DANGER:

STORED ENERGY! Air under pressure will cause severe personal injury or death. Shut down compressor and relieve system of all pressure before removing components such as valves, plugs, fittings and bolts.

August 2007

7-3

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Air Compressor Installation

Manual No. 10500

7-4

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LUBRICATION The compressor is filled at the factory with the correct amount of synthetic fluid. The use of other brands or types of fluid may reduce the design life of the compressor or cause problems with filtration.

FLUID LEVEL CHECK The compressor’s fluid level is monitored by a sightglass or a dial gauge while in operation. The fluid level should be in the “run” area on the dial gauge or completely fill the sight gauge. DO NOT OVERFILL.

FLUID FILTER The compressor’s oil filter is a spin on, full flow unit. Always change the oil filter at every fluid change. The initial fluid change should occur after the first 500 hours of operation. During normal service, the filter should be replaced every 1,000 hours of operation.

FLUID CHANGE Refer to the manufacturer’s documentation for recommended fluid and fluid change intervals.

Total Fluid Capacity ................................................ 3.8 gallons Reservoir Capacity ................................................ 2.5 gallons

V-BELT TENSION The compressor is equipped with a spring activated belt tensioning device and does not require routine adjustment. Refer to the manufacturer’s documentation in cases of premature belt wear or sheave misalignment.

August 2007

7-5

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

V-BELT REMOVAL AND REPLACEMENT The compressor is equipped with a matched set of five belts.

NOTE: Always replace with a matched set of belts.

To remove the V-Belts: 1. Lock out and tag out the electrical power supply.

2. Remove any panels or guards to gain access to the belts.

3. Release the tension on the belt set by backing off nut (2). Remove the existing belts.

To install a new matched set of belts: 1.

Loosen nut (2) and lower motor plate until nut (2) contacts nut (3).

2.

Install the belts by rolling into position on the sheaves.

NOTE: The spring (4) will compress to allow the belts to cross into the grooves in the sheaves.

3.

Adjust the motor base with nut (2) until the belts are snug.

4.

Turn nut (1) on top of the adjusting arm to the end of the adjusting screw. Rotate the motor away from the compressor to the end of travel.

NOTE: Before the belts are properly tensioned, the sheaves may appear to be out of alignment. This condition is to be expected.

Manual No. 10500

7-6

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5.

Raise the motor into position by adjusting nut (2) until the pin (5) just reaches the bottom of the groove.

6.

Adjust nut (3) to compress the spring (4) to a height of 5.8 to 6.0 inches. Alternate adjusting nuts (2) and (3) to maintain pin (5) location, spring height and belt tension.

7.

Lock the height adjustment with nut (1).

8.

Reinstall any panels or guards that were removed.

PRESSURE SWITCH The pressure switch determines what pressure the compressor will load and unload. If a lower setting is desired, adjust the differential pilot valve first and set the pressure switch cut-out point to 15 PSIG over the desired full load pressure. The range adjustment is made by turning the screw clockwise to increase the cut-in/cut-out pressure. The pressure switch should unload the compressor by the time it reaches the 20% load point.

NOTE: Raising the pressure without changing the compressor speed above factory settings will result in high amp draw and drive belt failures.

August 2007

7-7

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LOCKOUT VALVES A series of lockout valves are provided to enable maintenance personnel to isolate and remove compressed air from the swing, crowd, hoist and propel brakes should they require maintenance.

This permits airflow to continue to the other brakes and features of the machine.

CAUTION: Isolating only one feature of the machine will not eliminate the danger of machine motion while maintenance is being performed. The user is responsible to ensure that all proper precautions including lock-out/ tag-out, bracing and any other necessary precautions have been taken, so that no unanticipated machine motions will occur.

Lockout Valve Locations

Manual No. 10500

7-8

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Lube Room Lockout Valves

August 2007

7-9

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SAFETY WARNINGS Ensure all personnel are aware of, and adhere to, the instructions of the following safety labels which are mounted on the compressor.

Manual No. 10500

7 - 10

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

August 2007

7 - 11

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

7 - 12

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500 Aug. 2007

Schematic No. 3

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

8

Air Filtration Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents HOUSE FANS ............................................................................................................................... 3 LUBRICATION ......................................................................................................................... 4 DYNAVANE AIR CLEANER ..................................................................................................... 4 Filter Components Overview ............................................................................................. 5

AIR CONDITIONER ...................................................................................................................... 6 SPECIFICATIONS ................................................................................................................... 7 Air Conditioner~Block Diagram ......................................................................................... 7

August 2007

8-1

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

8-2

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

8

Air Filtration

HOUSE FANS Check the blades for grease and/or dirt accumulation. Clean if necessary. Blades should rotate freely without binding.

If vibration is detected, check the following: 1.

Bearing and drive alignment

2.

Shaft straightness

3.

Wheel or sheaves loose on shaft

4.

Loose or worn bearings

5.

Loose mounting bolts

6.

Motor out-of-balance

7.

Sheaves out-of-balance

8.

Nose cap loose on wheel

9.

Worn or corroded wheel

10.

Accumulation of material on the wheel

11.

Cracks on blades and/or at the hub

12.

Worn fan blades and hubs

August 2007

8-3

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LUBRICATION All bearings are pre-lubricated and sealed at the factory. Under normal temperature condition (-20° to +150°F), when the fans are circulating clean air, the bearings are considered lubricated for life and additional lubrication is unnecessary.

If the fans are circulating contaminated air, or operating at elevated temperatures, periodic lubrication is required.

For normal temperatures, a high quality, light, neutral mineral grease is used. It is free of abrasive fillers and highly resistant to oxidation.

When fans are operating at elevated temperatures (166°F or higher), silicone or lithium soap base grease should be used. This high temperature grease should have a breakdown point above 350°F. Use a low pressure grease gun for fan bearings. Either the gun or the fitting should be vented. To prevent overfilling apply a small amount of grease. This is especially important when extended lubrication piping is used and the bearing cannot be observed.

DYNAVANE AIR CLEANER Dynavane air cleaners are self-cleaning and do not require the routine service typical of air filters which collect and hold the dirt removed from the air. There are a few maintenance procedures which should be observed.

•

The air entering the side of the cells should be kept free of rags, leaves and papers to assure free airflow. Applications exposed to this type of material should have intakes covered with a course mesh (5 mesh) screen to prevent entry of material larger than the bleed slot.

•

Check the bleed system to make sure nothing has impaired bleed air flow.

•

The cells should be examined for build-up of deposits on the blades. A light coating of dust is normal and will not impair the operation or efficiency of the cell. Occasionally, due to the presence of oil mist or similar vapors in the air, heavier surface accumulations will occur and the cell will require cleaning. Cleaning the cells can be accomplished by brushing the surface of the blades or blowing down with compressed air.

Manual No. 10500

8-4

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Filter Components Overview

•

Another method of cleaning the Dynavane filters is to reverse the direction of fan rotation.

This creates reverse air pressure which helps free up the dirt. The units can be removed for a more thorough cleaning.

August 2007

8-5

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

AIR CONDITIONER SIGMA MPV9 climate control units are heavy duty systems providing superior performance in a variety of climate and environmental conditions.

Air is drawn from beneath the unit, passes over the heat exchanger coil and the heating elements into a double-wheel fan where it is discharged through the base of the unit into the conditioned space below.

The refrigerant is metered by an externally mounted TX valve, and is cut off by a liquid line solenoid valve. The heat exchanger is large, constructed of heavy gauge tubing with a coarse fin pitch to reduce clogging. The fan motor is a large shaft, totally enclosed unit that is air cooled.

All pressure controls within the evaporator unit are fully sealed, preset and O-ring connected.

The compressor is a heavy duty, fully-sealed scroll-type device. The unit is mounted in flexible mounts in an effort to reduce noise and vibration. All connections are either soldered, O-ring type or rotalok.

A large liquid drier is placed within the liquid line to filter moisture from the refrigerant. The condenser operates at a single speed only.

Manual No. 10500

8-6

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SPECIFICATIONS Nominal Cooling Capacity

27,000 Btu/hr@415V/50Hz

Power requirements

415V/3ph/50Hz 21.0 Amps

Refrigerant

HFC 134a – 24 lbs.

Oil

POE Variety Mobil Arctic EAL22CC or ICI Emcarate RL32CF

Compressor

Fully sealed, scroll type

Condensor Coil

5 row, 3/8 inch copper tube with 8 aluminum fins/inch

Evaporator Coil

4 row, 3/8 inch copper tube with 10 aluminum fins/inch

Detailed information on the MPV9 can be found in the vendor’s documentation that accompanied the machine and the General Arrangement drawings provided by Bucyrus International.

Air Conditioner~Block Diagram

August 2007

8-7

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

8-8

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

9

Engineering Data Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents CAPSCREW (BOLT) GRADE ...................................................................................................... 3 BOLT TIGHTENING ....................................................................................................................... 4 TORQUE WRENCH METHOD ............................................................................................... 4 Table 1 - Lubricated or Plated Threads or with Hardened Washers .............................................. 4 Table 2 - Dry Threads .................................................................................................................. 4

TURN-OF-NUT METHOD ....................................................................................................... 5 Table of Snug Tight Torque Values ............................................................................................. 5

WIRE LOCKING CAPSCREWS ................................................................................................... 6 Patterns for Wirelocking Capscrews ........................................................................................... 6

TORQUE NUT INSTALLATION ..................................................................................................... 7 TIGHTENING PROCEDURE FOR ONE 2-INCH TORQUE NUT ........................................... 7 TIGHTENING PROCEDURE FOR ONE 3-INCH TORQUE NUT ........................................... 8 TIGHTENING PROCEDURE ~TORQUE ROD, TAPERED SLEEVE & 1.0 INCH NUT ......... 9 TIGHTENING PROCEDURE ~TORQUE ROD, TAPERED SLEEVE & 1.62 INCH NUT ..... 10 TIGHTENING PROCEDURE ~SWING TORQUE ROD & TAPERED SLEEVE ................... 11 TORQUE NUT REMOVAL PROCEDURE ............................................................................ 13 THREAD LUBRICATION ................................................................................................. 13 TORQUE NUT HELPFUL HINTS .......................................................................................... 14 LOCKING ASSEMBLIES ............................................................................................................. 15 LOCKING ASSEMBLY REMOVAL ......................................................................................... 16 PINION AND HUB INSTALLATION ............................................................................................... 17 REMOVAL FROM A SHAFT ................................................................................................... 17 MOUNTING A PINION OR HUB ON A SHAFT ....................................................................... 17 HUB ADAPTER PRE-HEAT ADVANCE REQUIREMENTS ............................................. 20 MOTOR COUPLING PRE-HEAT ADVANCE REQUIREMENTS ..................................... 20 MAINTENANCE WELDING ......................................................................................................... 21 WELDING ELECTRODES ................................................................................................... 22 REPAIR WELDING OF CRACKS ......................................................................................... 23 Joint Preparation for Repair of Cracks ....................................................................................... 23

