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CAT Bucyrus 495HF Mining Shovel Maintenance & Operation Manual SN 141258 PDF DOWNLOAD
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CAT Bucyrus 495HF Mining Shovel Maintenance & Operation Manual SN 141258 PDF DOWNLOAD
Manual No. 10653
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Description
CAT Bucyrus 495HF Mining Shovel Maintenance & Operation Manual SN 141258 PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus 495HF Mining Shovel Maintenance & Operation Manual SN 141258 PDF DOWNLOAD
Language : English
Pages : 548
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT Bucyrus 495HF Mining Shovel Maintenance & Operation Manual SN 141258 PDF DOWNLOAD
Manual No. 10653
Safety Precautions........................................................ 4 General Precautions................................................... 5 Maintenance Precautions............................................... 6 Operating Precautions................................................. 7 FIRE PREVENTION....................................................... 8 Warning Signs And Decals.............................................. 9 Introduction.............................................................. 27 General Information....................................................... 27 SWINGING RESTRAINT & BALLAST BOX SUPPORT.............................. 28 Ballast Box Support............................................... 28 Swinging Restraint................................................ 29 Machine Overview.......................................................... 31 Lower Works............................................................... 32 Crawlers.............................................................. 33 Truck Frame........................................................... 34 Swing Rack............................................................ 35 Roller Circle......................................................... 36 Propel Machinery...................................................... 37 Collector Rings....................................................... 38 Rotating Deck............................................................. 39 Revolving Frame....................................................... 39 Center Pintle......................................................... 39 Deck Extensions....................................................... 41 Ballast Box........................................................... 41 Machinery House....................................................... 41 Boarding Stairs................................................... 42 Vertical Boarding Ladder.......................................... 43 A-Frame............................................................... 44 Hoist Machinery....................................................... 45 Swing Machinery....................................................... 46 Crowd Machinery....................................................... 47 Operator’s Cab........................................................ 48 Compressed Air System................................................. 49 Automatic Lubrication System.......................................... 50 Lube Reservoir fill / Overflow Plumbing............................... 51 Front End Equipment....................................................... 52 Suspension Strands.................................................... 52 Boom.................................................................. 53 Running Ropes......................................................... 54 Saddle Block.......................................................... 55 Dipper Handle......................................................... 55 Dipper................................................................ 56 Padlocks.............................................................. 57 Dipper Trip........................................................... 58 Typical Machine Specifications............................................ 58 General Estimated Component Weights....................................... 61 Lower Works........................................................... 61 Upper Works........................................................... 62 Front End............................................................. 64 Side View................................................................. 67 Deck Plan................................................................. 68 Operation................................................................. 73 General Information....................................................... 73 Operation Near Electrical Lines....................................... 73 Controls.................................................................. 74 Primary Operating Controls................................................ 75 Controls on the left console.......................................... 76 Left Joystick..................................................... 77 Dipper Trip....................................................... 77 Signal Horn....................................................... 77 Start Pushbutton.................................................. 78 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.................................................... 79 Cabin Lights...................................................... 79 Auxiliary Heater.................................................. 79 CONTROLS ON THE RIGHT CONSOLE......................................... 80 Right Joystick.................................................... 81 Emergency Stop Pushbutton......................................... 82 Windshield Wiper Switches......................................... 82 Control Stop Pushbutton........................................... 82 Control Reset Pushbutton.......................................... 82 Air Compressor.................................................... 83 Dig/propel Transfer Switch........................................ 83 Main Power Off Pushbutton......................................... 83 Earth Continuity Lockout Pushbutton............................... 83 Seat Position..................................................... 84 Radio/cassette/cd................................................. 84 Heated Mirrors.................................................... 84 Man On Ground..................................................... 84 Operator’s Display........................................................ 85 Display Area and Indicators........................................... 86 Display Screens....................................................... 87 Lubrication Control Panel............................................. 94 Fire Suppression System............................................... 95 Pre-start Checks.......................................................... 95 Walk-around Ground Level Inspection................................... 96 On-board Inspection................................................... 