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CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual SN 141320 PDF DOWNLOAD
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CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual SN 141320 PDF DOWNLOAD
Manual No. 10977
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Description
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual SN 141320 PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual SN 141320 PDF DOWNLOAD
Language : English
Pages : 494
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual SN 141320 PDF DOWNLOAD
Manual No. 10977
Safety Precautions........................................................ 0 General Precautions................................................... 0 Maintenance Precautions............................................... 0 Operating Precautions................................................. 0 Fire Prevention....................................................... 0 Warning Signs And Decals.............................................. 0 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 Vertical Boarding Ladder.......................................... 42 A-Frame............................................................... 43 Hoist Machinery....................................................... 44 Swing Machinery....................................................... 44 Crowd Machinery....................................................... 46 OPERATOR’S CAB........................................................ 47 Compressed Air System................................................. 48 Automatic Lubrication System.......................................... 49 Lube Reservoir fill / Overflow Plumbing............................... 50 Front End Equipment....................................................... 51 Suspension Strands.................................................... 51 Boom.................................................................. 52 Running Ropes......................................................... 53 Saddle Block.......................................................... 54 Dipper Handle......................................................... 55 Dipper................................................................ 56 Padlocks.............................................................. 56 Dipper Trip........................................................... 58 Typical Machine Specifications............................................ 59 General Estimated Component Weights....................................... 61 Lower Works........................................................... 61 Upper Works........................................................... 62 Front End............................................................. 64 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........................................................171 Truck Frame Assembly..................................................171 Swing Rack Assembly...................................................172 Roller Circle Rail Replacement - Lower............................172 Roller Circle Rail Replacement - Upper............................173 Roller Circle Assembly................................................175 Roller Circle Adjustment..........................................177 Adjustment Procedure..............................................177 Run-in Procedure for the Roller Circle............................177 Roller Circle Segment Removal.....................................178 Roller Circle - Roller Replacement................................178 Crawler Belts.........................................................179 Crawler Belt Maintenance..........................................179 Crawler Belt Tension Adjustment...............................181 Crawler Shoe Replacement......................................183 Crawler Belt Replacement......................................183 Crawler Side Frame Assembly...........................................185 Crawler Side Frame Maintenance....................................186 Slide Bar Replacement.............................................187 Crawler Front Idler Roller Assembly...............................188 Load and Idler Rollers............................................191 Roller Removal or Replacement.................................191 Propel Assembly.......................................................194 Installation Notes................................................196 Main Propel Drive Shaft Removal...................................197 Main Propel Shaft - Disassembly...................................200 Tumbler Rebuild Procedure.........................................201 Propel Machinery......................................................203 Propel Gearcase Removal...........................................204 Propel Gearcase Installation......................................205 Propel Planetary Gearcase.........................................207 Propel Motors.....................................................208 Propel Motor Removal..........................................208 Propel Motor Installation.....................................210 Rotating Deck.............................................................212 Revolving Frame.......................................................212 Center Pintle.........................................................213 Center Pintle Adjustment..........................................218 Center Pintle Sleeve Removal......................................218 Collector Rings.......................................................220 Collector Ring Inspection.........................................221 Collector Ring Repair.............................................221 Swing Machinery.......................................................221 Swing Support Mounting Bolts......................................223 Swing Motor.......................................................223 Swing Blower..................................................223 Swing Motor Removal...........................................224 Swing Motor Installation......................................225 Swing Planetary Gearcase..........................................225 Swing Gearcase Removal........................................226 Gearcase Inspection...........................................227 Swing Pinion Shafts...............................................228 Swing Pinion Shaft Removal....................................228 Swing Pinion Shaft Disassembly................................230 Swing Pinion Shaft Assembly...................................231 Swing Pinion Shaft Installation...............................232 Hoist Machinery.......................................................233 Hoist Motor Removal...............................................234 Motor Coupling Shaft..............................................237 Hoist Gearcase Assembly...........................................238 Hoist Gearcase Repair.............................................242 Hoist Drum Assembly...............................................245 Hoist Gear Replacement........................................247 Bearing Removal...............................................249 Bearing Installation..........................................250 Hoist Oil Cooler..................................................252 Hoist Mounting Bolts..............................................253 Hoist Limit Switch................................................254 