CAT Bucyrus Electric 495-B Mining Shovel Mechanical Maintenance Manual BI115934 PDF DOWNLOAD

Description

CAT Bucyrus Electric 495-B Mining Shovel Mechanical Maintenance Manual BI115934 PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus Electric 495-B Mining Shovel Mechanical Maintenance Manual BI115934 PDF DOWNLOAD

Language : English
Pages : 308
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT Bucyrus Electric 495-B Mining Shovel Mechanical Maintenance Manual BI115934 PDF DOWNLOAD

CHAPTER 1 MECHANICAL MAINTENANCE
Section 1 MECHANICAL PROCEDURE
General 1-1-1
Maintenance Schedules and Reports 1-11
Safety 1-1-2
General 1-1-2
In-Operation Maintenance 1-1-2
Precautions Before and During Maintenance Work 1-1-2
Section 2 – LOWER WORKS
Crawler Belts 1-2-1
Take-up Tumbler 1-2-4
Upper Rollers 1-2-5
Lower Rollers 1-2-6
Drive Tumbler 1-2-7
Tumbler Drive Shaft and Gear 1·2·8
Transverse Shaft 12-9
Propel Clutches 1-2-10
Propel Brakes 1-2-12
Propel Motor 1-2-15
Propel Tach Assembly 1-2-17·
Propel Machinery 00 1-2-18
Crawler Frames and Truck Frame 1-2-23
Swing Rack 1-2-24
Roller Circle 1-2-24
Center Pintle 1-2-25
Collector Rings 1-2-28
Cable Reel 1-2-29
Section 3 – ROTATING DECK
Revolving Frame 1-3-1
Deck Machinery 1-3-2
Hoist Machinery 1-3-2
Gear Train 1-3-2·
Hoist Gear and Drum 1-3-4
Hoist Brake 1-3-6
Hoist Limit Switch 1-38
Hoist Motor 1-3-8
Crowd Machinery 1-3-9
Gear Train 1-3 9
Crowd Motor 1-3 12
Crowd Brake 1-3-13
Crowd Gear and Drum 1-3·15
Crowd and Retract Limit Switch 1-3-15
Swing Machinery 1-3-16
Gear Train 1 3-16
Swing Mo’tor 1-3 22
Swing Brake 13-23
Machinery-House 1 324
House Fans 1 325
Dynavane Air Cleaner 1 3 26
Walkways 1 3026
Operator’s Cab 1-3-27
Seat 1-3-27
Windshield Wipers 1-3-27
Windshield Washer 1-3-29
Retractable Boarding Stair 1-3-30
Section 4 -FRONT END EQUIPMENT
Boom Point Sheaves 1-4-1
Boom Bumpers 1-4-2
Saddle Block 1-4 2
Dipper Handle 1·44
Dipper Handle Removal 1-4-4
Retract Take-up Mechanism Removal 1-4-4
Front Stop and Spreader Removal 1-4-4
Crowd Cushion (with Pre-assembled Cushion Stack) 1-4-6
Dipper 1-4-8
Dipper Padlock 1-4-9
Dipper Trip Assembly 1-4-11
A-Frame 1-4-12
Boom Structural Strands 1-4-12
Wire Running Ropes 1-4-13
Inspection 1-4-13
Hoist Rope Reeving 1-4-13
Retract Rope Reeving 1-4-16
Crowd Rope Reeving 1-4-17
Dipper Trip Reeving 1-4-19
CHAPTER 2 -AIR SYSTEM
Section 1 – GENERAL MAINTENANCE
Safety 2-1-1
General 2-1-1
Air Compressor (Quincy QSB20) 2-1-3
Air Lines 2-1-4
Air Tank 2-1-4
Air Line Lubricator 2-1-4
Air Line Filter 2-1-4
Air Line Regulator 2-1-4
Air Dryer (Optional) 2-1-4
Air Lube Swivel Assembly 2-1-5
Pressure Switches 2-1-5
Solenoid Valves 2-1-5
Section 2 – COMPONENT MAINTENANCE·
Air Compressor (Quincy QSB20) 2-2-1
Compressor Operation 2-2-4
Starting the Compressor 2-2-5
Stopping the Compressor 2-2-5
Preparing for Maintenance or Service 2-2-5
Servicing 2·2 5
Assembly and Disassembly of Common Wearing Parts 2-2-7
Drive Belt Replacement 2-2-9
MrILube Swivel Assembly Removal 2-2 11
CHAPTER 3· LUBRICATION
Section 1 – GENERAL LUBRICATION
Lower Works 3-1-2
Rotating Deck 3-1-2
Front End 3-1-3
Lubrication Bench Marks 3-1-3
Multi-Purpose Type Grease (MPG) 3-1-3
Air Compressor (Piston Type) Lubricant (ACPL) 3-1-4
Multi-Purpose Oil (MPO) 3-1-6
Open Gear Lubricant (OGL) 3-1-6
Regular Type Gear Lubricant (RGL) 3-1-7
Roller Circle Rail and Lubricant (RCRL) 3-1-9
Running Wire Rope Lubricant (RWRL) 3-1-11
Structural Strand and Stationary Wire Rope Lubricant (SWRL) 3-1-13
Lubrication Charts 3-1-14
Section 2 -AUTOMATIC LUBRICATION SYSTEMS
Inspection 3-2-1
Lube System 3-2-1
Air Pump Service 3-2-2
Lines and Control Service 3-2-2
Injectors and Spray Nozzles 3-2-3
Startup of Automatic Lubrication Systems 3-2-4
CHAPTER 4 TROUBLESHOOTING
Section 1 – LOWER WORKS
Crawler 4-1-1
3rd Intermediate Propel Shaft 4-1-7
2nd Intermediate Propel Shaft 4-1-8
1st Intermediate Propel Shaft 4-1-8
Propel Motor Shaft 4-1-9
Propel Clutch 4-1-11
Propel Brake 4-1-11
Propel Motor Blower and Gear Case 4-1-13
Swing Rack Teeth 4-1-13
House Roller Rails 4-1-14
House Rollers 4-1-14
Center Pintle 4-1-15
Section 2 – ROTATING DECK
Hoist Machinery 4-2-1
Hoist Motor Pinion Shaft 4-2-1
Hoist Intermediate Shaft Assembly 4-2-2
Hoist Drum Assembly 4-2-3
Crowd Machinery 4-2-5
Crowd Drum Gear and Pinion Lubrication 4-2-6
Crowd Disc Type Brake 4-2-8
A-Frame 4-2-8
Swing Machinery 4-2-9
Section 3 – FRONT END EQUIPMENT
Boom 4-3-1
Dippers – Pin Connected 4-3-4
Dipper Door Snubbers 4-3-5
Dipper Handle 4-3-6
Air Lube Swivel 4-3-7
Section 4 – AIR SYSTEM
Quincy QSB20 Screw Compressor 4-4-1
Appendix Al- GEAR INSPECTION Al-l
Appendix A2 – BOLT TORQUING
Torque Wrench Method A2-l
Tum-Of-The Nut Method A2-2
Appendix A3 – MAINTENANCE WELDING
Principal Structures A3-l
General <> 0 A3 1
Maintenance Welding A3-l
Structural Materials A3-2
Welding Electrodes A3-2
Preheat Requirements A3-5
Removal of Cracks A3-6
Weld Groove Preparation A3-6
Butter Welding A3-6
Welding Technique A3·6
Weld Inspection A3-6
Repair of Broken Parts A3-8
Dipper Handles A3-8
Maintenance Welding A3-8
Flame Straightening Bent Tube A3-B
Welding Tube Without Backing Ring A310
Welding Tube Using Backing Ring A3-l3
Handle End Casting Replacement A3-l4
Tube Replacement A3-15
Stress Relieving Welded Tube A3-l5
Repair Welding of Swing Racks A3-l5
Crack Repair Welding A3-l5
Broken Teeth Repair Welding A3-l7
Crawler Frame to Truck Frame Welding A3-l8
Swing Rack to Truck Frame Welding A3-l9
Appendix A4 – PINION BRAKE DRUM AND COUPLING INSTALLATION A4-l
Appendix A5 – PREVENTIVE MAINTENANCE CHECKLISTS
Visual Weekly Checklist A5-l
Visual Monthly Checklist A5-7
Visual Semi-Annual Checklist A5-ll
AppendixA6 – ROLLER REPLACEMENT A6-l
Appendix A 7 – BRAKE OR CLUTCH MAINTENANCE CHECKLIST A7-1
AppendixA8 – ROLLER CIRCLE REPAIR MODIFICATION A8-l
Appendix A9 _ SHIMMING INSTRUCTIONS A9-1
Appendix AIO – DRIVE TUMBLER REBUILD PROCEDURE AlO-l
Appendix All- ELECTRIC MINING SHOVEL BREAK-IN INSTRUCTIONS All-l
Appendix A12 -MOTOR COUPLING ALIGNMENT Al2-1
Appendix Al3 – FIGURE TO GA DRAWING CROSS REFERENCE Al3-1