98 Machine Start-up...................................................... 98 Restarting After An Electrical Fault..................................100 Machine Operation.....................................................100 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 ACSL - Air Compressor (Screw-Type) Lubricant..........................152 MPO - Multipurpose OIL................................................152 RWRL - Running Wire Rope Lubricant....................................154 EGL - Enclosed Gearcase Lubricant.....................................155 MPG - Multipurpose Grease.............................................158 OGL - Open Gear Lubricant.............................................162 Certified Lubricants Listing..........................................166 Schematics - Automatic Lubrication........................................171 OGL System A & B Schematic................................................173 Grease System C Schematic.................................................174 Preventive Maintenance....................................................177 Introduction..............................................................177 Preventive Maintenance Program........................................177 Elements of an Effective Maintenance Program..........................178 Scheduled Preventive Maintenance Program..............................179 General Safety Considerations.........................................179 Maintenance During Machine Operation......................................180 Maintenance Precautions...............................................181 Preventive Maintenance for Lubrication....................................182 Lubricant Cleanliness.................................................183 Frequency of Inspection and Maintenance...................................184 Maintenance Schedules.....................................................184 Maintenance Inspection Check Points...................................184 Daily.............................................................185 Every 100 Hours or Weekly.........................................188 Every 500 Hours Or Monthly........................................189 Every 1250 Hours or Quarterly.....................................192 Every 2500 Hours or Semi-Annually.................................195 5000 Hours or Annually............................................197 MAJOR COMPONENT LOCATIONS.................................................199 Service Procedures........................................................227 LOWER WORKS...............................................................227 Truck Frame Assembly..................................................227 Swing Rack Assembly...................................................228 Roller Circle Rail Replacement - Lower............................228 Roller Circle Rail Replacement - Upper............................229 Roller Circle Assembly................................................231 Roller Circle Adjustment..........................................233 Adjustment Procedure..............................................233 Run-in Procedure for the Roller Circle............................233 Roller Circle Segment Removal.....................................234 Roller Circle - Roller Replacement................................235 Crawler Belts.............................................................236 Crawler Belt Maintenance..............................................236 Crawler Belt Tension Adjustment...................................237 Crawler Shoe Replacement..........................................239 Crawler Belt Replacement..........................................240 Crawler Side Frame Assembly...........................................241 Crawler Side Frame Maintenance....................................242 Slide Bar Replacement.............................................243 Crawler Front Idler Roller Assembly...............................244 Load and Idler Rollers............................................247 Roller Removal or Replacement.................................247 Propel Assembly...........................................................251 Installation Notes....................................................253 Main Propel Drive Shaft Removal.......................................254 Main Propel Shaft - Disassembly...................................258 Tumbler Rebuild Procedure.........................................259 Propel Machinery......................................................262 Propel Gearcase Removal...........................................263 Propel Gearcase Installation......................................264 Propel Planetary Gearcase.........................................266 Propel Motors.....................................................267 Propel Motor Removal..........................................267 Propel Motor Installation.....................................269 Center Pintle.........................................................270 Center Pintle Adjustment..........................................275 Center Pintle Sleeve Removal......................................276 Collector Rings.......................................................278 Collector Ring Inspection.........................................279 Collector Ring Repair.............................................280 Rotating Deck.............................................................280 Swing Machinery...........................................................281 Swing Support Mounting Bolts..........................................283 Swing Motor...........................................................283 Swing Blower......................................................283 Swing Motor Removal...............................................284 Swing Motor Installation..........................................284 Swing Planetary Gearcase..............................................285 Swing Gearcase Removal............................................286 Gearcase Inspection...............................................287 Swing Pinion Shafts...............................................288 Swing Pinion Shaft Removal....................................289 Swing Pinion Shaft Disassembly................................290 Swing Pinion Shaft Assembly...................................291 Swing Pinion Shaft Installation...............................292 Hoist Machinery.......................................................293 Hoist Motor Removal...............................................294 Motor Coupling Shaft..............................................297 HOIST GEARCASE ASSEMBLY...........................................298 Hoist Gearcase Repair.............................................300 Hoist Drum Assembly...............................................303 Hoist Gear Replacement........................................306 Bearing Removal...............................................308 Bearing Installation..........................................309 Hoist Oil Cooler..................................................310 Hoist Mounting Bolts..................................................311 Hoist Limit Switch....................................................312 Crowd Machinery...........................................................313 Crowd Gearcase Disassembly............................................315 Crowd Gearcase Assembly...............................................318 Crowd Motor...............................................................320 Crowd Gear and Drum...................................................322 Crowd Drum Removal....................................................323 Operator’s Cab Mounting...............................................325 Machinery House...........................................................326 Walkways, Stairways, and Handrails....................................327 Boarding Stairs.......................................................327 Vertical Boarding Ladder, left........................................330 Front End