Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM020981 – PDF DOWNLOAD
$30.95
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM020981 – PDF DOWNLOAD
SN: 141311
SN: 141313
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM020981 – PDF DOWNLOAD
FILE DETAILS:
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM020981 – PDF DOWNLOAD
Language : English
Pages : 532
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM020981 – PDF DOWNLOAD
SN: 141311
SN: 141313
Safety
The safety alert symbols displayed here and throughout this manual are used to call attention to instructions concerning 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 that anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions. If it is impossible 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.
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 person 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.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM020981 – PDF DOWNLOAD
Safety Precautions........................................................ 4 General Precautions................................................... 5 Maintenance Precautions............................................... 6 Operating Precautions................................................. 7 Fire Prevention....................................................... 8 Warning Signs And Decals.............................................. 9 Introduction.............................................................. 27 General Information....................................................... 27 SWINGING RESTRAINT & BALLAST BOX SUPPORT.............................. 28 Ballast Box Support............................................... 28 Swinging Restraint................................................ 29 Machine Overview.......................................................... 31 Lower Works............................................................... 32 Crawlers.............................................................. 33 Truck Frame........................................................... 34 Swing Rack............................................................ 35 Roller Circle......................................................... 36 Propel Machinery...................................................... 37 Collector Rings....................................................... 38 Rotating Deck............................................................. 39 Revolving Frame....................................................... 39 Center Pintle......................................................... 39 Deck Extensions....................................................... 41 Ballast Box........................................................... 41 Machinery House....................................................... 41 Boarding Stairs................................................... 42 Vertical Boarding Ladder.......................................... 43 A-Frame............................................................... 44 Hoist Machinery....................................................... 45 Swing Machinery....................................................... 46 Crowd Machinery....................................................... 47 OPERATOR’S CAB........................................................ 48 Compressed Air System................................................. 49 Automatic Lubrication System.......................................... 50 Lube Reservoir fill / Overflow Plumbing............................... 51 Front End Equipment....................................................... 52 Suspension Strands.................................................... 52 Boom.................................................................. 53 Running Ropes......................................................... 54 Saddle Block.......................................................... 55 Dipper Handle......................................................... 56 Dipper................................................................ 57 Padlocks.............................................................. 58 Dipper Trip........................................................... 59 Typical Machine Specifications............................................ 60 General Estimated Component Weights....................................... 62 Lower Works........................................................... 62 Upper Works........................................................... 63 Front End............................................................. 65 Operation................................................................. 71 General Information....................................................... 71 Operation Near Electrical Lines....................................... 71 Operator’s Seat........................................................... 73 Adjustable Armrest.................................................... 73 Adjustable Footrest................................................... 74 Controls.................................................................. 75 Controls On The Left Console.......................................... 76 Left Joystick..................................................... 77 Dipper Trip....................................................... 77 Signal Horn....................................................... 77 Start Pushbutton.................................................. 77 PLC Power On...................................................... 78 Drive Cabinet Temperature......................................... 78 Incomplete Sequence............................................... 78 System Ready...................................................... 78 Phase Sequence.................................................... 78 Auxiliary Ground Fault............................................ 78 Hoist Brake....................................................... 78 Crowd Brake....................................................... 78 Swing Brake....................................................... 78 Propel Brake...................................................... 78 HVAC Unit Selector................................................ 78 Temperature....................................................... 78 HVAC System Control............................................... 78 HVAC Fan Speed.................................................... 78 Cabin Lights...................................................... 78 Controls On The Right Console..................................... 79 Right Joystick.................................................... 80 Emergency Stop Pushbutton......................................... 81 Windshield Wiper Switches......................................... 81 Control Stop Pushbutton........................................... 81 Control Reset Pushbutton.......................................... 81 Air Compressor.................................................... 82 Dig/propel Transfer Switch........................................ 82 Main Power Off Pushbutton......................................... 82 Earth Continuity Lockout Pushbutton............................... 82 Seat Position..................................................... 82 Radio/cassette/cd................................................. 82 Operator’s Display........................................................ 83 Display Area and Indicators........................................... 84 Display Screens....................................................... 84 Lubrication Control Panel............................................. 92 Fire Suppression System............................................... 92 Pre-start Checks.......................................................... 92 Walk-around Ground Level Inspection................................... 93 On-board Inspection................................................... 95 Start-up, Operation And Shutdown.......................................... 96 Machine Start-up...................................................... 96 Restarting After An Electrical Fault.................................. 97 Machine Operation..................................................... 