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CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL SN 141318 – PDF DOWNLOAD
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CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL SN 141318 – PDF DOWNLOAD
FILE DETAILS:
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL SN 141318 – PDF DOWNLOAD
Language : English
Pages : 534
Downloadable : Yes
File Type : PDF
DESCRIPTION:
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL SN 141318 – 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.
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 SN 141318 – 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......................................................... 40 Deck Extensions....................................................... 42 Ballast Box........................................................... 42 Machinery House....................................................... 42 Boarding Stairs................................................... 43 Vertical Boarding Ladder.......................................... 44 A-Frame............................................................... 45 Hoist Machinery....................................................... 46 Swing Machinery....................................................... 47 Crowd Machinery....................................................... 48 OPERATOR’S CAB........................................................ 49 Compressed Air System................................................. 50 Automatic Lubrication System.......................................... 51 Lube Reservoir fill / Overflow Plumbing............................... 52 Front End Equipment....................................................... 53 Suspension Strands.................................................... 53 Boom.................................................................. 54 Running Ropes......................................................... 55 Saddle Block.......................................................... 56 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 Operation................................................................. 73 General Information....................................................... 73 Operation Near Electrical Lines....................................... 73 Operator’s Seat........................................................... 75 Adjustable Armrest.................................................... 75 Adjustable Footrest................................................... 76 Controls.................................................................. 77 Primary Operating Controls............................................ 77 Controls On The Left Console.......................................... 78 Left Joystick..................................................... 79 Dipper Trip....................................................... 79 Signal Horn....................................................... 79 Start Pushbutton.................................................. 79 PLC Power On...................................................... 80 Drive Cabinet Temperature......................................... 80 Incomplete Sequence............................................... 80 System Ready...................................................... 80 Phase Sequence.................................................... 80 Auxiliary Ground Fault............................................ 80 Hoist Brake....................................................... 80 Crowd Brake....................................................... 80 Swing Brake....................................................... 80 Propel Brake...................................................... 80 HVAC Unit Selector................................................ 80 Temperature....................................................... 80 HVAC System Control............................................... 80 HVAC Fan Speed.................................................... 80 Cabin Lights...................................................... 80 Controls On The Right Console..................................... 81 Right Joystick.................................................... 82 Emergency Stop Pushbutton......................................... 83 Windshield Wiper Switches......................................... 83 Control Stop Pushbutton........................................... 83 Control Reset Pushbutton.......................................... 83 Air Compressor.................................................... 84 Dig/propel Transfer Switch........................................ 84 Main Power Off Pushbutton......................................... 84 Earth Continuity Lockout Pushbutton............................... 84 Seat Position..................................................... 84 Radio Receiver with CD Changer.................................... 85 Operator’s Display........................................................ 85 Display Area and Indicators........................................... 86 Display Screens....................................................... 86 Lubrication Control Panel............................................. 94 Fire Suppression System............................................... 94 Pre-start Checks.......................................................... 94 Walk-around Ground Level Inspection................................... 95 On-board Inspection................................................... 97 Start-up, Operation And Shutdown.......................................... 98 Machine Start-up...................................................... 98 Restarting After An Electrical Fault..................................100 Machine Operation.....................................................100 Machinery Motions.....................................................101 Hoist Motion......................................................101 Crowd Motion......................................................102 Propel Motion.....................................................103 Swing Motion......................................................104 Proper Swing Motion...........................................105 Steering..........................................................106 Counter-rotation Turns........................................108 Positioning the Machine...........................................109 Back-up Method................................................109 Drive-by Method...............................................110 Start Of The Dig Cycle............................................111 Engaging The Bank.................................................114 Slope Limitations.................................................116 Excavated Material....................................................118 Operation Checks......................................................118 Operating