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CAT Bucyrus 495HR2 MINING SHOVEL Maintenance Manual BI619869 PDF DOWNLOAD
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Description
CAT Bucyrus 495HR2 MINING SHOVEL Maintenance Manual BI619869 PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus 495HR2 MINING SHOVEL Maintenance Manual BI619869 PDF DOWNLOAD
Language : English
Pages : 510
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT Bucyrus 495HR2 MINING SHOVEL Maintenance Manual BI619869 PDF DOWNLOAD
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......................................................... 38 Deck Extensions....................................................... 40 Ballast Box........................................................... 40 Machinery House....................................................... 40 Boarding Stairs................................................... 41 Power Step........................................................ 43 A-Frame............................................................... 44 Hoist Machinery....................................................... 45 Swing Machinery....................................................... 45 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 Lubrication............................................................... 69 Greasing Main A.C. Drive Motors........................................... 70 1. Type of Grease..................................................... 70 2. Initial Commissioning.............................................. 70 3. Maintenance........................................................ 70 4. Regreasing Intervals............................................... 71 Lubricant Selection....................................................... 72 Oil Fill Capacities....................................................... 73 Types Of Lubricants And Capacities Guidelines......................... 73 Quantities for First Fill of Lubricants........................... 73 Automatic Lubrication System.............................................. 74 Lube Room............................................................. 75 Lube Reservoir fill / Overflow Plumbing............................... 76 Auto Lube Control Panel........................................... 77 Lower Works Lubrication............................................... 77 Propel Machinery Lubrication.......................................... 78 Lubricant Replacement/sampling.................................... 79 Lubricant Change Cycle........................................ 79 Revolving Frame Lubrication........................................... 80 Hoist Machinery Lubrication........................................... 81 Hoist Oil Cooler.................................................. 82 Filter Element Cleaning........................................... 85 Hoist Rope Rollers Lubrication........................................ 86 Oil Pump.......................................................... 87 Crowd Machinery Lubrication........................................... 88 Swing Machinery Lubrication........................................... 89 Air Compressor Lubrication............................................ 90 Crowd Rope Take-up Mechanism Lubrication.............................. 90 Front End Lubrication................................................. 92 Lincoln Type SL-1 Lubricant Injectors................................. 93 SL-1 Lubricant Injector Operation................................. 95 Injector Advantages............................................... 97 ACSL - Air Compressor (Screw-Type) Lubricant.......................... 98 MPO - Multipurpose OIL................................................ 99 RWRL - Running Wire Rope Lubricant....................................100 EGL - Enclosed Gearcase Lubricant.....................................101 MPG - Multipurpose Grease.............................................104 OGL - Open Gear Lubricant.............................................108 Certified Lubricants Listing..........................................112 Preventive Maintenance....................................................121 Preventive Maintenance Program........................................121 Elements of an Effective Maintenance Program..........................122 Scheduled Preventive Maintenance Program..............................123 General Safety Considerations.........................................123 Maintenance During Machine Operation......................................124 Maintenance Precautions...............................................125 Preventive Maintenance for Lubrication....................................126 Lubricant Cleanliness.................................................127 Frequency of Inspection and Maintenance...................................128 Maintenance Inspection Check Points...................................128 Daily.............................................................129 Every 100 Hours or Weekly.........................................132 Every 500 Hours Or Monthly........................................133 Every 1250 Hours or Quarterly.....................................136 Every 2500 Hours or Semi-Annually.................................139 5000 Hours or Annually............................................141 Major Component Locations.................................................143 Service Procedures........................................................173 Truck Frame Assembly..................................................173 Swing Rack Assembly...................................................174 Roller Circle Rail Replacement - Lower............................174 Roller Circle Rail Replacement - Upper............................175 Roller Circle Assembly................................................177 Roller Circle Adjustment..........................................179 Adjustment Procedure..............................................179 Run-in Procedure for the Roller Circle............................179 Roller Circle Segment Removal.....................................180 Roller Circle - Roller Replacement................................180 Crawler Belts.........................................................181 Crawler Belt Maintenance..........................................181 Crawler Belt Tension Adjustment...............................183 Crawler Shoe Replacement......................................185 Crawler Belt Replacement......................................185 