Cat Electric Role Shovel 495HF Mining Shovel Maintenance & Operation Manual – PDF DOWNLOAD

Description

Cat Electric Role Shovel 495HF Mining Shovel Maintenance & Operation Manual – PDF DOWNLOAD

DESCRIPTION:

Cat Electric Role Shovel 495HF Mining Shovel Maintenance & Operation Manual – PDF DOWNLOAD

Introduction

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.
• Periodic additions or revisions may be made to this manual. Should you require additional information or factory service assistance contact your regional service representative or:

Bucyrus International, Inc.
1100 Milwaukee Avenue
P.O. Box 500
South Milwaukee, Wisconsin, USA 53172-0500
Telephone (414)-768-4000

• It is the policy of Bucyrus International, Inc. to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to its machines at any time.
• This will be without incurred obligations 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

TABLE OF CONTENTS:

Cat Electric Role Shovel 495HF Mining Shovel Maintenance & Operation Manual – PDF DOWNLOAD

Safety Precautions........................................................  4
	General Precautions...................................................  5
	Maintenance Precautions...............................................  6
	Operating Precautions.................................................  7
	FIRE PREVENTION.......................................................  8
	Warning Signs And Decals..............................................  9
Introduction.............................................................. 27
General Information....................................................... 27
	SWINGING RESTRAINT & BALLAST BOX SUPPORT.............................. 28
		Ballast Box Support............................................... 28
		Swinging Restraint................................................ 29
Machine Overview.......................................................... 31
Lower Works............................................................... 32
	Crawlers.............................................................. 33
	Truck Frame........................................................... 34
	Swing Rack............................................................ 35
	Roller Circle......................................................... 36
	Propel Machinery...................................................... 37
	Collector Rings....................................................... 38
Rotating Deck............................................................. 39
	Revolving Frame....................................................... 39
	Center Pintle......................................................... 39
	Deck Extensions....................................................... 41
	Ballast Box........................................................... 41
	Machinery House....................................................... 41
		Boarding Stairs................................................... 42
		Vertical Boarding Ladder.......................................... 43
	A-Frame............................................................... 44
	Hoist Machinery....................................................... 45
	Swing Machinery....................................................... 46
	Crowd Machinery....................................................... 47
	Operator’s Cab........................................................ 48
	Compressed Air System................................................. 49
	Automatic Lubrication System.......................................... 50
	Lube Reservoir fill / Overflow Plumbing............................... 51
Front End Equipment....................................................... 52
	Suspension Strands.................................................... 52
	Boom.................................................................. 53
	Running Ropes......................................................... 54
	Saddle Block.......................................................... 55
	Dipper Handle......................................................... 55
	Dipper................................................................ 56
	Padlocks.............................................................. 57
	Dipper Trip........................................................... 58
Typical Machine Specifications............................................ 58
General Estimated Component Weights....................................... 61
	Lower Works........................................................... 61
	Upper Works........................................................... 62
	Front End............................................................. 64
Side View................................................................. 67
Deck Plan................................................................. 68
Operation................................................................. 73
General Information....................................................... 73
	Operation Near Electrical Lines....................................... 73
Controls.................................................................. 74
Primary Operating Controls................................................ 75
	Controls on the left console.......................................... 76
		Left Joystick..................................................... 77
		Dipper Trip....................................................... 77
		Signal Horn....................................................... 77
		Start Pushbutton.................................................. 78
		PLC Power On...................................................... 78
		Drive Cabinet Temperature......................................... 78
		Incomplete Sequence............................................... 78
		System Ready...................................................... 78
		Phase Sequence.................................................... 78
		Auxiliary Ground Fault............................................ 78
		Hoist Brake....................................................... 78
		Crowd Brake....................................................... 78
		Swing Brake....................................................... 78
		Propel Brake...................................................... 78
		HVAC Unit Selector................................................ 78
		Temperature....................................................... 78
		HVAC System Control............................................... 78
		HVAC Fan Speed.................................................... 79
		Cabin Lights...................................................... 79
		Auxiliary Heater.................................................. 79
	CONTROLS ON THE RIGHT CONSOLE......................................... 80
		Right Joystick.................................................... 81
