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

Description

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

DESCRIPTION:

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

Safety

• The safety alert symbols displayed here and throughout this manual are used to call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine.
• Be certain that anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions. If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional Bucyrus service representative or the factory.
• The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.

NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken.

CAUTION: This signal word serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to.

DANGER: This signal word denotes an imminently dangerous hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken

DANGER: This signal word denotes an imminently dangerous electrical hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

• Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand.
• It is critical that all the methods used are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance.
• The operator must be alert, physically fit and free from the influence of alcohol, drugs, or any medications that might impair his/her eyesight, hearing or reactions.

CAUTION: STORED ENERGY! Components on machine are heavy and removal of pins without proper preparation and precaution can cause serious bodily injury and/or damage to the front-end of the machine.

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 495HR 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......................................................... 40
	Deck Extensions....................................................... 42
	Ballast Box........................................................... 42
	Machinery House....................................................... 42
		Boarding Stairs................................................... 43
		Vertical Boarding Ladder.......................................... 44
	A-Frame............................................................... 45
	Hoist Machinery....................................................... 46
	Swing Machinery....................................................... 47
	Crowd Machinery....................................................... 48
	OPERATOR’S CAB........................................................ 49
	Compressed Air System................................................. 50
	Automatic Lubrication System.......................................... 51
	Lube Reservoir fill / Overflow Plumbing............................... 52
Front End Equipment....................................................... 53
	Suspension Strands.................................................... 53
	Boom.................................................................. 54
	Running Ropes......................................................... 55
	Saddle Block.......................................................... 56
	Dipper Handle......................................................... 57
	Dipper................................................................ 58
	Padlocks.............................................................. 59
	Dipper Trip........................................................... 60
Typical Machine Specifications............................................ 61
General Estimated Component Weights....................................... 63
	Lower Works........................................................... 63
	Upper Works........................................................... 64
	Front End............................................................. 66
Operation................................................................. 73
General Information....................................................... 73
	Operation Near Electrical Lines....................................... 73
Operator’s Seat........................................................... 75
	Adjustable Armrest.................................................... 75
	Adjustable Footrest................................................... 76
Controls.................................................................. 77
	Primary Operating Controls............................................ 77
	Controls On The Left Console.......................................... 78
		Left Joystick..................................................... 79
		Dipper Trip....................................................... 79
		Signal Horn....................................................... 79
		Start Pushbutton.................................................. 79
		PLC Power On...................................................... 80
		Drive Cabinet Temperature......................................... 80
		Incomplete Sequence............................................... 80
		System Ready...................................................... 80
		Phase Sequence.................................................... 80
		Auxiliary Ground Fault............................................ 80
		Hoist Brake....................................................... 80
		Crowd Brake....................................................... 80
		Swing Brake....................................................... 80
		Propel Brake...................................................... 80
		HVAC Unit Selector................................................ 80
		Temperature....................................................... 80
		HVAC System Control............................................... 80
		HVAC Fan Speed.................................................... 80
		Cabin Lights...................................................... 80
		Controls On The Right Console..................................... 81
		Right Joystick.................................................... 82
		Emergency Stop Pushbutton......................................... 83
		Windshield Wiper Switches......................................... 83
		Control Stop Pushbutton........................................... 83
		Control Reset Pushbutton.......................................... 83
		Air Compressor.................................................... 84
		Dig/propel Transfer Switch........................................ 84
		Main Power Off Pushbutton......................................... 84
		Earth Continuity Lockout Pushbutton............................... 84
		Seat Position..................................................... 84
		Radio Receiver with CD Changer.................................... 85
