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CAT Bucyrus 495HR2 Mining Shovel Maintenace Manual SN 141456 PDF DOWNLOAD
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CAT Bucyrus 495HR2 Mining Shovel Maintenace Manual SN 141456 PDF DOWNLOAD
Manual No.10988
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Description
CAT Bucyrus 495HR2 Mining Sovel Maintenace Manual SN 141456 PDF DOWNLOAD
FILE DETAILS:
CAT Bucyrus 495HR2 Mining Shovel Maintenace Manual SN 141456 PDF DOWNLOAD
Language : English
Pages : 500
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
CAT Bucyrus 495HR2 Mining Shovel Maintenace Manual SN 141456 PDF DOWNLOAD
Manual No.10988
Safety Precautions........................................................ 4 General Precautions................................................... 5 Maintenance Precautions............................................... 6 Operating Precautions................................................. 7 Fire Prevention....................................................... 8 Warning Signs And Decals.............................................. 9 Introduction.............................................................. 25 Swinging Restraint & Ballast Box Support.............................. 26 Ballast Box Support................................................... 26 Swinging Restraint.................................................... 27 Machine Overview.......................................................... 29 Lower Works............................................................... 30 Crawlers.............................................................. 31 Truck Frame........................................................... 32 Swing Rack............................................................ 33 Roller Circle......................................................... 34 Propel Machinery...................................................... 35 Collector Rings....................................................... 36 Rotating Deck............................................................. 37 Revolving Frame....................................................... 37 Center Pintle......................................................... 37 Deck Extensions....................................................... 39 Ballast Box........................................................... 39 Machinery House....................................................... 39 Boarding Stairs................................................... 40 A-Frame............................................................... 42 Hoist Machinery....................................................... 43 Swing Machinery....................................................... 43 Crowd Machinery....................................................... 45 OPERATOR’S CAB........................................................ 46 Compressed Air System................................................. 47 Automatic Lubrication System.......................................... 48 Lube Reservoir fill / Overflow Plumbing............................... 49 Front End Equipment....................................................... 50 Suspension Strands.................................................... 50 Boom.................................................................. 51 Running Ropes......................................................... 52 Saddle Block.......................................................... 53 Dipper Handle......................................................... 54 Dipper................................................................ 55 Padlocks.............................................................. 56 Dipper Trip........................................................... 57 Typical Machine Specifications............................................ 58 General Estimated Component Weights....................................... 60 Lower Works........................................................... 60 Upper Works........................................................... 61 Front End............................................................. 63 Lubrication............................................................... 67 Greasing Main A.C. Drive Motors........................................... 68 1. Type of Grease..................................................... 68 2. Initial Commissioning.............................................. 68 3. Maintenance........................................................ 68 4. Regreasing Intervals............................................... 69 Lubricant Selection....................................................... 70 Oil Fill Capacities....................................................... 71 Types Of Lubricants And Capacities Guidelines......................... 71 Quantities for First Fill of Lubricants........................... 71 Automatic Lubrication System.............................................. 72 Lube Room............................................................. 73 Lube Reservoir fill / Overflow Plumbing............................... 74 Auto Lube Control Panel........................................... 75 Lower Works Lubrication............................................... 75 Propel Machinery Lubrication.......................................... 76 Lubricant Replacement/sampling.................................... 77 Lubricant Change Cycle........................................ 77 Revolving Frame Lubrication........................................... 78 Hoist Machinery Lubrication........................................... 79 Hoist Oil Cooler.................................................. 80 Filter Element Cleaning........................................... 83 Hoist Rope Rollers Lubrication........................................ 84 Oil Pump.......................................................... 85 Crowd Machinery Lubrication........................................... 86 Swing Machinery Lubrication........................................... 87 Air Compressor Lubrication............................................ 88 Crowd Rope Take-up Mechanism Lubrication.............................. 88 Front End Lubrication................................................. 90 Lincoln Type SL-1 Lubricant Injectors................................. 91 SL-1 Lubricant Injector Operation................................. 93 Injector Advantages............................................... 95 ACSL - Air Compressor (Screw-Type) Lubricant.......................... 96 MPO - Multipurpose OIL................................................ 97 RWRL - Running Wire Rope Lubricant.................................... 98 EGL - Enclosed Gearcase Lubricant..................................... 