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CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141323 PDF DOWNLOAD
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CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141323 PDF DOWNLOAD
Manual No. 10907
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Description
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141323 PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141323 PDF DOWNLOAD
Language : English
Pages : 542
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141323 PDF DOWNLOAD
Manual No. 10907
Safety Precautions........................................................ 4 General Precautions................................................... 5 Maintenance Precautions............................................... 6 Operating Precautions................................................. 7 Fire Prevention....................................................... 8 Warning Signs And Decals.............................................. 9 Introduction.............................................................. 27 General Information....................................................... 27 SWINGING RESTRAINT & BALLAST BOX SUPPORT.............................. 28 Ballast Box Support............................................... 28 Swinging Restraint.................................................... 29 Machine Overview.......................................................... 31 Lower Works............................................................... 32 Crawlers.............................................................. 33 Truck Frame........................................................... 34 Swing Rack............................................................ 35 Roller Circle......................................................... 36 Propel Machinery...................................................... 37 Collector Rings....................................................... 38 Rotating Deck............................................................. 39 Revolving Frame....................................................... 39 Center Pintle......................................................... 40 Deck Extensions....................................................... 42 Ballast Box........................................................... 42 Machinery House....................................................... 42 Boarding Stairs................................................... 43 Vertical Boarding Ladder.......................................... 44 A-Frame............................................................... 45 Hoist Machinery....................................................... 46 Swing Machinery....................................................... 47 Crowd Machinery....................................................... 48 OPERATOR’S CAB........................................................ 49 Compressed Air System................................................. 50 Automatic Lubrication System.......................................... 51 Lube Reservoir fill / Overflow Plumbing............................... 52 Front End Equipment....................................................... 53 Suspension Strands.................................................... 53 Boom.................................................................. 54 Running Ropes......................................................... 55 Saddle Block.......................................................... 56 Dipper Handle......................................................... 57 Dipper................................................................ 58 Padlocks.............................................................. 59 Dipper Trip........................................................... 60 Typical Machine Specifications............................................ 61 General Estimated Component Weights....................................... 63 Lower Works........................................................... 63 Upper Works........................................................... 64 Front End............................................................. 66 Operation................................................................. 73 General Information....................................................... 73 Operation Near Electrical Lines....................................... 73 Operator’s Seat........................................................... 75 Adjustable Armrest.................................................... 75 Adjustable Footrest................................................... 76 Controls.................................................................. 77 Primary Operating Controls............................................ 77 Controls On The Left Console.......................................... 78 Left Joystick..................................................... 79 Dipper Trip....................................................... 79 Signal Horn....................................................... 79 Start Pushbutton.................................................. 79 PLC Power On...................................................... 80 Drive Cabinet Temperature......................................... 80 Incomplete Sequence............................................... 80 System Ready...................................................... 80 Phase Sequence.................................................... 80 Auxiliary Ground Fault............................................ 80 Hoist Brake....................................................... 80 Crowd Brake....................................................... 80 Swing Brake....................................................... 80 Propel Brake...................................................... 80 HVAC Unit Selector................................................ 80 Temperature....................................................... 80 HVAC System Control............................................... 80 HVAC Fan Speed.................................................... 80 Cabin Lights...................................................... 80 Controls On The Right Console..................................... 81 Right Joystick.................................................... 82 Emergency Stop Pushbutton......................................... 83 Windshield Wiper Switches......................................... 83 Control Stop Pushbutton........................................... 83 Control Reset Pushbutton.......................................... 83 Air Compressor.................................................... 84 Dig/propel Transfer Switch........................................ 84 Main Power Off Pushbutton......................................... 84 Earth Continuity Lockout Pushbutton............................... 