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Operation & Maintenance Manual for CAT Bucyrus 495HR Shovel SN 141257 PDF
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CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141257 PDF DOWNLOAD
MANUAL No. 10674
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Description
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141257 PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141257 PDF DOWNLOAD
Language : English
Pages : 532
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141257 PDF DOWNLOAD
MANUAL No. 10674
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 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......................................................... 56 Dipper................................................................ 57 Padlocks.............................................................. 58 Dipper Trip........................................................... 59 Typical Machine Specifications............................................ 60 General Estimated Component Weights....................................... 62 Lower Works........................................................... 62 Upper Works........................................................... 63 Front End............................................................. 65 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 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.................................. 99 Machine Operation..................................................... 99 Machinery Motions.....................................................100 Hoist Motion......................................................100 Crowd Motion......................................................101 Propel Motion.....................................................102 Swing Motion......................................................103 Proper Swing Motion...........................................104 Steering..........................................................105 Counter-rotation Turns........................................107 Positioning the Machine...........................................108 Back-up Method................................................108 Drive-by Method...............................................109 Start Of The Dig Cycle............................................110 Engaging The Bank.................................................113 Slope Limitations.................................................115 Excavated Material....................................................117 Operation Checks......................................................117 Operating Hints.......................................................118 Stopping the Machine..................................................119 Shutdown..............................................................119 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 ACSL - Air Compressor (Screw-Type) Lubricant..........................152 MPO - Multipurpose OIL................................................153 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........................................172 OGL System A & B Schematic................................................173 Grease System C Schematic.................................................174 Preventive Maintenance.................................................... 0 Introduction.............................................................. 0 Preventive Maintenance Program........................................ 0 Elements of an Effective Maintenance Program.......................... 0 Scheduled Preventive Maintenance Program.............................. 0 General Safety Considerations......................................... 0 Maintenance During Machine Operation...................................... 0 Maintenance Precautions............................................... 0 Preventive Maintenance for Lubrication.................................... 0 Lubricant Cleanliness................................................. 0 Frequency of Inspection and Maintenance................................... 0 Maintenance Schedules..................................................... 0 Maintenance Inspection Check Points................................... 0 Daily............................................................. 0 Every 100 Hours or Weekly......................................... 0 Every 500 Hours Or Monthly........................................ 0 Every 1250 Hours or Quarterly..................................... 0 Every 2500 Hours or Semi-Annually................................. 0 5000 Hours or Annually............................................ 0 Major Component Locations................................................. 0 Service Procedures........................................................229 Lower Works...............................................................229 Truck Frame Assembly..................................................229 Swing Rack Assembly...................................................230 Roller Circle Rail Replacement - Lower............................230 Roller Circle Rail Replacement - Upper............................231 Roller Circle Assembly................................................233 Roller Circle Adjustment..........................................235 Adjustment Procedure..............................................235 Run-in Procedure for the Roller Circle............................235 Roller Circle Segment Removal.....................................236 Roller Circle - Roller Replacement................................237 Crawler Belts.............................................................238 Crawler Belt Maintenance..............................................238 Crawler Belt Tension Adjustment...................................239 Crawler Shoe Replacement..........................................241 Crawler Belt Replacement..........................................242 Crawler Side Frame Assembly...........................................243 Crawler Side Frame Maintenance....................................244 Slide Bar Replacement.............................................245 Crawler Front Idler Roller Assembly...............................246 Load and Idler Rollers............................................249 Roller Removal or Replacement.................................249 Propel Assembly...........................................................252 Installation Notes....................................................254 Main Propel Drive Shaft Removal.......................................255 Main Propel Shaft - Disassembly...................................258 Tumbler Rebuild Procedure.........................................259 Propel Machinery......................................................261 Propel Gearcase Removal...........................................262 Propel Gearcase Installation......................................263 Propel Planetary Gearcase.........................................265 Propel Motors.....................................................266 Propel Motor Removal..........................................266 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 Stinger (Trail Cable Support).............................................281 Rotating Deck.............................................................281 Swing Machinery...........................................................282 Swing Support Mounting Bolts..........................................284 Swing Motor...........................................................284 Swing Blower......................................................284 Swing Motor Removal...............................................285 Swing Motor Installation..........................................286 Swing Planetary Gearcase..............................................286 Swing Gearcase Removal............................................287 