Operator’s Display........................................................ 85
	Display Area and Indicators........................................... 86
	Display Screens....................................................... 86
	Lubrication Control Panel............................................. 93
	Fire Suppression System............................................... 94
Pre-start Checks.......................................................... 94
	Walk-around Ground Level Inspection................................... 95
	On-board Inspection................................................... 96
Start-up, Operation And Shutdown.......................................... 97
	Machine Start-up...................................................... 97
	Restarting After An Electrical Fault.................................. 98
	Machine Operation..................................................... 98
	Machinery Motions..................................................... 99
		Hoist Motion...................................................... 99
		Crowd Motion......................................................100
		Propel Motion.....................................................101
		Swing Motion......................................................102
			Proper Swing Motion...........................................103
		Steering..........................................................104
			Counter-rotation Turns........................................106
		Positioning the Machine...........................................107
			Back-up Method................................................107
			Drive-by Method...............................................108
		Start Of The Dig Cycle............................................109
		Engaging The Bank.................................................111
		Slope Limitations.................................................113
	Excavated Material....................................................116
	Operation Checks......................................................116
	Operating Hints.......................................................117
	Stopping the Machine..................................................118
	Shutdown..............................................................118
Lubrication...............................................................121
Lubrication Principles....................................................121
Greasing Main A.C. Drive Motors...........................................122
	1. Type of Grease.....................................................122
	2. Initial Commissioning..............................................122
	3. Maintenance........................................................122
	4. Regreasing Intervals...............................................123
Lubricant Selection.......................................................123
Oil Fill Capacities.......................................................125
	Types Of Lubricants And Capacities Guidelines.........................125
		Quantities for First Fill of Lubricants...........................125
Automatic Lubrication System..............................................126
	Lube Room.............................................................127
	Lube Reservoir fill / Overflow Plumbing...............................128
		Auto Lube Control Panel...........................................129
	Lower Works Lubrication...............................................129
	Propel Machinery Lubrication..........................................130
		Lubricant Replacement/sampling....................................131
			Lubricant Change Cycle........................................131
	Revolving Frame Lubrication...........................................132
	Hoist Machinery Lubrication...........................................133
		Hoist Oil Cooler..................................................134
		Filter Element Cleaning...........................................137
	Hoist Rope Rollers Lubrication........................................138
		Oil Pump..........................................................139
	Crowd Machinery Lubrication...........................................140
	Swing Machinery Lubrication...........................................141
	Air Compressor Lubrication............................................142
	Crowd Rope Take-Up Mechanism Lubrication..............................143
	Front End Lubrication.................................................144
	Lincoln Type SL-1 Lubricant Injectors.................................145
		SL-1 Lubricant Injector Operation.................................147
		Injector Advantages...............................................149
	Air Compressor Lubricant..............................................149
	MPO - Multipurpose OIL................................................151
	RWRL - Running Wire Rope Lubricant....................................152
	EGL - Enclosed Gearcase Lubricant.....................................153
	MPG - Multipurpose Grease.............................................156
	OGL - Open Gear Lubricant.............................................160
	Certified Lubricants Listing..........................................164
Preventive Maintenance....................................................173
Introduction..............................................................173
	Preventive Maintenance Program........................................173
	Elements of an Effective Maintenance Program..........................174
	Scheduled Preventive Maintenance Program..............................175
	General Safety Considerations.........................................175
Maintenance During Machine Operation......................................176
	Maintenance Precautions...............................................177
Preventive Maintenance for Lubrication....................................178
	Lubricant Cleanliness.................................................179
Frequency of Inspection and Maintenance...................................180
Maintenance Schedules.....................................................180
	Maintenance Inspection Check Points...................................180
		Daily.............................................................181
		Every 100 Hours or Weekly.........................................184
		Every 500 Hours Or Monthly........................................185
		Every 1250 Hours or Quarterly.....................................188
		Every 2500 Hours or Semi-Annually.................................191
