Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual 10982 PDF DOWNLOAD
$30.95
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual 10982 PDF DOWNLOAD
SN 141446
SN 141454
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual 10982 PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual 10982 PDF DOWNLOAD
Language : English
Pages : 504
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual 10982 PDF DOWNLOAD
SN 141446
SN 141454
Safety Precautions........................................................ 4 General Precautions................................................... 5 Maintenance Precautions............................................... 6 Operating Precautions................................................. 7 Fire Prevention....................................................... 8 Warning Signs And Decals.............................................. 9 Introduction.............................................................. 25 Swinging Restraint & Ballast Box Support.................................. 26 Ballast Box Support................................................... 26 Swinging Restraint.................................................... 27 Machine Overview.......................................................... 29 Lower Works............................................................... 30 Crawlers.............................................................. 31 Truck Frame........................................................... 32 Swing Rack............................................................ 33 Roller Circle......................................................... 34 Propel Machinery...................................................... 35 Collector Rings....................................................... 36 Rotating Deck............................................................. 37 Revolving Frame....................................................... 37 Center Pintle......................................................... 37 Deck Extensions....................................................... 39 Ballast Box........................................................... 39 Machinery House....................................................... 39 Boarding Stairs................................................... 40 Vertical Boarding Ladder.......................................... 41 A-Frame............................................................... 42 Hoist Machinery....................................................... 43 Swing Machinery....................................................... 43 Crowd Machinery....................................................... 45 OPERATOR’S CAB........................................................ 46 Compressed Air System................................................. 47 Automatic Lubrication System.......................................... 48 Lube Reservoir fill / Overflow Plumbing............................... 49 Front End Equipment....................................................... 50 Suspension Strands.................................................... 50 Boom.................................................................. 51 Running Ropes......................................................... 52 Saddle Block.......................................................... 53 Dipper Handle......................................................... 54 Dipper................................................................ 55 Padlocks.............................................................. 56 Dipper Trip........................................................... 57 Typical Machine Specifications............................................ 58 General Estimated Component Weights....................................... 60 Lower Works........................................................... 60 Upper Works........................................................... 61 Front End............................................................. 63 Lubrication............................................................... 67 Greasing Main A.C. Drive Motors........................................... 68 1. Type of Grease..................................................... 68 2. Initial Commissioning.............................................. 68 3. Maintenance........................................................ 68 4. Regreasing Intervals............................................... 69 Lubricant Selection....................................................... 70 Oil Fill Capacities....................................................... 71 Types Of Lubricants And Capacities Guidelines......................... 71 Quantities for First Fill of Lubricants........................... 71 Automatic Lubrication System.............................................. 72 Lube Room............................................................. 73 Lube Reservoir fill / Overflow Plumbing............................... 74 Auto Lube Control Panel........................................... 75 Lower Works Lubrication............................................... 75 Propel Machinery Lubrication.......................................... 76 Lubricant Replacement/sampling.................................... 77 Lubricant Change Cycle........................................ 77 Revolving Frame Lubrication........................................... 78 Hoist Machinery Lubrication........................................... 79 Hoist Oil Cooler.................................................. 80 Filter Element Cleaning........................................... 83 Hoist Rope Rollers Lubrication........................................ 84 Oil Pump.......................................................... 85 Crowd Machinery Lubrication........................................... 86 Swing Machinery Lubrication........................................... 87 Air Compressor Lubrication............................................ 88 Crowd Rope Take-up Mechanism Lubrication.............................. 88 Front End Lubrication................................................. 90 Lincoln Type SL-1 Lubricant Injectors................................. 91 SL-1 Lubricant Injector Operation................................. 93 Injector Advantages............................................... 95 ACSL - Air Compressor (Screw-Type) Lubricant.......................... 96 MPO - Multipurpose OIL................................................ 97 RWRL - Running Wire Rope Lubricant.................................... 98 EGL - Enclosed Gearcase Lubricant..................................... 