PREHEAT ........................................................................................................................ 24 WELDING TECHNIQUE .................................................................................................. 24 REPAIR WELDING OF BROKEN PARTS ............................................................................ 25 REPAIR WELDING SWING RACK TEETH ........................................................................... 26 PREPARATION ............................................................................................................... 26 SWING RACK WELDING ELECTRODES ..................................................................... 27 PREHEAT ........................................................................................................................ 27 WELDING PROCEDURE ............................................................................................... 28 August 2007

9-1

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

WELDING AND CUTTING EQUIPMENT ..................................................................................... 30 STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT ....................................... 30 WIRE ROPE CARE AND MAINTENANCE .................................................................................. 32 STORAGE ............................................................................................................................. 32 CHECKING DIAMETER ........................................................................................................ 32 Correct Method for Checking Wire Rope Diameter ..................................................................... 32

HANDLING WIRE ROPE ...................................................................................................... 33 Improper Methods for Uncoiling Wire Rope ................................................................................ 34

SEIZING WIRE ROPE ........................................................................................................... 34 END PREPARATIONS/TERMINATIONS ............................................................................... 35 WIRE ROPE CLIPS .............................................................................................................. 36 WIRE ROPE CLIP APPLICATION ................................................................................... 36 WEDGE SOCKETS ........................................................................................................ 38 INSPECTION OF SHEAVES AND DRUMS ........................................................................... 39 Examples of Sheave Groove Conditions ..................................................................................... 39 Groove Gauge for New or Re-Worked Sheaves .......................................................................... 39 Inspecting for Worn Sheave ....................................................................................................... 40

BREAKING IN A NEW WIRE ROPE ..................................................................................... 40 INSPECTION DATA ............................................................................................................... 41 GUIDELINE TO INSPECTIONS AND REPORTS ........................................................... 42 Wire Rope Stretch vs Rope Life .................................................................................................44 Examples of Broken Wires ........................................................................................................ 47

SEALS ......................................................................................................................................... 48 SEAL INSTALLATION ............................................................................................................ 48 GEARCASE SEALING .......................................................................................................... 50 DUO-CONE SEAL INSTALLATION ............................................................................................. 51 INSTALLATION ...................................................................................................................... 51 Installation Tool .......................................................................................................................... 52 Examples of Incorrect Installations and Assemblies .................................................................. 54

SEAL RING STAND-OUT-HEIGHT .................................................................................. 55

Manual No. 10500

9-2

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Section

9

Engineering Data

CAPSCREW (BOLT) GRADE The grade classification of a capscrew (bolt) is identified by the marks on the head as shown below:

Use the SAME GRADE washer and nut as the capscrew. NEVER SUBSTITUTE A LESSER GRADE CAPSCREW IN PLACE OF THAT WHICH IS SPECIFIED.

August 2007

9-3

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

BOLT TIGHTENING TORQUE WRENCH METHOD The following tables show torque values for bolt grades 2, 5 and 8 with UNC threads only. Table 1 lists torque values for lubricated or plated threads and for using hardened washers. Table 2 lists those for dry threads.

The bolts should be tightened to the specified total value in increments, alternating from bolt to bolt to assure gradual, even pull-up of mating parts.

Tightening should progress systematically from the most rigid part of a joint to its free edges.

Circular bolt patterns should be tightened in a diametric crosshatch pattern while applying torque in increasing values to ensure proper pull-up of parts.

Table 1 - Lubricated or Plated Threads or with Hardened Washers

Table 2 - Dry Threads

Manual No. 10500

9-4

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TURN-OF-NUT METHOD CAUTION:

THIS TIGHTENING PROCEDURE IS ONLY APPLICABLE FOR BOLT GRADES 5 AND 8 WITH UNC THREADS. For bolts with other than UNC threads, contact the Bucyrus International Service Department.

NOTE: When using this procedure the bolt threads and the surfaces under the bolt head and nut must be lubricated. This procedure is applicable only if the joint and under head surfaces for bolt and nut are machined for parallelism.

1.

The bolts should be brought to a “snug tight” condition to insure that the parts of the joint have good contact with each other. “Snug Tight” is defined as the tightness attained by torquing a bolt to the value specified in the table on the following page. Snug tightening should progress systematically from the most rigid part of the joint to its free edges while alternating from bolt to bolt to assure gradual even pull up of the mating parts. After all bolts have been snugged, the first bolts tightened at the most rigid part of the joint should be rechecked for proper torque retention. If these bolts are loose due to pull up of the joint, the snug tightening sequence should be repeated for all bolts in the connection. This rechecking and re-torquing procedure should be repeated as many times as is required until the joint is completely pulled up and all bolts are at the specified “snug tight” torque. Tightness of the mating surfaces of the joint should then be verified by using feeler gauges.

Table of Snug Tight Torque Values

2.

The nuts and bolts should then be matched marked by center punching the bolt end and nut.

On rod bolts match mark both rod ends and nuts. The bolts and nuts should then be tightened additionally by the applicable amount of nut rotation as specified in Table 4. It is not necessary to follow any particular bolt to bolt sequence during this portion of the “turn of the nut” tightening.

August 2007

9-5

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

NOTE: Nut rotation is read between the punch mark on the bolt and the punch mark on the nut.

For rod bolts, nut rotation is the cumulative total rotational movement between punch marks on both ends of the rod bolt.

WIRE LOCKING CAPSCREWS Wire locking of capscrews is used when maximum lock assurance is required when periodic visual inspection is not possible.

The illustrations below show the recommended wire locking methods for various right hand thread capscrew patterns. For patterns not shown, wire lock the screws “in pairs”. For odd numbered patterns, wire lock the screws in pairs except the remaining 3 capscrews wire lock together

Patterns for Wirelocking Capscrews

Use 14 gauge soft annealed lockwire. Thread the wire through the capscrew head so that tightening stress on the wire will exert a tightening torque on the direction of capscrew thread. (The illustrations show lock wire threading for right hand threaded capscrews. Reverse the lock wire patterns shown for left hand capscrews.)

Manual No. 10500

9-6

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TORQUE NUT INSTALLATION TIGHTENING PROCEDURE FOR ONE 2-INCH TORQUE NUT 1.

Ensure that a special steel washer, supplied with the torque nut, is placed beneath the torque nut. DO NOT USE STANDARD COMMERCIAL WASHERS.

2.

Check the base of the torque nut to ensure that all jackbolts are flush with the bottom.

3.

Spin the torque nut onto the rod or bolt by hand.

4.

Tighten the jackbolts to 100 Ft.Lb. as follows: a.

Snug all jackbolts to 10 Ft.Lb. each.

b.

Using the STAR pattern shown, tighten all jackbolts to 50 Ft.Lb.

c.

Switch to the circular pattern shown and tighten all jackbolts to 75 Ft.Lb.

d.

Continue with the circular pattern and tighten all jackbolts to 110 Ft.Lb.

NOTES: •

With longer rods and bolts, stretch in the rod or bolt occurs during tightening of the jackbolts. Therefore, after tightening with the circular pattern in step 4-d above, the first jackbolt may have loosened. The higher torque value is used in this step only to speed the tightening process. After performing the above steps, use a torque wrench for the final torque values and continue tightening the jackbolts in a circular pattern until all jackbolts are tightened to a value of 100 Ft.Lb.

•

An impact wrench can be used for the initial tightening sequences, however a torque wrench must be used to achieve the final torque values.

•

Repeat the above steps for all remaining torque nuts.

August 2007

9-7

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TIGHTENING PROCEDURE FOR ONE 3-INCH TORQUE NUT 1.

Ensure that 2 special steel washers, supplied with the torque nut, is placed beneath the torque nut. DO NOT USE STANDARD COMMERCIAL WASHERS.

2.

Check the base of the torque nut to ensure that all jackbolts are flush with the bottom.

3.

Spin the torque nut onto the rod or bolt by hand.

4.

Tighten the jackbolts to 200 Ft.Lb. as follows: a.

Snug all jackbolts to 10 Ft.Lb. each.

b.

Using the STAR pattern shown, tighten all jackbolts to 100 Ft.Lbs.

c.

Switch to the circular pattern shown and tighten all jackbolts to 150 Ft.Lb.

d.

Continue with the circular pattern and tighten all jackbolts to 220 Ft.Lb.

NOTES: •

With longer rods and bolts, stretch in the rod or bolt occurs during tightening of the jackbolts.

Therefore, after tightening with the circular pattern in step 4-d above, the first jackbolt may have loosened. The higher torque value is used in this step only to speed the tightening process. After performing the above steps, use a torque wrench for the final torque values and continue tightening the jackbolts in a circular pattern until all jackbolts are tightened to a value of 200 Ft.Lb.

•

An impact wrench can be used for the initial tightening sequences, however a torque wrench must be used to achieve the final torque values.

•

Repeat the above steps for all remaining torque nuts.

Manual No. 10500

9-8

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TIGHTENING PROCEDURE ~TORQUE ROD, TAPERED SLEEVE & 1.0 INCH NUT 1.

Check the base of the torque nut to ensure that all jackbolts are flush with the bottom.

2.

Insert the expansion sleeve from the top of the structure.

3.

Insert the tapered stud into the sleeve. Note the direction of the taper on the rod.

4.

Slip the special washer (spacer) over the lower threaded end of the stud.

5.

Spin the lower torque nut onto the stud by hand.

6.

Tighten the lower nut jackbolts to 27 Ft.Lb. as follows: a.

Snug all jackbolts to 5 Ft.Lb. each.

b.

Using the STAR pattern shown, tighten all jackbolts to 15 Ft.Lb.

c.

Switch to the circular pattern shown and tighten all jackbolts to 20 Ft.Lb.

d.

Continue with the circular pattern and tighten all jackbolts to 30 Ft.Lb. Refer to the notes below.

7.

Ensure that a special steel washer, supplied with the torque nut, is placed beneath the upper torque nut. DO NOT USE STANDARD COMMERCIAL WASHERS.

8.

Spin the upper torque nut onto the stud by hand. Using the STAR pattern shown, tighten all jackbolts to 10 Ft.Lb.

NOTES: •

With longer rods and bolts, stretch in the rod or bolt occurs during tightening of the jackbolts. Therefore, after tightening with the circular pattern in step 4-d above, the first jackbolt may have loosened. The higher torque value is used in this step only to speed the tightening process. After performing the above steps, use a torque wrench for the final torque values and continue tightening the jackbolts in a circular pattern until all jackbolts are tightened to a value of 27 Ft.Lb.

•

An impact wrench can be used for the initial tightening sequences, however a torque wrench must be used to achieve the final torque values.

•

Repeat the above steps for all remaining torque nuts.

August 2007

9-9

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TIGHTENING PROCEDURE ~TORQUE ROD, TAPERED SLEEVE & 1.62 INCH NUT 1.

Check the base of the torque nut to ensure that all jackbolts are flush with the bottom.

2.

Insert the expansion sleeve from the top of the structure.

3.

Insert the tapered stud into the sleeve. Note the direction of the taper on the rod.

4.

Slip the special washer (spacer) over the lower threaded end of the stud.