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DESCRIPTION:

CAT Bucyrus Electric 495-B Mining Shovel Mechanical Maintenance Manual BI115934 PDF DOWNLOAD

• The rotating deck includes the revolving frame, ballast box, and machinery house. The machinery house encloses all of the hoist, swing, and crowd machinery, and the electrical systems required to control machine functions.
• It also contains an air filtration system to minimize heat and dirt build-up in the machinery house. An elevated cab mounted on the house provides the machinery operator’s station. The cab contains all machine operating controls. The front end equipment is comprised of the A-frame, dipper, dipper handle, boom, running ropes, and boom structural strands.
• This manual consists of five chapters, each divided into sections. A table of contents is located in the front of the manual.
• Throughout this manual, the words CAUTION, WARNING, and NOTE appear in boldface type. CAUTION is preceded by the safety alert symbol ⚠️ and indicates that injury to personnel could occur if the proper procedures are not followed during operation or maintenance. Always read the CAUTION note carefully and use extreme care while performing that particular function.
• WARNING indicates a possible hazard to the machine or its components if the proper procedures are not followed. Whenever the word WARNING appears, special attention should be given to prevent possible equipment damage.
• NOTE is used to stress a point or to give additional information concerning the procedure being discussed.
• These CAUTIONs and WARNINGs are not all-inclusive. It is impossible for Bucyrus-Erie Company to know, evaluate, and advise maintenance and service personnel in every conceivable way a service operation might be performed and of the resulting possible hazardous consequences of each method.
• It is therefore extremely important that anyone who uses a service procedure or tool which is not recommended by Bucyrus-Erie Company first satisfy himself that the service procedure or tool he chooses will not jeopardize his own safety, the safety of others, or cause machine or component damage.
• Every effort has been made to make this manual as complete and accurate as possible at the time of publication. Bucyrus-Erie Company, however, reserves the right to continually improve its products.
• For this reason, changes may have been made to the machine or its equipment that are not detailed in this manual.

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