Equipment...................................................332 Boom Assembly.........................................................333 Boom Repair.......................................................334 Boom Limit Switch Installation........................................335 Boom Point Sheaves................................................337 Boom Point Sheave Removal and Disassembly.........................338 Boom Point Sheave Reassembly and Installation.....................340 Boom Bumper...........................................................342 Saddle Block..........................................................343 Saddle Block Repair...............................................343 Saddle Block Removal..........................................344 Dipper Handle.........................................................346 Dipper Handle Removal.............................................348 Crowd Rope Take-Up Mechanism......................................350 Crowd Rope Take-Up Mechanism Disassembly......................351 Crowd Rope Take-Up Mechanism Assembly.........................353 Retract Rope Take-up Mechanism....................................355 Spreader Repair...................................................357 Dipper Assembly...........................................................358 Latch Bar Adjusting...................................................361 Dipper Door bumpers...................................................362 Dipper Removal & Installation.....................................363 Dipper Door Snubbers..............................................368 Snubber Adjustment............................................369 Allowable Wear................................................369 Dipper Pitch Brace....................................................370 Dipper Padlock........................................................371 Dipper Trip Assembly..................................................374 Auxiliary Winch.......................................................376 A-Frame...............................................................376 Hoist Rope Support Roller.............................................379 Boom Support Ropes....................................................380 Wire Ropes............................................................381 Wire Rope Inspection..............................................382 Crowd Rope Take-up Hydraulic Unit.........................................383 Hoist Rope Reeving & Replacement......................................385 Crowd Rope Reeving & Replacement..................................389 Retract Rope Reeving & Replacement........................................392 Crowd Rope Tightening.................................................396 Retract Rope Tightening...............................................398 Dipper Trip Rope Reeving & Replacement................................399 Hoist and Crowd Limit Systems.........................................399 Setting Limits In The Hoist & Crowd System........................400 Crowd Slowdown/Stop Limits....................................402 Retract Slowdown/Stop Limits..................................403 Lower Slowdown/Stop Limits....................................404 Hoist Slowdown/Stop Limits....................................405 Brakes and Couplings......................................................409 Brakes....................................................................409 Disc Brake Operation..................................................410 Maintenance...........................................................410 Brake Adjustment Specifications.......................................410 Hoist Brake...........................................................411 Hoist Brake Adjustment............................................413 Hoist Brake Installation..........................................415 Hoist Brake Wear & Release Switches...............................415 Crowd Brake...........................................................416 Crowd Brake Installation..........................................418 Crowd Brake Wear & Release Switches...............................419 Propel Brake..........................................................421 Propel Brake Adjustment...........................................423 Propel Brake Installation.........................................425 Tachometer Mounting & Alignment...................................427 Swing Brake...........................................................429 Swing Brake Installation..........................................431 Swing Brake Wear & Release Switches...............................432 Swing Brake Burnishing............................................433 Spring Replacement — All Brakes.......................................433 Friction Disc Replacement — All Brakes................................435 O-Ring Replacement — All Brakes.......................................436 Brake Wear & Release Switches — Single Disc Brakes....................438 Brake Wear & Release Switches — Multiple Disc Brakes..................439 Couplings.................................................................440 Grid Couplings........................................................440 Lubrication.......................................................440 Coupling Disassembly and Grid Removal.............................441 Grid Coupling Installation........................................442 Seal Replacement without Hub Removal..............................445 Grid Coupling Alignment...........................................447 Gear Couplings........................................................448 Coupling Installation.............................................448 Gear Coupling Alignment...........................................450 Hoist Coupling Shaft Alignment....................................451 Compressed Air System.....................................................455 Air Compressor - dual.....................................................455 Compressor Start-Up Procedure.........................................457 Compressor SHutdown Procedure.........................................457 Compressor Fluid Level Check..........................................457 Compressor Maintenance....................................................458 Fluid & Fluid Filter Change Procedure.................................458 Air Filter Maintenance................................................459 Air/Fluid Separator Element Change....................................460 Recommended Lubrication Guide.........................................461 Auxiliary Air Dryer Assembly..............................................462 In-Line PREFilters........................................................463 MACHINERY HOUSE HOSE REELS................................................464 Additional Maintenance Requirements.......................................464 Lockout Valves........................................................465 Safety Warnings.......................................................467 Air Schematic.............................................................469 Air Filtration............................................................473 House Filter Fans.........................................................473 Lubrication...........................................................474 Dynavane Air Cleaner..................................................475 Air Conditioner.......................................................476 Specifications........................................................477 