		5000 Hours or Annually............................................193
Major Component Locations.................................................195
Service Procedures........................................................223
Lower Works...............................................................223
	Truck Frame Assembly..................................................223
	Swing Rack Assembly...................................................224
		Roller Circle Rail Replacement - Lower............................224
		Roller Circle Rail Replacement - Upper............................225
	Roller Circle Assembly................................................227
		Roller Circle Adjustment..........................................229
		Adjustment Procedure..............................................229
		Run-in Procedure for the Roller Circle............................229
		Roller Circle Segment Removal.....................................230
		Roller Circle - Roller Replacement................................231
	Crawler Belts.........................................................232
		Crawler Belt Maintenance..........................................232
			Crawler Belt Tension Adjustment...............................234
			Crawler Shoe Replacement......................................236
			Crawler Belt Replacement......................................237
	Crawler Side Frame Assembly...........................................238
		Crawler Side Frame Maintenance....................................239
		Slide Bar Replacement.............................................240
		Load and Idler Rollers............................................244
			Roller Removal or Replacement.................................244
	Propel Assembly.......................................................247
		Installation Notes................................................249
		Main Propel Drive Shaft Removal...................................250
		Main Propel Shaft - Disassembly...................................253
		Tumbler Rebuild Procedure.........................................254
	Propel Machinery......................................................256
		Propel Gearcase Removal...........................................257
		Propel Gearcase Installation......................................258
		Propel Planetary Gearcase.........................................260
		Propel Motors.....................................................261
			Propel Motor Removal..........................................261
			Propel Motor Installation.....................................263
	Revolving Frame.......................................................264
	Center Pintle.........................................................265
		Center Pintle Adjustment..........................................270
		Center Pintle Sleeve Removal......................................270
	Collector Rings.......................................................272
		Collector Ring Inspection.........................................273
		Collector Ring Repair.............................................273
	Cable Reel............................................................274
Rotating Deck.............................................................275
	Swing Machinery.......................................................275
		Swing Support Mounting Bolts......................................277
		Swing Motor.......................................................277
			Swing Blower..................................................277
			Swing Motor Removal...........................................278
			Swing Motor Installation......................................279
		Swing Planetary Gearcase..........................................279
			Swing Gearcase Removal........................................280
			Gearcase Inspection...........................................281
		Swing Pinion Shafts...............................................282
			Swing Pinion Shaft Removal....................................283
			Swing Pinion Shaft Disassembly................................284
			Swing Pinion Shaft Assembly...................................285
			Swing Pinion Shaft Installation...............................286
	Hoist Machinery.......................................................287
		Hoist Motor Removal...............................................288
		Motor Coupling Shaft..............................................291
		Hoist Gearcase Assembly...........................................292
		Hoist Gearcase Repair.............................................296
		Hoist Drum Assembly...............................................299
			Hoist Gear Replacement........................................301
			Bearing Removal...............................................303
			Bearing Installation..........................................304
		Hoist Oil Cooler..................................................306
		Hoist Mounting Bolts..............................................307
		Hoist Limit Switch................................................308
	Crowd Machinery.......................................................309
	GEARCASE REPAIR.......................................................311
		Crowd Gearcase Disassembly........................................311
		Crowd Gearcase Assembly...........................................314
		Crowd Motor.......................................................315
			Crowd Gear and Drum...........................................317
			Crowd Drum Removal............................................317
	Operator’s Cab Mounting...............................................319
	Operator’s Seat Installation..........................................320
	Footrest Installation.................................................322
	Machinery House.......................................................323
		Walkways, Stairways, and Handrails................................324
		Boarding Stairs...................................................325
		Vertical Boarding Ladder, left....................................327
Front End Equipment.......................................................329
	Boom Assembly.........................................................330
	Boom Repair...........................................................331
	Boom Limit Switch Installation........................................332
	Boom Point Sheaves....................................................334
		Boom Point Sheave Removal and Disassembly.........................335
		Boom Point Sheave Reassembly and Installation.....................337
