SHE73 Lubricación

Bucyrus International, Inc.
495HR 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. 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 ensure 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: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.
Jul. 2009 3–3 Manual No. 10732

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 greased 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 @ 40°C.
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.
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.
Manual No. 10732 3–4 Jul. 2009

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.
Motor Regreasing Interval Drive End Grease Non-Drive End Grease

Amount Grams (oz.) Amount Grams (oz.)
Hoist motor 3000 operating hours or every 6 months 88 (3.1) 140 (5.0)
Propel motor 3000 operating hours or every 6 months 54 (1.9) 94 (3.3)
Crowd motor 3000 operating hours or every 6 months 54 (1.9) 94 (3.3)
Swing motor 1500 operating hours or every 3 months 54 (1.9) 80 (2.8)
NOTES:
• It is critical that the drainpipe not be allowed to become plugged with caked or
contaminated grease. If it does, then the pipe must be cleared.
• 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.
• Bucyrus part number 59100651 is a 14 ounce cartridge of Mobilith SHC100 grease.
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 the petroleum supplier of the following information to assist 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.
Jul. 2009 3–5 Manual No. 10732

• 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. 10732 3–6 Jul. 2009

OIL FILL CAPACITIES

TYPES OF LUBRICANTS AND CAPACITIES GUIDELINES
NOTE: Use the chart below as a guideline. Fill to the proper level as determined by the dipstick
or oil sensor.
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 (horizontal) 2-cases EGL 190
Propel, planetary (angled 10°) 2-cases EGL 222
Swing, planetary 2-cases EGL 172
Hoist, planetary case 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 Enclosed Gearcase Lubricant
NOTE: 1 drum = 55 gallons = 208 liters
Jul. 2009 3–7 Manual No. 10732

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!
DANGER:STORED ENERGY! Automatic lubrication systems operate under

pressure. Before opening any lube supply line, relieve the system
and that line in particular, of any residual pressure.
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 theses record there
will be no adequate date 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. 10732 3–8 Jul. 2009

LUBE ROOM
The lubrication room is located at the left front corner of the machinery house. The lube room can
be accessed by external walkways. The lube room contains the pumps, tanks, transducers and
the basic components associated with the automatic lubrication system of the machine.
Figure 3-1: Lubrication Room Details
Jul. 2009 3–9 Manual No. 10732

LUBE RESERVOIR FILL / OVERFLOW PLUMBING
The lube reservoir fill/overflow plumbing is located in the support structure directly below the lube
room at the front, left side of the machine. Lubricants can be added at this location. The overflow
connections are also located here. DO NOT plug the overflow connections.
Figure 3-2: Lube Reservoir Fill / Overflow Plumbing
Manual No. 10732 3 – 10 Jul. 2009

AUTO LUBE CONTROL PANEL

The automatic lubrication control panel is mounted on the inboard most wall of the lubrication
room. The panel provides the switches and override functions required to activate, reset and
override the automatic functions.
POWER ON Allows electrical power to energize the system.

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 Energizes the system for normal operation.
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.
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 1/2 hour. Bearings and bushings should be carefully watched and
force lubricated until they run cool if evidence of heat buildup 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.
Jul. 2009 3 – 11 Manual No. 10732

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.
For gearcases with the input shaft in a horizontal position, check the propel gearcase oil level
using the dipstick located at the input shaft housing. Gearcase capacity is 95 gallons (360 liters)
with the input shaft in a horizontal position.
For gearcases with the input shaft rotated 10° from horizontal, check the propel gearcase oil level
using the dipstick located at the input shaft housing. Gearcase capacity is 111 gallons (420
liters) with the input shaft rotated 10° from horizontal.
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.
Manual No. 10732 3 – 12 Jul. 2009

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 5157 part 3: CLP 220

ISO viscosity to DIN 51519: ISO - VG 220
min. 199 mm2/s (cSt)
Kinematic viscosity at 40° C:
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:
• All values are Parts per Million.
• Particle count may be higher during the initial run-in period.
• The oil should be changed when any element value exceeds normal levels.
• Maintain an analysis record using the gearcase serial number and machine operating
hours.
LUBRICANT CHANGE CYCLE

For all machinery motions - Hoist, Crowd, Swing & Propel - the gearcase lubricant should
be first changed after approx. 500 machine operating hours.
Thereafter, the lubricant should then be changed every 6,000 hours or 12 months,
whichever comes first. Flush the gearcase prior to refilling with new oil.
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).
Jul. 2009 3 – 13 Manual No. 10732