Crowd Machinery.......................................................255 GEARCASE REPAIR.......................................................257 Crowd Gearcase Disassembly........................................257 Crowd Gearcase Assembly...........................................260 Crowd Motor.......................................................261 Crowd Gear and Drum...........................................263 Crowd Drum Removal............................................263 Operator’s Cab Mounting...............................................264 JOYSTICK REPLACEMENT..................................................265 JOYSTICK CALIBRATION..............................................267 Wiper Arm Replacement.................................................269 Wiper Blade Replacement...........................................270 Wiper MOTOR REPLACEMENT...........................................271 Machinery House.......................................................274 Walkways, Stairways, and Handrails................................276 Boarding Stairs...................................................277 Vertical Boarding Ladder, left....................................280 Front End Equipment.......................................................282 Boom Assembly.........................................................283 Boom Repair...........................................................284 Boom Limit Switch Installation........................................284 Boom Point Sheaves....................................................286 Boom Point Sheave Removal and Disassembly.........................287 Boom Point Sheave Reassembly and Installation.....................289 Boom Bumper...........................................................290 Saddle Block..........................................................291 Saddle Block Repair...............................................291 Saddle Block Removal..............................................292 Dipper Handle.........................................................294 Dipper Handle Removal.............................................296 Crowd Rope Take-Up Mechanism......................................298 Crowd Rope Take-Up Mechanism Disassembly......................299 Crowd Rope Take-Up Mechanism Assembly.........................301 Retract Rope Take-up Mechanism....................................303 Spreader Repair...................................................305 Dipper Assembly.......................................................306 Latch Bar Adjusting...............................................308 Dipper Door bumpers...............................................309 Dipper Removal & Installation.....................................310 Dipper Door Snubbers..............................................316 Snubber Adjustment............................................317 Allowable Wear................................................317 Dipper Pitch Brace................................................318 Dipper Padlock....................................................319 Dipper Trip Assembly..............................................321 A-Frame...............................................................323 Auxiliary Winch.......................................................325 Hoist Rope Support Roller.............................................326 Boom Support Ropes....................................................327 Wire Ropes............................................................328 Wire Rope Inspection..............................................329 Crowd Rope Take-up Hydraulic Unit.....................................330 Hoist Rope Reeving & Replacement......................................332 Crowd Rope Reeving & Replacement......................................336 Retract Rope Reeving & Replacement....................................338 Crowd Rope Tightening.................................................342 Retract Rope Tightening...............................................344 Dipper Trip Rope Reeving & Replacement................................345 Hoist and Crowd Limit Systems.........................................346 Setting Limits In The Hoist & Crowd System........................347 Crowd Slowdown/Stop Limits....................................349 Retract Slowdown/Stop Limits..................................350 Lower Slowdown/Stop Limits....................................351 Hoist Slowdown/Stop Limits....................................352 Brakes and Couplings......................................................355 Disc Brake Operation..................................................356 Maintenance...........................................................356 Brake Adjustment Specifications.......................................356 Hoist Brake...........................................................357 Hoist Brake Adjustment............................................359 Hoist Brake Installation..........................................361 Hoist Brake Wear & Release Switches...............................361 Crowd Brake...........................................................362 Crowd Brake Installation..........................................364 Crowd Brake Wear & Release Switches...............................366 Propel Brake..........................................................367 Propel Brake Adjustment...........................................369 Propel Brake Installation.........................................371 Tachometer Mounting & Alignment...................................372 Swing Brake...........................................................374 Swing Brake Installation..........................................376 Swing Brake Wear & Release Switches...............................377 Swing Brake Burnishing............................................378 Spring Replacement — All Brakes.......................................378 Friction Disc Replacement — All Brakes................................380 O-Ring Replacement — All Brakes.......................................381 Brake Wear & Release Switches — Single Disc Brakes....................384 Brake Wear & Release Switches — Multiple Disc Brakes..................385 Couplings.................................................................386 Grid Couplings........................................................386 Lubrication.......................................................386 Coupling Disassembly and Grid Removal.............................387 Grid Coupling Installation........................................388 Seal Replacement without Hub Removal..............................391 Grid Coupling Alignment...........................................393 Gear Couplings........................................................394 Coupling Installation.............................................394 Gear Coupling Alignment...........................................396 Hoist Coupling Shaft Alignment....................................397 Compressed Air System.....................................................401 Lockout Valves........................................................403 Safety Warnings.......................................................405 Air Filtration............................................................409 Lubrication...........................................................410 Dynavane Air Cleaner..................................................410 Air Conditioner/heater....................................................412 