Hints.......................................................119 Stopping the Machine..................................................120 Shutdown..............................................................120 Lubrication...............................................................123 Lubrication Principles....................................................123 Greasing Main A.C. Drive Motors...........................................124 1. Type of Grease.....................................................124 2. Initial Commissioning..............................................124 3. Maintenance........................................................124 4. Regreasing Intervals...............................................125 Lubricant Selection.......................................................125 Oil Fill Capacities.......................................................127 Types Of Lubricants And Capacities Guidelines.........................127 Quantities for First Fill of Lubricants...........................127 Automatic Lubrication System..............................................128 Lube Room.............................................................129 Lube Reservoir fill / Overflow Plumbing...............................130 Auto Lube Control Panel...........................................131 Lower Works Lubrication...............................................131 Propel Machinery Lubrication..........................................132 Lubricant Replacement/sampling....................................133 Lubricant Change Cycle........................................133 Revolving Frame Lubrication...........................................134 Hoist Machinery Lubrication...........................................135 Hoist Oil Cooler..................................................136 Filter Element Cleaning...........................................139 Hoist Rope Rollers Lubrication........................................140 Oil Pump..........................................................141 Crowd Machinery Lubrication...........................................142 Swing Machinery Lubrication...........................................143 Air Compressor Lubrication............................................144 Crowd Rope Take-Up Mechanism Lubrication..............................145 Front End Lubrication.................................................145 Lincoln Type SL-1 Lubricant Injectors.................................147 SL-1 Lubricant Injector Operation.................................149 Injector Advantages...............................................151 Air Compressor Lubricant..............................................151 MPO - Multipurpose OIL................................................152 RWRL - Running Wire Rope Lubricant....................................153 EGL - Enclosed Gearcase Lubricant.....................................154 MPG - Multipurpose Grease.............................................157 OGL - Open Gear Lubricant.............................................161 Certified Lubricants Listing..........................................165 Preventive Maintenance....................................................173 Introduction..............................................................173 Preventive Maintenance Program........................................173 Elements of an Effective Maintenance Program..........................174 Scheduled Preventive Maintenance Program..............................175 General Safety Considerations.........................................175 Maintenance During Machine Operation......................................176 Maintenance Precautions...............................................177 Preventive Maintenance for Lubrication....................................178 Lubricant Cleanliness.................................................179 Frequency of Inspection and Maintenance...................................180 Maintenance Schedules.....................................................180 Maintenance Inspection Check Points...................................180 Daily.............................................................181 Every 100 Hours or Weekly.........................................184 Every 500 Hours Or Monthly........................................185 Every 1250 Hours or Quarterly.....................................188 Every 2500 Hours or Semi-Annually.................................191 5000 Hours or Annually............................................193 Major Component Locations.................................................195 Service Procedures........................................................223 Lower Works...............................................................223 Truck Frame Assembly..................................................223 Swing Rack Assembly...................................................224 Roller Circle Rail Replacement - Lower............................224 Roller Circle Rail Replacement - Upper............................225 Roller Circle Assembly................................................227 Roller Circle Adjustment..........................................229 Adjustment Procedure..............................................229 Run-in Procedure for the Roller Circle............................229 Roller Circle Segment Removal.....................................230 Roller Circle - Roller Replacement................................231 Crawler Belts.........................................................232 Crawler Belt Maintenance..........................................232 Crawler Belt Tension Adjustment...............................234 Crawler Shoe Replacement......................................236 Crawler Belt Replacement......................................237 Crawler Side Frame Assembly...........................................238 Crawler Side Frame Maintenance....................................239 Slide Bar Replacement.............................................240 Crawler Front Idler Roller Assembly...............................241 Load and Idler Rollers............................................244 Roller Removal or Replacement.................................244 Propel Assembly.......................................................247 Installation Notes................................................249 Main Propel Drive Shaft Removal...................................250 Main Propel Shaft - Disassembly...................................253 Tumbler Rebuild Procedure.........................................254 Propel Machinery......................................................256 Propel Gearcase Removal...........................................257 Propel Gearcase Installation......................................258 Propel Planetary Gearcase.........................................260 Propel Motors.....................................................261 Propel Motor Removal..........................................261 Propel Motor