97 Machinery Motions..................................................... 98 Hoist Motion...................................................... 98 Crowd Motion...................................................... 99 Propel Motion.....................................................100 Swing Motion......................................................101 Proper Swing Motion...........................................102 Steering..........................................................103 Counter-rotation Turns........................................105 Positioning the Machine...........................................106 Back-up Method................................................106 Drive-by Method...............................................107 Start Of The Dig Cycle............................................108 Engaging The Bank.................................................111 Slope Limitations.................................................113 Excavated Material....................................................115 Operation Checks......................................................115 Operating Hints.......................................................116 Stopping the Machine..................................................117 Shutdown..............................................................117 Lubrication...............................................................121 Lubrication Principles....................................................121 Greasing Main A.C. Drive Motors...........................................122 1. Type of Grease.....................................................122 2. Initial Commissioning..............................................122 3. Maintenance........................................................122 4. Regreasing Intervals...............................................123 Lubricant Selection.......................................................123 Oil Fill Capacities.......................................................125 Types Of Lubricants And Capacities Guidelines.........................125 Quantities for First Fill of Lubricants...........................125 Automatic Lubrication System..............................................126 Lube Room.............................................................127 Lube Reservoir fill / Overflow Plumbing...............................128 Auto Lube Control Panel...........................................129 Lower Works Lubrication...............................................129 Propel Machinery Lubrication..........................................130 Lubricant Replacement/sampling....................................131 Lubricant Change Cycle........................................131 Revolving Frame Lubrication...........................................132 Hoist Machinery Lubrication...........................................133 Hoist Oil Cooler..................................................134 Filter Element Cleaning...........................................137 Hoist Rope Rollers Lubrication........................................138 Oil Pump..........................................................139 Crowd Machinery Lubrication...........................................140 Swing Machinery Lubrication...........................................141 Air Compressor Lubrication............................................142 Crowd Rope Take-Up Mechanism Lubrication..............................143 Front End Lubrication.................................................143 Lincoln Type SL-1 Lubricant Injectors.................................145 SL-1 Lubricant Injector Operation.................................147 Injector Advantages...............................................149 Air Compressor Lubricant..............................................149 MPO - Multipurpose OIL................................................150 RWRL - Running Wire Rope Lubricant....................................151 EGL - Enclosed Gearcase Lubricant.....................................152 MPG - Multipurpose Grease.............................................155 OGL - Open Gear Lubricant.............................................159 Certified Lubricants Listing..........................................163 Preventive Maintenance....................................................171 Introduction..............................................................171 Preventive Maintenance Program........................................171 Elements of an Effective Maintenance Program..........................172 Scheduled Preventive Maintenance Program..............................173 General Safety Considerations.........................................173 Maintenance During Machine Operation......................................174 Maintenance Precautions...............................................175 Preventive Maintenance for Lubrication....................................176 Lubricant Cleanliness.................................................177 Frequency of Inspection and Maintenance...................................178 Maintenance Schedules.....................................................178 Maintenance Inspection Check Points...................................178 Daily.............................................................179 Every 100 Hours or Weekly.........................................182 Every 500 Hours Or Monthly........................................183 Every 1250 Hours or Quarterly.....................................186 Every 2500 Hours or Semi-Annually.................................189 5000 Hours or Annually............................................191 Major Component Locations.................................................193 Service Procedures........................................................221 Lower Works...............................................................221 Truck Frame Assembly..................................................221 Swing Rack Assembly...................................................222 Roller Circle Rail Replacement - Lower............................222 Roller Circle Rail Replacement - Upper............................223 Roller Circle Assembly................................................225 Roller Circle Adjustment..........................................227 Adjustment Procedure..............................................227 Run-in Procedure for the Roller Circle............................227 Roller Circle Segment Removal.....................................228 Roller Circle - Roller Replacement................................229 Crawler Belts.............................................................230 Crawler Belt Maintenance..............................................230 Crawler Belt Tension Adjustment...................................231 Crawler Shoe Replacement..........................................233 Crawler Belt Replacement..........................................234 Crawler Side Frame Assembly...........................................235 Crawler Side Frame Maintenance....................................236 Slide Bar Replacement.............................................237 Crawler Front Idler Roller Assembly...............................238 Load and Idler Rollers............................................241 Roller Removal or Replacement.................................241 Propel Assembly...........................................................244 Installation Notes....................................................246 Main Propel Drive Shaft Removal.......................................247 Main Propel Shaft - Disassembly...................................250 Tumbler Rebuild Procedure.........................................251 Propel Machinery......................................................253 Propel Gearcase Removal...........................................254 Propel Gearcase Installation......................................255 Propel Planetary Gearcase.........................................257 Propel Motors.....................................................258 Propel Motor Removal..........................................258 Propel Motor Installation.....................................261 