5.

Spin the lower torque nut onto the stud by hand.

6.

Tighten the lower nut jackbolts to 49 Ft.Lb. as follows: a.

Snug all jackbolts to 10 Ft.Lb. each.

b.

Using the STAR pattern shown, tighten all jackbolts to 25 Ft.Lb.

c.

Switch to the circular pattern shown and tighten all jackbolts to 35 Ft.Lb.

d.

Continue with the circular pattern and tighten all jackbolts to 55 Ft.Lb. Refer to the notes below.

7.

Ensure that a special steel washer, supplied with the torque nut, is placed beneath the upper torque nut. DO NOT USE STANDARD COMMERCIAL WASHERS.

8.

Spin the upper torque nut onto the stud by hand. Using the STAR pattern shown, tighten all jackbolts to 10 Ft.Lb.

NOTES: •

With longer rods and bolts, stretch in the rod or bolt occurs during tightening of the jackbolts. Therefore, after tightening with the circular pattern in step 4-d above, the first jackbolt may have loosened. The higher torque value is used in this step only to speed the tightening process. After performing the above steps, use a torque wrench for the final torque values and continue tightening the jackbolts in a circular pattern until all jackbolts are tightened to a value of 49 Ft.Lb.

•

An impact wrench can be used for the initial tightening sequences, however a torque wrench must be used to achieve the final torque values.

•

Repeat the above steps for all remaining torque nuts.

Manual No. 10500

9 - 10

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TIGHTENING PROCEDURE ~SWING TORQUE ROD & TAPERED SLEEVE 1.

The jack bolt threads, tapered portion of the rod bolt and the expansion sleeve ID are prelubricated with graphite lube. Ensure that this lube is present. Apply additional lube as needed. Also apply a thin film of lube to the OD of the expansion sleeve, the revolving frame and swing girder bores, and the jack bolt end faces and threads.

2.

Check the base of the torque nut to ensure that all jackbolts are flush with the bottom.

3.

Insert the expansion sleeve from inside the frame structure.

4.

Insert the tapered stud into the sleeve. Note the direction of the taper on the rod.

5.

Slip the special washer (spacer) over the outer threaded end of the stud.

6.

Spin the outer torque nut onto the stud by hand.

7.

Tighten the outer nut jackbolts to 182 Ft.Lb. as follows: a.

Using the star pattern shown, snug all jackbolts (one round only) to approx. 30 Ft.Lb. each.

b.

Continue using the STAR pattern shown, tighten all jackbolts (one round only) to approx.

90 Ft.Lb.

c.

Switch to the circular pattern shown and tighten all jackbolts (one round only) to 182 Ft.Lb.

d.

Inside the revolving frame, measure the protrusion of the rod bolt beyond the face of the expansion sleeve flange. Refer to View - A. It must be within the acceptable range shown.

August 2007

9 - 11

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

8.

Ensure that a special steel washer, supplied with the torque nut, is placed beneath the upper torque nut. DO NOT USE STANDARD COMMERCIAL WASHERS.

9.

Spin the upper torque nut onto the stud by hand and spin tighten against the hardened washer.

10.

Finalize the preload of the inner torque nut by tightening the inner torque nut jack bolts to 182 Ft.Lb. as follows:

11.

a.

Using the star pattern shown and a torque wrench, tighten the jack bolts (one round only) to approx. 90 Ft.Lb.

b.

Set the torque wrench to 182 Ft.Lb. Working in the circular pattern, continue tightening the jack bolts of the inner torque nut until they are stabilized at full torque. This may take several rounds. (Stabilized is when the torque wrench is moving less than 1/8 turn.)

Finalize the preload of the outer torque nut by tightening the outer torque nut jackbolts to 182 Ft.Lb. as follows: Set the torque wrench to 182 Ft.Lb. Working in the circular pattern, continue tightening the jack bolts of the outer torque nut until they are stabilized at full torque. This may take several rounds.

NOTES: •

An impact wrench can be used for the initial tightening sequences, however a torque wrench must be used to achieve the final torque values.

•

Repeat the above steps for all remaining torque

Manual No. 10500

9 - 12

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TORQUE NUT REMOVAL PROCEDURE CAUTION: THE PROPER REMOVAL OF TORQUE NUTS REQUIRES FOLLOWING STRICT PROCEDURES. LONGER ANCHOR BOLTS AND RODS REQUIRE GREATER CARE. If some jackbolts are completely unloaded prematurely, the remaining jackbolts will carry the entire load of the fastener. This may cause the jackbolts to become extremely hard to turn or even deformed.

NOTE: It is a good practice to spray the entire fastener and jackbolts with a penetrating type lubricant prior to attempting removal. This step will be critical if rust exists on the components.

1.

Turn the first jackbolt counter-clockwise until it feels loose, but no more than 1/2 turn.

2.

Repeat the loosening with the rest of the jackbolts. Use the reverse of the star pattern used to tighten the jackbolts. This will minimize loading on the last few jackbolts.

3.

Repeat the entire loosening pattern, turning each jackbolt no more than 1/2 turn at a time, until the torque nut can be spun off the rod or bolt by hand.

After removal of the torque nut: •

Remove all jackbolts from the torque nut. Clean, inspect and lubricate the toque nut, hardened washer and the jackbolts for later reassembly.

NOTE: On smaller torque nut fasteners it may be possible to utilize impact tools to speed removal after performing step 2 above. However, DO NOT USE IMPACT TOOLS FOR THE INITIAL LOOSENING PROCEDURE. Longer anchor bolts may require several repetitions of the initial loosening process prior to switching to impact tools for assistance.

THREAD LUBRICATION For the main studs of torque nut fasteners any standard anti-seize compound may be used. A thin, brush-on type application, or aerosol spray lubricant is acceptable.

Jackbolts are pre-lubricated from the factory with either moly or graphite lubricants depending on the intended use. Similar lubricants may be used on the jackbolt tips and hardened washer during installation.

August 2007

9 - 13

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

TORQUE NUT HELPFUL HINTS Prior to Tightening: 1.

Threads: Check all threads of the main stud to verify that the torque nut will spin on freely prior to installation. If a restriction is found, use a lapping compound on the main threads or chase the threads in either the torque nut or the main stud using a good die or tap. THE UNRESTRICTED MOVEMENT OF THE torque nut ON THE MAIN STUD IS CRITICAL IN THE INSTALLATION PROCESS.

2.

Spacers: The torque nut should be positioned at the end of the main stud when installation is complete in order to minimize exposed threads which could be damaged. This will also serve to minimize any difficulty in reaching the jackbolts and avoid the need for thinwall, or deepwell sockets. A spacer or stacked washers can be used beneath the hardened washer to accomplish this. The spacer will also allow a step-over of a damaged area on stud from repeated installations.

3.

Gaps: Back off the torque nut to provide a gap of 1/16 to 1/8 inch between the torque nut and the hardened washer prior to beginning the torque application process. This will allow additional jackbolt extension which provides easy access for jackbolt tip lubrication prior to removal.

When closing a gap between flanges, or where long fasteners are used, there may be insufficient jackbolt stroke to allow this step.

4.

Sockets: Use only six-point quality sockets in good condition. Worn sockets will eventually round out the corners of the jackbolts possibly causing damage or injury.

While Tightening: 5.

Do not tighten a jackbolt completely prior to moving on to the next jackbolt. As the torque nut is tightened, the first jackbolt that was tightened in that sequence will have a tendency to loosen. It will be faster to make multiple passes by moving quickly between jackbolts.

6.

Overshoot the Target Torque as indicated PRIOR to the final tightening. This will quicken the tightening sequence by stabilizing previously tightened jackbolts sooner. BE CERTAIN NOT TO “STABILIZE” THE JACKBOLTS AT THIS HIGHER TORQUE VALUE!

While Removing: 7.

Removing the jackbolts too quickly during disassembly may increase the removal torque of the remaining jackbolts. If a jackbolt should become jammed, re-tighten several jackbolts to either side to even the tension on the torque nut.

8.

If a jackbolt tip “mushrooms” its tip must be cut off with a cutoff wheel or abrasive disc, then the jackbolt removed.

Manual No. 10500

9 - 14

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

LOCKING ASSEMBLIES To install a locking assembly: 1.

Clean and lightly oil all parts of the locking assembly, the shaft or pin and the housing bores. Be sure the bores to be connected are properly aligned.

2.

Loosen all socket head capscrews on the locking assembly.

3.

Install the locking assembly and the shaft or pin into the housing. Carefully note any measurements required to align the locking assembly.

4.

Tighten the capscrews of the locking assembly evenly. Do not tighten each screw all at once. Instead, gradually tighten each one and proceed with the entire set, using a criss-cross pattern, and repeat until all screws are tight. Refer to the proper section of the maintenance manual for the specific torque required.

Where pilot bushings are used: 1.

Insert the locking assembly as stated above - except remove all socket head capscrews.

August 2007

2.

Insert 3 pilot bushings, equally spaced. Insert the longer capscrews supplied with the pilot bushings.

3.

Tighten the capscrews using the same procedure required for the locking assembly capscrews.

9 - 15

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

4.

Once the pilot bushing is has been properly tightened, remove the longer socket head capscrews and the pilot bushings. Replace the capscrews in the locking assembly with the socket head capscrews that came with the locking assembly.

5.

Tighten all capscrews using the procedure above. Retain the pilot bushings and longer capscrews for future use.

LOCKING ASSEMBLY REMOVAL

For series 1015 assemblies with a center collar: 1.

Loosen all capscrews on the locking assembly by at least 2 turns in 1/4 turn increments.

2.

Transfer all the capscrews to the push-off threads provided in the clamp collar and in the center collar.

3.

Progressively tighten all screws in a diametrical pattern except the screws adjacent to the slit in the clamp collar these should be tightened one after the other.

For series 4000 assemblies with NO center collar:

Manual No. 10500

1.

Loosen all capscrews on the locking assembly by at least 2 turns in 1/4 turn increments.

2.

The locking assembly incorporates a self-releasing taper, which should allow the assembly to be removed.

However if the thrust rings jam, tap on the heads of 3 equally spaced capscrews to positively release the connection.

3.

Insert pullout screws in the threads under the cadmium plated locking screws to remove the assembly.

9 - 16

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PINION AND HUB INSTALLATION REMOVAL FROM A SHAFT CAUTION: A properly mounted pinion, brake drum or coupling will have an interference fit with the shaft causing it to release suddenly and violently when broken loose. Loosen the shaft nut just enough to allow the pinion, brake drum or coupling to free itself. The shaft nut will stop the pinion or coupling and avoid injury to personnel.

NOTE: When removing the pinion, brake drum or coupling from a motor shaft, always use a suitable puller to avoid causing damage to either the pinion, coupling, motor frame, bearings or shaft. Do not heat the pinion, brake drum or coupling before pulling and do not use wedges between them and the bearing cap. To prevent damage to the antifriction bearings, avoid the use of a sledge hammer on the puller.

