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 SN 141266 – PDF DOWNLOAD
$40.95
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL SN 141266 – PDF DOWNLOAD
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 SN 141266 – PDF DOWNLOAD
FILE DETAILS:
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL SN 141266 – PDF DOWNLOAD
Language : English
Pages : 546
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL SN 141266 – PDF DOWNLOAD
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.
Operation
GENERAL INFORMATION
- This section of the manual will assist in the operation of this machine. It provides the operator with the location and explanation of the controls, instructions for machine operation and certain maneuvering techniques. Throughout this section and the remainder of the manual, the use of the terms “LEFT, RIGHT, FRONT and REAR” refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.
- Safe operation of the machine minimizes production delays and costly damage to equipment. Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to prevent accidents from occurring and are provided in the interest of all mine personnel. Overall safety depends upon the use of good judgment and the alertness of the entire mining crew. Refer to Section 1 in this manual for specific safety precautions.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL SN 141266 – 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 Stinger (Trail Cable Support)............................................. 39 Rotating Deck............................................................. 39 Revolving Frame....................................................... 40 Center Pintle......................................................... 40 Deck Extensions....................................................... 42 Ballast Box........................................................... 42 Machinery House....................................................... 42 Boarding Stairs................................................... 43 Vertical Boarding Ladder.......................................... 44 Power Step............................................................ 45 A-Frame............................................................... 46 Hoist Machinery....................................................... 47 Swing Machinery....................................................... 48 Crowd Machinery....................................................... 49 OPERATOR’S CAB........................................................ 50 Compressed Air System................................................. 51 Automatic Lubrication System.......................................... 52 Lube Reservoir fill / Overflow Plumbing............................... 53 Front End Equipment....................................................... 54 Suspension Strands.................................................... 54 Boom.................................................................. 55 Running Ropes......................................................... 56 Saddle Block.......................................................... 57 Dipper Handle......................................................... 57 Dipper................................................................ 58 Padlocks.............................................................. 59 Dipper Trip........................................................... 60 Typical Machine Specifications............................................ 61 General Estimated Component Weights....................................... 63 Lower Works........................................................... 63 Upper Works........................................................... 64 Front End............................................................. 66 Side View................................................................. 69 Deck Plan................................................................. 70 Operation................................................................. 75 General Information....................................................... 75 Operation Near Electrical Lines....................................... 75 Adjustable Armrest.................................................... 77 Adjustable Footrest................................................... 78 Controls.................................................................. 78 Controls On The Left Console.......................................... 80 Left Joystick..................................................... 81 Dipper Trip....................................................... 81 Signal Horn....................................................... 81 Start Pushbutton.................................................. 81 PLC Power On...................................................... 82 Drive Cabinet Temperature......................................... 82 Incomplete Sequence............................................... 82 System Ready...................................................... 82 Phase Sequence.................................................... 82 Auxiliary Ground Fault............................................ 82 Hoist Brake....................................................... 82 Crowd Brake....................................................... 82 Swing Brake....................................................... 82 Propel Brake...................................................... 82 HVAC Unit Selector................................................ 82 Temperature....................................................... 82 HVAC System Control............................................... 82 HVAC Fan Speed.................................................... 82 Cabin Lights...................................................... 83 Auxiliary Heater.................................................. 83 Controls On The Right Console......................................... 84 Right Joystick.................................................... 85 Emergency Stop Pushbutton......................................... 86 Windshield Wiper Switches......................................... 86 Control Stop Pushbutton........................................... 86 Control Reset Pushbutton.......................................... 86 Air Compressor.................................................... 87 Dig/propel Transfer Switch........................................ 87 Main Power Off Pushbutton......................................... 87 Earth Continuity Lockout Pushbutton............................... 87 Seat Position..................................................... 87 Radio/cassette/cd................................................. 88 Heated Mirrors.................................................... 88 Operator’s Display........................................................ 89 Display Area and Indicators........................................... 90 Display Screens....................................................... 90 Lubrication Control Panel............................................. 98 Fire Suppression System............................................... 98 Pre-start Checks.......................................................... 98 Walk-around Ground Level Inspection................................... 