Crawler Side Frame Assembly...........................................187 Crawler Side Frame Maintenance....................................188 Slide Bar Replacement.............................................189 Crawler Front Idler Roller Assembly...................................190 Load and Idler Rollers............................................193 Roller Removal or Replacement.................................193 Propel Assembly.......................................................196 Installation Notes................................................198 Main Propel Drive Shaft Removal...................................199 Main Propel Shaft - Disassembly...................................202 Tumbler Rebuild Procedure.........................................203 Propel Machinery......................................................205 Propel Gearcase Removal...........................................206 Propel Gearcase Installation......................................207 Propel Planetary Gearcase.........................................209 Propel Motors.....................................................210 Propel Motor Removal..........................................210 Propel Motor Installation.....................................212 Revolving Frame.......................................................213 Center Pintle.........................................................214 Center Pintle Adjustment..........................................219 Center Pintle Sleeve Removal......................................219 Collector Rings.......................................................221 Collector Ring Inspection.........................................222 Collector Ring Repair.............................................222 Rotating Deck.............................................................223 Swing Machinery.......................................................223 Swing Support Mounting Bolts......................................225 Swing Motor.......................................................225 Swing Blower..................................................225 Swing Motor Removal...........................................226 Swing Motor Installation......................................227 Swing Planetary Gearcase..........................................227 Swing Gearcase Removal........................................228 Gearcase Inspection...........................................229 Swing Pinion Shafts...............................................230 Swing Pinion Shaft Removal....................................230 Swing Pinion Shaft Disassembly................................232 Swing Pinion Shaft Assembly...................................233 Swing Pinion Shaft Installation...............................234 Hoist Machinery.......................................................235 Hoist Motor Removal...............................................236 Motor Coupling Shaft..............................................239 Hoist Gearcase Assembly...........................................240 Hoist Gearcase Repair.............................................244 Hoist Drum Assembly...............................................247 Hoist Gear Replacement........................................249 Bearing Removal...............................................251 Bearing Installation..........................................252 Hoist Oil Cooler..................................................254 Hoist Mounting Bolts..............................................255 Hoist Limit Switch................................................256 Crowd Machinery.......................................................257 GEARCASE REPAIR.......................................................259 Crowd Gearcase Disassembly........................................259 Crowd Gearcase Assembly...........................................262 Crowd Motor.......................................................263 Crowd Gear and Drum...........................................265 Crowd Drum Removal............................................265 Operator’s Cab Mounting...............................................266 JOYSTICK REPLACEMENT..................................................267 JOYSTICK CALIBRATION..............................................269 Wiper Arm Replacement.................................................271 Wiper Blade Replacement...........................................272 Wiper MOTOR REPLACEMENT...........................................273 Machinery House.......................................................276 Walkways, Stairways, and Handrails....................................278 Boarding Stairs...................................................278 Power Step........................................................282 Front End Equipment.......................................................283 Boom Assembly.........................................................284 Boom Repair...........................................................285 Boom Limit Switch Installation........................................285 Boom Point Sheaves....................................................287 Boom Point Sheave Removal and Disassembly.........................288 Boom Point Sheave Reassembly and Installation.....................290 Boom Bumper...........................................................291 Saddle Block..........................................................292 Saddle Block Repair...............................................292 Saddle Block Removal..............................................293 Dipper Handle.........................................................295 Dipper Handle Removal.............................................297 Crowd Rope Take-Up Mechanism......................................299 Crowd Rope Take-Up Mechanism Disassembly......................300 Crowd Rope Take-Up Mechanism Assembly.........................302 Retract Rope Take-up Mechanism....................................304 Spreader Repair...................................................306 Dipper Assembly.......................................................307 Latch Bar Adjusting...............................................309 Dipper Door bumpers...............................................310 Dipper Removal & Installation.....................................311 Dipper Door Snubbers..............................................317 Snubber Adjustment............................................318 Allowable Wear................................................318 