MOUNTING A PINION OR HUB ON A SHAFT Successful operation of the gearing largely depends on the proper mounting of the pinion, brake drum or coupling on the shaft.

NOTE: Mounting pinions, brake drums or coupling by heating them in boiling water and driving them on the shaft with a blow from a heavy sledge hammer is not recommended. This results in uncontrolled advance of the pinion or coupling on the shaft. Too great an advance can cause breakage of the pinion, brake drum or coupling core, while insufficient advance can cause slippage and wear in spite of the presence of the key. In addition, hammer blows can injure the finished surface of the anti-friction bearings.

Pinions, brake drums or couplings must be mounted to a definite advance on the shaft, without hammer blows. This requires heating them to a higher temperature than is obtainable with boiling water, and is based on a difference in temperature between them and the shaft. The following is the recommended method for mounting pinions, brake drums or couplings: 1.

Thoroughly clean the pinion, brake drum or coupling seating surface on the shaft and the bore of the pinion, brake drum or couplings. Use toluol or percholoethylene; do not use kerosene.

CAUTION:

Solvents may be toxic or flammable. Adequate ventilation must be provided to minimize fire and health hazards. Use away from sparks, heat or flame to prevent fire or explosion. Follow the manufacturer’s instructions.

Remove any scoring from either part. Spot the cold pinion, brake drum or coupling on the shaft by hand to obtain at least a 75% fit. Check the fit with bluing. Remove the pinion, brake drum or coupling.

2.

Break all sharp edges of the key and the keyway with a fine file, so there will be a radius of about 1/64 inch at each edge. Fit the key to the shaft, taking care to avoid upsetting the metal of the shaft adjacent to the key. If previously upset, file lightly, checking the fit with bluing until a 75% fit results. Try the pinion, brake drum or coupling on the shaft to make certain it does not bind on the key.

August 2007

9 - 17

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

3.

Mount the pinion, brake drum or coupling cold by placing it on the shaft and snapping it into position by hand.

Measure the “cold” position of the pinion, brake drum or coupling using a micrometer depth gauge. The following figure illustrates the method of using the depth gauge.

Mark the places where the depth gauge was resting so measurements can be made from the same position after the pinion, brake drum or coupling has been mounted.

4.

Remove the pinion, brake drum or coupling from the shaft and heat it in a suitable oven to the temperature specified. If the pinion, brake drum or coupling is heated in oil, the bore must be thoroughly cleaned before mounting. To avoid the cleaning, the use of an oven is recommended.

CAUTION: Use suitable protective equipment when handling hot items.

The pinion, brake drum or coupling temperature is indicated as a temperature difference between the shaft and pinion; this temperature difference is estimated only and can be adjusted to maintain the specified advance. Heat the pinion, brake drum or coupling in the oven until the temperature is uniform at the required number of degrees above the shaft temperature.

For example, if the shaft temperature is 25oC (77oF) and the estimated difference is 125oC (225oF), heat the pinion, brake drum or coupling to 150oC (320oF) for mounting.

WARNING: Pinion, brake drum or coupling temperature must never exceed 190oC (374oF).

Some accurate method must be provided for quickly measuring the temperatures of the pinion, brake drum or coupling and shaft before mounting them. This is best done with a hand pyrometer (refer to the figure). When a hand pyrometer is not available, a centigrade thermometer can be used by placing putty over the bulb to hold it against the pinion or coupling. Heat the pinion, brake drum or coupling a few degrees above the desired temperature before removing it from the oven. Wait until it has cooled to the temperature desired, remove the thermometer and quickly mount the pinion, brake drum or coupling as described below.

Manual No. 10500

9 - 18

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

5.

After making sure the bore is clean, quickly mount the hot pinion, brake drum or coupling on the shaft. When it is nearly engaged with the taper fit (but not actually in contact), snap it forcible into place with a quick push. It is important that the hot pinion, brake drum or coupling be instantly snapped into position before it has cooled appreciably; otherwise it will immediately “freeze” to the shaft and cannot be adjusted further.

6.

Check the “hot” or shrunk-on position of the pinion, brake drum or coupling on the shaft, using the micrometer depth gauge. The actual advance is the difference between depth gauge readings at the hot and cold positions. To control the stresses in the pinion, brake drum or coupling, the advance must be within the limits specified in the table below.

If the advance is not within the limits given, the pinion, brake drum or coupling should be pulled and remounted.

7.

Assemble the lockwasher and nut, tighten firmly and lock. Where a lockwasher is not used, retaining compound must be used to keep the nut tight during operation.

WARNING: When a lockwasher is used, the nut must be firmly tightened against it, then the tab on the lockwasher must be bent against the flat of the nut. This is required to keep the nut tight during operation.

August 2007

9 - 19

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HUB ADAPTER PRE-HEAT ADVANCE REQUIREMENTS

MOTOR COUPLING PRE-HEAT ADVANCE REQUIREMENTS

Manual No. 10500

9 - 20

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

MAINTENANCE WELDING These recommendations for repair welding apply to the major structural members of the machine.

The high cyclic loading characteristics of the machine are considered in the design and material selected for the construction of the machine. However, due to unusual operational conditions that may be encountered and to the great number of cyclic loadings that may be applied to the machine, fatigue cracks or other abnormalities may occur. Early detection of these conditions through regular machine inspection helps to avoid problems or emergency breakdowns.

Maintenance welding is applied to the repair of cracked or broken structural components.

Reconditioning of broken parts by the application of heating, cutting and welding processes requires attention to a number of details, careful adherence to the repair procedure and observance of federal, state and local safety regulations.

CAUTION: WELDING AND THERMAL-CUTTING OF METALS INVOLVE THE GENERATION OF TEMPERATURES UP TO THOUSANDS OF DEGREES AT WHICH METALS MELT AND VAPORIZE. When proper precautions are taken to protect personnel and property against the heat, evolved gases and fumes, electric shock and radiation, no harm will result either to personnel or property. In gas heating and cutting, the handling and storage of compressed gases present other hazards that also must be protected against to provide a safe working environment.

Safety precautions should conform to the latest edition of ANSI standard Z49.1, Safety in Welding and Cutting, published by the American Welding Society.

Reconditioning of failed members requires attention to a number of details and careful application of the repair procedure. Only in certain cases is it necessary to strengthen members by added reinforcement.

WARNING: REINFORCING STRUCTURAL MEMBERS SHOULD BE MADE ONLY UPON RECOMMENDATION BY BUCYRUS INTERNATIONAL, INC. IMPROPERLY APPLIED REINFORCEMENTS CAN HAVE AN ADVERSE EFFECT ON THE PERFORMANCE AND LIFE OF THE STRUCTURE. A broken member is best repaired by making a complete penetration weld, preferably by welding from both sides, using the correct welding electrode and observing all precautions such as preheat, back-gouging, etc. The complete penetration groove weld should be ground flush with the base metal on both sides to remove all surface irregularities. An alternate procedure incorporates backup bars to ensure sound, complete penetration welds in the repair area. Be sure to follow all applicable safety measures and federal, state and local regulations.

A complete penetration weld repair conditioned by grinding instead of adding reinforcement is favored to maintain the original pattern of stress flow designed into the structural members. Addition of reinforcement which is not part of the design can reduce fatigue strength because of the change in geometry from the original structure.

August 2007

9 - 21

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Effective repair welding of cracked, broken or bent structural members of the machine involves knowledge of the types of steel used, proper welding electrodes and recognized good welding practice. The chemical composition, mechanical properties and thickness of the steel determine the welding electrode to be used and the preheat temperature required.

WELDING ELECTRODES With the exception of the boom, weld repairs on the various structures of the machine can be made with two basic classifications of shielded metal arc electrodes: E7018 and E8018-C1. Both are low hydrogen electrodes which deposit weld metal having excellent properties at strength levels with 70,000 to 80,000 PSI, and impact properties from -20o to -75oF. These are all-position electrodes which produce high quality welds for repairing the structural components of heavy machinery.

NOTE: Although these electrodes are of superior quality, care must be exercised in their application. Low hydrogen electrodes are highly susceptible to moisture pickup after removal from sealed containers. To maintain low hydrogen, crack-resistant properties, they must be stored in electrode ovens at 250oF up to the time of use. Small portable rod ovens at the welder’s side are ideal. Use of dry low hydrogen electrodes cannot be over-emphasized.

Cracks caused by hydrogen are extremely fine and occur invisibly below the surface in the base metal heat affected zone, as shown. Therefore, they are not detectable at the time of welding.

These cracks can propagate in service and lead to ultimate failure of the part. It is necessary to adhere strictly to recognized good welding practice regarding the handling, storage and use of low hydrogen electrodes. To avoid underbead cracks, remove all oil or grease or other contaminates from the surface and be sure the steel is dry.

Preheat to the required temperature. Use only dry electrodes taken from the electrode oven. After exposure to the air, the electrodes must be returned to the oven. Time limit outside the oven is four hours for E7018 and two hours for E8018C1 electrodes.

Manual No. 10500

9 - 22

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

REPAIR WELDING OF CRACKS

Joint Preparation for Repair of Cracks

Remove the entire crack by arc air-gouging or grinding. Prepare a V-groove of approximately 4560o included angle for rewelding. If cracked through the full thickness and if it is possible to make the repair from both sides, a double V preparation is preferred. When welding from both sides, back-gouging for complete penetration is always recommended.

When it is not physically possible to back-gouge and weld the second side, an alternate approach must be taken. Sometimes it is possible to gouge through to completely remove the crack, then fit a backup bar on the underside to facilitate making a complete penetration weld.

NOTE: The backup bar must fit tightly to the underside otherwise poor welding conditions conducive to cracking may occur.

When it is not possible to fit a backup due to limited accessibility to the underside, it is advisable to remove a portion of the defective plate and weld in a new piece, using back up bars on all sides to ensure complete penetration welds.

A further alternative is to gouge through, removing the crack, and then weld small stringer beads to close the gap and prepare a groove for a repair weld. In this case, the repair weld will be essentially full penetration, but will be less than perfect on the under side. The other methods are preferred in the order described, that is, welding both sides, welding against a backup bar, or completely replacing a section of plate.

August 2007

9 - 23

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

PREHEAT When preheating, apply heat to a broad, general area surrounding the repair location. A soaking heat which thoroughly penetrates the material through the full thickness is preferred to high surface temperature quickly applied. Electrical resistance or radiant heating is suggested since the heat source can be left operating during welding to maintain the minimum preheat temperature. Preheat temperatures up to 400oF, depending upon the steel analysis, are adequate under most conditions for major repairs. As previously stated, preheat temperatures are determined by the type of steel in the structure. Temperatures should be measured with temperature indicating crayons.

WELDING TECHNIQUE Maximum electrode sizes are 1/4 inch for flat position, 3/16 inch for horizontal position and 5/32 inch for vertical and overhead positions. Use a split weave as soon as bead width is large enough to accommodate beads side by side. Throughout all welding be certain thorough fusion with the base metal and adjacent weld beads is obtained on all weld passes. Clean off all slag between passes and all craters before starting the next electrode.