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. 10732 3 – 14 Jul. 2009

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.
Jul. 2009 3 – 15 Manual No. 10732

HOIST OIL COOLER

The hoist gearcase temperature is maintained by recirculating lubricating oil through a gearcase
oil cooler.
The gearcase cooler is located beneath the revolving frame, on the left side of the machine, just
behind the hoist machinery. It is supported by a set of beams bolted to the bottom of the
revolving frame.
Should the cooler assembly require removal or replacement:
1. Drain any fluid from the cooler, oil pump and lines between the cooler and the hoist
gearcase.
2. Shut off the valves and disconnect the fluid lines at the oil pump and at the oil filter.
3. Support the cooler and support beam assembly with a jack(s) beneath the base of the
cooler.
DANGER:DO NOT PROCEED UNTIL THE COOLER AND SUPPORT ASSEMBLY

IS FULLY SUPPORTED. The weight of the cooler assembly and
support beams is approximately 2870 Lbs.
Manual No. 10732 3 – 16 Jul. 2009

4. With the supports and the cooler fully supported, remove the 0.75 inch capscrews
(16 places) that fasten the 4 vertical posts of the supports to 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.
The cooler pump and pump gearcase can be serviced without removal of the cooler or support
structure. The filter assembly is in the output line at the rear of the cooler assembly. The filter
cartridge can be replaced by removing the screws and cover at the top of the filter canister.
The relief pump is factory set at 150 PSI for protection of the pump and should not be changed.
The cooler relief valve is factory set at 100 PSI for protection of the cooler core and should not be
changed. The 51 PSI relief valve built into the filter downstream of the cooler is for the protection
of the filter element. The check valve downstream of the filter is intended only as a means of
preventing backflow from the gearcase when the filter element is being serviced.
The plumbing on the gearcase has varying orifices that are not adjustable. Based on the
temperature/viscosity of the oil in the system, the operating pressure will vary considerably from
cold start to fully stabilized conditions. The operating pressure may not be the same between
different sized gearcases and may vary somewhat between individual units. Normal operating
conditions will be acceptable for a pressure range of 20 PSI to 150 PSI without causing a trip
condition.
Jul. 2009 3 – 17 Manual No. 10732

Figure 3-3: Hoist Oil Cooler Schematic
Manual No. 10732 3 – 18 Jul. 2009

FILTER ELEMENT CLEANING

The oil filter for the hoist planetary gearcase oil cooler has a removable, wire mesh filter element
that can be cleaned and reused several times. Use the following method:
1. Clean any coarse dirt from the pressure side of the element with normal cleaning solvents
and a smooth bristled brush (not a wire brush). This process can be done under a jet-
stream, not a bath, to help prevent the removed particles from reaching the clean side of
the element.
2. After cleaning, use compressed air to blow through the element from the clean side.
NOTE: Filter elements which are filtered from inside to outside must use a dirt pan as shown in
the figure.
3. Next dip the cleaned element in cleaning fluid to pick up any remaining dirt particles. Use
compressed air to blow out the element as in step 2 above.
4. Repeat the above steps until all dirt particles have been removed from the filter element.
NOTES:
• Handle the mesh of the element carefully to avoid damage through improper handling.
• The filter element cannot be 100% cleaned. Therefore, the element should be cleaned a
maximum of 3 times then discarded.
• Filter seals should be inspected and replaced as required during filter cleaning and
maintenance.
Jul. 2009 3 – 19 Manual No. 10732

HOIST ROPE ROLLERS LUBRICATION
The hoist rope rollers are located above and in front of the hoist drum, centered between the lube
room and the utility room. The rollers are supported with bearing blocks, which are lubricated
through the automatic lube system. Check for proper lubrication during daily inspection.
Manual No. 10732 3 – 20 Jul. 2009

OIL PUMP
The heart of the power unit is the hydraulic pump. It is self-lubricating. Preventive maintenance is
limited to keeping the system fluid clean. This is done by changing the filters frequently. The
recommendations listed below are a minimum requirement.
All return line filters and pressure filters should be changed a minimum of two times per year or,
upon the visual or electrical indicator signaling otherwise.
The suction strainer (immersed below the oil level in the reservoir) should be cleaned once a
year or every 4000 operating hours. The suction strainer should be removed from the reservoir
and can be cleaned with compressed air, blowing from the inside out. If there are holes in the
mesh or if there is mechanical damage, the strainer should be replaced. It is especially important
that the suction or inlet piping and fittings be tight and in good condition to prevent air from being
drawn into the pump.
The reservoir air breather should be changed or cleaned once a year or every 4000 hours. The
air breather filters all air drawn into the reservoir.
IMPORTANT! Failure to change or clean this filter can result in pump failure.
The electric motor requires very little attention when kept clean and dry.
Jul. 2009 3 – 21 Manual No. 10732