		Emergency Stop Pushbutton......................................... 82
		Windshield Wiper Switches......................................... 82
		Control Stop Pushbutton........................................... 82
		Control Reset Pushbutton.......................................... 82
		Air Compressor.................................................... 83
		Dig/propel Transfer Switch........................................ 83
		Main Power Off Pushbutton......................................... 83
		Earth Continuity Lockout Pushbutton............................... 83
		Seat Position..................................................... 84
		Radio/cassette/cd................................................. 84
		Heated Mirrors.................................................... 84
		Man On Ground..................................................... 84
Operator’s Display........................................................ 85
	Display Area and Indicators........................................... 86
	Display Screens....................................................... 87
	Lubrication Control Panel............................................. 94
	Fire Suppression System............................................... 95
Pre-start Checks.......................................................... 95
	Walk-around Ground Level Inspection................................... 96
	On-board Inspection................................................... 98
	Machine Start-up...................................................... 98
	Restarting After An Electrical Fault..................................100
	Machine Operation.....................................................100
		Hoist Motion......................................................101
		Crowd Motion......................................................102
		Propel Motion.....................................................103
		Swing Motion......................................................104
			Proper Swing Motion...........................................105
		Steering..........................................................106
			Counter-rotation Turns........................................108
		Positioning the Machine...........................................109
			Back-up Method................................................109
			Drive-by Method...............................................110
		Start Of The Dig Cycle............................................111
		Engaging The Bank.................................................114
		Slope Limitations.................................................116
	Excavated Material....................................................118
	Operation Checks......................................................118
	Operating Hints.......................................................119
	Stopping the Machine..................................................120
	Shutdown..............................................................120
Lubrication...............................................................123
Lubrication Principles....................................................123
Greasing Main A.C. Drive Motors...........................................124
	1. Type of Grease.....................................................124
	2. Initial Commissioning..............................................124
	3. Maintenance........................................................124
	4. Regreasing Intervals...............................................125
Lubricant Selection.......................................................125
Oil Fill Capacities.......................................................127
	Types Of Lubricants And Capacities Guidelines.........................127
		Quantities for First Fill of Lubricants...........................127
Automatic Lubrication System..............................................128
	Lube Room.............................................................129
	Lube Reservoir fill / Overflow Plumbing...............................130
		Auto Lube Control Panel...........................................131
	Lower Works Lubrication...............................................131
	Propel Machinery Lubrication..........................................132
		Lubricant Replacement/sampling....................................133
			Lubricant Change Cycle........................................133
	Revolving Frame Lubrication...........................................134
	Hoist Machinery Lubrication...........................................135
		Hoist Oil Cooler..................................................136
		Filter Element Cleaning...........................................139
	Hoist Rope Rollers Lubrication........................................140
		Oil Pump..........................................................141
	Crowd Machinery Lubrication...........................................142
	Swing Machinery Lubrication...........................................143
	Air Compressor Lubrication............................................144
	Crowd Rope Take-Up Mechanism Lubrication..............................145
	Front End Lubrication.................................................145
	Lincoln Type SL-1 Lubricant Injectors.................................147
		SL-1 Lubricant Injector Operation.................................149
		Injector Advantages...............................................151
	ACSL - Air Compressor (Screw-Type) Lubricant..........................152
	MPO - Multipurpose OIL................................................152
	RWRL - Running Wire Rope Lubricant....................................154
	EGL - Enclosed Gearcase Lubricant.....................................155
	MPG - Multipurpose Grease.............................................158
	OGL - Open Gear Lubricant.............................................162
	Certified Lubricants Listing..........................................166
Schematics - Automatic Lubrication........................................171
OGL System A & B Schematic................................................173
Grease System C Schematic.................................................174
Preventive Maintenance....................................................177
Introduction..............................................................177
	Preventive Maintenance Program........................................177
	Elements of an Effective Maintenance Program..........................178
	Scheduled Preventive Maintenance Program..............................179
	General Safety Considerations.........................................179
Maintenance During Machine Operation......................................180
	Maintenance Precautions...............................................181
