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CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141271 PDF DOWNLOAD
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CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141271 PDF DOWNLOAD
Manual No. 10822
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Description
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141271 PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141271 PDF DOWNLOAD
Language : English
Pages : 534
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141271 PDF DOWNLOAD
Manual No. 10822
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......................................................... 56 Dipper................................................................ 57 Padlocks.............................................................. 58 Dipper Trip........................................................... 59 Typical Machine Specifications............................................ 60 General Estimated Component Weights....................................... 62 Lower Works........................................................... 62 Upper Works........................................................... 63 Front End............................................................. 65 Operation................................................................. 71 General Information....................................................... 71 Operation Near Electrical Lines....................................... 71 Operator’s Seat........................................................... 73 Adjustable Armrest.................................................... 73 Adjustable Footrest................................................... 74 Controls.................................................................. 75 Controls On The Left Console.......................................... 76 Left Joystick..................................................... 77 Dipper Trip....................................................... 77 Signal Horn....................................................... 77 Start Pushbutton.................................................. 77 PLC Power On...................................................... 78 Drive Cabinet Temperature......................................... 78 Incomplete Sequence............................................... 78 System Ready...................................................... 78 Phase Sequence.................................................... 78 Auxiliary Ground Fault............................................ 78 Hoist Brake....................................................... 78 Crowd Brake....................................................... 78 Swing Brake....................................................... 78 Propel Brake...................................................... 78 HVAC Unit Selector................................................ 78 Temperature....................................................... 78 HVAC System Control............................................... 78 HVAC Fan Speed.................................................... 78 Cabin Lights...................................................... 78 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..................................................... 83 Radio/cassette/cd................................................. 84 Heated Mirrors.................................................... 84 Man On Ground..................................................... 84 Operator’s Display........................................................ 84 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 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...................................233 Crawler Shoe Replacement..........................................235 Crawler Belt Replacement..........................................236 Crawler Side Frame Assembly...........................................237 Crawler Side Frame Maintenance....................................238 Slide Bar Replacement.............................................239 Crawler Front Idler Roller Assembly...............................240 Load and Idler Rollers............................................243 Roller Removal or Replacement.................................243 Propel Assembly...........................................................246 Installation Notes....................................................248 Main Propel Drive Shaft Removal.......................................249 Main Propel Shaft - Disassembly...................................252 Tumbler Rebuild Procedure.........................................253 Propel Machinery......................................................255 Propel Gearcase Removal...........................................256 Propel Gearcase Installation......................................257 Propel Planetary Gearcase.........................................259 Propel Motors.....................................................260 Propel Motor Removal..........................................260 Propel Motor Installation.....................................263 Center Pintle.........................................................264 Center Pintle Adjustment..........................................269 Center Pintle Sleeve Removal......................................269 Collector Rings.......................................................271 Collector Ring Inspection.........................................272 Collector Ring Repair.............................................272 Rotating Deck.............................................................272 Swing Machinery...........................................................273 Swing Support Mounting Bolts..........................................275 Swing Motor...........................................................275 Swing Blower......................................................275 Swing Motor Removal...............................................276 Swing Motor Installation..........................................276 Swing Planetary Gearcase..............................................277 Swing Gearcase Removal............................................278 Gearcase Inspection...............................................279 Swing Pinion Shafts...............................................280 Swing Pinion Shaft Removal....................................281 Swing Pinion Shaft Disassembly................................282 Swing Pinion Shaft Assembly...................................283 Swing Pinion Shaft Installation...............................284 Hoist Machinery.......................................................285 Hoist Motor Removal...............................................286 Motor Coupling Shaft..............................................289 Hoist Gearcase Assembly...........................................290 Hoist Gearcase Repair.............................................292 Hoist Drum Assembly...............................................295 Hoist Gear Replacement........................................297 Bearing Removal...............................................299 Bearing Installation..........................................300 Hoist Oil Cooler..................................................302 Hoist Mounting Bolts..................................................303 Hoist Limit Switch....................................................304 Crowd Machinery...........................................................305 Crowd Gearcase Disassembly............................................307 Crowd Gearcase Assembly...............................................310 Crowd Motor...............................................................311 Crowd Gear and Drum...................................................313 Crowd Drum Removal....................................................313 Operator’s Cab Mounting...............................................315 Operator’s Seat Installation..............................................316 Footrest Installation.....................................................318 Machinery House...........................................................319 Walkways, Stairways, and Handrails....................................320 Boarding Stairs.......................................................320 Vertical Boarding Ladder, left........................................323 Boom Assembly.........................................................326 Boom Repair.......................................................327 Boom Limit Switch Installation........................................328 Boom Point Sheaves................................................330 Boom Point Sheave Removal and Disassembly.........................331 Boom Point Sheave Reassembly and Installation.....................333 Boom Bumper...........................................................334 Saddle Block..........................................................335 Saddle Block Repair...............................................335 Saddle Block Removal..........................................336 Dipper Handle.........................................................338 Dipper Handle Removal.............................................340 Crowd Rope Take-Up Mechanism......................................342 Crowd Rope Take-Up Mechanism Disassembly......................343 Crowd Rope Take-Up Mechanism Assembly.........................344 Retract Rope Take-up Mechanism....................................347 Spreader Repair...................................................349 