84 Seat Position..................................................... 84 Radio Receiver with CD Changer.................................... 85 Operator’s Display........................................................ 85 Display Area and Indicators........................................... 86 Display Screens....................................................... 86 Lubrication Control Panel............................................. 93 Fire Suppression System............................................... 94 Pre-start Checks.......................................................... 94 Walk-around Ground Level Inspection................................... 95 On-board Inspection................................................... 96 Start-up, Operation And Shutdown.......................................... 97 Machine Start-up...................................................... 97 Restarting After An Electrical Fault.................................. 98 Machine Operation..................................................... 98 Machinery Motions..................................................... 99 Hoist Motion...................................................... 99 Crowd Motion......................................................100 Propel Motion.....................................................101 Swing Motion......................................................102 Proper Swing Motion...........................................103 Steering..........................................................104 Counter-rotation Turns........................................106 Positioning the Machine...........................................107 Back-up Method................................................107 Drive-by Method...............................................108 Start Of The Dig Cycle............................................109 Engaging The Bank.................................................111 Slope Limitations.................................................113 Excavated Material....................................................116 Operation Checks......................................................116 Operating Hints.......................................................117 Stopping the Machine..................................................118 Shutdown..............................................................118 Lubrication...............................................................121 Lubrication Principles....................................................121 Greasing Main A.C. Drive Motors...........................................122 1. Type of Grease.....................................................122 2. Initial Commissioning..............................................122 3. Maintenance........................................................122 4. Regreasing Intervals...............................................123 Lubricant Selection.......................................................123 Oil Fill Capacities.......................................................125 Types Of Lubricants And Capacities Guidelines.........................125 Quantities for First Fill of Lubricants...........................125 Automatic Lubrication System..............................................126 Lube Room.............................................................127 Lube Reservoir fill / Overflow Plumbing...............................128 Auto Lube Control Panel...........................................129 Lower Works Lubrication...............................................129 Propel Machinery Lubrication..........................................130 Lubricant Replacement/sampling....................................131 Lubricant Change Cycle........................................131 Revolving Frame Lubrication...........................................132 Hoist Machinery Lubrication...........................................133 Hoist Oil Cooler..................................................134 Filter Element Cleaning...........................................137 Hoist Rope Rollers Lubrication........................................138 Oil Pump..........................................................139 Crowd Machinery Lubrication...........................................140 Swing Machinery Lubrication...........................................141 Air Compressor Lubrication............................................142 Crowd Rope Take-Up Mechanism Lubrication..............................143 Front End Lubrication.................................................144 Lincoln Type SL-1 Lubricant Injectors.................................145 SL-1 Lubricant Injector Operation.................................147 Injector Advantages...............................................149 Air Compressor Lubricant..............................................149 MPO - Multipurpose OIL................................................151 RWRL - Running Wire Rope Lubricant....................................152 EGL - Enclosed Gearcase Lubricant.....................................153 MPG - Multipurpose Grease.............................................156 OGL - Open Gear Lubricant.............................................160 Certified Lubricants Listing..........................................164 Preventive Maintenance....................................................173 Introduction..............................................................173 Preventive Maintenance Program........................................173 Elements of an Effective Maintenance Program..........................174 Scheduled Preventive Maintenance Program..............................175 General Safety Considerations.........................................175 Maintenance During Machine Operation......................................176 Maintenance Precautions...............................................177 Preventive Maintenance for Lubrication....................................178 Lubricant Cleanliness.................................................179 Frequency of Inspection and Maintenance...................................180 Maintenance Schedules.....................................................180 Maintenance Inspection Check Points...................................180 Daily.............................................................181 Every 100 Hours or Weekly.........................................184 Every 500 Hours Or Monthly........................................185 Every 1250 Hours or Quarterly.....................................188 Every 2500 Hours or Semi-Annually.................................191 5000 Hours or Annually............................................193 Major Component Locations.................................................195 Service Procedures........................................................223 Lower