Installation.....................................263 Revolving Frame.......................................................264 Center Pintle.........................................................265 Center Pintle Adjustment..........................................270 Center Pintle Sleeve Removal......................................270 Collector Rings.......................................................272 Collector Ring Inspection.........................................273 Collector Ring Repair.............................................273 Rotating Deck.............................................................273 Swing Machinery.......................................................274 Swing Support Mounting Bolts......................................276 Swing Motor.......................................................276 Swing Blower..................................................276 Swing Motor Removal...........................................277 Swing Motor Installation......................................277 Swing Planetary Gearcase..........................................278 Swing Gearcase Removal........................................279 Gearcase Inspection...........................................280 Swing Pinion Shafts...............................................281 Swing Pinion Shaft Removal....................................282 Swing Pinion Shaft Disassembly................................283 Swing Pinion Shaft Assembly...................................284 Swing Pinion Shaft Installation...............................285 Hoist Machinery.......................................................286 Hoist Motor Removal...............................................287 Motor Coupling Shaft..............................................290 Hoist Gearcase Assembly...........................................291 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...................................................321 Vertical Boarding Ladder, left....................................324 Front End Equipment.......................................................326 Boom Assembly.........................................................327 Boom Repair.......................................................328 Boom Limit Switch Installation........................................329 Boom Point Sheaves....................................................331 Boom Point Sheave Removal and Disassembly.........................332 Boom Point Sheave Reassembly and Installation.....................334 Boom Bumper...........................................................335 Saddle Block..........................................................336 Saddle Block Repair...............................................336 Saddle Block Removal..........................................337 Dipper Handle.........................................................339 Dipper Handle Removal.............................................341 Crowd Rope Take-Up Mechanism......................................343 Crowd Rope Take-Up Mechanism Disassembly......................344 Crowd Rope Take-Up Mechanism Assembly.........................345 Retract Rope Take-up Mechanism....................................348 Spreader Repair...................................................350 Dipper Assembly...........................................................351 Latch Bar Adjusting...................................................354 Dipper Door bumpers...................................................355 Dipper Removal & Installation.....................................356 Dipper Door Snubbers..................................................361 Snubber Adjustment................................................362 Allowable Wear....................................................362 Dipper Pitch Brace....................................................363 Dipper Padlock........................................................364 Dipper Trip Assembly..................................................367 A-Frame...............................................................368 Auxiliary Winch.......................................................370 Hoist Rope Support Roller.............................................371 Boom Support Ropes....................................................372 Wire Ropes............................................................373 Wire Rope Inspection..............................................374 Crowd Rope Take-up Hydraulic Unit.....................................375 Hoist Rope Reeving & Replacement......................................377 Crowd Rope Reeving & Replacement......................................381 Retract Rope Reeving & Replacement....................................383 Crowd Rope Tightening.................................................387 Retract Rope Tightening...............................................389 Dipper Trip Rope Reeving & Replacement................................390 Hoist and Crowd Limit Systems.........................................390 Setting Limits In The Hoist & Crowd System........................391 Crowd Slowdown/Stop Limits....................................393 Retract Slowdown/Stop Limits..................................394 Lower Slowdown/Stop Limits....................................395 Hoist Slowdown/Stop Limits....................................396 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................................................482 Final Tensioning..................................................482 Expansion Bolt Installation...............................................484 Tightening Procedures - Expansion Bolts...............................484 Hoist Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut............484 Rack & Roller Torque Rod, Tapered Sleeve & 1.5 Inch Torque Nut....485 Swing Torque Rod & Tapered Sleeve & 3.5 Inch Torque Nut...........487 Torque Nut Removal Procedure..............................................489 Thread Lubrication....................................................489 Torque Nut Helpful Hints..................................................490 Locking Assemblies........................................................491 Locking Assembly Removal..............................................493 Pinion and Hub Installation...........................................494 Removal from a Shaft..................................................494 Mounting a Pinion or Hub on a Shaft...................................494 Hub Adapter Pre-heat Advance Requirements.........................497 Motor Coupling Pre-Heat Advance Requirements......................497 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.................... 0 Storage............................................................... 0 Checking Diameter..................................................... 0 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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