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 an oil
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 lube system “B-1”. The bearings of the
crowd drum, along with the shafts of the crowd reduction system are lubricated by grease from
lube system “C-1”.
Manual No. 10732 3 – 22 Jul. 2009

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.
A filter breather is provided on each planetary gearcase to allow air entry to equalize pressure
differentials created by the warming and cooling of the gearcase. The filter breather allows
moisture to escape and prevents contaminants from entering.
The swing pinions and lower swing shaft bearings are lubricated with open gear lubricant from
System “B-1”
Jul. 2009 3 – 23 Manual No. 10732

AIR COMPRESSOR LUBRICATION

The air compressor supplied with the machine has very specific lubrication needs. For the details
of servicing, refer to the manufacturer’s instructions and the specific lubricant recommendations
made later in this section. Also refer to Section 7 - COMPRESSED AIR SYSTEM in this manual.
Manual No. 10732 3 – 24 Jul. 2009

CROWD ROPE TAKE-UP MECHANISM LUBRICATION
Whenever the hydraulic motor adapter is installed in the crowd rope take-up mechanism to
tension the crowd rope, fresh OGL lubricant should be applied to the assembly. Refer to Section
5 - CROWD ROPE TIGHTENING in this manual.
1. Hoist the dipper until the dipper handle is horizontal, parallel to the ground. 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. Refill the crowd rope worm gear housing with OGL, if required. (Total capacity is
approximately 3.0 gallons.)
• Add, at the least a small amount of OGL through all four of the lube fittings in the crowd
rope worm gear housing, to lubricate friction surfaces adjacent to those fittings.
• Look for OGL to bleed from the relief valve fitting in the side of the worm gear housing,
when lubricant capacity of the housing is reached.
• Pump a small amount of OGL through the fitting on the half-sheave clevis pin.
NOTE: During initial assembly, prior to shipping, grease lubricant is applied to all friction
surfaces of the assembly. Traces of grease lubricant will be visible during initial
maintenance, but for all lubrication procedures in the field, use Open Gear Lubricant
(OGL) – not grease.
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.
Jul. 2009 3 – 25 Manual No. 10732
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 from
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 approximately every 3 months or 1250 hours of machine operation.
Manual No. 10732 3 – 26 Jul. 2009

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 0.08 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: 3,500 PSI
RECOMMENDED Operating Pressure: 2,500 PSI
MINIMUM Operating Pressure: 1,850 PSI
MAXIMUM Recharge Pressure: 600 PSI
CAUTION: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. Loosen locknut.
2. Turn adjusting screw until there is a small gap at the top of the stem.
3. Orient the adjusting screw so that the opening is toward the front of the injector.
4. Tighten the locknut.
Jul. 2009 3 – 27 Manual No. 10732

To reduce an injector’s output:
1. Loosen locknut.
2. Turn adjusting screw clockwise (CW) until desired discharge rate is obtained. This forces
the stem into the body, retarding the stem’s movement.
3. Set the locknut.
CAUTION:Do not turn adjusting screw 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 screw 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.
Manual No. 10732 3 – 28 Jul. 2009

SL-1 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
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.
Jul. 2009 3 – 29 Manual No. 10732

STAGE 3
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
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.
NOTE: The injectors may be mounted individually, or grouped in a manifold at one location.
Manual No. 10732 3 – 30 Jul. 2009

INJECTOR ADVANTAGES
AIR COMPRESSOR LUBRICANT

Quin-Cip lubricant has proven under extensive testing to minimize friction and wear, limit
lubricant carryover, and reduce carbon and varnish deposits. It will support the performance
characteristics and life designed into all Quincy compressors and is highly recommended.
Jul. 2009 3 – 31 Manual No. 10732

LUBRICANT RECOMMENDATIONS
Use Quin-Cip lubricant. The lubricant must have a pour point at least 15°F lower than the
minimum expected ambient temperature.
Ambient Lubrication SAE Viscosity ISO Viscosity Period (Hrs)