99 MPG - Multipurpose Grease.............................................102 OGL - Open Gear Lubricant.............................................106 Certified Lubricants Listing..........................................110 Preventive Maintenance....................................................117 Preventive Maintenance Program........................................117 Elements of an Effective Maintenance Program..........................118 Scheduled Preventive Maintenance Program..............................119 General Safety Considerations.........................................119 Maintenance During Machine Operation......................................120 Maintenance Precautions...............................................121 Preventive Maintenance for Lubrication....................................122 Lubricant Cleanliness.................................................123 Frequency of Inspection and Maintenance...................................124 Maintenance Inspection Check Points...................................124 Daily.............................................................125 Every 100 Hours or Weekly.........................................128 Every 500 Hours Or Monthly........................................129 Every 1250 Hours or Quarterly.....................................132 Every 2500 Hours or Semi-Annually.................................135 5000 Hours or Annually............................................137 Major Component Locations.................................................139 Service Procedures........................................................167 Truck Frame Assembly..................................................167 Swing Rack Assembly...................................................168 Roller Circle Rail Replacement - Lower............................168 Roller Circle Rail Replacement - Upper............................169 Roller Circle Assembly................................................171 Roller Circle Adjustment..........................................173 Adjustment Procedure..............................................173 Run-in Procedure for the Roller Circle............................173 Roller Circle Segment Removal.....................................174 Roller Circle - Roller Replacement................................174 Crawler Belts.........................................................175 Crawler Belt Maintenance..........................................175 Crawler Belt Tension Adjustment...............................177 Crawler Shoe Replacement......................................179 Crawler Belt Replacement......................................179 Crawler Side Frame Assembly...........................................180 Crawler Side Frame Maintenance....................................181 Slide Bar Replacement.............................................182 Crawler Front Idler Roller Assembly...................................183 Load and Idler Rollers............................................186 Roller Removal or Replacement.................................186 Propel Assembly.......................................................189 Installation Notes................................................191 Main Propel Drive Shaft Removal...................................192 Main Propel Shaft - Disassembly...................................195 Tumbler Rebuild Procedure.........................................196 Propel Machinery......................................................198 Propel Gearcase Removal...........................................199 Propel Gearcase Installation......................................200 Propel Planetary Gearcase.........................................202 Propel Motors.....................................................203 Propel Motor Removal..........................................203 Propel Motor Installation.....................................205 Rotating Deck.............................................................207 Revolving Frame.......................................................207 Center Pintle.........................................................207 Center Pintle Adjustment..........................................212 Center Pintle Sleeve Removal......................................212 Collector Rings.......................................................214 Collector Ring Inspection.........................................215 Collector Ring Repair.............................................215 Cable Reel............................................................216 Swing Machinery.......................................................217 Swing Support Mounting Bolts......................................219 Swing Motor.......................................................219 Swing Blower..................................................219 Swing Motor Removal...........................................220 Swing Motor Installation......................................221 Swing Planetary Gearcase..........................................221 Swing Gearcase Removal........................................222 Gearcase Inspection...........................................223 Swing Pinion Shafts...............................................224 Swing Pinion Shaft Removal....................................224 Swing Pinion Shaft Disassembly................................226 Swing Pinion Shaft Assembly...................................227 Swing Pinion Shaft Installation...............................228 Hoist Machinery.......................................................229 Hoist Motor Removal...............................................230 Motor Coupling Shaft..............................................233 Hoist Gearcase Assembly...........................................234 Hoist Gearcase Repair.............................................238 Hoist Drum Assembly...............................................241 Hoist Gear Replacement........................................243 Bearing Removal...............................................245 Bearing Installation..........................................246 Hoist Oil Cooler..................................................248 Hoist Mounting Bolts..............................................249 Hoist Limit Switch................................................250 Crowd Machinery.......................................................251 Gearcase Repair.......................................................253 Crowd Gearcase Disassembly........................................253 Crowd Gearcase Assembly...........................................256 Crowd Motor.......................................................257 Crowd Gear and Drum...........................................259 Crowd Drum Removal............................................259 Operator’s Cab Mounting...............................................260 Joystick Replacement..................................................261 Joystick Calibration..............................................263 Wiper Arm Replacement.................................................265 Wiper Blade Replacement...........................................266 Wiper Motor Replacement...........................................267 Machinery House...........................................................271 Walkways, Stairways, and Handrails....................................272 Boarding Stairs...................................................273 Vertical Boarding Ladder, left....................................276 Front End Equipment.......................................................278 Boom Assembly.........................................................279 Boom Repair...........................................................280 Boom Limit Switch Installation........................................280 Boom Point Sheaves....................................................282 Boom Point Sheave Removal and Disassembly.........................283 Boom Point Sheave Reassembly