Dipper Pitch Brace................................................319 Dipper Padlock....................................................320 Dipper Trip Assembly..............................................322 A-Frame...............................................................324 Auxiliary Winch.......................................................326 Hoist Rope Support Roller.............................................327 Boom Support Ropes....................................................328 Wire Ropes............................................................329 Wire Rope Inspection..............................................330 Crowd Rope Take-up Hydraulic Unit.....................................331 Hoist Rope Reeving & Replacement......................................333 Crowd Rope Reeving & Replacement......................................337 Retract Rope Reeving & Replacement....................................339 Crowd Rope Tightening.................................................343 Retract Rope Tightening...............................................345 Dipper Trip Rope Reeving & Replacement................................346 Hoist and Crowd Limit Systems.........................................347 Setting Limits In The Hoist & Crowd System........................348 Crowd Slowdown/Stop Limits....................................350 Retract Slowdown/Stop Limits..................................351 Lower Slowdown/Stop Limits....................................352 Hoist Slowdown/Stop Limits....................................353 Brakes and Couplings......................................................357 Disc Brake Operation..................................................358 Maintenance...........................................................358 Brake Adjustment Specifications.......................................358 Hoist Brake...........................................................359 Hoist Brake Adjustment............................................361 Hoist Brake Installation..........................................363 Hoist Brake Wear & Release Switches...............................363 Crowd Brake...........................................................364 Crowd Brake Installation..........................................366 Crowd Brake Wear & Release Switches...............................368 Propel Brake..........................................................369 Propel Brake Adjustment...........................................371 Propel Brake Installation.........................................373 Tachometer Mounting & Alignment...................................374 Swing Brake...........................................................376 Swing Brake Installation..........................................378 Swing Brake Wear & Release Switches...............................379 Swing Brake Burnishing............................................380 Spring Replacement — All Brakes.......................................380 Friction Disc Replacement — All Brakes................................382 O-Ring Replacement — All Brakes.......................................383 Brake Wear & Release Switches — Single Disc Brakes....................386 Brake Wear & Release Switches — Multiple Disc Brakes..................387 Couplings.................................................................388 Grid Couplings........................................................388 Lubrication.......................................................388 Coupling Disassembly and Grid Removal.............................389 Grid Coupling Installation........................................390 Seal Replacement without Hub Removal..............................393 Grid Coupling Alignment...........................................395 Gear Couplings........................................................396 Coupling Installation.............................................396 Gear Coupling Alignment...........................................398 Hoist Coupling Shaft Alignment....................................399 Compressed Air System.....................................................403 Lockout Valves........................................................405 Safety Warnings.......................................................407 Air Filtration............................................................411 Lubrication...........................................................412 Dynavane Air Cleaner..................................................412 Air Filtration System.....................................................414 Description...........................................................415 Operation.............................................................416 Operational Checklist.................................................416 Compressed Air Installation.......................................417 Filter Removal....................................................417 Solid-State Timer Installation....................................418 Solenoid Connection...........................................418 Timer and Solenoid Specifications.............................418 Delta P Plus......................................................420 Operation.....................................................420 Alarm.........................................................421 Setpoint Adjustments..............................................421 Quick Start Instructions......................................421 Adjustments...................................................421 Password Protected Settings...................................422 Delta P Plus Control Calibration..................................423 Preliminary Start-Up Check........................................425 Maintenance Information...........................................425 Air Conditioner/heater....................................................427 Evaporator............................................................427 Condenser.............................................................427 Pressurizer...........................................................428 Cleaning The Washable Filter......................................428 Specifications........................................................429 Engineering Data..........................................................435 Bolt Tightening.......................................................435 Torque Wrench Method..............................................435 Turn-of-nut Method................................................437 