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 SN 141324 PDF DOWNLOAD
$29.95
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual SN 141324 PDF DOWNLOAD
Manual No. 10968
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 SN 141324 PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual SN 141324 PDF DOWNLOAD
Language : English
Pages : 498
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual SN 141324 PDF DOWNLOAD
Manual No. 10968
Safety Precautions........................................................ 4 General Precautions................................................... 5 Maintenance Precautions............................................... 6 Operating Precautions................................................. 7 Fire Prevention....................................................... 8 Warning Signs And Decals.............................................. 9 Introduction.............................................................. 25 General Information....................................................... 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....................................................... 45 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.............................................................. 57 Dipper Trip........................................................... 58 Typical Machine Specifications............................................ 59 General Estimated Component Weights....................................... 61 Lower Works........................................................... 61 Upper Works........................................................... 62 Front End............................................................. 64 Lubrication............................................................... 69 Lubrication Principles.................................................... 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....................................................... 71 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.............................. 91 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 Introduction..............................................................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 Schedules.....................................................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 Lower Works...............................................................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................................179 Crawler Belts.........................................................180 Crawler Belt Maintenance..........................................180 Crawler Belt Tension Adjustment...............................182 Crawler Shoe Replacement......................................184 Crawler Belt Replacement......................................185 Crawler Side Frame Assembly...........................................186 Crawler Side Frame Maintenance....................................187 Slide Bar Replacement.............................................188 Crawler Front Idler Roller Assembly...................................189 Load and Idler Rollers............................................192 Roller Removal or Replacement.................................192 Propel Assembly.......................................................195 Installation Notes................................................197 Main Propel Drive Shaft Removal...................................198 Main Propel Shaft - Disassembly...................................201 Tumbler Rebuild Procedure.........................................202 Propel Machinery......................................................204 Propel Gearcase Removal...........................................205 Propel Gearcase Installation......................................206 Propel Planetary Gearcase.........................................208 Propel Motors.....................................................209 Propel Motor Removal..........................................209 Propel Motor Installation.....................................211 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 Cable Reel............................................................222 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....................................231 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...............................................267 JOYSTICK REPLACEMENT..................................................268 JOYSTICK CALIBRATION..............................................269 Wiper Arm Replacement.................................................271 Wiper Blade Replacement...........................................273 Wiper MOTOR REPLACEMENT...........................................274 Machinery House.......................................................277 Walkways, Stairways, and Handrails....................................278 Boarding Stairs...................................................279 Vertical Boarding Ladder, left....................................282 Front End Equipment.......................................................284 Boom Assembly.........................................................285 Boom Repair...........................................................286 Boom Limit Switch Installation........................................286 Boom Point Sheaves....................................................288 Boom Point Sheave Removal and Disassembly.........................289 Boom Point Sheave Reassembly and Installation.....................291 Boom Bumper...........................................................292 Saddle Block..........................................................293 Saddle Block Repair...............................................293 Saddle Block Removal..............................................294 Dipper Handle.........................................................296 Dipper Handle Removal.............................................298 Crowd Rope Take-Up Mechanism......................................300 Crowd Rope Take-Up Mechanism Disassembly......................301 Crowd Rope Take-Up Mechanism Assembly.........................303 Retract Rope Take-up Mechanism....................................305 Spreader Repair...................................................307 Dipper Assembly.......................................................308 Latch Bar Adjusting...............................................314 Dipper Door bumpers...............................................314 Dipper Removal & Installation.....................................315 Dipper Door Snubbers..............................................321 Snubber Adjustment............................................322 Allowable Wear................................................322 Dipper Pitch Brace................................................323 Dipper Padlock....................................................324 Dipper Trip Assembly..............................................327 A-Frame...............................................................328 Auxiliary Winch.......................................................330 Hoist Rope Support Roller.............................................331 Boom Support Ropes....................................................332 Wire Ropes............................................................333 Wire Rope Inspection..............................................334 Crowd Rope Take-up Hydraulic Unit.....................................335 Hoist Rope Reeving & Replacement......................................337 Crowd Rope Reeving & Replacement......................................341 Retract Rope Reeving & Replacement....................................343 Crowd Rope Tightening.................................................347 Retract Rope Tightening...............................................349 Dipper Trip Rope Reeving & Replacement................................350 Hoist and Crowd Limit Systems.........................................351 Setting Limits In The Hoist & Crowd System........................352 Crowd Slowdown/Stop Limits....................................354 Retract Slowdown/Stop Limits..................................355 Lower Slowdown/Stop Limits....................................356 Hoist Slowdown/Stop Limits....................................357 Brakes and Couplings......................................................361 Brakes....................................................................361 Disc Brake Operation..................................................362 Maintenance...........................................................362 Brake Adjustment Specifications.......................................362 Hoist Brake...........................................................363 Hoist Brake Adjustment............................................365 Hoist Brake Installation..........................................367 Hoist Brake Wear & Release Switches...............................367 Crowd Brake...........................................................368 Crowd Brake Installation..........................................370 Crowd Brake Wear & Release Switches...............................372 Propel Brake..........................................................373 Propel Brake Adjustment...........................................375 Propel Brake Installation.........................................377 Tachometer Mounting & Alignment...................................379 Swing Brake...........................................................381 Swing Brake Installation..........................................383 Swing Brake Wear & Release Switches...............................384 Swing Brake Burnishing............................................385 Spring Replacement — All Brakes.......................................385 Friction Disc Replacement — All Brakes................................387 O-Ring Replacement — All Brakes.......................................388 Brake Wear & Release Switches — Single Disc Brakes....................390 Brake Wear & Release Switches — Multiple Disc Brakes..................391 Couplings.................................................................392 Grid Couplings........................................................392 Lubrication.......................................................392 Coupling Disassembly and Grid Removal.............................393 Grid Coupling Installation........................................394 Seal Replacement without Hub Removal..............................397 Grid Coupling Alignment...........................................399 Gear Couplings........................................................400 Coupling Installation.............................................400 Gear Coupling Alignment...........................................402 Hoist Coupling Shaft Alignment....................................403 Compressed Air System.....................................................407 Air Compressor............................................................407 Lockout Valves........................................................409 Safety Warnings.......................................................411 Air Filtration............................................................415 House Filter Fans.........................................................415 Lubrication...........................................................416 Dynavane Air Cleaner..................................................417 Air Conditioner/heater....................................................418 Evaporator............................................................418 Condenser.............................................................418 Pressurizer...........................................................419 Cleaning The Washable Filter......................................419 Specifications........................................................420 Engineering Data..........................................................425 Capscrew (Bolt) Grade.....................................................425 Bolt Tightening.......................................................425 Torque Wrench Method..............................................425 Turn-of-nut Method................................................427 Measurement Systems.......................................................429 Linear Measurements...................................................429 Area Measurements.....................................................429 Volume Measurements...................................................430 Torque Measurements...................................................431 Weight Measurements - Conventional................................432 Split Flange Assembly Procedure...........................................433 Wire Locking Capscrews....................................................435 Torque Nut Installation...................................................436 Expansion Bolt Installation...............................................436 Tightening Procedure for 1.25-Inch Torque Nut.........................437 Tightening Procedure for 2-Inch Torque Nut............................438 Tightening Procedure for 2-Inch Torque Nut............................439 Tightening Procedure for 2-Inch Torque Nut............................440 Tightening Procedure for 2.5-Inch Torque Nut..........................441 Tightening Procedure for 3-Inch Torque Nut............................442 Tightening Procedure for 3.5-Inch Torque Nut..........................443 Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods....444 Initial Tensioning................................................444 Final Tensioning..................................................444 Tightening Procedures - Expansion Bolts...............................446 Rack & Roller Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut....446 Hoist Torque Rod, Tapered Sleeve & 1.62 Inch Torque Nut...........447 Swing Torque Rod & Tapered Sleeve & 3.25 Inch Torque Nut..........449 Torque Nut Removal Procedure..............................................451 Thread Lubrication....................................................451 Torque Nut Helpful Hints..................................................452 Locking Assemblies........................................................453 Locking Assembly Removal..............................................455 Pinion and Hub Installation...............................................456 Removal from a Shaft..................................................456 Mounting a Pinion or Hub on a Shaft...................................456 Pre-heat Advance Requirements - Pinions and Hubs..................459 Motor Coupling Pre-Heat Advance Requirements......................459 Maintenance Welding.......................................................461 Welding Electrodes....................................................462 Repair Welding of Cracks..............................................463 Preheat...........................................................464 Welding Technique.................................................464 Repair Welding of Broken Parts........................................465 Repair Welding Swing Rack Teeth.......................................466 Preparation.......................................................466 Swing Rack Welding Electrodes.....................................466 Preheat...........................................................466 Welding Procedure.................................................468 Welding and Cutting Equipment.........................................470 Stress Relieving & Temperature Measuring Equipment....................471 Wire Rope Care and Maintenance............................................472 Storage...............................................................472 Checking Diameter.....................................................472 Handling Wire Rope....................................................473 Seizing Wire Rope.....................................................474 End Preparations/Terminations.........................................476 Wire Rope Clips.......................................................476 Wire Rope Clip Application........................................476 Wedge Sockets.....................................................478 Inspection of Sheaves and Drums.......................................479 Breaking In a New Wire Rope...........................................480 Inspection Data.......................................................481 Guideline to Inspections and Reports..................................482 Wire Rope Inspection Criteria.....................................483 Reduction in Rope Diameter....................................483 Rope Stretch..................................................484 Abrasion......................................................485 Corrosion.....................................................485 Kinks.........................................................485 Bird Caging...................................................485 Localized Conditions..........................................485 Heat Damage...................................................485 Protruding Core...............................................485 Damaged End Attachments.......................................486 Peening.......................................................486 Scrubbing.....................................................486 Fatigue Fracture..............................................486 Broken Wires..................................................486 Electric Arc..................................................487 Seals.....................................................................487 Seal Installation.....................................................488 Gearcase Sealing......................................................489 Schematics................................................................492 Schematics................................................................492 Side View.................................................................493 Deck Plan.................................................................494 HVAC Schematic............................................................495 OGL System A & B Schematic................................................496 Grease System C Schematic.................................................497 Air Schematic.............................................................498 10968-ServiceProcedures X32.pdf........................................... 0 Page 1................................................................196
Questions? Email us: [email protected]
https://vimeo.com/856336632?share=copy
DESCRIPTION:
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual SN 141324 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