and Installation.....................285 Boom Bumper...........................................................286 Saddle Block..........................................................287 Saddle Block Repair...............................................287 Saddle Block Removal..............................................288 Dipper Handle.........................................................290 Dipper Handle Removal.............................................292 Crowd Rope Take-Up Mechanism......................................294 Crowd Rope Take-Up Mechanism Disassembly......................295 Crowd Rope Take-Up Mechanism Assembly.........................297 Retract Rope Take-up Mechanism....................................299 Spreader Repair...................................................301 Dipper Assembly.......................................................302 Dipper Door...........................................................304 Latch Lever Assembly..............................................305 Rope Bracket and Deflector Assembly...............................307 Latch Bar Adjusting...............................................307 Dipper Door bumpers...............................................308 Dipper Removal & Installation.....................................309 Dipper Door Snubbers..............................................315 Snubber Adjustment............................................316 Allowable Wear................................................316 Dipper Pitch Brace................................................317 Dipper Padlock....................................................318 Dipper Trip Assembly..............................................320 A-Frame...............................................................322 Auxiliary Winch.......................................................324 Hoist Rope Support Roller.............................................325 Boom Support Ropes....................................................326 Wire Ropes............................................................327 Wire Rope Inspection..............................................328 Crowd Rope Take-up Hydraulic Unit.....................................329 Hoist Rope Reeving & Replacement......................................331 Crowd Rope Reeving & Replacement......................................335 Retract Rope Reeving & Replacement....................................337 Crowd Rope Tightening.................................................341 Retract Rope Tightening...............................................343 Dipper Trip Rope Reeving & Replacement................................344 Hoist and Crowd Limit Systems.........................................344 Setting Limits In The Hoist & Crowd System........................345 Crowd Slowdown/Stop Limits....................................347 Retract Slowdown/Stop Limits..................................348 Lower Slowdown/Stop Limits....................................349 Hoist Slowdown/Stop Limits....................................350 Brakes and Couplings......................................................353 Disc Brake Operation..................................................354 Maintenance...........................................................354 Brake Adjustment Specifications.......................................354 Hoist Brake...........................................................355 Hoist Brake Adjustment............................................357 Hoist Brake Installation..........................................359 Hoist Brake Wear & Release Switches...............................359 Crowd Brake...........................................................360 Crowd Brake Installation..........................................362 Crowd Brake Wear & Release Switches...............................364 Propel Brake..........................................................365 Propel Brake Adjustment...........................................367 Propel Brake Installation.........................................369 Tachometer Mounting & Alignment...................................370 Swing Brake...........................................................372 Swing Brake Installation..........................................374 Swing Brake Wear & Release Switches...............................375 Swing Brake Burnishing............................................376 Spring Replacement — All Brakes.......................................376 Friction Disc Replacement — All Brakes................................378 O-Ring Replacement — All Brakes.......................................379 Brake Wear & Release Switches — Single Disc Brakes....................382 Brake Wear & Release Switches — Multiple Disc Brakes..................383 Couplings.................................................................384 Grid Couplings........................................................384 Lubrication.......................................................384 Coupling Disassembly and Grid Removal.............................385 Grid Coupling Installation........................................386 Seal Replacement without Hub Removal..............................389 Grid Coupling Alignment...........................................391 Gear Couplings........................................................392 Coupling Installation.............................................392 Gear Coupling Alignment...........................................394 Hoist Coupling Shaft Alignment....................................395 Compressed Air System.....................................................399 Lockout Valves........................................................401 Safety Warnings.......................................................403 Air Filtration............................................................407 Lubrication...........................................................408 Dynavane Air Cleaner..................................................408 Air Filtration System.....................................................410 Description...........................................................411 Operation.............................................................412 Operational Checklist.................................................412 Compressed Air Installation.......................................413 Filter Removal....................................................413 Solid-State Timer Installation....................................413 Solenoid Connection...........................................414 Timer and Solenoid Specifications.............................414 Delta P Plus......................................................416 Operation.....................................................416 Alarm.........................................................417 Setpoint Adjustments..............................................417 Quick Start Instructions......................................417 Adjustments...................................................417 Password Protected Settings...................................418 Delta P Plus Control Calibration..................................419 Preliminary Start-Up Check........................................421 Maintenance Information...........................................421 