Gearcase Inspection...............................................288 Swing Pinion Shafts...............................................289 Swing Pinion Shaft Removal....................................290 Swing Pinion Shaft Disassembly................................291 Swing Pinion Shaft Assembly...................................292 Swing Pinion Shaft Installation...............................293 Hoist Machinery.......................................................294 Hoist Motor Removal...............................................295 Motor Coupling Shaft..............................................298 Hoist Gearcase Assembly...........................................299 Hoist Gearcase Repair.............................................301 Hoist Drum Assembly...............................................304 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...............................................................319 Crowd Gear and Drum...................................................321 Crowd Drum Removal....................................................321 Operator’s Cab Mounting...............................................323 Machinery House...........................................................324 Walkways, Stairways, and Handrails....................................325 Boarding Stairs.......................................................325 Vertical Boarding Ladder, left........................................328 Boom Assembly.........................................................331 Boom Repair.......................................................332 Boom Limit Switch Installation........................................333 Boom Point Sheaves................................................335 Boom Point Sheave Removal and Disassembly.........................336 Boom Point Sheave Reassembly and Installation.....................338 Boom Bumper...........................................................339 Saddle Block..........................................................340 Saddle Block Repair...............................................340 Saddle Block Removal..........................................341 Dipper Handle.........................................................343 Dipper Handle Removal.............................................345 Crowd Rope Take-Up Mechanism......................................347 Crowd Rope Take-Up Mechanism Disassembly......................348 Retract Rope Take-up Mechanism....................................350 Spreader Repair...................................................352 Dipper Assembly...........................................................353 Dipper Door...........................................................355 Latch Lever Assembly..............................................356 Rope Bracket and Deflector Assembly...............................358 Latch Bar Adjusting...............................................359 Dipper Door bumpers...................................................360 Dipper Removal & Installation.....................................361 Dipper Door Snubbers..............................................366 Snubber Adjustment............................................367 Allowable Wear................................................367 Dipper Pitch BracE....................................................368 Dipper Padlock........................................................368 Dipper Trip Assembly..................................................372 A-Frame...............................................................373 Auxiliary Winch.......................................................375 Hoist Rope Support Roller.............................................376 Boom Support Ropes....................................................377 Wire Ropes............................................................378 Wire Rope Inspection..............................................379 Crowd Rope Take-up Hydraulic Unit.........................................380 Hoist Rope Reeving & Replacement......................................382 Crowd Rope Reeving & Replacement..................................386 Retract Rope Reeving & Replacement........................................389 Crowd Rope Tightening.................................................392 Retract Rope Tightening...............................................395 Dipper Trip Rope Reeving & Replacement................................396 Hoist and Crowd Limit Systems.........................................396 Setting Limits In The Hoist & Crowd System........................397 Crowd Slowdown/Stop Limits....................................399 Retract Slowdown/Stop Limits..................................400 Lower Slowdown/Stop Limits....................................401 Hoist Slowdown/Stop Limits....................................402 Brakes and Couplings......................................................405 Brakes....................................................................405 Disc Brake Operation..................................................406 Maintenance...........................................................406 Brake Adjustment Specifications.......................................406 Hoist Brake...........................................................407 Hoist Brake Adjustment............................................409 Hoist Brake Installation..........................................411 Hoist Brake Wear & Release Switches...............................411 Crowd Brake...........................................................412 Crowd Brake Installation..........................................414 Crowd Brake Wear & Release Switches...............................415 Propel Brake..........................................................416 Propel Brake Adjustment...........................................418 Propel Brake Installation.........................................420 Tachometer Mounting & Alignment...................................421 Swing Brake...........................................................424 Swing Brake Installation..........................................426 Swing Brake Wear & Release Switches...............................427 Swing Brake Burnishing............................................428 Spring Replacement — All Brakes.......................................428 Friction Disc Replacement — All Brakes................................430 O-Ring Replacement — All Brakes.......................................431 Brake Wear & Release Switches — Single Disc Brakes....................433 Brake Wear & Release Switches — Multiple Disc Brakes..................434 Couplings.................................................................435 Grid Couplings........................................................435 Lubrication.......................................................435 Coupling Disassembly and Grid Removal.............................436 Grid Coupling Installation........................................437 Seal Replacement without Hub Removal..............................440 Grid Coupling Alignment...........................................442 Gear Couplings........................................................443 Coupling Installation.............................................443 Gear Coupling Alignment...........................................445 Hoist Coupling Shaft Alignment....................................446 Compressed Air System.....................................................449 Air Compressor............................................................449 Lockout Valves........................................................451 Safety Warnings.......................................................453 Air Schematic.............................................................455 Air Filtration............................................................459 House Filter Fans.........................................................459 