Inspect closely for cracks, undercut or overlap of beads, and gouge out or grind flaws where they occur before continuing. It is very important on highly loaded parts, particularly members subject to cyclic or dynamic stresses, to obtain sound repair welds.

The presence of any stress risers on the surface of a part is detrimental to fatigue life and can result in future cracking. Therefore, it is essential that the finished repair be smooth and well blended into the base metal. Repair weld any undercuts, grind off overlapped weld beads and blend out any notches or gouges. The best condition in a repair weld location is provided by grinding the repair smooth and flush with the surface of the base metal. Final grinding direction is to be identical with the direction of applied load on the structure. Refer to the figure.

Manual No. 10500

9 - 24

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

REPAIR WELDING OF BROKEN PARTS All recommendations given for repair of cracks apply to repair of broken parts, with additional corrections. Depending on the size and cross-section of the part, a specific sequence of welding procedures may be required in making the repair. These techniques include back-step welding sequence, block welding sequence, alternating from side to side, welding simultaneously on opposite sides, etc. All of these precautionary measures are intended to minimize shrinkage stresses and subsequent distortion or cracking during welding. The method to follow should be determined after a careful analysis of the situation and by approaching the problem with common sense. Generally a procedure which has proven successful in previous experience could logically be applied in most cases.

Use of doubling plates, stiffeners or other reinforcements to strengthen a member which has cracked in service, must be carefully considered before that repair measure is decided upon. Additional material added for strengthening alters the configuration and geometry of the member, possibly with a pronounced effect on the fatigue life of that structure. Many times, such attempts at strengthening by added plates only serves to “chase the crack someplace else.” The stress flow in the part has been altered, creating a location for stress concentration. Attachments requiring fillet welds across a tension member for example, are poor repair methods. A sound repair weld, carefully made and smoothly blended into the base metal on all sides, is preferable to additional reinforcements. Any application of reinforcements requires careful consideration regarding total overall effect on the structure during service, and should be done only after consulting Bucyrus International, Inc.

August 2007

9 - 25

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

REPAIR WELDING SWING RACK TEETH The following is a suggested method for the repair of cracked or broken swing rack teeth. The repair method should produce satisfactory results and provide a serviceable swing rack, provided the procedure is carefully followed in all details. The welding procedure is essentially the same for the three conditions shown.

PREPARATION 1.

Clean off the swing rack in the area of the tooth to be repaired to remove all traces of grease, oil or dirt. Wash down thoroughly with a solvent cleaner and wipe dry with clean rags.

2.

Grind to completely remove the crack and prepare a groove for welding as shown in the figures.

3.

Dye penetrant test for complete crack removal.

4.

In the case of a broken tooth, grind the fracture surface on the swing rack smooth and round off edges as shown.

Manual No. 10500

9 - 26

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SWING RACK WELDING ELECTRODES 1.

All welding is to be done using oven dry E11018-M low hydrogen electrodes. Connect an electrode drying oven as close as possible to the work area. Set the oven temperature at 300oF. As sealed containers of electrodes are opened, place the entire contents of the container in the oven. Remove no more electrodes than can be consumed in one-half hour. If all electrodes are not used in 1/2 hour, return them to the oven. Discard any electrodes which have been wet.

PREHEAT 1.

Two levels of preheat are required for tooth repair, 250oF minimum for butter welding and 175oF minimum for filling in the groove. Temperatures should be measured with temperature indicating crayons.

2.

Preheat will be difficult to maintain because of the mass of metal in the swing rack to draw the heat away from the repair area. It is therefore recommended to apply heat to a large section of the swing rack to offset this quench effect. A section covering at least 3 teeth on either side of the tooth being repaired should be heated so that the minimum preheat temperature is obtained at the repair location. It is suggested that electrical resistance heaters be applied behind the teeth as shown, if such physical arrangement is possible. If the repair area cannot be heated to the required minimum temperature by this arrangement, supplementary heat must be applied from the tooth side of the swing rack. Electrical resistance heaters can be applied, or heat provided by oxy-propane torches. Adjacent areas of the swing rack should be covered with ‘heavy insulation to avoid beat loss.

August 2007

9 - 27

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

NOTE: Contract services are available for field application of resistance heating equipment.

Suggested source: Stresstech Box 11 Red Wing, MN 55066 (612) 388-7117 3.

During welding, the repair area must be continually checked with temperature indicating crayons to be sure that the minimum temperature is being maintained. Do not weld at temperatures below the specified minimums.

WELDING PROCEDURE 1.

Refer to the previous butter-welding figures. The purpose of the butter weld layer is to provide a buffer between the weld required to fill the groove and the alloy cast steel. This technique is essential in preventing heat affected zone cracking in the cast steel which otherwise is likely to occur due to the shrinkage of the weld as the groove is filled. Butter welding permits the repair weld to be made at the preheat temperatures specified. Much higher temperature would otherwise be required for crack free welding.

2.

Butter welding is done using 1/8 inch diameter E11018-M electrodes at a minimum preheat temperature of 250oF. (See section under WELDING ELECTRODES regarding use of the electrode drying oven.) Horizontal weld beads are applied to completely cover the cavity or surface to be welded. The edges of the butter weld must overlap the adjacent surface about ½ inch. This is to prevent subsequent welding from impinging upon the cast steel.

3.

Before starting the butter weld, position a piece of thin mild steel plate under the bottom end of the tooth. This is to provide a shelf for starting the weld and to avoid irregular weld beads at the bottom which would become stress risers to cause cracking when the tooth is loaded in service.

4.

Apply the butter weld, progressing with horizontal beads from bottom to top. Use care to keep the butter weld layer as smooth and regular as possible. When finished, remove all slag and grind any high spot which could trap slag when welding to fill the groove. In the case of repairing a broken tooth the prepared tooth segment is butter welded separately before positioning for final welding in place.

5.

Filling the groove is done with 1/8 inch or 5/32 inch E11018-M electrodes at a minimum preheat temperature of 175oF. (See section under WELDING ELECTRODES regarding the use of the electrode drying oven.) Weld vertically up using a split layer technique as soon as the groove is wide enough to accommodate 2 or more beads. Refer to the butter-weld figures for the approximate weld bead sequence.

6.

For replacing a tooth segment as shown, it will be necessary to prepare a tooth profile template.

The template must be carefully made to fit the rack teeth as accurately as possible. Use the template to position the tooth segment prior to tack welding. When welding the tooth segment in place alternate welding from side to side to control distortion. Check frequently with the template.

Manual No. 10500

9 - 28

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

7.

When groove welding is finished check carefully for low spots and fill in as required. Grind the weld smooth and flush with the adjacent tooth surfaces. Use the tooth profile template to check grinding of a welded-on tooth segment. Grinding of the radius at the root of the tooth is very important. Avoid any nicks, gouges or grinding marks in a vertical direction. Grind a smooth radius using small diameter (peanut) grinders. Failure to achieve a smooth, notchfree radius may result in future cracking at the root of the tooth.

8.

After the swing rack has cooled to ambient temperature, dye-penetrant test the repaired tooth for soundness.

August 2007

9 - 29

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

WELDING AND CUTTING EQUIPMENT The welding and cutting equipment needed for general repair welding is listed below.

WELDING MACHINES, Arc - 600 ampere (for Welding and Air Arcing) OXY ACETYLENE TORCHES with Gauges - 150' Long Hoses HEATING TORCHES, Butane (for Boom Welding) ARC AIR ATTACHMENTS (for use with 600 Ampere Welding Machines) WELD RODS - E7018, E8018, E11018 - 1/8", 5/32". 3/16", 1/4" C02 - Welding Grade - 45oF Max. Dew Point OXYGEN - Cutting, and Heating ACETYLENE WELD FLUX CHIPPERS - Pneumatic with Chisels and Spare Parts BLOWERS, Ventilating (for Compartment Welding,) GRINDERS, Wheel - Air Powered w/Wheels TARPAULINS - Fireproof (for Boom Welding Shelters) HIGH TEMPERATURE GLOVES CUTTING GOGGLES, Dark SOAPSTONE MARKERS ANTI-SPATTER COMPOUND TEMPILSTIKS - 200o and 400o

STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT The equipment recommended for stress relieving, after repair welding, is listed below.

TEMPERATURE MEASURING EQUIPMENT SPEEDOMAX, “W” Multipoint, Potentiometer Recorder POWER REQUIREMENT - 120 Volts, 60 or 50 Hz. RANGE - 0 to 1500oF CALIBRATION - Chromel-Alumel Thermocouple Wire ACCURACY RATING - 0.3% of Electrical Span CHART SPEED - 2" per Hour THERMOCOUPLE SELECTION - Six (6) Points FLUORESCENT LIGHTING MANUFACTURER - Leeds & Northrup Company THERMOCOUPLE EXTENSION WIRE Manual No. 10500

9 - 30

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DUPLEX WIRES - Chromel-Alumel - Type K - 16 AWG Stranded LENGTH - Total External Resistance for both Wires including Thermocouple not to exceed 2500 Ohms or 410 Feet.

WIRE RESISTANCE - Nominal Resistance, Ohm per Foot at 20oC (66oF) - Chromel - Ohms Alumel - .0683 Ohms.

WIRE INSULATION - each Conductor Enamel, Asbestos (Twisted Pair) Overall Asbestos Braid WIRE CODE -Alumel, Negative Wire (Red); Chromel, Positive Wire (Yellow) OVERALL COLOR - Yellow CATALOG No. 16-59-17 POLARITY DISCONNECT CHROMEL-ALUMEL COMPENSATED CONNECTION JACK Color Code (Yellow) - Catalog No. 040419 PLUG Color Code (Yellow) - Catalog No. 040434 CABLE CLAMP - Catalog No. 072513 ADAPTER - Catalog No. 076794 THERMOCOUPLE ELEMENT CHROMEL-ALUMEL - Type K - Swaged One (1) Inch Stripped CHROMEL POSITIVE WIRE Color Code (None) ALUMEL NEGATIVE WIRE Color Code (Red) CATALOG No. 8784-K-1-3-12"-D 1.

588003 Kaopak Flex Heaters

2.

588004 Kaopak Collector Streamer Type

3.

Kaopak Blankets 3, 5, or 6 Pocket Size as needed for Size Pipe being Stressed Relieved

Thermocouple Assembly, Complete Catalog No. 8784-K-1-3-12"-Q Temperature Indicating Pellets (Tempil° Pellets) Indicating Temperature: 1050°F, 1100°F, 1200°F, and 1250°F. (Several of each temperature)

August 2007

9 - 31

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

WIRE ROPE CARE AND MAINTENANCE STORAGE Reels of wire rope stock may be kept on hand for a considerable length of time. This is particularly true of slow-moving special ropes that may not be disposed of completely for several years.

Consequently, wire rope should be stored in an are that is well-ventilated and stable with regard to temperature and humidity.

Do not store rope in contact with the bare ground or expose it to the elements. Excessive atmospheric vapors will condense moisture on the rope causing corrosion. If exposed to the direct sun, next to a boiler or in similarly warm conditions, the original lubrication will dry out and lose its preservation properties.