Works...............................................................223 Truck Frame Assembly..................................................223 Swing Rack Assembly...................................................224 Roller Circle Rail Replacement - Lower............................224 Roller Circle Rail Replacement - Upper............................225 Roller Circle Assembly................................................227 Roller Circle Adjustment..........................................229 Adjustment Procedure..............................................229 Run-in Procedure for the Roller Circle............................229 Roller Circle Segment Removal.....................................230 Roller Circle - Roller Replacement................................231 Crawler Belts.........................................................232 Crawler Belt Maintenance..........................................232 Crawler Belt Tension Adjustment...............................234 Crawler Shoe Replacement......................................236 Crawler Belt Replacement......................................237 Crawler Side Frame Assembly...........................................238 Crawler Side Frame Maintenance....................................239 Slide Bar Replacement.............................................240 Load and Idler Rollers............................................244 Roller Removal or Replacement.................................244 Propel Assembly.......................................................247 Installation Notes................................................249 Main Propel Drive Shaft Removal...................................250 Main Propel Shaft - Disassembly...................................253 Tumbler Rebuild Procedure.........................................254 Propel Machinery......................................................256 Propel Gearcase Removal...........................................257 Propel Gearcase Installation......................................258 Propel Planetary Gearcase.........................................260 Propel Motors.....................................................261 Propel Motor Removal..........................................261 Propel Motor Installation.....................................263 Revolving Frame.......................................................264 Center Pintle.........................................................265 Center Pintle Adjustment..........................................270 Center Pintle Sleeve Removal......................................270 Collector Rings.......................................................272 Collector Ring Inspection.........................................273 Collector Ring Repair.............................................273 Cable Reel............................................................274 Rotating Deck.............................................................275 Swing Machinery.......................................................275 Swing Support Mounting Bolts......................................277 Swing Motor.......................................................277 Swing Blower..................................................277 Swing Motor Removal...........................................278 Swing Motor Installation......................................279 Swing Planetary Gearcase..........................................279 Swing Gearcase Removal........................................280 Gearcase Inspection...........................................281 Swing Pinion Shafts...............................................282 Swing Pinion Shaft Removal....................................283 Swing Pinion Shaft Disassembly................................284 Swing Pinion Shaft Assembly...................................285 Swing Pinion Shaft Installation...............................286 Hoist Machinery.......................................................287 Hoist Motor Removal...............................................288 Motor Coupling Shaft..............................................291 Hoist Gearcase Assembly...........................................292 Hoist Gearcase Repair.............................................296 Hoist Drum Assembly...............................................299 Hoist Gear Replacement........................................301 Bearing Removal...............................................303 Bearing Installation..........................................304 Hoist Oil Cooler..................................................306 Hoist Mounting Bolts..............................................307 Hoist Limit Switch................................................308 Crowd Machinery.......................................................309 GEARCASE REPAIR.......................................................311 Crowd Gearcase Disassembly........................................311 Crowd Gearcase Assembly...........................................314 Crowd Motor.......................................................315 Crowd Gear and Drum...........................................317 Crowd Drum Removal............................................317 Operator’s Cab Mounting...............................................319 Operator’s Seat Installation..........................................320 Footrest Installation.................................................322 Machinery House.......................................................323 Walkways, Stairways, and Handrails................................324 Boarding Stairs...................................................325 Vertical Boarding Ladder, left....................................327 Front End Equipment.......................................................329 Boom Assembly.........................................................330 Boom Repair...........................................................331 Boom Limit Switch Installation........................................332 Boom Point Sheaves....................................................334 Boom Point Sheave Removal and Disassembly.........................335 Boom Point Sheave Reassembly and Installation.....................337 Boom Bumper...........................................................338 Saddle Block..........................................................339 Saddle Block Repair...............................................339 Saddle Block Removal..............................................340 Dipper Handle.........................................................342 Dipper Handle Removal.............................................344 Crowd Rope Take-Up Mechanism......................................346 Crowd Rope Take-Up Mechanism Disassembly......................347 Crowd Rope Take-Up Mechanism Assembly.........................349 Retract Rope Take-up Mechanism....................................351 