99 On-board Inspection...................................................101 Start-up, Operation And Shutdown..........................................102 Machine Start-up......................................................102 Restarting After An Electrical Fault..................................103 Machine Operation.....................................................103 Machinery Motions.....................................................104 Hoist Motion......................................................104 Crowd Motion......................................................105 Propel Motion.....................................................106 Swing Motion......................................................107 Proper Swing Motion...........................................108 Steering..........................................................109 Counter-rotation Turns........................................111 Positioning the Machine...........................................112 Back-up Method................................................112 Drive-by Method...............................................113 Start Of The Dig Cycle............................................114 Engaging The Bank.................................................117 Slope Limitations.................................................119 Excavated Material....................................................121 Operation Checks......................................................121 Operating Hints.......................................................122 Stopping the Machine..................................................123 Shutdown..............................................................123 Lubrication...............................................................127 Lubrication Principles....................................................127 Greasing Main A.C. Drive Motors...........................................128 1. Type of Grease.....................................................128 2. Initial Commissioning..............................................128 3. Maintenance........................................................128 4. Regreasing Intervals...............................................129 Lubricant Selection.......................................................129 Oil Fill Capacities.......................................................131 Types Of Lubricants And Capacities Guidelines.........................131 Quantities for First Fill of Lubricants...........................131 Automatic Lubrication System..............................................132 Lube Room.............................................................133 Lube Reservoir fill / Overflow Plumbing...............................134 Auto Lube Control Panel...........................................135 Lower Works Lubrication...............................................135 Propel Machinery Lubrication..........................................136 Lubricant Replacement/sampling....................................137 Lubricant Change Cycle........................................137 Revolving Frame Lubrication...........................................138 Hoist Machinery Lubrication...........................................139 Hoist Oil Cooler..................................................140 Filter Element Cleaning...........................................143 Hoist Rope Rollers Lubrication........................................144 Oil Pump..........................................................145 Crowd Machinery Lubrication...........................................146 Swing Machinery Lubrication...........................................147 Air Compressor Lubrication............................................148 Crowd Rope Take-Up Mechanism Lubrication..............................149 Front End Lubrication.................................................149 Lincoln Type SL-1 Lubricant Injectors.................................151 SL-1 Lubricant Injector Operation.................................153 Injector Advantages...............................................155 Air Compressor Lubricant..............................................155 MPO - Multipurpose OIL................................................156 RWRL - Running Wire Rope Lubricant....................................157 EGL - Enclosed Gearcase Lubricant.....................................158 MPG - Multipurpose Grease.............................................161 OGL - Open Gear Lubricant.............................................165 Certified Lubricants Listing..........................................169 Schematics - Automatic Lubrication........................................174 OGL System A & B Schematic................................................177 Grease System C Schematic.................................................178 Preventive Maintenance....................................................181 Introduction..............................................................181 Preventive Maintenance Program........................................181 Elements of an Effective Maintenance Program..........................182 Scheduled Preventive Maintenance Program..............................183 General Safety Considerations.........................................183 Maintenance During Machine Operation......................................184 Maintenance Precautions...............................................185 Preventive Maintenance for Lubrication....................................186 Lubricant Cleanliness.................................................187 Frequency of Inspection and Maintenance...................................188 Maintenance Schedules.....................................................188 Maintenance Inspection Check Points...................................188 Daily.............................................................189 Every 100 Hours or Weekly.........................................192 Every 500 Hours Or Monthly........................................193 Every 1250 Hours or Quarterly.....................................196 Every 2500 Hours or Semi-Annually.................................199 5000 Hours or Annually............................................201 Major Component Locations.................................................203 Service Procedures........................................................233 Lower Works...............................................................233 Truck Frame Assembly..................................................233 Swing Rack Assembly...................................................234 Roller Circle Rail Replacement - Lower............................234 Roller Circle Rail Replacement - Upper............................235 Roller Circle Assembly................................................237 Roller Circle Adjustment..........................................239 Adjustment Procedure..............................................239 Run-in Procedure for the Roller Circle............................239 Roller Circle Segment Removal.....................................240 Roller Circle - Roller Replacement................................241 Crawler Belts.............................................................242 Crawler Belt Maintenance..............................................242 Crawler Belt Tension Adjustment...................................243 Crawler Shoe Replacement..........................................245 Crawler Belt Replacement..........................................246 Crawler Side Frame Assembly...........................................247 Crawler Side Frame Maintenance....................................248 Slide Bar Replacement.............................................249 Crawler Front Idler Roller Assembly...............................250 Load and Idler Rollers............................................253 Roller Removal or Replacement.................................253 Propel Assembly...........................................................256 Installation Notes....................................................258 Main Propel Drive Shaft Removal.......................................259 Main Propel Shaft - Disassembly...................................262 Tumbler Rebuild Procedure.........................................263 Propel Machinery......................................................265 Propel Gearcase Removal...........................................266 Propel Gearcase Installation......................................267 Propel Planetary Gearcase.........................................269 Propel Motors.....................................................270 Propel Motor Removal..........................................270 Propel Motor Installation.....................................273 Center