Dipper Assembly...........................................................350 Latch Bar Adjusting...................................................353 Dipper Door bumpers...................................................354 Dipper Removal & Installation.....................................355 Dipper Door Snubbers..............................................360 Snubber Adjustment............................................361 Allowable Wear................................................361 Dipper Pitch Brace....................................................362 Dipper Padlock........................................................363 Dipper Trip Assembly..................................................366 A-Frame...............................................................367 Auxiliary Winch.......................................................369 Hoist Rope Support Roller.............................................370 Boom Support Ropes....................................................371 Wire Ropes............................................................372 Wire Rope Inspection..............................................373 Crowd Rope Take-up Hydraulic Unit.........................................374 Hoist Rope Reeving & Replacement......................................376 Crowd Rope Reeving & Replacement..................................380 Retract Rope Reeving & Replacement........................................382 Crowd Rope Tightening.................................................386 Retract Rope Tightening...............................................388 Dipper Trip Rope Reeving & Replacement................................389 Hoist and Crowd Limit Systems.........................................389 Setting Limits In The Hoist & Crowd System........................390 Crowd Slowdown/Stop Limits....................................392 Retract Slowdown/Stop Limits..................................393 Lower Slowdown/Stop Limits....................................394 Hoist Slowdown/Stop Limits....................................395 Brakes and Couplings......................................................399 Brakes....................................................................399 Disc Brake Operation..................................................400 Maintenance...........................................................400 Brake Adjustment Specifications.......................................400 Hoist Brake...........................................................401 Hoist Brake Adjustment............................................403 Hoist Brake Installation..........................................405 Hoist Brake Wear & Release Switches...............................405 Crowd Brake...........................................................406 Crowd Brake Installation..........................................408 Crowd Brake Wear & Release Switches...............................410 Propel Brake..........................................................411 Propel Brake Adjustment...........................................413 Propel Brake Installation.........................................415 Tachometer Mounting & Alignment...................................417 Swing Brake...........................................................419 Swing Brake Installation..........................................421 Swing Brake Wear & Release Switches...............................422 Swing Brake Burnishing............................................423 Spring Replacement — All Brakes.......................................423 Friction Disc Replacement — All Brakes................................425 O-Ring Replacement — All Brakes.......................................426 Brake Wear & Release Switches — Single Disc Brakes....................428 Brake Wear & Release Switches — Multiple Disc Brakes..................429 Couplings.................................................................430 Grid Couplings........................................................430 Lubrication.......................................................430 Coupling Disassembly and Grid Removal.............................431 Grid Coupling Installation........................................432 Seal Replacement without Hub Removal..............................435 Grid Coupling Alignment...........................................437 Gear Couplings........................................................438 Coupling Installation.............................................438 Gear Coupling Alignment...........................................440 Hoist Coupling Shaft Alignment....................................441 Compressed Air System.....................................................445 Air Compressor............................................................445 Lockout Valves........................................................447 Safety Warnings.......................................................449 Air Filtration............................................................453 House Filter Fans.........................................................453 Lubrication...........................................................454 Dynavane Air Cleaner..................................................455 Air Conditioner.......................................................456 Specifications........................................................457 Engineering Data..........................................................463 Capscrew (Bolt) Grade.....................................................463 Bolt Tightening.......................................................463 Torque Wrench Method..............................................463 Turn-of-nut Method................................................465 Measurement Systems.......................................................467 Linear Measurements...................................................467 Area Measurements.....................................................467 Volume Measurements...................................................468 Torque Measurements...................................................469 Weight Measurements - Conventional................................470 Split Flange Assembly Procedure...........................................471 Wire Locking Capscrews....................................................473 Torque Nut Installation...................................................474 Tightening Procedure for 1.25-Inch Torque Nut.........................475 Tightening Procedure for 2-Inch Torque Nut............................476 Tightening Procedure for 2-Inch Torque Nut............................477 Tightening Procedure for 2.5-Inch Torque Nut..........................478 Tightening Procedure for 3-Inch Torque Nut............................479 Tightening Procedure for 3.5-Inch Torque Nut..........................480 Procedure for Use of Mechanical Tensioner on Crawler Rods.............481 Initial Tensioning................................................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....................508 Storage...............................................................508 Checking Diameter.....................................................509 Handling Wire Rope....................................................510 Seizing Wire Rope.....................................................511 End Preparations/Terminations.........................................513 Wire Rope Clips.......................................................513 Wire Rope Clip Application........................................513 Wedge Sockets.....................................................515 Inspection of Sheaves and Drums.......................................516 Breaking In a New Wire Rope...........................................517 Inspection Data.......................................................518 Guideline to Inspections and Reports..................................519 Wire Rope Inspection Criteria.....................................520 Reduction in Rope Diameter....................................520 Rope Stretch..................................................521 Abrasion......................................................522 Corrosion.....................................................522 Kinks.........................................................522 Bird Caging...................................................522 Localized Conditions..........................................522 Heat Damage...................................................522 Protruding Core...............................................522 Damaged End Attachments.......................................523 Peening.......................................................523 Scrubbing.....................................................523 Fatigue Fracture..............................................523 Broken Wires..................................................523 Electric Arc..................................................524 Seals.....................................................................524 Seal Installation.....................................................525 Gearcase Sealing......................................................526 Schematics................................................................528 Schematics - Automatic Lubrication........................................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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DESCRIPTION:
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141271 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