Spreader Repair...................................................353 LatchFreeTM Dipper Assembly...........................................354 Dipper Assembly.......................................................354 Latch Bar Adjusting...............................................356 Dipper Door bumpers...............................................356 DIPPER INSPECTION.....................................................358 Dipper Removal & Installation.....................................359 Dipper Door Snubbers..............................................364 Snubber Adjustment............................................365 Dipper Pitch Brace................................................366 Dipper Padlock....................................................367 Dipper Trip Assembly..................................................370 A-Frame...............................................................371 Auxiliary Winch.......................................................373 Hoist Rope Support Roller.............................................374 Boom Support Ropes....................................................375 Wire Ropes............................................................376 Wire Rope Inspection..............................................377 Crowd Rope Take-up Hydraulic Unit.....................................378 Hoist Rope Reeving & Replacement......................................380 Crowd Rope Reeving & Replacement......................................384 Retract Rope Reeving & Replacement....................................386 Crowd Rope Tightening.................................................390 Retract Rope Tightening...............................................392 Dipper Trip Rope Reeving & Replacement................................393 Hoist and Crowd Limit Systems.........................................394 Setting Limits In The Hoist & Crowd System........................395 Crowd Slowdown/Stop Limits....................................397 Retract Slowdown/Stop Limits..................................398 Lower Slowdown/Stop Limits....................................399 Hoist Slowdown/Stop Limits....................................400 Brakes and Couplings......................................................403 Brakes....................................................................403 Disc Brake Operation..................................................404 Maintenance...........................................................404 Brake Adjustment Specifications.......................................404 Hoist Brake...........................................................405 Hoist Brake Adjustment............................................407 Hoist Brake Installation..........................................409 Hoist Brake Wear & Release Switches...............................409 Crowd Brake...........................................................410 Crowd Brake Installation..........................................412 Crowd Brake Wear & Release Switches...............................414 Propel Brake..........................................................415 Propel Brake Adjustment...........................................417 Propel Brake Installation.........................................419 Tachometer Mounting & Alignment...................................421 Swing Brake...........................................................423 Swing Brake Installation..........................................425 Swing Brake Wear & Release Switches...............................426 Swing Brake Burnishing............................................427 Spring Replacement — All Brakes.......................................427 Friction Disc Replacement — All Brakes................................429 O-Ring Replacement — All Brakes.......................................430 Brake Wear & Release Switches — Single Disc Brakes....................432 Brake Wear & Release Switches — Multiple Disc Brakes..................433 Couplings.................................................................434 Grid Couplings........................................................434 Lubrication.......................................................434 Coupling Disassembly and Grid Removal.............................435 Grid Coupling Installation........................................436 Seal Replacement without Hub Removal..............................439 Grid Coupling Alignment...........................................441 Gear Couplings........................................................442 Coupling Installation.............................................442 Gear Coupling Alignment...........................................444 Hoist Coupling Shaft Alignment....................................445 Compressed Air System.....................................................449 Air Compressor............................................................449 Lockout Valves........................................................451 Safety Warnings.......................................................453 Air Filtration............................................................457 House Filter Fans.........................................................457 Lubrication...........................................................458 Dynavane Air Cleaner..................................................459 Air Filtration System.....................................................460 Air Conditioner...........................................................462 Specifications........................................................463 Engineering Data..........................................................469 Capscrew (Bolt) Grade.....................................................469 Bolt Tightening.......................................................469 Torque Wrench Method..............................................469 Turn-of-nut Method................................................471 Measurement Systems.......................................................473 Linear Measurements...................................................473 Area Measurements.....................................................473 Volume Measurements...................................................474 Torque Measurements...................................................475 Weight Measurements - Conventional................................476 Split Flange Assembly Procedure...........................................477 Wire Locking Capscrews....................................................479 Torque Nut Installation...................................................480 Expansion Bolt Installation...............................................480 Tightening Procedure for 1.25-Inch Torque Nut.........................481 Tightening Procedure for 2-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 