Pintle.........................................................274 Center Pintle Adjustment..........................................279 Center Pintle Sleeve Removal......................................280 Collector Rings.......................................................282 Collector Ring Inspection.........................................283 Collector Ring Repair.............................................284 Stinger (Trail Cable Support).............................................285 Rotating Deck.............................................................285 Swing Machinery...........................................................286 Swing Support Mounting Bolts..........................................288 Swing Motor...........................................................288 Swing Blower......................................................288 Swing Motor Removal...............................................289 Swing Motor Installation..........................................289 Swing Planetary Gearcase..............................................290 Swing Gearcase Removal............................................291 Gearcase Inspection...............................................292 Swing Pinion Shafts...............................................293 Swing Pinion Shaft Removal....................................294 Swing Pinion Shaft Disassembly................................295 Swing Pinion Shaft Assembly...................................296 Swing Pinion Shaft Installation...............................297 Hoist Machinery.......................................................298 Hoist Motor Removal...............................................299 Motor Coupling Shaft..............................................302 Hoist Gearcase Assembly...........................................303 Hoist Gearcase Repair.............................................305 Hoist Drum Assembly...............................................308 Hoist Gear Replacement........................................310 Bearing Removal...............................................312 Bearing Installation..........................................313 Hoist Oil Cooler..................................................315 Hoist Mounting Bolts..................................................316 Hoist Limit Switch....................................................317 Crowd Machinery...........................................................318 Crowd Gearcase Disassembly............................................320 Crowd Gearcase Assembly...............................................323 Crowd Motor...............................................................324 Crowd Gear and Drum...................................................326 Crowd Drum Removal....................................................326 Operator’s Cab Mounting...............................................328 Operator’s Seat Installation..............................................329 Footrest Installation.....................................................331 Machinery House...........................................................332 Walkways, Stairways, and Handrails....................................333 Boarding Stairs.......................................................334 Power Step............................................................336 Vertical Boarding Ladder, left....................................337 Boom Assembly.........................................................340 Boom Repair.......................................................341 Boom Limit Switch Installation........................................342 Boom Point Sheaves................................................344 Boom Point Sheave Removal and Disassembly.........................345 Boom Point Sheave Reassembly and Installation.....................347 Boom Bumper...........................................................348 Saddle Block..........................................................349 Saddle Block Repair...............................................349 Saddle Block Removal..........................................350 Dipper Handle.........................................................352 Dipper Handle Removal.............................................354 Crowd Rope Take-Up Mechanism......................................356 Crowd Rope Take-Up Mechanism Disassembly......................357 Crowd Rope Take-Up Mechanism Assembly.........................358 Retract Rope Take-up Mechanism....................................361 Spreader Repair...................................................363 Dipper Assembly...........................................................364 Latch Bar Adjusting...................................................367 Dipper Door bumpers...................................................368 Dipper Removal & Installation.....................................369 Dipper Door Snubbers..............................................374 Snubber Adjustment............................................375 Allowable Wear................................................375 Dipper Pitch Brace....................................................376 Dipper Padlock........................................................377 Dipper Trip Assembly..................................................380 A-Frame...............................................................381 Auxiliary Winch.......................................................383 Hoist Rope Support Roller.............................................384 Boom Support Ropes....................................................385 Wire Ropes............................................................386 Wire Rope Inspection..............................................387 Crowd Rope Take-up Hydraulic Unit.........................................388 Hoist Rope Reeving & Replacement......................................390 Crowd Rope Reeving & Replacement..................................394 Retract Rope Reeving & Replacement........................................397 Crowd Rope Tightening.................................................400 Retract Rope Tightening...............................................403 Dipper Trip Rope Reeving & Replacement................................404 Hoist and Crowd Limit Systems.........................................404 Setting Limits In The Hoist & Crowd System........................405 Crowd Slowdown/Stop Limits....................................407 Retract Slowdown/Stop Limits..................................408 Lower Slowdown/Stop Limits....................................409 Hoist Slowdown/Stop Limits....................................410 Brakes and Couplings......................................................413 Brakes....................................................................413 Disc Brake Operation..................................................414 Maintenance...........................................................414 Brake Adjustment Specifications.......................................414 Hoist Brake...........................................................415 Hoist Brake Adjustment............................................417 Hoist Brake Installation..........................................419 Hoist Brake Wear & Release Switches...............................419 Crowd Brake...........................................................420 Crowd Brake Installation..........................................422 Crowd Brake Wear & Release Switches...............................423 Propel Brake..........................................................425 Propel Brake Adjustment...........................................427 Propel Brake Installation.........................................429 Tachometer Mounting & Alignment...................................431 Swing Brake...........................................................433 Swing Brake Installation..........................................435 Swing Brake Wear & Release Switches...............................436 Swing Brake Burnishing............................................437 