99 MPG - Multipurpose Grease.............................................102 OGL - Open Gear Lubricant.............................................106 Certified Lubricants Listing..........................................110 Preventive Maintenance....................................................119 Preventive Maintenance Program........................................119 Elements of an Effective Maintenance Program..........................120 Scheduled Preventive Maintenance Program..............................121 General Safety Considerations.........................................121 Maintenance During Machine Operation......................................122 Maintenance Precautions...............................................123 Preventive Maintenance for Lubrication....................................124 Lubricant Cleanliness.................................................125 Frequency of Inspection and Maintenance...................................126 Maintenance Inspection Check Points...................................126 Daily.............................................................127 Every 100 Hours or Weekly.........................................130 Every 500 Hours Or Monthly........................................131 Every 1250 Hours or Quarterly.....................................134 Every 2500 Hours or Semi-Annually.................................137 5000 Hours or Annually............................................140 Major Component Locations.................................................142 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...........................................184 Crawler Side Frame Maintenance....................................185 Slide Bar Replacement.............................................186 Crawler Front Idler Roller Assembly...................................187 Load and Idler Rollers............................................190 Roller Removal or Replacement.................................190 Propel Assembly.......................................................193 Installation Notes................................................195 Main Propel Drive Shaft Removal...................................196 Main Propel Shaft - Disassembly...................................199 Tumbler Rebuild Procedure.........................................200 Propel Machinery......................................................202 Propel Gearcase Removal...........................................203 Propel Gearcase Installation......................................204 Propel Planetary Gearcase.........................................206 Propel Motors.....................................................207 Propel Motor Removal..........................................207 Propel Motor Installation.....................................209 Rotating Deck.............................................................211 Revolving Frame.......................................................211 Center Pintle.........................................................211 Center Pintle Adjustment..........................................216 Center Pintle Sleeve Removal......................................216 Collector Rings.......................................................218 Collector Ring Inspection.........................................219 Collector Ring Repair.............................................219 Swing Machinery.......................................................219 Swing Support Mounting Bolts......................................221 Swing Motor.......................................................221 Swing Blower..................................................221 Swing Motor Removal...........................................222 Swing Motor Installation......................................223 Swing Planetary Gearcase..........................................223 Swing Gearcase Removal........................................224 Gearcase Inspection...........................................225 Swing Pinion Shafts...............................................226 Swing Pinion Shaft Removal....................................226 Swing Pinion Shaft Disassembly................................228 Swing Pinion Shaft Assembly...................................229 Swing Pinion Shaft Installation...............................230 Hoist Machinery.......................................................231 Hoist Motor Removal...............................................232 Motor Coupling Shaft..............................................235 Hoist Gearcase Assembly...........................................236 Hoist Gearcase Repair.............................................240 Hoist Drum Assembly...............................................243 Hoist Gear Replacement........................................245 Bearing Removal...............................................247 Bearing Installation..........................................248 Hoist Oil Cooler..................................................250 Hoist Mounting Bolts..............................................251 Hoist Limit Switch................................................252 Crowd Machinery.......................................................253 Gearcase Repair.......................................................255 Crowd Gearcase Disassembly........................................255 Crowd Gearcase Assembly...........................................258 Crowd Motor.......................................................259 Crowd Gear and Drum...........................................261 Crowd Drum Removal............................................261 Operator’s Cab Mounting...............................................262 Joystick Replacement..................................................263 Joystick Calibration..............................................266 Wiper Arm Replacement.................................................268 Wiper Blade Replacement...........................................270 Wiper Motor Replacement...........................................271 Machinery House.......................................................274 Walkways, Stairways, and Handrails....................................275 Boarding Stairs...................................................276 Front End Equipment.......................................................279 Boom Assembly.........................................................280 Boom Repair...........................................................281 Boom Limit Switch Installation........................................281 Boom Point Sheaves....................................................283 Boom Point Sheave Removal and Disassembly.........................284 Boom Point Sheave Reassembly and Installation.....................286 Boom Bumper...........................................................287 Saddle Block..........................................................288 Saddle Block Repair...............................................288 Saddle Block Removal..............................................289 Dipper Handle.........................................................291 Dipper Handle Removal.............................................293 Crowd Rope Take-Up Mechanism......................................295 Crowd Rope Take-Up Mechanism Disassembly......................296 Crowd Rope Take-Up Mechanism Assembly.........................298 Retract Rope Take-up Mechanism....................................300 Spreader Repair...................................................302 Dipper Assembly.......................................................303 Latch Bar Adjusting...............................................306 