Temperature
0º to 32ºF Quin-Cip SAE 10W ISO 32 1000 hrs*
* Change lubricant more frequently in harsher environments.
* Change lubricant and filter every 500 Hrs if using any other lubricant than Quin-Cip.
NOTES:
• Replace the break-in lubricant after 100 hours of operation or 1 month (whichever comes
first). Use Quin-Cip lubricant. To order, see parts book for this machine.
• For additional information, refer to the Vendor supplied manual provided. For additional
questions, please contact either the Vendor or Bucyrus Service.
• These performance requirements are benchmarks and not a specification. Therefore,
meeting these limits as described above does not relieve the supplier of the responsibility
associated with brand name products.
MPO - MULTIPURPOSE OIL

SCOPE
Lubricant performance requirements for Multi-Purpose Oil.
APPLICATION
The addition of a lubricant to the compressed air system (not for screw-type air compressor
systems - see ACSL), hand oil cans, etc.
GENERAL REQUIREMENTS
• Must be fluid at temperature applied.
• Should contain rust inhibitor.
• Motor oil - API service classification “MS”.
VISCOSITY RECOMMENDATIONS
• Air Line Lubricant
Ambient Temperature SAE Number

Below 10°F (-12°C) 5W
Above 10°F (-12°C) 10W
• Hand Oil Can - Viscosity suitable for application and temperature.

NOTE: These performance requirements are benchmarks and not specifications. Therefore,
meeting these limits as described above does not relieve the supplier of the
responsibility associated with brand name products.
Manual No. 10732 3 – 32 Jul. 2009

RWRL - RUNNING WIRE ROPE LUBRICANT
SCOPE
Lubrication performance requirements for hoist rope lubricant.
APPLICATION
Primarily for hoist ropes or any other running ropes where fatigue and not wear is of prime
concern.
GENERAL REQUIREMENTS
• Penetrate between adjacent wires in order to lubricate and protect them against wear and to
keep the rope core from drying out and deteriorating.
• Provide a lubricant between sheaves and wire rope.
• Resist being washed off.
• Protect against rusting or corrosion.
• Form a non-sticky film so that dust and dirt will not build up on the wires.
• Remain pliable and resist stripping at the lowest temperatures to which the rope will be
exposed.
• Preferably, it should form a light colored transparent film so that wear, corrosion or broken
wires can be readily detected by inspection.
• Be capable of easy application, both manually and by devices without being heated.
COMPOUNDING
Suitable for penetrating between the adjacent wires of a rope in order to lubricate them and also
to replenish the lubricant in the core.
SPECIAL REQUIREMENTS
1. Must pass United States Steel Retention Test Using a Timken Tester
2. Shell Four Ball E.P. - (ASTM D-2596)
• Load wear index, kg., min.: 40
• Load weld kg., min.: 250
3. Shell Four Ball Wear - (ASTM D-2266)
• Wear scar diameter, mm., max.: 0.60
4. Timken O.K. Load lbs., min. - (ASTM D-2782): 45
5. Copper Strip Corrosion - (ASTM D-130): pass
6. Suggested Application Temperature Ranges. There should be a lubricant for each of the
following temperature ranges:
• 110°F to 30°F (43°C to -1°C)
• 40°F to 9°F (4°C to -13°C)
• 10°F to -50°F (43°C to -1°C)
NOTE: These performance requirements are benchmarks and not specifications. Therefore,
meeting these limits as described above does not relieve the supplier of the
responsibility associated with brand name products.
Jul. 2009 3 – 33 Manual No. 10732

EGL - 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
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.
Table 3-1: Guidelines for Selecting Approved Lubricant
Ambient Temperature Range ISO Viscosity Grade / Oil Type
14°F to 100°F (-10°C to 37°C) ISO VG 320 / Mineral or Synthetic (poly-a-olefin) Oil
Less than 14°F to 120°F ISO VG 320 / Synthetic (poly-a-olefin) Oil
(Less than -10°C to 50°C)
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.
2. Select an approved lubricant for the Hoist, Swing, Crowd and Propel Gearcases from the
Approved Lubricant Table 2 & Table 3.
Manual No. 10732 3 – 34 Jul. 2009