Spring Replacement — All Brakes.......................................437 Friction Disc Replacement — All Brakes................................439 O-Ring Replacement — All Brakes.......................................440 Brake Wear & Release Switches — Single Disc Brakes....................442 Brake Wear & Release Switches — Multiple Disc Brakes..................443 Couplings.................................................................444 Grid Couplings........................................................444 Lubrication.......................................................444 Coupling Disassembly and Grid Removal.............................445 Grid Coupling Installation........................................446 Seal Replacement without Hub Removal..............................449 Grid Coupling Alignment...........................................451 Gear Couplings........................................................452 Coupling Installation.............................................452 Gear Coupling Alignment...........................................454 Hoist Coupling Shaft Alignment....................................455 Compressed Air System.....................................................459 Air Compressor............................................................459 Lockout Valves........................................................461 Safety Warnings.......................................................463 Air Schematic.............................................................465 Air Filtration............................................................469 House Filter Fans.........................................................469 Lubrication...........................................................470 Dynavane Air Cleaner..................................................471 AIR FILTRATION SYSTEM.................................................472 Air Conditioner.......................................................474 Specifications........................................................475 Engineering Data..........................................................481 Capscrew (Bolt) Grade.....................................................481 Bolt Tightening.......................................................482 Torque Wrench Method..............................................482 Turn-of-nut Method................................................484 Measurement Systems.......................................................486 Linear Measurements...................................................486 Area Measurements.....................................................486 Volume Measurements...................................................487 Torque Measurements...................................................488 Weight Measurements - Conventional................................489 Split Flange Assembly Procedure...........................................490 Wire Locking Capscrews....................................................492 Torque Nut Installation...................................................493 Tightening Procedure for 1.25-Inch Torque Nut.........................494 Tightening Procedure for 2-Inch Torque Nut............................495 Tightening Procedure for 2-Inch Torque Nut............................496 Tightening Procedure for 2.5-Inch Torque Nut..........................497 Tightening Procedure for 3-Inch Torque Nut............................498 Tightening Procedure for 3.5-Inch Torque Nut..........................499 Procedure for Use of Mechanical Tensioner on Crawler Rods.............500 Initial Tensioning................................................501 Final Tensioning..................................................501 Expansion Bolt Installation...............................................503 Tightening Procedures - Expansion Bolts...............................503 Hoist Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut............503 Rack & Roller Torque Rod, Tapered Sleeve & 1.5 Inch Torque Nut....504 Swing Torque Rod & Tapered Sleeve & 3.5 Inch Torque Nut...........506 Torque Nut Removal Procedure..............................................508 Thread Lubrication....................................................508 Torque Nut Helpful Hints..................................................509 Locking Assemblies........................................................510 Locking Assembly Removal..............................................512 Pinion and Hub Installation...........................................513 Removal from a Shaft..................................................513 Mounting a Pinion or Hub on a Shaft...................................513 Hub Adapter Pre-heat Advance Requirements.........................516 Motor Coupling Pre-Heat Advance Requirements......................516 Maintenance Welding.......................................................517 Welding Electrodes....................................................518 Repair Welding of Cracks..............................................519 Preheat...........................................................520 Welding Technique.................................................520 Repair Welding of Broken Parts........................................521 Repair Welding Swing Rack Teeth.......................................522 Preparation.......................................................522 Swing Rack Welding Electrodes.....................................522 Preheat...........................................................522 Welding Procedure.................................................524 Welding and Cutting Equipment.........................................526 Stress Relieving & Temperature Measuring Equipment....................527 Storage...............................................................527 Checking Diameter.....................................................528 Handling Wire Rope....................................................529 Seizing Wire Rope.....................................................530 End Preparations/Terminations.........................................532 Wire Rope Clips.......................................................532 Wire Rope Clip Application........................................532 Wedge Sockets.....................................................534 Inspection of Sheaves and Drums.......................................535 Breaking In a New Wire Rope...........................................536 Inspection Data.......................................................537 Guideline to Inspections and Reports..................................538 Wire Rope Inspection Criteria.....................................539 Reduction in Rope Diameter....................................539 Rope Stretch..................................................540 Abrasion......................................................541 Corrosion.....................................................541 Kinks.........................................................541 Bird Caging...................................................541 Localized Conditions..........................................541 Heat Damage...................................................541 Protruding Core...............................................541 Damaged End Attachments.......................................542 Peening.......................................................542 Scrubbing.....................................................542 Fatigue Fracture..............................................542 Broken Wires..................................................542 Electric Arc..................................................543 Seals.....................................................................543 Seal Installation.....................................................544 Gearcase Sealing......................................................545
Contact us: [email protected]
https://vimeo.com/859765280?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