	Boom Bumper...........................................................338
	Saddle Block..........................................................339
		Saddle Block Repair...............................................339
		Saddle Block Removal..............................................340
	Dipper Handle.........................................................342
		Dipper Handle Removal.............................................344
		Crowd Rope Take-Up Mechanism......................................346
			Crowd Rope Take-Up Mechanism Disassembly......................347
			Crowd Rope Take-Up Mechanism Assembly.........................349
		Retract Rope Take-up Mechanism....................................351
		Spreader Repair...................................................353
	LatchFreeTM Dipper Assembly...........................................354
	Dipper Assembly.......................................................354
		Latch Bar Adjusting...............................................356
		Dipper Door bumpers...............................................356
	DIPPER INSPECTION.....................................................358
		Dipper Removal & Installation.....................................359
		Dipper Door Snubbers..............................................364
			Snubber Adjustment............................................365
		Dipper Pitch Brace................................................366
		Dipper Padlock....................................................367
	Dipper Trip Assembly..................................................370
	A-Frame...............................................................371
	Auxiliary Winch.......................................................373
	Hoist Rope Support Roller.............................................374
	Boom Support Ropes....................................................375
	Wire Ropes............................................................376
		Wire Rope Inspection..............................................377
	Crowd Rope Take-up Hydraulic Unit.....................................378
	Hoist Rope Reeving & Replacement......................................380
	Crowd Rope Reeving & Replacement......................................384
	Retract Rope Reeving & Replacement....................................386
	Crowd Rope Tightening.................................................390
	Retract Rope Tightening...............................................392
	Dipper Trip Rope Reeving & Replacement................................393
	Hoist and Crowd Limit Systems.........................................394
		Setting Limits In The Hoist & Crowd System........................395
			Crowd Slowdown/Stop Limits....................................397
			Retract Slowdown/Stop Limits..................................398
			Lower Slowdown/Stop Limits....................................399
			Hoist Slowdown/Stop Limits....................................400
Brakes and Couplings......................................................403
Brakes....................................................................403
	Disc Brake Operation..................................................404
	Maintenance...........................................................404
	Brake Adjustment Specifications.......................................404
	Hoist Brake...........................................................405
		Hoist Brake Adjustment............................................407
		Hoist Brake Installation..........................................409
		Hoist Brake Wear & Release Switches...............................409
	Crowd Brake...........................................................410
		Crowd Brake Installation..........................................412
		Crowd Brake Wear & Release Switches...............................414
	Propel Brake..........................................................415
		Propel Brake Adjustment...........................................417
		Propel Brake Installation.........................................419
		Tachometer Mounting & Alignment...................................421
	Swing Brake...........................................................423
		Swing Brake Installation..........................................425
		Swing Brake Wear & Release Switches...............................426
		Swing Brake Burnishing............................................427
	Spring Replacement — All Brakes.......................................427
	Friction Disc Replacement — All Brakes................................429
	O-Ring Replacement — All Brakes.......................................430
	Brake Wear & Release Switches — Single Disc Brakes....................432
	Brake Wear & Release Switches — Multiple Disc Brakes..................433
Couplings.................................................................434
	Grid Couplings........................................................434
		Lubrication.......................................................434
		Coupling Disassembly and Grid Removal.............................435
		Grid Coupling Installation........................................436
		Seal Replacement without Hub Removal..............................439
		Grid Coupling Alignment...........................................441
	Gear Couplings........................................................442
		Coupling Installation.............................................442
		Gear Coupling Alignment...........................................444
		Hoist Coupling Shaft Alignment....................................445
Compressed Air System.....................................................449
Air Compressor............................................................449
	Lockout Valves........................................................451
	Safety Warnings.......................................................453
Air Filtration............................................................457
House Filter Fans.........................................................457
	Lubrication...........................................................458
	Dynavane Air Cleaner..................................................459
Air Filtration System.....................................................460
Air Conditioner...........................................................462
	Specifications........................................................463
Engineering Data..........................................................469
Capscrew (Bolt) Grade.....................................................469