Similarly, storage in a dusty or chemical laden environment may coat the surface of the rope with corrosive materials or even deteriorate the fiber core. If it should be necessary to store rope outside, the reel should be set on blocks or raised off the ground, and covered with a waterproof covering.

CHECKING DIAMETER It is critical to check the diameter of the delivered rope BEFORE installation on the machine. This is to ensure that the rope diameter meets the specified requirements for the given machine or equipment. An UNDERSIZE diameter rope will bring about a condition where stresses are exceeding design limitations. This will increase the possibility of injury or machine damage as the chances of breaking the rope will be increased. Use of an OVERSIZE diameter rope will bring about premature wear of that rope. The rope constantly being pinched and compressed in the grooves of the sheaves and drum causes this.

Correct Method for Checking Wire Rope Diameter

When checking it is imperative that the actual rope diameter is measured. This is defined as the diameter of the circumscribing circle, or its largest cross-sectional dimension. To ensure accuracy this measurement should be made with a wire rope caliper to obtain the outside dimension of 2 diametrically opposing strands of the rope. When measuring a rope with an odd number of outer strands, special techniques must be employed. Refer to the manufacturer of the product for accurate information.

Manual No. 10500

9 - 32

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

HANDLING WIRE ROPE When re-reeling wire rope from a horizontally supported reel to a drum, keep in mind that a wire rope has a “memory” to be considered. If at all possible, it is preferable for the rope to travel from the top of the reel to the top of the drum during this process. The same would hold true for the bottom of the reel to the bottom of the drum. Re-reeling in this manner will avoid putting a reverse bend into the rope as it is being installed. If a rope is installed so that a reverse bend is induced, it may cause the rope to become “cranky” and, consequently, more difficult to work with.

There are several methods, which can be used to uncoil rope from a spool or coil. The particular situation, or application, will determine the method used.

One method begins by placing the coil or spool on a vertical unreeling stand. The stand consists of a base with a fixed vertical shaft. On this shaft there is a “swift” or rotating sleeve” consisting of a plate with inclined pins. This is positioned so that the coil or spool may be placed over them allowing the coil or spool to rotate in the horizontal axis. The whole swift and coil then rotate as the rope is pulled off without adding twist or the possibility of kinks. This method is particularly effective when the rope is to be wound on a vertical drum.

The most common, and the easiest uncoiling method is merely to hold one end of the rope while rolling the coil along the ground like a hoop.

NOTE: Avoid unreeling and uncoiling methods that are likely to provide kinks. Such IMPROPER procedures should be strenuously avoided in order to prevent the occurrence of loops. These loops, when pulled taut, will inevitably result in kinks. No matter how a kink develops, it will damage strands and wires, resulting in a kinked section that must be cut out. Proper and careful handling will keep the wire rope free from kinks.

August 2007

9 - 33

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Improper Methods for Uncoiling Wire Rope

SEIZING WIRE ROPE While there are numerous ways to cut wire rope, in every case, certain precautions must be observed. It is critical that before any cut is made proper seizings must be applied on both sides of the location where the cut is to be made. Carelessly or inadequately seized, ends may become distorted and flattened. This will also prevent the strands at the ends from loosening or fraying.

Subsequently, when the rope is installed there may be an uneven load distribution to the strands.

This will create a condition that will significantly shorten the life of the rope.

There are two widely accepted methods of applying a seizing, which are illustrated. The seizing material itself should be soft, or an annealed wire or strand. Seizing wire diameter, and the length of the seize, will be dependant on the diameter of the wire rope. But the length of the seize should never be less than the diameter of the rope in use. Normally, for a preformed rope, one seize on each side of the cut is sufficient. For ropes that are not preformed, a minimum of two seizings on each side is recommended; and these should be spaced six rope diameters apart.

For larger wire ropes: lay one end of the seizing wire in the groove between two strands; wrap the other end tightly in a close helix over a position of the groove using a seizing iron (a round bar 1/2" to 5/8" dia. x 18" long) as shown. Both ends of the seizing wire should be twisted together tightly, and the completed seize should appear as shown. Seizing widths should not be less than the rope diameter.

Manual No. 10500

9 - 34

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

The procedure illustrated below is the second of the two accepted methods for placing seizing on wire rope. This method is normally used on smaller ropes.

END PREPARATIONS/TERMINATIONS There may arise a need for special end preparations in order to compensate for certain applications such as tight drum openings, or other complicated reeving systems. When these situations are encountered a number of basic designs (and combinations) are available to choose from. Whenever possible end preparations should be removed after final installation.

“Beckets” are what is referred to when we discuss a termination utilized to pull the operating rope into place. The rope end must be fastened to a mechanism so that force and motion are transferred efficiently without distortion of the wire rope. End terminations become items of great importance for transferring these forces. Each basic type of termination has its own individual characteristic.

Hence, one type will usually fit the needs of a given installation better than others. It should be noted that not all end terminations will develop the full strength of the wire rope being utilized. To lessen the possibility of error, the wire rope industry has determined terminal efficiencies for various types of end terminations.

August 2007

9 - 35

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Four commonly used beckets are illustrated.

WIRE ROPE CLIPS Wire rope clips are widely used for making end terminations.

Clips are available in two basic designs; the U-BOLT and FIST GRIP. The efficiency of both types is approximately the same.

NOTE: When using U-BOLT clips, extreme care must be exercised to make certain that they are positioned correctly. The important factor is that the U-BOLT clip be applied in order that the “U” section is in contact with the dead end of the rope. Also, the tightening and re-tightening of the nuts must be accomplished as required.

WIRE ROPE CLIP APPLICATION The following is the recommended method of applying U-Bolt clips in order to get the maximum holding power from the installation: 1.

Turn back the specified amount of rope from the thimble. Apply the first clip a distance of one base width from the dead end of the wire rope (U-bolt over the dead end - live end rests in the clip saddle). Tighten nuts diametrically and evenly to recommended torque.

2.

Apply the next clip as near the loop as possible. Snug down the nuts, but do not tighten.

3.

Space additional clips (if required) equally between the first two. Turn on nuts evenly to take up rope slack. Continue to tighten all nuts evenly (on all clips) until recommended torque is reached.

NOTE: Apply the initial load to the strand of rope, and then re-tighten nuts to the recommended torque. This is accomplished because the rope will stretch and be reduced in diameter when loads are applied. Inspect periodically and tighten to recommended torque each time.

Manual No. 10500

9 - 36

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

A termination complying with the above instructions, using the number of clips shown, has approximately an 80% efficiency rating. This rating is based upon the nominal strength of the wire rope. If a pulley is used in place of a thimble where the rope turns back, add one additional clip.

The number of clips shown is based upon using right regular or lang lay wire rope, 6 x 19 class or 6 x 37 class, fiber core or IWRC, IPS or EIP. If Seale construction is to be used for sizes 1 inch and larger, or similar large outer wire type construction in the 6 x 19 class, add one additional clip.

The number of clips shown also applies to right regular lay wire rope, 8 x 19 class, fiber core, IPS, sizes 1-1/2 inch and smaller; and right regular lay wire rope, 18 x 7 class, fiber core, IPS or EIP, size 1-3/4 inch and smaller.

For other classes of wire rope not mentioned, it may be necessary to add additional clips to the number shown. If a greater number of clips are used than shown in the table, the amount of rope turn-back should be increased proportionately. THE ABOVE IS BASED ON THE USE OF CLIPS ON A NEW ROPE. IMPORTANT: Failure to make a termination in accordance with the aforementioned instructions, or failure to periodically check and re-tighten to recommended torque, will cause a reduction in the efficiency rating.

The correct spacing and number of clips is shown above.

August 2007

9 - 37

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

WEDGE SOCKETS One of the more popular field end attachments for wire rope is the wedge socket. Attachment, and the dismantling of this device is both easy and simple.

1.

Inspect the wedge and socket; remove all rough edges/ burrs that might damage the rope.

2.

Welded ends of the rope should be cut off prior to assembly. This will allow the rope strands to distort slightly as they bend sharply around the wedge. If the welded end were not removed the minimal sliding of the strands would be restricted and evidenced further up the rope. This may result in the development of high strands, wavy rope and uneven loading.

3.

Place the socket in an upright position and bring the rope around it in a large, easy to handle loop. Care must be taken to make certain that the live-loaded-side of the rope is in line with the ears.

4.

The dead end of the rope should extend from the socket for a distance of six to nine times the rope diameter. The wedge is now placed in the socket.

5.

Secure the socket and carefully apply a gradually increasing load to the live side of the rope in order to pull the wedge into position. Only tension sufficiently to hold the pieces in place.

6.

After checking alignment increase the load GRADUALLY until the wedge is properly seated.

IMPORTANT: Avoid sudden shock loads.

NOTE: This is the recommended procedure. If variations are made to suit special conditions, they should be carefully evaluated beforehand.

Manual No. 10500

9 - 38

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

INSPECTION OF SHEAVES AND DRUMS Machines should receive periodic inspections, and the results concerning their over-all condition recorded. Such inspections usually include the drum, sheaves, and any other parts that may come into contact with the wire rope. These are considered high wear items. As an additional precaution, any rope-related working parts, particularly those in the areas described below, should be re-inspected prior to the installation of a new wire rope.

Examples of Sheave Groove Conditions

These cross-sections are illustrating three sheave-groove contact areas. “A” is correct, “B” is too tight, and “C” is too loose.

The very first item to be checked when examining sheaves and drums is the condition of the grooves. To accurately check the size, contour and amount of wear, a groove gauge is used. As shown in the figure, the gauge should contact the groove for about 150 degrees of arc when in optimal condition.

There are two types of groove gauges in general use. The two differ by their respective percentage over nominal.

Groove Gauge for New or Re-Worked Sheaves August 2007

9 - 39

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

For new or re-machined grooves, the groove gauge is nominal plus the full oversize percentage.

The gauge carried by most wire rope representatives today is used for worn grooves and is made nominal plus 1/2 the oversize percentage.

This latter gauge is intended to act as a sort of “no-go” gauge. Any sheave with a groove smaller than this must be re-grooved or, in all likelihood, the existing rope will be damaged.

Inspecting for Worn Sheave

These sheave-groove cross-sections represent three wire rope seating conditions: “A” - a new rope in a new groove; “B” - a new rope in a worn groove; and “C” - a worn rope in a worn groove.

BREAKING IN A NEW WIRE ROPE A new wire rope requires careful installation. Adherence to the previously covered procedures is highly recommended. After the rope has been installed, and the ends secured in the applicable manner, the mechanisms should be started carefully and then permitted to run through a complete cycle of operation at greatly reduced speed. During this trial operation, a very close watch should be kept on all working parts such as sheaves, drums and rollers to ensure the rope runs freely. Be vigilant to ensure there are no obstructions as it makes its way through the system. If no problems are apparent, the next step should include several run-throughs of the normal operational cycle under light load conditions at a reduced speed. This procedure allows the component parts of the new rope to gradually adjust to the actual operating conditions.