3.5 Inch Crawler Rods....488 Initial Tensioning................................................488 Final Tensioning..................................................488 Tightening Procedures - Expansion Bolts...............................490 Rack & Roller Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut....490 Hoist Torque Rod, Tapered Sleeve & 1.62 Inch Torque Nut...........491 Swing Torque Rod & Tapered Sleeve & 3.25 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 Pre-heat Advance Requirements - Pinions and Hubs..................503 Motor Coupling Pre-Heat Advance Requirements......................503 Maintenance Welding.......................................................505 Welding Electrodes....................................................506 Repair Welding of Cracks..............................................507 Preheat...........................................................508 Welding Technique.................................................508 Repair Welding of Broken Parts........................................509 Repair Welding Swing Rack Teeth.......................................510 Preparation.......................................................510 Swing Rack Welding Electrodes.....................................510 Preheat...........................................................510 Welding Procedure.................................................512 Welding and Cutting Equipment.........................................514 Stress Relieving & Temperature Measuring Equipment....................515 Wire Rope Care and Maintenance............................................516 Storage...............................................................516 Checking Diameter.....................................................516 Handling Wire Rope....................................................517 Seizing Wire Rope.....................................................518 End Preparations/Terminations.........................................520 Wire Rope Clips.......................................................520 Wire Rope Clip Application........................................520 Wedge Sockets.....................................................522 Inspection of Sheaves and Drums.......................................523 Breaking In a New Wire Rope...........................................524 Inspection Data.......................................................525 Guideline to Inspections and Reports..................................526 Wire Rope Inspection Criteria.....................................527 Reduction in Rope Diameter....................................527 Rope Stretch..................................................528 Abrasion......................................................529 Corrosion.....................................................529 Kinks.........................................................529 Bird Caging...................................................529 Localized Conditions..........................................529 Heat Damage...................................................529 Protruding Core...............................................529 Damaged End Attachments.......................................530 Peening.......................................................530 Scrubbing.....................................................530 Fatigue Fracture..............................................530 Broken Wires..................................................530 Electric Arc..................................................531 Seals.....................................................................531 Seal Installation.....................................................532 Gearcase Sealing......................................................533 Schematics................................................................536 Schematics................................................................536 Side View.................................................................537 Deck Plan.................................................................538 OGL System A & B Schematic................................................539 Grease System C Schematic.................................................540 Air Schematic.............................................................541 10907-ServiceProcedures X32.pdf........................................... 0 Page 1................................................................248
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DESCRIPTION:
CAT Bucyrus 495HR Mining Shovel Maintenance & Operation Manual SN 141323 PDF DOWNLOAD
GENERAL INFORMATION
- This manual is designed to assist the owner in the operation and 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.
- When a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.
- Throughout this section, and the remainder of the manual, the use of the terms “LEFT, RIGHT, FRONT, and REAR” refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab. 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 for this purpose.
GENERAL PRECAUTIONS
• The employment of qualified maintenance personnel, through a scheduled maintenance program, is the best way to minimize machine downtime and maximize productivity of equipment.
Keep hands, feet and clothing away from rotating parts.
• Wear a hard hat, safety shoes and protective lenses at all times.
• Replace any and all safety and warning placards if they are defaced or removed from the machine.
• Think before you act. Carelessness is one luxury the service person cannot afford.
• Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested method of cleanup.
• Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip off of the hook if they are not functioning properly.
• If a heavy item begins to fall, let it fall, don’t try to catch it
. • Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.
• Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure all spillage is cleaned up.
• Electrical cords and wet metal floors make a dangerous combination.
• Regularly inspect for any loose bolts or locking devices and properly secure them.
• Use extreme caution while working near any electrical lines or equipment whether it be high or low voltage. Never attempt electrical repairs unless you are qualified
. • Check limit switches for proper operation.
• After servicing, be sure all tools, parts or servicing equipment are removed from the machine and secured in an appropriate storage area.
• Mechanical Brakes are designed for use as static holding brakes only. Use as a motion (dynamic) brake in emergency situations only.
• Use proper interior and exterior lighting.
• Install and maintain proper grounding and ground fault protection systems.
• Allow electrical inspection and maintenance to be performed only by a qualified electrician
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