Preventive Maintenance for Lubrication....................................182
	Lubricant Cleanliness.................................................183
Frequency of Inspection and Maintenance...................................184
Maintenance Schedules.....................................................184
	Maintenance Inspection Check Points...................................184
		Daily.............................................................185
		Every 100 Hours or Weekly.........................................188
		Every 500 Hours Or Monthly........................................189
		Every 1250 Hours or Quarterly.....................................192
		Every 2500 Hours or Semi-Annually.................................195
		5000 Hours or Annually............................................197
MAJOR COMPONENT LOCATIONS.................................................199
Service Procedures........................................................227
LOWER WORKS...............................................................227
	Truck Frame Assembly..................................................227
	Swing Rack Assembly...................................................228
		Roller Circle Rail Replacement - Lower............................228
		Roller Circle Rail Replacement - Upper............................229
	Roller Circle Assembly................................................231
		Roller Circle Adjustment..........................................233
		Adjustment Procedure..............................................233
		Run-in Procedure for the Roller Circle............................233
		Roller Circle Segment Removal.....................................234
		Roller Circle - Roller Replacement................................235
Crawler Belts.............................................................236
	Crawler Belt Maintenance..............................................236
		Crawler Belt Tension Adjustment...................................237
		Crawler Shoe Replacement..........................................239
		Crawler Belt Replacement..........................................240
	Crawler Side Frame Assembly...........................................241
		Crawler Side Frame Maintenance....................................242
		Slide Bar Replacement.............................................243
		Crawler Front Idler Roller Assembly...............................244
		Load and Idler Rollers............................................247
			Roller Removal or Replacement.................................247
Propel Assembly...........................................................251
	Installation Notes....................................................253
	Main Propel Drive Shaft Removal.......................................254
		Main Propel Shaft - Disassembly...................................258
		Tumbler Rebuild Procedure.........................................259
	Propel Machinery......................................................262
		Propel Gearcase Removal...........................................263
		Propel Gearcase Installation......................................264
		Propel Planetary Gearcase.........................................266
		Propel Motors.....................................................267
			Propel Motor Removal..........................................267
			Propel Motor Installation.....................................269
	Center Pintle.........................................................270
		Center Pintle Adjustment..........................................275
		Center Pintle Sleeve Removal......................................276
	Collector Rings.......................................................278
		Collector Ring Inspection.........................................279
		Collector Ring Repair.............................................280
Rotating Deck.............................................................280
Swing Machinery...........................................................281
	Swing Support Mounting Bolts..........................................283
	Swing Motor...........................................................283
		Swing Blower......................................................283
		Swing Motor Removal...............................................284
		Swing Motor Installation..........................................284
	Swing Planetary Gearcase..............................................285
		Swing Gearcase Removal............................................286
		Gearcase Inspection...............................................287
		Swing Pinion Shafts...............................................288
			Swing Pinion Shaft Removal....................................289
			Swing Pinion Shaft Disassembly................................290
			Swing Pinion Shaft Assembly...................................291
			Swing Pinion Shaft Installation...............................292
	Hoist Machinery.......................................................293
		Hoist Motor Removal...............................................294
		Motor Coupling Shaft..............................................297
		HOIST GEARCASE ASSEMBLY...........................................298
		Hoist Gearcase Repair.............................................300
		Hoist Drum Assembly...............................................303
			Hoist Gear Replacement........................................306
			Bearing Removal...............................................308
			Bearing Installation..........................................309
		Hoist Oil Cooler..................................................310
	Hoist Mounting Bolts..................................................311
	Hoist Limit Switch....................................................312
Crowd Machinery...........................................................313
	Crowd Gearcase Disassembly............................................315
	Crowd Gearcase Assembly...............................................318
Crowd Motor...............................................................320
	Crowd Gear and Drum...................................................322
	Crowd Drum Removal....................................................323
	Operator’s Cab Mounting...............................................325
Machinery House...........................................................326
	Walkways, Stairways, and Handrails....................................327
	Boarding Stairs.......................................................327
	Vertical Boarding Ladder, left........................................330
	Front End Equipment...................................................332
	Boom Assembly.........................................................333
		Boom Repair.......................................................334