Center Pintle.........................................................262 Center Pintle Adjustment..........................................267 Center Pintle Sleeve Removal......................................267 Collector Rings.......................................................269 Collector Ring Inspection.........................................270 Collector Ring Repair.............................................270 Rotating Deck.............................................................270 Swing Machinery...........................................................271 Swing Support Mounting Bolts..........................................273 Swing Motor...........................................................273 Swing Blower......................................................273 Swing Motor Removal...............................................274 Swing Motor Installation..........................................274 Swing Planetary Gearcase..............................................275 Swing Gearcase Removal............................................276 Gearcase Inspection...............................................277 Swing Pinion Shafts...............................................278 Swing Pinion Shaft Removal....................................279 Swing Pinion Shaft Disassembly................................280 Swing Pinion Shaft Assembly...................................281 Swing Pinion Shaft Installation...............................282 Hoist Machinery.......................................................283 Hoist Motor Removal...............................................284 Motor Coupling Shaft..............................................287 Hoist Gearcase Assembly...........................................288 Hoist Gearcase Repair.............................................290 Hoist Drum Assembly...............................................293 Hoist Gear Replacement........................................295 Bearing Removal...............................................297 Bearing Installation..........................................298 Hoist Oil Cooler..................................................300 Hoist Mounting Bolts..................................................301 Hoist Limit Switch....................................................302 Crowd Machinery...........................................................303 Crowd Gearcase Disassembly............................................305 Crowd Gearcase Assembly...............................................308 Crowd Motor...............................................................309 Crowd Gear and Drum...................................................311 Crowd Drum Removal....................................................311 Operator’s Cab Mounting...............................................313 Operator’s Seat Installation..............................................314 Footrest Installation.....................................................316 Machinery House...........................................................317 Walkways, Stairways, and Handrails....................................318 Boarding Stairs.......................................................318 Vertical Boarding Ladder, left........................................321 Boom Assembly.........................................................324 Boom Repair.......................................................325 Boom Limit Switch Installation........................................326 Boom Point Sheaves................................................328 Boom Point Sheave Removal and Disassembly.........................329 Boom Point Sheave Reassembly and Installation.....................331 Boom Bumper...........................................................332 Saddle Block..........................................................333 Saddle Block Repair...............................................333 Saddle Block Removal..........................................334 Dipper Handle.........................................................336 Dipper Handle Removal.............................................338 Crowd Rope Take-Up Mechanism......................................340 Crowd Rope Take-Up Mechanism Disassembly......................341 Crowd Rope Take-Up Mechanism Assembly.........................342 Retract Rope Take-up Mechanism....................................345 Spreader Repair...................................................347 Dipper Assembly...........................................................348 Latch Bar Adjusting...................................................351 Dipper Door bumpers...................................................352 Dipper Removal & Installation.....................................353 Dipper Door Snubbers..............................................358 Snubber Adjustment............................................359 Allowable Wear................................................359 Dipper Pitch Brace....................................................360 Dipper Padlock........................................................361 Dipper Trip Assembly..................................................364 A-Frame...............................................................365 Auxiliary Winch.......................................................367 Hoist Rope Support Roller.............................................368 Boom Support Ropes....................................................369 Wire Ropes............................................................370 Wire Rope Inspection..............................................371 Crowd Rope Take-up Hydraulic Unit.........................................372 Hoist Rope Reeving & Replacement......................................374 Crowd Rope Reeving & Replacement..................................378 Retract Rope Reeving & Replacement........................................380 Crowd Rope Tightening.................................................384 Retract Rope Tightening...............................................386 Dipper Trip Rope Reeving & Replacement................................387 Hoist and Crowd Limit Systems.........................................387 Setting Limits In The Hoist & Crowd System........................388 Crowd Slowdown/Stop Limits....................................390 Retract Slowdown/Stop Limits..................................391 Lower Slowdown/Stop Limits....................................392 Hoist Slowdown/Stop Limits....................................393 Brakes and Couplings......................................................397 Brakes....................................................................397 Disc Brake Operation..................................................398 Maintenance...........................................................398 Brake Adjustment Specifications.......................................398 Hoist Brake...........................................................399 Hoist Brake Adjustment............................................401 Hoist Brake Installation..........................................403 Hoist Brake Wear & Release Switches...............................403 Crowd Brake...........................................................404 Crowd Brake Installation..........................................406 Crowd Brake Wear & Release Switches...............................408 Propel Brake..........................................................409 Propel Brake Adjustment...........................................411 Propel Brake Installation.........................................413 Tachometer Mounting & Alignment...................................415 Swing Brake...........................................................417 Swing Brake Installation..........................................419 Swing Brake Wear & Release Switches...............................420 Swing Brake Burnishing............................................421 Spring Replacement — All Brakes.......................................421 Friction Disc Replacement — All Brakes................................423 O-Ring Replacement — All Brakes.......................................424 Brake Wear & Release Switches — Single Disc Brakes....................426 Brake Wear & Release Switches — Multiple Disc Brakes..................427 Couplings.................................................................428 Grid Couplings........................................................428 Lubrication.......................................................428 Coupling Disassembly and Grid Removal.............................429 Grid Coupling Installation........................................430 Seal Replacement without Hub Removal..............................433 Grid Coupling Alignment...........................................435 Gear Couplings........................................................436 Coupling Installation.............................................436 Gear Coupling Alignment...........................................438 Hoist Coupling Shaft Alignment....................................439 Compressed Air System.....................................................443 Air Compressor............................................................443 Lockout Valves........................................................445 Safety Warnings.......................................................447 Air Filtration............................................................451 House Filter Fans.........................................................451 Lubrication...........................................................452 Dynavane Air Cleaner..................................................453 Air Conditioner.......................................................454 Specifications........................................................455 Engineering Data..........................................................461 Capscrew (Bolt) Grade.....................................................461 Bolt Tightening.......................................................461 Torque Wrench Method..............................................461 Turn-of-nut Method................................................463 Measurement Systems.......................................................465 Linear Measurements...................................................465 Area Measurements.....................................................465 Volume Measurements...................................................466 Torque Measurements...................................................467 Weight Measurements - Conventional................................468 Split Flange Assembly Procedure...........................................469 Wire Locking Capscrews....................................................471 Torque Nut Installation...................................................472 Tightening Procedure for 1.25-Inch Torque Nut.........................473 Tightening Procedure for 2-Inch Torque Nut............................474 Tightening Procedure for 2-Inch Torque Nut............................475 Tightening Procedure for 2.5-Inch Torque Nut..........................476 Tightening Procedure for 3-Inch Torque Nut............................477 Tightening Procedure for 3.5-Inch Torque Nut..........................478 Procedure for Use of Mechanical Tensioner on Crawler Rods.............479 Initial Tensioning................................................480 Final Tensioning..................................................480 Expansion Bolt Installation...............................................482 Tightening Procedures - Expansion Bolts...............................482 Hoist Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut............482 Rack & Roller Torque Rod, Tapered Sleeve & 1.5 Inch Torque Nut....483 Swing Torque Rod & Tapered Sleeve & 3.5 Inch Torque Nut...........485 Torque Nut Removal Procedure..............................................487 Thread Lubrication....................................................487 Torque Nut Helpful Hints..................................................488 Locking Assemblies........................................................489 Locking Assembly Removal..............................................491 Pinion and Hub Installation...........................................492 Removal from a Shaft..................................................492 Mounting a Pinion or Hub on a Shaft...................................492 Hub Adapter Pre-heat Advance Requirements.........................495 Motor Coupling Pre-Heat Advance Requirements......................495 Maintenance Welding.......................................................496 Welding Electrodes....................................................497 Repair Welding of Cracks..............................................498 Preheat...........................................................499 Welding Technique.................................................499 Repair Welding of Broken Parts........................................500 Repair Welding Swing Rack Teeth.......................................501 Preparation.......................................................501 Swing Rack Welding Electrodes.....................................501 Preheat...........................................................501 Welding Procedure.................................................503 Welding and Cutting Equipment.........................................505 Stress Relieving & Temperature Measuring Equipment....................506 Storage...............................................................506 Checking Diameter.....................................................507 Handling Wire Rope....................................................508 Seizing Wire Rope.....................................................509 End Preparations/Terminations.........................................511 Wire Rope Clips.......................................................511 Wire Rope Clip Application........................................511 Wedge Sockets.....................................................513 Inspection of Sheaves and Drums.......................................514 Breaking In a New Wire Rope...........................................515 Inspection Data.......................................................516 Guideline to Inspections and Reports..................................517 Wire Rope Inspection Criteria.....................................518 Reduction in Rope Diameter....................................518 Rope Stretch..................................................519 Abrasion......................................................520 Corrosion.....................................................520 Kinks.........................................................520 Bird Caging...................................................520 Localized Conditions..........................................520 Heat Damage...................................................520 Protruding Core...............................................520 Damaged End Attachments.......................................521 Peening.......................................................521 Scrubbing.....................................................521 Fatigue Fracture..............................................521 Broken Wires..................................................521 Electric Arc..................................................522 Seals.....................................................................522 Seal Installation.....................................................523 Gearcase Sealing......................................................524 Schematics................................................................526 Schematics - Automatic Lubrication........................................526 Side View.................................................................527 Deck Plan.................................................................528 OGL System A & B Schematic................................................529 Grease System C Schematic.................................................530 Air Schematic.............................................................531
Need help? Contact: [email protected]
https://vimeo.com/859768447?share=copy
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.M