Manual No. 10500

9 - 40

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

INSPECTION DATA It is essential to maintain a well-planned program of periodic inspection. Frequently, there are statutory and/or regulatory agencies that incur additional requirements that must be adhered to.

Refer to the suggested procedures that follow.

Abrasion - Bending and crushing represent the ABC’s of wire rope abuse. It is the primary goal of a good inspection practice to uncover such conditions early enough that corrections may be made, or ropes replaced safely with minimum effort. When any sudden degradation indicates a loss of original rope strength, a timely decision is required as to allowing the rope to remain in service.

Such a decision can only be made by an experienced inspector. And his/her determination should be based on: 1.

Details of the equipment’s operation.

2.

Frequency of inspection.

3.

Maintenance history.

4.

Consequences of failure.

5.

Historical records of similar equipment.

To ensure sufficient information can be obtained, the following pages contain guidelines that should be adhered to.

August 2007

9 - 41

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

GUIDELINE TO INSPECTIONS AND REPORTS (Equipment, Wire Rope and Wire Rope Slings) 1.

Maintain all inspection records and reports for the length of time deemed appropriate.

2.

Prior to daily use, the following procedure should be followed.

3.

4.

a.

Check all equipment functions.

b.

Lower load blocks and check hooks for deformation or cracks.

c.

During lowering procedure and the following raising cycle, observe the rope and the reeving. Particular notice should be paid to kinking, twisting or other deformities. Drum winding conditions should also be noted.

d.

Check wire rope and slings for visual signs of any unsafe condition, including broken wires, excessive wear, kinking or twisting, and severe corrosion. Particular attention should be given to any new damage during operation.

Periodic inspections consistent with applicable standards are recommended with a signed report by an authorized and competent inspector. These Periodic Reports should include inspection of the following: a.

All functional operating mechanisms for excessive wear of components, brake system parts and lubrication.

b.

Limit switches.

c.

Crane hooks for excessive throat opening or twisting, along with a visual for cracks.

d.

Wire rope and reeving for conditions causing possible removal.

e.

Wire rope slings for excessive wear, broken wires, kinking, twisting and mechanical abuse.

f.

All end connections such as hooks, shackles, turnbuckles, plate clamps, sockets, etc. for excessive wear, and distortion.

At least one annual inspection with signed report must be made for the following: a.

Crane hook for cracks.

b.

Hoist drum for wear or cracks.

c.

Structural members for cracks, corrosion and distortion.

d.

For loose structural connections such as bolts, rivets, and weldments.

Manual No. 10500

9 - 42

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Wire Rope Inspection Criteria The following is a fairly comprehensive listing of critical inspection factors. It is not, however, presented as a substitute for an experienced inspector. It is rather a user’s guide to the accepted standards by which ropes must be judged.

Abrasion Rope abrades when it moves through an abrasive medium or over drums and sheaves. Most standards require that rope is to be removed if the outer wire wear exceeds 1/3 of the original outer wire diameter. This is not easy to determine and discovery relies upon the experience gained by the inspector in measuring wire diameters of discarded ropes.

Reduction in Rope Diameter: Any marked reduction in rope diameter indicates degradation. Such reduction may be attributed to: •

Excessive external abrasion.

•

Internal or external corrosion.

•

Loosening or tightening of rope lay.

•

Inner wire breakage.

•

Ironing or milking of strands.

In the past, the determination on the continued service of a rope was largely dependent on the rope’s diameter at the time of inspection. Recently this practice has undergone significant modification.

Previously, a decrease in the rope’s diameter was compared with published standards of minimum diameters. The amount of change in diameter is, of course, useful in assessing a rope’s condition.

But, comparing this figure with a fixed set of values can be misleading. These long-accepted minimums are not, in themselves, of any serious significance since they do not take into account such factors as: •

Variations in compressibility between IWRC and Fiber Core.

•

Differences in the amount of reduction in diameter from abrasive wear, or from core compression, or a combination of both.

•

The actual original diameter of the rope rather than its nominal value.

As a matter of fact, all ropes will show a significant reduction in diameter when a load is applied.

Therefore, a rope manufactured close to its nominal size may, when it is subjected to loading, be reduced to a smaller diameter that stipulated in the minimum diameter table. Yet, under these circumstances, the rope would be declared unsafe although it may, in actuality, be safe.

August 2007

9 - 43

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

As an example of the possible error at the other extreme, we can take the case of a rope manufactured near the upper limits of allowable size. If the diameter has reached a reduction to nominal or slightly below that, the tables would show this rope to be safe. But it should, perhaps, be removed.

Evaluations of the rope diameter are first predicated on a comparison of the original diameter when NEW and subjected to a KNOWN load with the current reading under comparable circumstances.

Periodically, throughout the life of the rope, the actual diameter should be recorded while the rope is under equivalent loading and in the same operation section. This procedure, if followed carefully, reveals a common rope characteristic: after an initial reduction, the diameter soon stabilizes. Later, there will be a continuous, albeit small, decrease in diameter throughout its life.

Core deterioration, when it occurs, is revealed by a more rapid reduction in diameter and is time for removal.

Deciding whether or not a rope is safe is not always a simple matter. A number of different but interrelated conditions must be evaluated. It would be dangerously unwise for an inspector to declare a rope safe for continued service simply because its diameter had not reached the minimum arbitrarily established in a table, while at the same time, other observations lead to an opposite conclusion.

Because criteria for removal are varied, and because diameter in itself, is a vague criterion, the table of minimum diameters has been deliberately omitted from this publication.

Rope Stretch All ropes will stretch when loads are initially applied.

Wire Rope Stretch vs Rope Life

Manual No. 10500

9 - 44

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

As a rope degrades from wear, fatigue, etc. (excluding accidental damage), continued application of a load of constant magnitude will produce varying amounts of rope stretch. A “stretch” curve plotted for stretch vs. time displays three distinct phases: PHASE 1. - Initial stretch, during the early (beginning) period of rope service, caused by the rope adjustments to operating conditions (constructional stretch).

PHASE 2. - Following break-in, there is a long period-the greatest part of the rope’s service lifeduring which a slight increase in stretch will take place over an extended time. This results from normal wear, fatigue, etc. On the plotted curve stretch vs. time-this portion would almost be a horizontal straight line inclined slightly upward from its initial level.

PHASE 3. - Thereafter, the stretch occurs at a quicker rate. This means that the rope has reached the point of rapid degradation; a result of prolonged subjection to abrasive wear, fatigue, etc. This second upturn of the curve is a warning indicating that the rope should soon be removed.

Corrosion Corrosion, while difficult to evaluate, is a more serious cause of degradation than abrasion. Usually, it signifies a lack of lubrication. Corrosion will often occur internally before there is any visible external evidence on the rope surface. Pitting of wires is a cause for immediate rope removal. Not only does it attack the metal wires, but also prevents the rope’s component parts from moving smoothly as it is flexed. Usually, a slight discoloration because of rust merely indicates a need for lubrication.

Severe rusting on the other hand, leads to premature fatigue failures in the wires necessitating the rope’s immediate removal from service. When a rope shows more than one wire failure adjacent to a terminal fitting, it should be removed immediately. To retard corrosive deterioration, the rope should be kept well lubricated. In situations where extreme corrosive action can occur, it may be necessary to use galvanized wire rope.

Kinks Kinks are permanent distortions caused by loops drawn too tightly. Ropes with kinks must be removed from service.

Bird Caging Bird caging results from torsional imbalance that comes about due to mistreatment such as sudden stops, rope being pulled through excessively tight sheaves, or wound on too small a drum for a given rope diameter. This is cause for rope replacement unless the affected section can be removed.

Localized Conditions Careful attention must be paid to wear at the equalizing sheaves. During normal operation this wear is not visible. Excessive vibration, or whip can cause abrasion and/or fatigue. Drum crossover and flange point areas must be carefully evaluated. All end fittings, to include splices, should be examined for worn or broken wires, loose or damaged strands, cracked fittings and worn or distorted thimbles and tucks of strands.

August 2007

9 - 45

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Heat Damage After a fire, or exposure to elevated temperatures, there may be discoloration, or an apparent loss of internal lubrication. Fiber core ropes are particularly vulnerable. Under these circumstances the rope should be replaced.

Protruding Core If, for any cause, the rope core protrudes from an opening between the strands, the rope is unfit for service and should be removed.

Damaged End Attachments Cracked, bent, or broken end fittings must be eliminated. The cause should be sought out and corrected. In the case of bent hooks, the throat openings must be measured at the narrowest point and should not exceed 15% over normal. Twisting to be no greater than 10 degrees.

Peening Continuous pounding is one of the causing of peening. The rope can strike against an object, such as some structural part of the machine, or it beats against a roller, or itself. Often this can be avoided by placing protectors between the rope and the object it is striking. Another common cause of peening is continuous working under high loads over a sheave or drum. Where peening action cannot be controlled it is necessary to have more frequent inspections and be prepared for premature rope replacement.

Scrubbing Scrubbing refers to the displacement of wires and strands as a result of rubbing against itself or another object. This, in turn, causes wear and displacement of wires and strands along one side of the rope. Corrective measures should be taken as soon as this condition is observed.

Fatigue Fracture Wires that break with square ends and show little surface wear have usually failed as a result of fatigue. Such fractures can occur on the crown of the strands, or in the valleys between the strands where adjacent strand contact exists. In almost all cases, these failures are related to bending stresses or vibration.

If diameter of the sheaves, rollers or drum cannot be increased, a more flexible rope should be used. But, if the rope in use is already of maximum flexibility, the only remaining course that will help prolong its service life is to move the rope through the system by cutting off the dead end. By moving the rope through the system, the fatigued sections are moved to less fatiguing areas of the reeving.

Manual No. 10500

9 - 46

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Broken Wires The number of broken wires on the outside of a wire rope are an index of 1) its general condition, and 2) whether or not it must be considered for replacement. Frequent inspection will help determine the elapsed time between breaks.

On occasion, a single wire will break shortly after installation. However, if no other wires break at that time, there is no need for concern. On the other hand, should more wires break, the cause should be immediately investigated.

On any application, valley breaks (where the wire fractures between strands) should be given serious attention. When two or more such fractures are found, the rope should be replaced immediately.

NOTE: No valley breaks are permitted in elevator ropes.

Once broken wires appear within a rope operating under normal conditions many more will show up within a relatively short period. Attempting to squeeze the last measure of service from a rope that is beyond the allowable number of broken wires, will create an intolerably hazardous situation.

A wire broken under a tensile load that has exceeded its strength is recognized by the “cup and cone” configuration at the fracture point (Rope A). The necking down of the wire at this point shows that failure occurred while the wire retained its ductility.

Shear-tensile fracture (Rope B) occurs in wire subjected to a combination of transverse and axial loads. Fatigue breaks are usually characterized by squared-off ends perpendicular to the wire either straight across or Z-shaped (Ropes C and D).

Examples of Broken Wires

Electric Arc Rope that has either been in contact with a live power line or been used as “ground” in an electric welding circuit, will have wires that are fused, discolored and/or annealed, and must be removed.