	Boom Limit Switch Installation........................................335
		Boom Point Sheaves................................................337
		Boom Point Sheave Removal and Disassembly.........................338
		Boom Point Sheave Reassembly and Installation.....................340
	Boom Bumper...........................................................342
	Saddle Block..........................................................343
		Saddle Block Repair...............................................343
			Saddle Block Removal..........................................344
	Dipper Handle.........................................................346
		Dipper Handle Removal.............................................348
		Crowd Rope Take-Up Mechanism......................................350
			Crowd Rope Take-Up Mechanism Disassembly......................351
			Crowd Rope Take-Up Mechanism Assembly.........................353
		Retract Rope Take-up Mechanism....................................355
		Spreader Repair...................................................357
Dipper Assembly...........................................................358
	Latch Bar Adjusting...................................................361
	Dipper Door bumpers...................................................362
		Dipper Removal & Installation.....................................363
		Dipper Door Snubbers..............................................368
			Snubber Adjustment............................................369
			Allowable Wear................................................369
	Dipper Pitch Brace....................................................370
	Dipper Padlock........................................................371
	Dipper Trip Assembly..................................................374
	Auxiliary Winch.......................................................376
	A-Frame...............................................................376
	Hoist Rope Support Roller.............................................379
	Boom Support Ropes....................................................380
	Wire Ropes............................................................381
		Wire Rope Inspection..............................................382
Crowd Rope Take-up Hydraulic Unit.........................................383
	Hoist Rope Reeving & Replacement......................................385
		Crowd Rope Reeving & Replacement..................................389
Retract Rope Reeving & Replacement........................................392
	Crowd Rope Tightening.................................................396
	Retract Rope Tightening...............................................398
	Dipper Trip Rope Reeving & Replacement................................399
	Hoist and Crowd Limit Systems.........................................399
		Setting Limits In The Hoist & Crowd System........................400
			Crowd Slowdown/Stop Limits....................................402
			Retract Slowdown/Stop Limits..................................403
			Lower Slowdown/Stop Limits....................................404
			Hoist Slowdown/Stop Limits....................................405
Brakes and Couplings......................................................409
Brakes....................................................................409
	Disc Brake Operation..................................................410
	Maintenance...........................................................410
	Brake Adjustment Specifications.......................................410
	Hoist Brake...........................................................411
		Hoist Brake Adjustment............................................413
		Hoist Brake Installation..........................................415
		Hoist Brake Wear & Release Switches...............................415
	Crowd Brake...........................................................416
		Crowd Brake Installation..........................................418
		Crowd Brake Wear & Release Switches...............................419
	Propel Brake..........................................................421
		Propel Brake Adjustment...........................................423
		Propel Brake Installation.........................................425
		Tachometer Mounting & Alignment...................................427
	Swing Brake...........................................................429
		Swing Brake Installation..........................................431
		Swing Brake Wear & Release Switches...............................432
		Swing Brake Burnishing............................................433
	Spring Replacement — All Brakes.......................................433
	Friction Disc Replacement — All Brakes................................435
	O-Ring Replacement — All Brakes.......................................436
	Brake Wear & Release Switches — Single Disc Brakes....................438
	Brake Wear & Release Switches — Multiple Disc Brakes..................439
Couplings.................................................................440
	Grid Couplings........................................................440
		Lubrication.......................................................440
		Coupling Disassembly and Grid Removal.............................441
		Grid Coupling Installation........................................442
		Seal Replacement without Hub Removal..............................445
		Grid Coupling Alignment...........................................447
	Gear Couplings........................................................448
		Coupling Installation.............................................448
		Gear Coupling Alignment...........................................450
		Hoist Coupling Shaft Alignment....................................451
Compressed Air System.....................................................455
Air Compressor - dual.....................................................455
	Compressor Start-Up Procedure.........................................457
	Compressor SHutdown Procedure.........................................457
	Compressor Fluid Level Check..........................................457
Compressor Maintenance....................................................458
	Fluid & Fluid Filter Change Procedure.................................458
	Air Filter Maintenance................................................459
	Air/Fluid Separator Element Change....................................460
	Recommended Lubrication Guide.........................................461
Auxiliary Air Dryer Assembly..............................................462
In-Line PREFilters........................................................463
MACHINERY HOUSE HOSE REELS................................................464
Additional Maintenance Requirements.......................................464