Measurement Systems.......................................................439 Linear Measurements...................................................439 Area Measurements.....................................................439 Volume Measurements...................................................440 Torque Measurements...................................................441 Weight Measurements - Conventional................................442 Split Flange Assembly Procedure...........................................443 Wire Locking Capscrews....................................................445 Torque Nut Installation...................................................446 Expansion Bolt Installation...............................................447 Tightening Procedure for 1.25-Inch Torque Nut.........................447 Tightening Procedure for 2-Inch Torque Nut............................448 Tightening Procedure for 2-Inch Torque Nut............................449 Tightening Procedure for 2-Inch Torque Nut............................450 Tightening Procedure for 2.5-Inch Torque Nut..........................450 Tightening Procedure for 3-Inch Torque Nut............................451 Tightening Procedure for 3.5-Inch Torque Nut..........................452 Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods....453 Initial Tensioning................................................453 Final Tensioning..................................................453 Tightening Procedures - Expansion Bolts...............................455 Rack & Roller Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut....455 Hoist Torque Rod, Tapered Sleeve & 1.62 Inch Torque Nut...........456 Swing Torque Rod & Tapered Sleeve & 3.25 Inch Torque Nut..........457 Torque Nut Removal Procedure..............................................460 Thread Lubrication....................................................460 Torque Nut Helpful Hints..................................................461 Locking Assemblies........................................................462 Locking Assembly Removal..............................................464 Pinion and Hub Installation...............................................465 Removal from a Shaft..................................................465 Mounting a Pinion or Hub on a Shaft...................................465 Pre-heat Advance Requirements - Pinions and Hubs..................468 Motor Coupling Pre-Heat Advance Requirements......................468 Maintenance Welding.......................................................470 Welding Electrodes....................................................471 Repair Welding of Cracks..............................................472 Preheat...........................................................473 Welding Technique.................................................473 Repair Welding of Broken Parts........................................474 Repair Welding Swing Rack Teeth.......................................475 Preparation.......................................................475 Swing Rack Welding Electrodes.....................................475 Preheat...........................................................475 Welding Procedure.................................................477 Welding and Cutting Equipment.........................................479 Stress Relieving & Temperature Measuring Equipment....................480 Wire Rope Care and Maintenance............................................481 Storage...............................................................481 Checking Diameter.....................................................481 Handling Wire Rope....................................................482 Seizing Wire Rope.....................................................483 End Preparations/Terminations.........................................485 Wire Rope Clips.......................................................485 Wire Rope Clip Application........................................485 Wedge Sockets.....................................................487 Inspection of Sheaves and Drums.......................................488 Breaking In a New Wire Rope...........................................489 Inspection Data.......................................................490 Guideline to Inspections and Reports..................................491 Wire Rope Inspection Criteria.....................................492 Reduction in Rope Diameter....................................492 Rope Stretch..................................................493 Abrasion......................................................494 Corrosion.....................................................494 Kinks.........................................................494 Bird Caging...................................................494 Localized Conditions..........................................494 Heat Damage...................................................494 Protruding Core...............................................494 Damaged End Attachments.......................................495 Peening.......................................................495 Scrubbing.....................................................495 Fatigue Fracture..............................................495 Broken Wires..................................................495 Electric Arc..................................................496 Seals.....................................................................497 Seal Installation.....................................................498 Gearcase Sealing......................................................499 Schematics................................................................503 Side View.................................................................505 Deck Plan.................................................................506 HVAC Schematic............................................................507 OGL System A & B Schematic................................................508 Grease System C Schematic.................................................509 Air Schematic.............................................................510 10932-ServiceProcedures 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DESCRIPTION:
CAT Bucyrus 495HR2 MINING SHOVEL Maintenance Manual BI619869 PDF DOWNLOAD
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
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- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
G.P