APPROVED LUBRICANTS
Lubricants that have been approved for use by the gearcase manufacturers are listed in the
Approved Lubricant Table 2 & Table 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.
Table 3-2: Approved Mineral Oil Lubricants (ISO VG 320)
Manufacturer Product Description
Bel-Ray Bel-Ray 100 Gear Oil 90
BP Energol GR-XF 320
Castrol Alpha SP 320
Alpha MAX 320
Optigear BM 320
Tribol 1100/320
Chevron Chevron Ultra Gear Lube 320
Gear Compound EP 320
Esso Spartan EP 320 (Only Product Originating from Europe)
Fuchs Renolin CLP 320 Plus
LE (Lubrication Engineers) Almasol 605
Mobil Mobilgear XMP 320
Petro-Canada Ultima EP 320
Shell Omala F 320
Texaco Auriga EP 320
Meropa 320
Meropa WM 320
Whitmore Mfg. Co. 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 Non- Planetary
type Crowd Gearcase.
Jul. 2009 3 – 35 Manual No. 10732

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

Bel-Ray Synth. Gear Oil 6692
BP Enersyn EP-XF 320
Enersyn HTX 320
Castrol Optigear Synth. A 320
Optigear Synth. X 320
Alphasyn EP 320
Alphasyn T 320
Tribol 1510/320
Tribol 1710/320
Chevron Tegra Synth. Gear Lube 320
Fuchs Renolin Unisyn CLP 320
Mobil Mobil SHC 632
Mobilgear SHC XMP 320
Petro-Canada Ultima Synth. EP 320
Traxon E Synth. 80W-140
Shell Omala HD 320
Texaco Pinnacle EP 320
Whitmore Mfg. Co. 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 Non-Planetary
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.
Manual No. 10732 3 – 36 Jul. 2009

MPG - MULTIPURPOSE 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.
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.
Jul. 2009 3 – 37 Manual No. 10732

MINIMUM PERFORMANCE REQUIREMENTS
Property Reference Requirement

Ambient Temperature -1°C to +43°C -18°C to +27°C Less than -12°C
(See Note #1) (+30°F to +110°F) (0°F to +80°F) (Less than +10°F)
NGLI Consistency # ASTM D-217 2 1 1, 0, 00
(See Note #2)
Dropping Point °C (°F) ASTM D-2265 177 (350) 177 (350) 177 (350)
Minimum
Timken O.K. load-lbs (kgf) ASTM D-2509 50 (23) 50 (23) 50 (23)
Minimum
Shell Four Ball EP ASTM D-2596 65 65 65
Load wear index (LWI) kg
Minimum
Load Weld kg Minimum ASTM D-2596 400 400 400
Shell Four Ball Wear ASTM D-2266 0.6 0.6 0.6
Wear Scar mm
Maximum 40KG for 1 hour
@ 75°C @ 1200 RPM
Copper Strip Corrosion ASTM D-4048 2e 2e 2e
24 Hrs @ 100°C (212°F)
Rust Test ASTM D-1743 Pass Pass Pass
Viscosity of Base Fluid ASTM D-445 460cSt @ 40°C 220cSt @ 40°C 130cSt @ 40°C
Minimum
Motormatic Grease Worker ASTM D-217A 10% 10% 10%
Mechanical Stability 10,000
strokes, Maximum change
Roll Stability Test ASTM D-1831 15% 15% 15%
Maximum change in 2 hours
Wheel Bearing Test ASTM D1263 10% 10% 10%
6 hours @ 104°C (220°F) (NLGI #1 Only)
Maximum loss
Water Washout Test ASTM D-1264
Loss @ 38°C (100°F), 5% 5% 5%
Maximum (NLGI #1 Only)
Loss @ 80°C (175°F),
Maximum 15% 15% 15%
(NLGI #1 Only)
Manual No. 10732 3 – 38 Jul. 2009


Pressure Oil Separation The Lubrication Engineers Manual U.S. Steel test method - Cake
(United States Steel). penetration not less than 25% of
grease penetration.
Grease Mobility The Lubrication Engineers Manual U.S. Steel method - not less than
(United States Steel). 0.10 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
Lincoln Ventmeter Manual (United States Steel). (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).
Lubricating Solids Less than or equal to 5%
(Molybdenum Disulfide,
Graphite, Etc.) % by Weight
Lubricating Solids 10 Microns
(Molybdenum Disulfide,
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.
Jul. 2009 3 – 39 Manual No. 10732

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.
on climate, application, performance and regional/local regulatory requirements.
Lubricant manufacturers seeking to certify their products should contact the following for
direction:

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:

Phone (414) 768-4000
Manual No. 10732 3 – 40 Jul. 2009

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.
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
Jul. 2009 3 – 41 Manual No. 10732
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.
Manual No. 10732 3 – 42 Jul. 2009

