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CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM021121 – PDF DOWNLOAD
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CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM021121 – PDF DOWNLOAD
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Description
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM021121 – PDF DOWNLOAD
FILE DETAILS:
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM021121 – PDF DOWNLOAD
Language : English
Pages : 534
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM021121 – PDF DOWNLOAD
SN: 141322
SN: 141425
SN: 141440
SN: 141449
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 EM021121 – 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 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 Primary Operating 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 Receiver with CD Changer.................................... 83 Operator’s Display........................................................ 83 Display Area and Indicators........................................... 84 Display Screens....................................................... 84 Lubrication Control Panel............................................. 91 Fire Suppression System............................................... 92 Pre-start Checks.......................................................... 92 Walk-around Ground Level Inspection................................... 93 On-board Inspection................................................... 94 Start-up, Operation And Shutdown.......................................... 95 Machine Start-up...................................................... 95 Restarting After An Electrical Fault.................................. 96 Machine Operation..................................................... 96 Machinery Motions..................................................... 97 Hoist Motion...................................................... 97 Crowd Motion...................................................... 98 Propel Motion..................................................... 99 Swing Motion......................................................100 Proper Swing Motion...........................................101 Steering..........................................................102 Counter-rotation Turns........................................104 Positioning the Machine...........................................105 Back-up Method................................................105 Drive-by Method...............................................106 Start Of The Dig Cycle............................................107 Engaging The Bank.................................................109 Slope Limitations.................................................111 Excavated Material....................................................114 Operation Checks......................................................114 Operating Hints.......................................................115 Stopping the Machine..................................................116 Shutdown..............................................................116 Lubrication...............................................................119 Lubrication Principles....................................................119 Greasing Main A.C. Drive Motors...........................................120 1. Type of Grease.....................................................120 2. Initial Commissioning..............................................120 3. Maintenance........................................................120 4. Regreasing Intervals...............................................121 Lubricant Selection.......................................................121 Oil Fill Capacities.......................................................123 Types Of Lubricants And Capacities Guidelines.........................123 Quantities for First Fill of Lubricants...........................123 Automatic Lubrication System..............................................124 Lube Room.............................................................125 Lube Reservoir fill / Overflow Plumbing...............................126 Auto Lube Control Panel...........................................127 Lower Works Lubrication...............................................127 Propel Machinery Lubrication..........................................128 Lubricant Replacement/sampling....................................129 Lubricant Change Cycle........................................129 Revolving Frame Lubrication...........................................130 Hoist Machinery Lubrication...........................................131 Hoist Oil Cooler..................................................132 Filter Element Cleaning...........................................135 Hoist Rope Rollers Lubrication........................................136 Oil Pump..........................................................137 Crowd Machinery Lubrication...........................................138 Swing Machinery Lubrication...........................................139 Air Compressor Lubrication............................................140 Crowd Rope Take-Up Mechanism Lubrication..............................141 Front End Lubrication.................................................141 Lincoln Type SL-1 Lubricant Injectors.................................143 SL-1 Lubricant Injector Operation.................................145 Injector Advantages...............................................147 ACSL - Air Compressor (Screw-Type) Lubricant..........................148 MPO - Multipurpose OIL................................................149 RWRL - Running Wire Rope Lubricant....................................150 EGL - Enclosed Gearcase Lubricant.....................................151 MPG - Multipurpose Grease.............................................154 OGL - Open Gear Lubricant.............................................158 Certified Lubricants Listing..........................................162 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...............................232 Crawler Shoe Replacement......................................234 Crawler Belt Replacement......................................235 Crawler Side Frame Assembly...........................................236 Crawler Side Frame Maintenance....................................237 Slide Bar Replacement.............................................238 Crawler Front Idler Roller Assembly...................................239 Load and Idler Rollers............................................242 Roller Removal or Replacement.................................242 Propel Assembly.......................................................245 Installation Notes....................................................247 Main Propel Drive Shaft Removal...................................248 Main Propel Shaft - Disassembly...................................251 Tumbler Rebuild Procedure.........................................252 Propel Machinery......................................................254 Propel Gearcase Removal...........................................255 Propel Gearcase Installation......................................256 Propel Planetary Gearcase.........................................258 Propel Motors.....................................................259 Propel Motor Removal..........................................259 Propel Motor Installation.....................................261 Revolving Frame.......................................................262 Center Pintle.........................................................262 Center Pintle Adjustment..........................................268 Center Pintle Sleeve Removal......................................268 Collector Rings.......................................................270 Collector Ring Inspection.........................................271 Collector Ring