Lubrication...........................................................460 Dynavane Air Cleaner..................................................461 Air Conditioner.......................................................462 Specifications........................................................463 Engineering Data..........................................................469 Capscrew (Bolt) Grade.....................................................469 Bolt Tightening.......................................................470 Torque Wrench Method..............................................470 Turn-of-nut Method................................................472 Measurement Systems.......................................................474 Linear Measurements...................................................474 Area Measurements.....................................................474 Volume Measurements...................................................475 Torque Measurements...................................................476 Weight Measurements - Conventional................................477 Split Flange Assembly Procedure...........................................478 Wire Locking Capscrews....................................................480 Torque Nut Installation...................................................481 Tightening Procedure for 1.25-Inch Torque Nut.........................482 Tightening Procedure for 2-Inch Torque Nut............................483 Tightening Procedure for 2-Inch Torque Nut............................484 Tightening Procedure for 2.5-Inch Torque Nut..........................485 Tightening Procedure for 3-Inch Torque Nut............................486 Tightening Procedure for 3.5-Inch Torque Nut..........................487 Procedure for Use of Mechanical Tensioner on Crawler Rods.............488 Initial Tensioning................................................488 Final Tensioning..................................................488 Expansion Bolt Installation...............................................490 Tightening Procedures - Expansion Bolts...............................490 Hoist Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut............490 Rack & Roller Torque Rod, Tapered Sleeve & 1.5 Inch Torque Nut....491 Swing Torque Rod & Tapered Sleeve & 3.5 Inch Torque Nut...........493 Torque Nut Removal Procedure..............................................495 Thread Lubrication....................................................495 Torque Nut Helpful Hints..................................................496 Locking Assemblies........................................................497 Locking Assembly Removal..............................................499 Pinion and Hub Installation...........................................500 Removal from a Shaft..................................................500 Mounting a Pinion or Hub on a Shaft...................................500 Hub Adapter Pre-heat Advance Requirements.........................503 Motor Coupling Pre-Heat Advance Requirements......................503 Maintenance Welding.......................................................504 Welding Electrodes....................................................505 Repair Welding of Cracks..............................................506 Preheat...........................................................507 Welding Technique.................................................507 Repair Welding of Broken Parts........................................508 Repair Welding Swing Rack Teeth.......................................509 Preparation.......................................................509 Swing Rack Welding Electrodes.....................................509 Preheat...........................................................509 Welding Procedure.................................................511 Welding and Cutting Equipment.........................................513 Stress Relieving & Temperature Measuring Equipment....................514 Storage...............................................................515 Checking Diameter.....................................................515 Handling Wire Rope....................................................516 Seizing Wire Rope.....................................................517 End Preparations/Terminations.........................................519 Wire Rope Clips.......................................................519 Wire Rope Clip Application........................................519 Wedge Sockets.....................................................521 Inspection of Sheaves and Drums.......................................522 Breaking In a New Wire Rope...........................................523 Inspection Data.......................................................524 Guideline to Inspections and Reports..................................525 Wire Rope Inspection Criteria.....................................526 Reduction in Rope Diameter....................................526 Rope Stretch..................................................527 Abrasion......................................................528 Corrosion.....................................................528 Kinks.........................................................528 Bird Caging...................................................528 Localized Conditions..........................................528 Heat Damage...................................................528 Protruding Core...............................................528 Damaged End Attachments.......................................529 Peening.......................................................529 Scrubbing.....................................................529 Fatigue Fracture..............................................529 Broken Wires..................................................529 Electric Arc..................................................530 Seals.....................................................................530 Seal Installation.....................................................531 Gearcase Sealing......................................................532 10674-4.pdf............................................................... 0 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........................................198 Major Component Locations.............................................200
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DESCRIPTION:
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141257 PDF DOWNLOAD
INTRODUCTION:
GENERAL INFORMATION:
This manual is designed to assist the owner in the operation and preventive maintenance of this machine. By following easy to understand step-by-step procedures the operators and maintenance personnel can perform all tasks in a safe manner. It is important to remember that when a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.
- THIS MANUAL IS NOT THE PARTS BOOK and cannot be used as reference material 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 the associated item/part numbers for THIS SPECIFIC MACHINE.
- Order parts in the exact quantity needed. RIGHT and LEFT refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.
- Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments.
- Records on each machine are filed by serial number and when given this number, the machine’s specific design and original equipment is accessed quickly by the Bucyrus International parts representative. Periodic additions or revisions may be made to this manual.
- It is Bucyrus International’s policy to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to it’s machines at any time. This will be without incurred obligation to install such changes on machines sold previously.
- Due to this ongoing program of product research and development, some procedures, specifications and parts may be altered in a constant effort to improve our 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