MINIMUM PERFORMANCE REQUIREMENTS

Flash point of product as applied, minimum (base ASTM D92 / ISO 2592 61°C (142°F)
product with diluent) 80°C (176°F)
Ambient Temperature (See Note #1)
-50°C (-58°F) to +10°C (50°F)
Above +10°C (50°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 800 800
(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
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).
Lubricating Solids 15 Microns
(Molybdenum Disulfide, Graphite, Etc.)
Particle Size, (Microns, max.)
Minimum Base Fluid Viscosity ASTM D 445
Ambient Temperature (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
NOTE:
1. Ambient Temperature - The ambient temperature shall be the temperature at the point of
lubricant application.
Jul. 2009 3 – 43 Manual No. 10732

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.
direction:

Phone (414) 768-4000
This specification is subject to change without notice. Please contact the following for the latest
specification:

Phone (414) 768-4000
Manual No. 10732 3 – 44 Jul. 2009

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.
Lubricants certified by their manufacturers as complying with these Bucyrus International, Inc.
specifications are listed in the tables below.
LUBRICANT SELECTION
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.
Jul. 2009 3 – 45 Manual No. 10732

Table 3-4: Certified Lubricant Listing for “OGL–Open Gear Lubricant (SD4713)”
Bel-Ray Molylube SF 100 Sub-Arctic 77070
Bel-Ray Molylube SF 100 Arctic 77020
Bel-Ray Molylube SF 100 Light 76990
Bel-Ray Molylube SF 100 Medium 77010
Bel-Ray Molylube SF 100 Heavy 77000
Bel-Ray Molylube Unee NS 70550
Bel-Ray Molylube Unee 70600
Bel-Ray Molylube Unee 70540
Bel-Ray Molylube SD-1 70620
Bel-Ray Molylube Gear TAC Light 68990
Bel-Ray Molylube Gear TAC Regular 68940
Bel-Ray Molylube Gear TAC Medium 68950
Castrol Molub-Alloy 936 SF Light
Castrol Molub-Alloy 936 SF Medium
Castrol Molub-Alloy 936 SF Heavy
Castrol Molub-Alloy 936 SF Heavy A
Chemtool Inc. Alpha OGL-680
Haycock Petroleum Shovel Lube OGL 1.5 Ultra
Imperial Oil / Esso Dynagear Heavy
Imperial Oil / Esso Dynagear Extra
Lubritene Lubrene Multi Serv OGL
Lubritene Lubrene Multi Serv OGL-H
Lubritene Lubrene OGL-e
Lubritene Lubrene Bio Serv OGL
Petro-Canada Vulcan Synthetic All Season
Petro-Canada Vulcan Synthetic 2200
Petro-Canada Vulcan Heavy
Petron Petrotac EP Premium 30-B
Petron Petrotac EP Premium 10-B
Schaeffer Mfg. Silver Streak Quickvent All Season (#196ALL)
Schaeffer Mfg. Silver Streak Quickvent Arctic (#196ARC)
Schaeffer Mfg. Silver Streak BGL 100
Shell Malleus Grease GL 3500
Shell Malleus OGM Heavy
Shell Malleus OGM Extra Heavy
Stewart Lubricants & Service SLS BI OGL Heavy
Co. (SLS)
Talcor OGP V
Whitmore Mfg. Co. Axiom Multiservice Mining Lubricant – Arctic / SurStik 800 – Arctic
Whitmore Mfg. Co. Axiom Multiservice Mining Lubricant – Medium / SurStik 800 – Medium
Whitmore Mfg. Co. Axiom Multiservice Mining Lubricant – Heavy / SurStik 800 – Heavy
Manual No. 10732 3 – 46 Jul. 2009

Table 3-5: Certified Lubricant Listing for “MPG-Multi-Purpose Grease (SD4711)”

Bel-Ray Molylube AC 1000 40890
Bel-Ray Molylube LC135 67800
Bel-Ray Molylube 126 EP 23200
Bel-Ray Termalene EP 72400
Bel-Ray Termalene EP 72420
Castrol Molub-Alloy 4086-0
Castrol Molub-Alloy 4086/460-1
Castrol Molub-Alloy 777-1 ES
Castrol Molub-Alloy 777-2 ES
Chemtool Inc. CSC 174 MGD
Chemtool Inc. CSC MP1-220
Chemtool Inc. CSC MP1
Exxon Ronex Extra Duty 2
Exxon Ronex Extra Duty Moly 2 / Mobilgrease XHP 462 Moly
Haycock Petroleum Calcuplex M5 NLGI #1
Haycock Petroleum Calcuplex M5 NLGI #2
Imperial Oil Epic EP Moly
Imperial Oil Unirex EP 1 Moly
Lubrication Engineers Almagard Vari-Purpose 3750
Lubrication Engineers Almaplex Ultra-Synthetic 1299
Lubritene Lubrene Li 500 EP 2
Lubritene Lubrene LiM 500 EP 2
Lubritene Lubrene AXM 1000 EP 1
Lubritene Lubrene LXCa 700 EP 2
Jul. 2009 3 – 47 Manual No. 10732