	Lockout Valves........................................................465
	Safety Warnings.......................................................467
Air Schematic.............................................................469
Air Filtration............................................................473
House Filter Fans.........................................................473
	Lubrication...........................................................474
	Dynavane Air Cleaner..................................................475
	Air Conditioner.......................................................476
	Specifications........................................................477
Engineering Data..........................................................483
Capscrew (Bolt) Grade.....................................................483
	BOLT TIGHTENING.......................................................484
		Torque Wrench Method..............................................484
		Turn-of-nut Method................................................486
Measurement Systems.......................................................488
	Linear Measurements...................................................488
	Area Measurements.....................................................488
	Volume Measurements...................................................489
	Torque Measurements...................................................490
		Weight Measurements - Conventional................................491
Split Flange Assembly Procedure...........................................492
Wire Locking Capscrews....................................................494
Torque Nut Installation...................................................495
	Tightening Procedure for 1.25-Inch Torque Nut.........................496
	Tightening Procedure for 2-Inch Torque Nut............................497
	Tightening Procedure for 2-Inch Torque Nut............................498
	Tightening Procedure for 2.5-Inch Torque Nut..........................499
	Tightening Procedure for 3-Inch Torque Nut............................500
	Tightening Procedure for 3.5-Inch Torque Nut..........................501
	Procedure for Use of Mechanical Tensioner on Crawler Rods.............502
		Initial Tensioning................................................503
		Final Tensioning..................................................503
Expansion Bolt Installation...............................................505
	Tightening Procedures - Expansion Bolts...............................505
		Hoist Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut............505
		Rack & Roller Torque Rod, Tapered Sleeve & 1.5 Inch Torque Nut....506
		Swing Torque Rod & Tapered Sleeve & 3.5 Inch Torque Nut...........508
Torque Nut Removal Procedure..............................................510
	Thread Lubrication....................................................510
Torque Nut Helpful Hints..................................................511
Locking Assemblies........................................................512
	Locking Assembly Removal..............................................514
Pinion and Hub Installation...............................................515
	Removal from a Shaft..................................................515
	Mounting a Pinion or Hub on a Shaft...................................515
		Hub Adapter Pre-heat Advance Requirements.........................518
		Motor Coupling Pre-Heat Advance Requirements......................518
Maintenance Welding.......................................................519
	Welding Electrodes....................................................520
	Repair Welding of Cracks..............................................521
		Preheat...........................................................522
		Welding Technique.................................................522
	Repair Welding of Broken Parts........................................523
	Repair Welding Swing Rack Teeth.......................................524
		Preparation.......................................................524
		Swing Rack Welding Electrodes.....................................524
		Preheat...........................................................524
		Welding Procedure.................................................526
	Welding and Cutting Equipment.........................................528
	Stress Relieving & Temperature Measuring Equipment....................529
	Storage...............................................................529
	Checking Diameter.....................................................530
	Handling Wire Rope....................................................531
	Seizing Wire Rope.....................................................532
	End Preparations/Terminations.........................................534
	Wire Rope Clips.......................................................534
		Wire Rope Clip Application........................................534
		Wedge Sockets.....................................................536
	Inspection of Sheaves and Drums.......................................537
	Breaking In a New Wire Rope...........................................538
	Inspection Data.......................................................539
	Guideline to Inspections and Reports..................................540
		Wire Rope Inspection Criteria.....................................541
			Reduction in Rope Diameter....................................541
			Rope Stretch..................................................542
			Abrasion......................................................543
			Corrosion.....................................................543
			Kinks.........................................................543
			Bird Caging...................................................543
			Localized Conditions..........................................543
			Heat Damage...................................................543
			Protruding Core...............................................543
			Damaged End Attachments.......................................544
			Peening.......................................................544
			Scrubbing.....................................................544
			Fatigue Fracture..............................................544
			Broken Wires..................................................544
			Electric Arc..................................................545
Seals.....................................................................545
	Seal Installation.....................................................546
	Gearcase Sealing......................................................547

CAT ELECTRIC ROLE SHOVEL 495HF MINING SHOVEL MAINTENANCE & OPERATION MANUAL – PDF DOWNLOAD:

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M