Dipper Door bumpers...............................................307 Dipper Removal & Installation.....................................308 Dipper Door Snubbers..............................................313 Snubber Adjustment............................................314 Allowable Wear................................................314 Dipper Pitch Brace................................................315 Dipper Padlock....................................................316 Dipper Trip Assembly..............................................318 A-Frame...............................................................320 Auxiliary Winch.......................................................322 Hoist Rope Support Roller.............................................323 Boom Support Ropes....................................................324 Wire Ropes............................................................325 Wire Rope Inspection..............................................326 Crowd Rope Take-up Hydraulic Unit.....................................327 Hoist Rope Reeving & Replacement......................................329 Crowd Rope Reeving & Replacement......................................333 Retract Rope Reeving & Replacement....................................335 Crowd Rope Tightening.................................................339 Retract Rope Tightening...............................................341 Dipper Trip Rope Reeving & Replacement................................342 Hoist and Crowd Limit Systems.........................................342 Setting Limits In The Hoist & Crowd System........................343 Crowd Slowdown/Stop Limits....................................345 Retract Slowdown/Stop Limits..................................346 Lower Slowdown/Stop Limits....................................347 Hoist Slowdown/Stop Limits....................................348 Brakes and Couplings......................................................351 Disc Brake Operation..................................................352 Maintenance...........................................................352 Brake Adjustment Specifications.......................................352 Hoist Brake...........................................................353 Hoist Brake Adjustment............................................355 Hoist Brake Installation..........................................357 Hoist Brake Wear & Release Switches...............................357 Crowd Brake...........................................................358 Crowd Brake Installation..........................................360 Crowd Brake Wear & Release Switches...............................362 Propel Brake..........................................................363 Propel Brake Adjustment...........................................365 Propel Brake Installation.........................................367 Tachometer Mounting & Alignment...................................368 Swing Brake...........................................................370 Swing Brake Installation..........................................372 Swing Brake Wear & Release Switches...............................373 Swing Brake Burnishing............................................374 Spring Replacement — All Brakes.......................................374 Friction Disc Replacement — All Brakes................................376 O-Ring Replacement — All Brakes.......................................377 Brake Wear & Release Switches — Single Disc Brakes....................380 Brake Wear & Release Switches — Multiple Disc Brakes..................381 Couplings.................................................................382 Grid Couplings........................................................382 Lubrication.......................................................382 Coupling Disassembly and Grid Removal.............................383 Grid Coupling Installation........................................384 Seal Replacement without Hub Removal..............................387 Grid Coupling Alignment...........................................389 Gear Couplings........................................................390 Coupling Installation.............................................390 Gear Coupling Alignment...........................................392 Hoist Coupling Shaft Alignment....................................393 Compressed Air System.....................................................397 Lockout Valves........................................................399 Safety Warnings.......................................................401 Air Filtration............................................................405 Lubrication...........................................................406 Dynavane Air Cleaner..................................................407 Air Filtration System.....................................................408 Description...........................................................409 Operation.............................................................410 Operational Checklist.................................................410 Compressed Air Installation.......................................411 Filter Removal....................................................411 Solid-State Timer Installation....................................411 Solenoid Connection...........................................412 Timer and Solenoid Specifications.............................412 Delta P Plus......................................................414 Operation.....................................................414 Alarm.........................................................415 Setpoint Adjustments..............................................415 Quick Start Instructions......................................415 Adjustments...................................................415 Password Protected Settings...................................416 Delta P Plus Control Calibration..................................417 Preliminary Start-Up Check........................................419 Maintenance Information...........................................419 Air Conditioner/heater....................................................421 Evaporator............................................................421 Condenser.............................................................421 Pressurizer...........................................................422 Cleaning The Washable Filter......................................422 Specifications........................................................423 Engineering Data..........................................................429 Bolt Tightening.......................................................429 Torque Wrench Method..............................................429 Turn-of-nut Method................................................431 Measurement Systems.......................................................433 Linear Measurements...................................................433 Area Measurements.....................................................433 Volume Measurements...................................................434 Torque