Repair.............................................271 Rotating Deck.............................................................271 Swing Machinery.......................................................272 Swing Support Mounting Bolts......................................274 Swing Motor.......................................................274 Swing Blower..................................................274 Swing Motor Removal...........................................275 Swing Motor Installation......................................275 Swing Planetary Gearcase..........................................276 Swing Gearcase Removal........................................277 Gearcase Inspection...........................................278 Swing Pinion Shafts...............................................279 Swing Pinion Shaft Removal....................................280 Swing Pinion Shaft Disassembly................................281 Swing Pinion Shaft Assembly...................................282 Swing Pinion Shaft Installation...............................283 Hoist Machinery.......................................................284 Hoist Motor Removal...............................................285 Motor Coupling Shaft..............................................288 Hoist Gearcase Assembly...........................................289 Hoist Gearcase Repair.............................................293 Hoist Drum Assembly...............................................296 Hoist Gear Replacement........................................298 Bearing Removal...............................................300 Bearing Installation..........................................301 Hoist Oil Cooler..................................................303 Hoist Mounting Bolts..............................................304 Hoist Limit Switch................................................305 Crowd Machinery.......................................................306 GEARCASE REPAIR.......................................................308 Crowd Gearcase Disassembly........................................308 Crowd Gearcase Assembly...........................................311 Crowd Motor.......................................................312 Crowd Gear and Drum...........................................314 Crowd Drum Removal............................................314 Operator’s Cab Mounting...............................................316 Operator’s Seat Installation..........................................317 Footrest Installation.................................................319 Machinery House.......................................................320 Walkways, Stairways, and Handrails................................321 Boarding Stairs...................................................322 Front End Equipment.......................................................325 Boom Assembly.........................................................326 Boom Repair.......................................................327 Boom Limit Switch Installation........................................328 Boom Point Sheaves....................................................330 Boom Point Sheave Removal and Disassembly.........................331 Boom Point Sheave Reassembly and Installation.....................333 Boom Bumper...........................................................334 Saddle Block..........................................................335 Saddle Block Repair...............................................335 Saddle Block Removal..............................................336 Dipper Handle.........................................................338 Dipper Handle Removal.............................................340 Crowd Rope Take-Up Mechanism......................................342 Crowd Rope Take-Up Mechanism Disassembly......................343 Crowd Rope Take-Up Mechanism Assembly.........................345 Retract Rope Take-up Mechanism....................................347 Spreader Repair...................................................349 Dipper Assembly...........................................................350 Latch Bar Adjusting...................................................353 Dipper Door bumpers...................................................354 Dipper Removal & Installation.....................................355 Dipper Door Snubbers..................................................360 Snubber Adjustment................................................361 Allowable Wear....................................................361 Dipper Pitch Brace....................................................362 Dipper Padlock........................................................363 Dipper Trip Assembly..................................................366 A-Frame...............................................................367 Auxiliary Winch.......................................................369 Hoist Rope Support Roller.............................................370 Boom Support Ropes....................................................371 Wire Ropes............................................................372 Wire Rope Inspection..............................................373 Crowd Rope Take-up Hydraulic Unit.....................................374 Hoist Rope Reeving & Replacement......................................376 Crowd Rope Reeving & Replacement......................................380 Retract Rope Reeving & Replacement....................................382 Crowd Rope Tightening.................................................386 Retract Rope Tightening...............................................388 Dipper Trip Rope Reeving & Replacement................................389 Hoist and Crowd Limit Systems.........................................389 Setting Limits In The Hoist & Crowd System........................390 Crowd Slowdown/Stop Limits....................................392 Retract Slowdown/Stop Limits..................................393 Lower Slowdown/Stop Limits....................................394 Hoist Slowdown/Stop Limits....................................395 Brakes and Couplings......................................................399 Brakes....................................................................399 Disc Brake Operation..................................................400 Maintenance...........................................................400 Brake Adjustment Specifications.......................................400 Hoist Brake...........................................................401 Hoist Brake Adjustment............................................403 Hoist Brake Installation..........................................405 Hoist Brake Wear & Release Switches...............................405 Crowd Brake...........................................................406 Crowd Brake Installation..........................................408 Crowd Brake Wear & Release Switches...............................410 Propel Brake..........................................................411 Propel Brake Adjustment...........................................413 Propel Brake Installation.........................................415 Tachometer Mounting & Alignment...................................417 Swing Brake...........................................................419 Swing Brake Installation..........................................421 Swing Brake Wear & Release Switches...............................422 Swing Brake Burnishing............................................423 Spring Replacement — All Brakes.......................................423 Friction Disc Replacement — All Brakes................................425 O-Ring Replacement — All Brakes.......................................426 Brake Wear & Release Switches — Single Disc Brakes....................428 Brake Wear & Release Switches — Multiple Disc Brakes..................429 Couplings.................................................................430 