	Bolt Tightening.......................................................469
		Torque Wrench Method..............................................469
		Turn-of-nut Method................................................471
Measurement Systems.......................................................473
	Linear Measurements...................................................473
	Area Measurements.....................................................473
	Volume Measurements...................................................474
	Torque Measurements...................................................475
		Weight Measurements - Conventional................................476
Split Flange Assembly Procedure...........................................477
Wire Locking Capscrews....................................................479
Torque Nut Installation...................................................480
Expansion Bolt Installation...............................................480
	Tightening Procedure for 1.25-Inch Torque Nut.........................481
	Tightening Procedure for 2-Inch Torque Nut............................482
	Tightening Procedure for 2-Inch Torque Nut............................483
	Tightening Procedure for 2-Inch Torque Nut............................484
	Tightening Procedure for 2.5-Inch Torque Nut..........................485
	Tightening Procedure for 3-Inch Torque Nut............................486
	Tightening Procedure for 3.5-Inch Torque Nut..........................487
	Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods....488
		Initial Tensioning................................................488
		Final Tensioning..................................................488
	Tightening Procedures - Expansion Bolts...............................490
		Rack & Roller Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut....490
		Hoist Torque Rod, Tapered Sleeve & 1.62 Inch Torque Nut...........491
		Swing Torque Rod & Tapered Sleeve & 3.25 Inch Torque Nut..........493
Torque Nut Removal Procedure..............................................495
	Thread Lubrication....................................................495
Torque Nut Helpful Hints..................................................496
Locking Assemblies........................................................497
	Locking Assembly Removal..............................................499
	Pinion and Hub Installation...........................................500
	Removal from a Shaft..................................................500
	Mounting a Pinion or Hub on a Shaft...................................500
		Pre-heat Advance Requirements - Pinions and Hubs..................503
		Motor Coupling Pre-Heat Advance Requirements......................503
Maintenance Welding.......................................................505
	Welding Electrodes....................................................506
	Repair Welding of Cracks..............................................507
		Preheat...........................................................508
		Welding Technique.................................................508
	Repair Welding of Broken Parts........................................509
	Repair Welding Swing Rack Teeth.......................................510
		Preparation.......................................................510
		Swing Rack Welding Electrodes.....................................510
		Preheat...........................................................510
		Welding Procedure.................................................512
	Welding and Cutting Equipment.........................................514
	Stress Relieving & Temperature Measuring Equipment....................515
Wire Rope Care and Maintenance............................................516
	Storage...............................................................516
	Checking Diameter.....................................................516
	Handling Wire Rope....................................................517
	Seizing Wire Rope.....................................................518
	End Preparations/Terminations.........................................520
	Wire Rope Clips.......................................................520
		Wire Rope Clip Application........................................520
		Wedge Sockets.....................................................522
	Inspection of Sheaves and Drums.......................................523
	Breaking In a New Wire Rope...........................................524
	Inspection Data.......................................................525
	Guideline to Inspections and Reports..................................526
		Wire Rope Inspection Criteria.....................................527
			Reduction in Rope Diameter....................................527
			Rope Stretch..................................................528
			Abrasion......................................................529
			Corrosion.....................................................529
			Kinks.........................................................529
			Bird Caging...................................................529
			Localized Conditions..........................................529
			Heat Damage...................................................529
			Protruding Core...............................................529
			Damaged End Attachments.......................................530
			Peening.......................................................530
			Scrubbing.....................................................530
			Fatigue Fracture..............................................530
			Broken Wires..................................................530
			Electric Arc..................................................531
Seals.....................................................................531
	Seal Installation.....................................................532
	Gearcase Sealing......................................................533
Schematics................................................................536
Schematics................................................................536
Side View.................................................................537
Deck Plan.................................................................538
OGL System A & B Schematic................................................539
Grease System C Schematic.................................................540
Air Schematic.............................................................541
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