Measurements...................................................435 Weight Measurements - Conventional................................436 Split Flange Assembly Procedure...........................................437 Wire Locking Capscrews....................................................439 Torque Nut Installation...................................................440 Tightening Procedure for 1.25-Inch Torque Nut.........................441 Tightening Procedure for 2-Inch Torque Nut............................442 Tightening Procedure for 2-Inch Torque Nut............................443 Tightening Procedure for 2-Inch Torque Nut............................444 Tightening Procedure for 2.5-Inch Torque Nut..........................445 Tightening Procedure for 3-Inch Torque Nut............................446 Tightening Procedure for 3.5-Inch Torque Nut..........................447 Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods....448 Initial Tensioning................................................448 Final Tensioning..................................................448 Tightening Procedures - Expansion Bolts...............................450 Rack & Roller Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut....450 Hoist Torque Rod, Tapered Sleeve & 1.62 Inch Torque Nut...........451 Swing Torque Rod & Tapered Sleeve & 3.25 Inch Torque Nut..........452 Thread Lubrication....................................................454 Locking Assemblies........................................................456 Locking Assembly Removal..............................................458 Pinion and Hub Installation...............................................459 Removal from a Shaft..................................................459 Mounting a Pinion or Hub on a Shaft...................................459 Pre-heat Advance Requirements - Pinions and Hubs..................462 Motor Coupling Pre-Heat Advance Requirements......................462 Maintenance Welding.......................................................464 Welding Electrodes....................................................465 Repair Welding of Cracks..............................................466 Preheat...........................................................467 Welding Technique.................................................467 Repair Welding of Broken Parts........................................468 Repair Welding Swing Rack Teeth.......................................469 Preparation.......................................................469 Swing Rack Welding Electrodes.....................................469 Preheat...........................................................469 Welding Procedure.................................................471 Welding and Cutting Equipment.........................................473 Stress Relieving & Temperature Measuring Equipment....................474 Wire Rope Care and Maintenance............................................475 Storage...............................................................475 Checking Diameter.....................................................475 Handling Wire Rope....................................................476 Seizing Wire Rope.....................................................477 End Preparations/Terminations.........................................479 Wire Rope Clips.......................................................479 Wire Rope Clip Application........................................479 Wedge Sockets.....................................................481 Inspection of Sheaves and Drums.......................................482 Breaking In a New Wire Rope...........................................483 Inspection Data.......................................................484 Guideline to Inspections and Reports..................................485 Wire Rope Inspection Criteria.....................................486 Reduction in Rope Diameter....................................486 Rope Stretch..................................................487 Abrasion......................................................488 Corrosion.....................................................488 Kinks.........................................................488 Bird Caging...................................................488 Localized Conditions..........................................488 Heat Damage...................................................488 Protruding Core...............................................488 Damaged End Attachments.......................................489 Peening.......................................................489 Scrubbing.....................................................489 Fatigue Fracture..............................................489 Broken Wires..................................................489 Electric Arc..................................................490 Seal Installation.....................................................491 Gearcase Sealing......................................................492 Schematics................................................................494 Side View.................................................................495 Deck Plan.................................................................496 HVAC Schematic............................................................497 OGL System A & B Schematic................................................498 Grease System C Schematic.................................................499 Air Schematic.............................................................500 10988-ServiceProcedures X30.pdf........................................... 0 Page 1................................................................194
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CAT Bucyrus 495HR2 Mining Shovel Maintenace Manual SN 141456 PDF DOWNLOAD
INTRODUCTION
GENERAL INFORMATION:
This manual is designed to assist the owner in the operation and preventive 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. It is im portant to remember that when a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.
- 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. Please carefully read the instructions in it.
- All parts are listed by group and/or product code numbers with the associated item/part numbers forTHIS SPECIFIC MACHINE. Order parts in the exact quantity needed.
- RIGHT and LEFT refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab. Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments.
- Records on each machine are filed by serial number and when given this number, the machine’s specific design and original equipment is accessed quickly by the Bucyrus International parts representative. Periodic additions or revisions may be made to this manual.
- It is Bucyrus International’s policy to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to it’s machines at any time.
- This will be without incurred obligation to install such changes on machines sold previously.
- Due to this ongoing program of product research and development, some procedures, specifications and parts may be altered in a constant effort to improve our machines
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
G.P