Engineering Data..........................................................483 Capscrew (Bolt) Grade.....................................................483 BOLT TIGHTENING.......................................................484 Torque Wrench Method..............................................484 Turn-of-nut Method................................................486 Measurement Systems.......................................................488 Linear Measurements...................................................488 Area Measurements.....................................................488 Volume Measurements...................................................489 Torque Measurements...................................................490 Weight Measurements - Conventional................................491 Split Flange Assembly Procedure...........................................492 Wire Locking Capscrews....................................................494 Torque Nut Installation...................................................495 Tightening Procedure for 1.25-Inch Torque Nut.........................496 Tightening Procedure for 2-Inch Torque Nut............................497 Tightening Procedure for 2-Inch Torque Nut............................498 Tightening Procedure for 2.5-Inch Torque Nut..........................499 Tightening Procedure for 3-Inch Torque Nut............................500 Tightening Procedure for 3.5-Inch Torque Nut..........................501 Procedure for Use of Mechanical Tensioner on Crawler Rods.............502 Initial Tensioning................................................503 Final Tensioning..................................................503 Expansion Bolt Installation...............................................505 Tightening Procedures - Expansion Bolts...............................505 Hoist Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut............505 Rack & Roller Torque Rod, Tapered Sleeve & 1.5 Inch Torque Nut....506 Swing Torque Rod & Tapered Sleeve & 3.5 Inch Torque Nut...........508 Torque Nut Removal Procedure..............................................510 Thread Lubrication....................................................510 Torque Nut Helpful Hints..................................................511 Locking Assemblies........................................................512 Locking Assembly Removal..............................................514 Pinion and Hub Installation...............................................515 Removal from a Shaft..................................................515 Mounting a Pinion or Hub on a Shaft...................................515 Hub Adapter Pre-heat Advance Requirements.........................518 Motor Coupling Pre-Heat Advance Requirements......................518 Maintenance Welding.......................................................519 Welding Electrodes....................................................520 Repair Welding of Cracks..............................................521 Preheat...........................................................522 Welding Technique.................................................522 Repair Welding of Broken Parts........................................523 Repair Welding Swing Rack Teeth.......................................524 Preparation.......................................................524 Swing Rack Welding Electrodes.....................................524 Preheat...........................................................524 Welding Procedure.................................................526 Welding and Cutting Equipment.........................................528 Stress Relieving & Temperature Measuring Equipment....................529 Storage...............................................................529 Checking Diameter.....................................................530 Handling Wire Rope....................................................531 Seizing Wire Rope.....................................................532 End Preparations/Terminations.........................................534 Wire Rope Clips.......................................................534 Wire Rope Clip Application........................................534 Wedge Sockets.....................................................536 Inspection of Sheaves and Drums.......................................537 Breaking In a New Wire Rope...........................................538 Inspection Data.......................................................539 Guideline to Inspections and Reports..................................540 Wire Rope Inspection Criteria.....................................541 Reduction in Rope Diameter....................................541 Rope Stretch..................................................542 Abrasion......................................................543 Corrosion.....................................................543 Kinks.........................................................543 Bird Caging...................................................543 Localized Conditions..........................................543 Heat Damage...................................................543 Protruding Core...............................................543 Damaged End Attachments.......................................544 Peening.......................................................544 Scrubbing.....................................................544 Fatigue Fracture..............................................544 Broken Wires..................................................544 Electric Arc..................................................545 Seals.....................................................................545 Seal Installation.....................................................546 Gearcase Sealing......................................................547
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DESCRIPTION:
CAT Bucyrus 495HF Mining Shovel Maintenance & Operation Manual SN 141258 PDF DOWNLOAD
INTRODUCTION:
GENERAL INFORMATION
This manual is designed to assist the owner in the operation and preventive maintenance of this machine. Following easy to understand step-by-step procedures, maintenance personnel can perform these tasks in a safe manner. When a systematic and thorough maintenance/service procedure (a responsibility of the maintenance superintendent) is used for this machine, minimum unplanned downtime and reliable operation will result.
- THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it.
- All parts are listed by group and/or product code numbers with item/part numbers for THIS SPECIFIC MACHINE.
- Order parts in exact quantity. Parts ordered by mistake and returned, are subject to a rehandling charge. RIGHT HAND and LEFT HAND parts on the upper frame correspond to the operator’s hands at the controls; as seated when operating the machine.
- Please state the correct machine SERIAL NUMBER (lo9ated on a plate in the operator’s cab) when corresponding or contacting factory service or parts departments.
- Records on each machine are filed by serial number and when given this number, your machine’s specific design and original equipment is accessed quickly by the Marion parts representative.
- It is Marion’s policy to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements at any time without incurring any obligation to install such changes on machines sold previously.
- Due to this continuous program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve machines.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
G.P