Lubritene Lubrene Li 900 WP EP 2
Lubritene Lubrene EMV-2
Petro-Canada Supreme Arctic
Petro-Canada Supreme EP1
Petro-Canada Supreme EP2
Petro-Canada Precision XL 3 Moly EP1
Petron Petro-Plate M5/800 NLGI #1
Schaeffer Mfg. Moly Ultra 800 EP #1 (#221)
Schaeffer Mfg. Moly Ultra Red EP #1 (#229)
Schaeffer Mfg. Moly Supreme #1 (#238)
Schaeffer Mfg. Moly EP Synthetic Blend #1 (#274)
Shell Albida Grease HDX2
Shell Albida Grease MDX 1
Shell Albida Grease MDX 2
Shell Alvania Grease SDX2
Shell Albida SLC 460
Shell Limona LX1
Shell Limona LX2
Shell Albida HLS00
Shell Albida HLS2
Talcor Super HD 2-M5
Whitmore Mfg. Co. Omnilith 500 Extreme Pressure Grease EP 0
Whitmore Mfg. Co. Omnilith 500 M Extreme Pressure Grease EP 0
Whitmore Mfg. Co. Caliber 3M Extreme Pressure Grease EP 00
Manual No. 10732 3 – 48 Jul. 2009

Table 3-6: Certified Lubricant Listing for “Dragline Enclosed Gearcase Lubricant
(SD4721 Part A)” - Mineral Oils
Bel-Ray 100 Gear Oil 140 (ISO VG 460)
Bel-Ray 100 Gear Oil 460 SBF (ISO VG 460)
Exxon / Esso Spartan EP 460 (ISO VG 460)
Exxon / Esso Spartan EP 1000 (ISO VG 1000)
Lubritene Lubrene Syn 1500 (ISO VG 1500)
Lubritene Lubrene Super Series Gear Oil 1500 (ISO VG 1500)
Lubritene Lubrene Super Series Gear Oil 1000 (ISO VG 1000)
Mobil Mobilgear 600XP 460 (ISO VG 460)
Mobil Mobilgear 634 (ISO VG 460)
Mobil Mobilgear XMP 460 (ISO VG 460)
Mobil Mobilgear 639 (ISO VG 1000)
Petro-Canada Ultima 460 (ISO VG 460)
Petro-Canada Ultima 1000 (ISO VG 1000)
Schaeffer Mfg. #209A Universal Gear Lube (ISO VG 460)
Schaeffer Mfg. #209A Universal Gear Lube (ISO VG 1000)
Schaeffer Mfg. #294 Supreme Gear Lube (ISO VG 460)
Schaeffer Mfg. #294A Supreme Gear Lube No Tack (ISO VG 460)
Shell Omala 460 (ISO VG 460)
Shell SP Plus Gear Oil (ISO VG 1500)
Talcor Gear Oil EP (ISO VG 1000)
Whitmore Mfg. Co. Paragon Heavy Duty Enclosed Gear Oil (ISO VG 460)
Whitmore Mfg. Co. Paragon Gold High Performance Gear Oil (ISO VG 1000)
Jul. 2009 3 – 49 Manual No. 10732