Evaporator............................................................412 Condenser.............................................................412 Pressurizer...........................................................413 Cleaning The Washable Filter......................................413 Specifications........................................................414 Engineering Data..........................................................419 Bolt Tightening.......................................................419 Torque Wrench Method..............................................419 Turn-of-nut Method................................................421 Measurement Systems.......................................................423 Linear Measurements...................................................423 Area Measurements.....................................................423 Volume Measurements...................................................424 Torque Measurements...................................................425 Weight Measurements - Conventional................................426 Split Flange Assembly Procedure...........................................427 Wire Locking Capscrews....................................................429 Torque Nut Installation...................................................430 Expansion Bolt Installation...............................................431 Tightening Procedure for 1.25-Inch Torque Nut.........................431 Tightening Procedure for 2-Inch Torque Nut............................432 Tightening Procedure for 2-Inch Torque Nut............................433 Tightening Procedure for 2-Inch Torque Nut............................434 Tightening Procedure for 2.5-Inch Torque Nut..........................434 Tightening Procedure for 3-Inch Torque Nut............................435 Tightening Procedure for 3.5-Inch Torque Nut..........................436 Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods....437 Initial Tensioning................................................437 Final Tensioning..................................................437 Tightening Procedures - Expansion Bolts...............................439 Rack & Roller Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut....439 Hoist Torque Rod, Tapered Sleeve & 1.62 Inch Torque Nut...........440 Swing Torque Rod & Tapered Sleeve & 3.25 Inch Torque Nut..........441 Torque Nut Removal Procedure..............................................444 Thread Lubrication....................................................444 Torque Nut Helpful Hints..................................................445 Locking Assemblies........................................................446 Locking Assembly Removal..............................................448 Pinion and Hub Installation...........................................449 Removal from a Shaft..................................................449 Mounting a Pinion or Hub on a Shaft...................................449 Pre-heat Advance Requirements - Pinions and Hubs..................452 Motor Coupling Pre-Heat Advance Requirements......................452 Maintenance Welding.......................................................454 Welding Electrodes....................................................455 Repair Welding of Cracks..............................................456 Preheat...........................................................457 Welding Technique.................................................457 Repair Welding of Broken Parts........................................458 Repair Welding Swing Rack Teeth.......................................459 Preparation.......................................................459 Swing Rack Welding Electrodes.....................................459 Preheat...........................................................459 Welding Procedure.................................................461 Welding and Cutting Equipment.........................................463 Stress Relieving & Temperature Measuring Equipment....................464 Wire Rope Care and Maintenance............................................465 Storage...............................................................465 Checking Diameter.....................................................465 Handling Wire Rope....................................................466 Seizing Wire Rope.....................................................467 End Preparations/Terminations.........................................469 Wire Rope Clips.......................................................469 Wire Rope Clip Application........................................469 Wedge Sockets.....................................................471 Inspection of Sheaves and Drums.......................................472 Breaking In a New Wire Rope...........................................473 Inspection Data.......................................................474 Guideline to Inspections and Reports..................................475 Wire Rope Inspection Criteria.....................................476 Reduction in Rope Diameter....................................476 Rope Stretch..................................................477 Abrasion......................................................478 Corrosion.....................................................478 Kinks.........................................................478 Bird Caging...................................................478 Localized Conditions..........................................478 Heat Damage...................................................478 Protruding Core...............................................478 Damaged End Attachments.......................................479 Peening.......................................................479 Scrubbing.....................................................479 Fatigue Fracture..............................................479 Broken Wires..................................................479 Electric Arc..................................................480 Seals.....................................................................481 Seal Installation.....................................................482 Gearcase Sealing......................................................483 Schematics................................................................487 Side View.................................................................489 Deck Plan.................................................................490 HVAC Schematic............................................................491 OGL System A & B Schematic................................................492 Grease System C Schematic.................................................493 Air Schematic.............................................................494 10977-Safety.pdf.......................................................... 0 Safety Precautions.................................................... 4 General Precautions............................................... 5 Maintenance Precautions........................................... 6 Operating Precautions............................................. 7 Fire Prevention................................................... 8 Warning Signs And Decals.......................................... 9
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DESCRIPTION:
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual SN 141320 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