August 2007

9 - 47

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SEALS Oil and grease seals are critical to machine availability. Careless storage, handling, removal and installation can contribute to reduced service life of machine components and higher cost of operation.

Seals come in all sizes, shapes and materials. Wherever possible, Bucyrus has specified the use of the most common solid molded element type seals for use on Bucyrus machines.

All types of oil and grease seals have a limited shelf life. Store seals in a cool, dry location protected from direct sunlight. Keep in sealed containers or packaging until ready to use. Seals keep lubricant clean and contained in their respective housings, bearings or passageways. Always handle seals carefully to prevent exposure to nicks, bends or pinching. Do not wash them in solvents as some solvents may destroy properties of the seal.

SEAL INSTALLATION Solid molded seals are installed at time of manufacture with interference fit between seal and bore.

This method of installation creates an oil tight fit. When partial disassembly of a machine component involves removal of solid molded seal before reassembly inspect it carefully for cuts, nicks or cracking. Replace with a split seal if complete disassembly is inconvenient or with a new solid molded seal. Split seals, especially those made with interference fit at butt, also install with compression at the joint. Split seals used as substitutes for solid molded seals should be replaced at next major component overhaul.

CAUTION:

Do not cut a solid seal and reuse for a split seal.

Check shaft for scratches, burrs or surface roughness that may cut or score the lip of seal. Be aware of sharp threads keyways or splines over which the seal must travel. Protect seal lip by covering these interferences with tape.

Inspect the bore area for surface roughness, dirt or burrs. Remove and clean as required. The bore and shaft need .0625 in. (1.588 mm) chamfer to accommodate a leak free installation. If shaft or bore do not have chamfer, carefully provide one by trimming inside flange of seal.

Determine the correct direction for lip installation and start the seal into the cavity by finger pressure, then tap evenly all around until seated or flush with the housing face. (Tap only on outer edge of seal with hammer on wood block.)

A double seal, installed back to back can be used to retain grease or oil plus be more effective in preventing egress of contaminants.

Manual No. 10500

9 - 48

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Follow this installation procedure for split seals: •

Remove garter spring and separate at the hook and eye.

•

Open the seal, ends sideways, for installation on shaft as shown by moving the butt ends along the axis of the seal.

•

Lubricate spring and install around shaft. Connect ends and insert spring in lip groove with spring ends 90o away from butt joint.

Split Seal Installation

CAUTION:

Do not trim or cut ends of split seals or pull ends apart. This will destroy seal.

Gearcase seals used for all oil tight gearcase assemblies require surface preparation on one side of case flanges with a 1/100 inch thick Form-a-Gasket #3 (Permatex Co.) coating. If using a manila paper gasket always replace with a new one, never reuse. Apply Form-a-Gasket #3 to both sides of the paper gasket. Tighten gearcase cover bolts until seal material “squeezes out” at joint.

When surface finishes range up to 250 micro-inches, a compression type gasket seal is recommended. This material (VELLUMOID) available in standard thickness inches (mm) 1/64 (0.397), 1/32 (0.794), 1/16 (0.063), and 1/8 (0.125) should also be installed with Permatex applied to both sides.

August 2007

9 - 49

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

GEARCASE SEALING Use the information in the following image to properly seal gearcase halves and /or covers.

NOTE:

Before applying any sealants or gaskets, clean all mating surfaces of all dirt, rust and scale.

Manual No. 10500

9 - 50

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

DUO-CONE SEAL INSTALLATION This section covers the basic Duo-Cone Seal installation methods and provides helpful tips and inspection dimensions in order to verify an accurate assembly. Installation tools are available to facilitate a fast, accurate assembly process.

CAUTION:

Proper care and handling practices must be followed when installing Duo-Cone Seals to ensure maximum life and the positive sealing protection afforded by these precision components. The Duo-Cone Seal group is specially packaged to protect the rings during shipment. Similar care must be exercised during handling and the installation process. Improper care and installation can result in immediate leakage or reduced service life.

To obtain maximum performance the seals must be installed accurately to ensure uniform loading at the mating faces and a stable running position. Misalignment of the seal rings during assembly can produce nonuniform loading and wobbling of the seals in their housings. This may result in leakage due to scoring, pumping of debris past the toric rings or breakage of the metal seal rings.

INSTALLATION Seal rings, torics, and housings must be clean and free of any oil film, dust, or foreign matter. Use a solvent that evaporates quickly, leaves no residue, and is compatible with the rubber toric rings.

Some recommended solvents are isopropyl alcohol and naptha.

CAUTION:

Solvents may be toxic or flammable. Adequate ventilation must be provided to minimize fire and health hazards caused by using solvents for cleaning. Use away from sparks, heat or flame to prevent fire or explosion. Follow the solvent manufacturer’s instructions.

Wipe the Toric ring and housings with a solvent-soaked lint free cloth or paper towel. After being wiped clean, the torics should be installed on the metal seal rings so that they rest in the radius on the tail of the metal ring as shown above.

August 2007

9 - 51

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Ensure that the toric rings are not twisted by inspecting the mold flash line on the outside diameter of the toric for true circumferential tracking around the seal. The toric ring may twist if it is not completely wet during installation, or if there are burrs or fins on the retaining lip of the housing.

Twisted toric rings will cause nonuniform face load that can result in leakage of lubricant and pumping of debris past the toric ring.

If a twist is apparent, it can be eliminated by gently pulling a section of the toric ring rapidly away from the metal seal ring and letting it “snap” back as shown below. Repeating this in several places around the toric ring will eliminate any twist.

After the toric rings are installed on the seal rings, the seal assembly is ready to be installed into the retainer housing. It is recommended to use installation tools available to ensure accurate assembly.

These installation tools are designed to locate the toric ring and slide it past the housing retaining lip. A second locator is designed into larger seal installation tools to insure the proper seal stand-out height. See below.

Installation Tool

NOTE: Improper seal assembly installation into the retainer housing can result in poor seal performance due to nonuniform loading. Duo-Cone Seal installation tools help insure precise installation.

Manual No. 10500

9 - 52

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Place the installation tool around the seal with toric ring. Lower the seal ring into a container of solvent until the toric ring is completely lubricated.

NOTE: It is essential to lubricate the toric ring with an approved cleaning solution so that the toric will slip past the housing retaining lip and seal uniformly in the housing nose radius. Insufficient lubrication can cause poor seal performance due to nonuniform loading (e.g. twisted toric rings or cocked seals).

NOTE: Use of solvents other than those recommended can leave a residue on the toric or ramps and allow the toric to slide rather than roll in the seat. This can also result in poor seal performance due to nonuniform loading.

After dipping the seal assembly into the solvent, shake the excess solvent from the seal assembly and immediately “pop” the toric ring into the housing with a even and firm push of the installation tool. Refer to the figure at left.

Remove the installation tool and check the seal stand-out height in at least four places (90° apart) around the circumference of the seal ring to verify an accurate installation. If the seal ring does not meet the height specification, inspect the toric ring for twists or obvious bulges. For specifications, refer to the table SEAL RING STAND-OUT HEIGHT later in this section.

The seal ring can be adjusted by gently pushing the toric ring into position by hand or by using a fabricated adjustment hook. If the seal can not be adjusted to meet the stand-out height specification, remove the seal and repeat the procedure.

August 2007

9 - 53

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

NOTES: •

If small adjustments are necessary, DO NOT push directly on the seal ring, use the installation tool to PUSH DOWN or the adjustment tool to PULL UP.

•

A thin film of light oil should be applied to the seal faces prior to assembly. Use an applicator, a disposable tissue or a clean finger to distribute the oil evenly. Be careful not to get any oil on the rubber toric rings.

•

Be sure there is no visible debris on either of the seal faces - even a small piece of lint can hold the seal faces apart and cause leakage.

After successful installation, wait one minute for the solvent to dry before assembling the two seal halves in the final loaded position. This delay is to allow any excess solvent to dry so that the torics roll, rather than slide, in the housing as the faceload is increased. If the torics slide, this can produce a nonuniform load that can result in poor seal performance.

After the unit to be sealed is assembled, a post-assembly leakage test can be performed to insure the seal is properly installed. A vacuum check is recommended rather than a pressure check as vacuum checks are more sensitive. Many users find this is an easy check to combine with a vacuum fill technique for the lubricant. It is recommended that the compartment be filled to the correct level with lubricant and then rotated slowly several revolutions to seat the seals. A vacuum test will catch gross seal damage such as broken seal rings or cut torics that may have been caused in the last phases of assembly. The Duo-Cone Seal is not designed to seal air, so some leakage can be expected using such a procedure.

Following these guidelines and recommendations should ensure optimum performance from your Duo-Cone Seals.

Examples of Incorrect Installations and Assemblies

Manual No. 10500

9 - 54

August 2007

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

SEAL RING STAND-OUT-HEIGHT All values are in Inches (mm)

Diameter Toric Cross Section

Assembled Seal Ring Outside Diameter

Height Dimension (see Note 2)

0.373 (9.47) 0.373 (9.47) 0.245 (6.22) 0.373 (9.47) 0.373 (9.47) 0.245 (6.22) 0.373 (9.47) 0.245 (6.22) 0.245 ((6.22) 0.50 (12.70) 0.50 (12.70) 0.50 (12.70) 0.50 (12.70) 0.50 (12.70) 0.50 (12.70) 0.50 (12.70) 0.50 (12.70) 0.50 (12.70) 0.50 (12.70) 0.50 (12.70)

3.25 ( 82.55) 3.63 ( 92.08) 4.13 (104.78) 4.31 (109.52) 4.69 (119.08) 5.56 (141.22) 5.75 (146.05) 6.18 (156.97) 6.62 (168.15) 6.76 (171.70) 7.33 (191.26) 8.28 (210.31) 9.90 (251.46) 10.22 (259.59) 11.52 (292.86) 13.64 (346.46) 15.53 (394.46) 18.00 (457.20) 21.00 (533.40) 27.56 (700.00)

0.35± .02 (8.8 ± 0.6) 0.35 ± .02 (8.8 ± 0.6) 0.30 ± .02 (7.7 ± 0.6) 0.35 ± .02 (8.8 ± 0.6) 0.35 ± .02 (8.8 ± 0.6) 0.30 ± .02 (7.7 ± 0.6) 0.35 ± .02 (8.8 ± 0.6) 0.30 ± .02 (7.7 ± 0.6) 0.30 ± .02 (7.7 ± 0.6) See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 0.51 ± .05 (14.5 ± 1.2) 0.51 ± .05 (14.5 ± 1.2)

NOTES: 1.

0.45 ± .04 in (11.50 ± 1.0 mm) for 15° ramp angle seals and 0.57 ± .04 in (14.6 ± 0.9 mm) for 8° ramp angle seals.

2.

Height is 0.039 inch (0 mm) maximum variation per seal ring.

August 2007

9 - 55

Manual No. 10500

BI617098

Bucyrus International, Inc. 495HD Electric Mining Shovel

Manual No. 10500

9 - 56

August 2007