Grid Couplings........................................................430 Lubrication.......................................................430 Coupling Disassembly and Grid Removal.............................431 Grid Coupling Installation........................................432 Seal Replacement without Hub Removal..............................435 Grid Coupling Alignment...........................................437 Gear Couplings........................................................438 Coupling Installation.............................................438 Gear Coupling Alignment...........................................440 Hoist Coupling Shaft Alignment....................................441 Compressed Air System.....................................................445 Air Compressor............................................................445 Lockout Valves........................................................447 Safety Warnings.......................................................449 Air Filtration............................................................453 House Filter Fans.........................................................453 Lubrication...........................................................454 Dynavane Air Cleaner..................................................455 Air Conditioner...........................................................456 Specifications........................................................457 Engineering Data..........................................................463 Capscrew (Bolt) Grade.....................................................463 Bolt Tightening.......................................................463 Torque Wrench Method..............................................463 Turn-of-nut Method................................................465 Measurement Systems.......................................................467 Linear Measurements...................................................467 Area Measurements.....................................................467 Volume Measurements...................................................468 Torque Measurements...................................................469 Weight Measurements - Conventional................................470 Split Flange Assembly Procedure...........................................471 Wire Locking Capscrews....................................................473 Torque Nut Installation...................................................474 Tightening Procedure for 1.25-Inch Torque Nut.........................475 Tightening Procedure for 2-Inch Torque Nut............................476 Tightening Procedure for 2-Inch Torque Nut............................477 Tightening Procedure for 2.5-Inch Torque Nut..........................478 Tightening Procedure for 3-Inch Torque Nut............................479 Tightening Procedure for 3.5-Inch Torque Nut..........................480 Procedure for Use of Mechanical Tensioner on Crawler Rods.............481 Initial Tensioning................................................481 Final Tensioning..................................................481 Expansion Bolt Installation...............................................483 Tightening Procedures - Expansion Bolts...............................483 Hoist Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut............483 Rack & Roller Torque Rod, Tapered Sleeve & 1.5 Inch Torque Nut....485 Swing Torque Rod & Tapered Sleeve & 3.5 Inch Torque Nut...........486 Torque Nut Removal Procedure..............................................488 Thread Lubrication....................................................488 Torque Nut Helpful Hints..................................................489 Locking Assemblies........................................................490 Locking Assembly Removal..............................................492 Pinion and Hub Installation...............................................493 Removal from a Shaft..................................................493 Mounting a Pinion or Hub on a Shaft...................................493 Pre-heat Advance Requirements - Pinions and Hubs..................496 Motor Coupling Pre-Heat Advance Requirements......................496 Maintenance Welding.......................................................498 Welding Electrodes....................................................499 Repair Welding of Cracks..............................................500 Preheat...........................................................501 Welding Technique.................................................501 Repair Welding of Broken Parts........................................502 Repair Welding Swing Rack Teeth.......................................503 Preparation.......................................................503 Swing Rack Welding Electrodes.....................................503 Preheat...........................................................503 Welding Procedure.................................................505 Welding and Cutting Equipment.........................................507 Stress Relieving & Temperature Measuring Equipment....................508 Wire Rope Care and Maintenance............................................509 Storage...............................................................509 Checking Diameter.....................................................509 Handling Wire Rope....................................................510 Seizing Wire Rope.....................................................511 End Preparations/Terminations.........................................513 Wire Rope Clips.......................................................513 Wire Rope Clip Application........................................513 Wedge Sockets.....................................................515 Inspection of Sheaves and Drums.......................................516 Breaking In a New Wire Rope...........................................517 Inspection Data.......................................................518 Guideline to Inspections and Reports..................................519 Wire Rope Inspection Criteria.....................................520 Reduction in Rope Diameter....................................520 Rope Stretch..................................................521 Abrasion......................................................522 Corrosion.....................................................522 Kinks.........................................................522 Bird Caging...................................................522 Localized Conditions..........................................522 Heat Damage...................................................522 Protruding Core...............................................522 Damaged End Attachments.......................................523 Peening.......................................................523 Scrubbing.....................................................523 Fatigue Fracture..............................................523 Broken Wires..................................................523 Electric Arc..................................................524 Seals.....................................................................524 Seal Installation.....................................................525 Gearcase Sealing......................................................526 Schematics................................................................528 Schematics................................................................528 Side View.................................................................529 Deck Plan.................................................................530 OGL System A & B Schematic................................................531 Grease System C Schematic.................................................532 Air Schematic.............................................................533
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