Table 3-7: Certified Lubricant Listing for “Dragline Enclosed Gearcase Lubricant
(SD4721 Part A)” - Synthetic (PAO) Oils
Bel-Ray Synthetic Gear Oil 460 (ISO VG 460)
Bel-Ray Synthetic Gear Oil 1000 (ISO VG 1000)
Lubrication Engineers 9846 Synolec Gear Lubricant (ISO VG 460)
Lubrication Engineers 9899 Synolec Gear Lubricant (ISO VG 1000)
Mobil Mobil SHC 634 (ISO VG 460)
Mobil Mobilgear SHC XMP 460 (ISO VG 460)
Mobil Mobilgear SHC 460 (ISO VG 460)
Mobil Mobil SHC 639 (ISO VG 1000)
Schaeffer Mfg. #167 Pure Synthetic Gear Lube (ISO VG 460)
Schaeffer Mfg. #167 Pure Synthetic Gear Lube (ISO VG 1000)
Shell Omala HD 460 (ISO VG 460)
Shell Omala HD 1000 (ISO VG 1000)
Whitmore Mfg. Co. GF 365 Synthetic Gear Fluid (ISO VG 460)
Whitmore Mfg. Co. GF 365 Synthetic Gear Fluid (ISO VG 1000)
Whitmore Mfg. Co. Decathlon HD Series Synthetic Enclosed Gear Oil (ISO VG 460)
Whitmore Mfg. Co. Decathlon HD Series Synthetic Enclosed Gear Oil (ISO VG 1000)
LUBRICANT CERTIFICATION PROCESS

direction:

Phone (414) 768-4000
This listing is subject to change without notice. Please refer to the Bucyrus International, Inc. web
site www.bucyrus.com for the latest listing.
SCHEMATICS - AUTOMATIC LUBRICATION

The following pages contain a series of block diagrams depicting the schematic layout of the
automatic lubrication systems.
Systems “A” and “B” automatically disperse Open Gear Lubricant (OGL) to critical portions of the
machine.
System “C” is a grease system that lubricates items requiring a lubricant of slightly different
characteristics.
Manual No. 10732 3 – 50 Jul. 2009

SHE73 Lubricación

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Bucyrus International, Inc.

495HR Electric Mining Shovel

CAUTION:Contact with or ingestion of petroleum products can be harmful.

Jul. 2009 3–3 Manual No. 10732

495HR Electric Mining Shovel

GREASING MAIN A.C. DRIVE MOTORS

Manual No. 10732 3–4 Jul. 2009

495HR Electric Mining Shovel

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

Motor Regreasing Interval Drive End Grease Non-Drive End Grease

Jul. 2009 3–5 Manual No. 10732

495HR Electric Mining Shovel

Manual No. 10732 3–6 Jul. 2009

495HR Electric Mining Shovel

OIL FILL CAPACITIES

Description Type Gallons

QUANTITIES FOR FIRST FILL OF LUBRICANTS

Gallons Drums Type Description

NOTE: 1 drum = 55 gallons = 208 liters

Jul. 2009 3–7 Manual No. 10732

495HR Electric Mining Shovel

AUTOMATIC LUBRICATION SYSTEM

DANGER:STORED ENERGY! Automatic lubrication systems operate under

Manual No. 10732 3–8 Jul. 2009

495HR Electric Mining Shovel

Figure 3-1: Lubrication Room Details

Jul. 2009 3–9 Manual No. 10732

495HR Electric Mining Shovel

LUBE RESERVOIR FILL / OVERFLOW PLUMBING

Figure 3-2: Lube Reservoir Fill / Overflow Plumbing

Manual No. 10732 3 – 10 Jul. 2009

495HR Electric Mining Shovel

AUTO LUBE CONTROL PANEL

POWER ON Allows electrical power to energize the system.

LOWER WORKS LUBRICATION

Jul. 2009 3 – 11 Manual No. 10732

495HR Electric Mining Shovel

PROPEL MACHINERY LUBRICATION

When radical changes in temperature, or at the recommendation of a testing facility, make it

Manual No. 10732 3 – 12 Jul. 2009

495HR Electric Mining Shovel

Designation to DIN 5157 part 3: CLP 220

Element Normal Excessive Critical

LUBRICANT CHANGE CYCLE

Jul. 2009 3 – 13 Manual No. 10732

495HR Electric Mining Shovel

REVOLVING FRAME LUBRICATION

Manual No. 10732 3 – 14 Jul. 2009

495HR Electric Mining Shovel

HOIST MACHINERY LUBRICATION

Jul. 2009 3 – 15 Manual No. 10732

495HR Electric Mining Shovel

HOIST OIL COOLER

DANGER:DO NOT PROCEED UNTIL THE COOLER AND SUPPORT ASSEMBLY

Manual No. 10732 3 – 16 Jul. 2009

495HR Electric Mining Shovel

Jul. 2009 3 – 17 Manual No. 10732

495HR Electric Mining Shovel

Figure 3-3: Hoist Oil Cooler Schematic

Manual No. 10732 3 – 18 Jul. 2009

495HR Electric Mining Shovel

FILTER ELEMENT CLEANING

Jul. 2009 3 – 19 Manual No. 10732