Air Conditioner/heater....................................................423 Evaporator............................................................423 Condenser.............................................................423 Pressurizer...........................................................424 Cleaning The Washable Filter......................................424 Specifications........................................................425 Engineering Data..........................................................431 Bolt Tightening.......................................................431 Torque Wrench Method..............................................431 Turn-of-nut Method................................................433 Measurement Systems.......................................................435 Linear Measurements...................................................435 Area Measurements.....................................................435 Volume Measurements...................................................436 Torque Measurements...................................................437 Weight Measurements - Conventional................................438 Split Flange Assembly Procedure...........................................439 Wire Locking Capscrews....................................................441 Torque Nut Installation...................................................442 Tightening Procedure for 1.25-Inch Torque Nut.........................443 Tightening Procedure for 2-Inch Torque Nut............................444 Tightening Procedure for 2-Inch Torque Nut............................445 Tightening Procedure for 2-Inch Torque Nut............................446 Tightening Procedure for 2.5-Inch Torque Nut..........................447 Tightening Procedure for 3-Inch Torque Nut............................448 Tightening Procedure for 3.5-Inch Torque Nut..........................449 Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods....450 Initial Tensioning................................................450 Final Tensioning..................................................450 Tightening Procedures - Expansion Bolts...............................452 Rack & Roller Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut....452 Hoist Torque Rod, Tapered Sleeve & 1.62 Inch Torque Nut...........453 Swing Torque Rod & Tapered Sleeve & 3.25 Inch Torque Nut..........455 Thread Lubrication....................................................457 Locking Assemblies........................................................459 Locking Assembly Removal..............................................461 Pinion and Hub Installation...............................................462 Removal from a Shaft..................................................462 Mounting a Pinion or Hub on a Shaft...................................462 Pre-heat Advance Requirements - Pinions and Hubs..................465 Motor Coupling Pre-Heat Advance Requirements......................465 Maintenance Welding.......................................................467 Welding Electrodes....................................................468 Repair Welding of Cracks..............................................469 Preheat...........................................................470 Welding Technique.................................................470 Repair Welding of Broken Parts........................................471 Repair Welding Swing Rack Teeth.......................................472 Preparation.......................................................472 Swing Rack Welding Electrodes.....................................472 Preheat...........................................................472 Welding Procedure.................................................474 Welding and Cutting Equipment.........................................476 Stress Relieving & Temperature Measuring Equipment....................477 Wire Rope Care and Maintenance............................................478 Storage...............................................................478 Checking Diameter.....................................................478 Handling Wire Rope....................................................479 Seizing Wire Rope.....................................................480 End Preparations/Terminations.........................................482 Wire Rope Clips.......................................................482 Wire Rope Clip Application........................................483 Wedge Sockets.....................................................485 Inspection of Sheaves and Drums.......................................486 Breaking In a New Wire Rope...........................................487 Inspection Data.......................................................488 Guideline to Inspections and Reports..................................489 Wire Rope Inspection Criteria.....................................490 Reduction in Rope Diameter....................................490 Rope Stretch..................................................491 Abrasion......................................................492 Corrosion.....................................................492 Kinks.........................................................492 Bird Caging...................................................492 Localized Conditions..........................................492 Heat Damage...................................................492 Protruding Core...............................................492 Damaged End Attachments.......................................493 Peening.......................................................493 Scrubbing.....................................................493 Fatigue Fracture..............................................493 Broken Wires..................................................493 Electric Arc..................................................494 Seal Installation.....................................................495 Gearcase Sealing......................................................496 Schematics................................................................498 Side View.................................................................499 Deck Plan.................................................................500 HVAC Schematic............................................................501 OGL System A & B Schematic................................................502 Grease System C Schematic.................................................503 Air Schematic.............................................................504 10982-ServiceProcedures X30.pdf........................................... 0 Page 1................................................................190
Contact us: [email protected]
https://vimeo.com/856362219?share=copy
DESCRIPTION:
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual 10982 PDF DOWNLOAD
INRODUCTION:
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. Periodic additions or revisions may be made to this manual
- It is the policy of Bucyrus International, Inc. to improve its products whenever possible and practical to do so.
- The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations 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
