CAT Electric Rope 495B Electric Mining Shovel Mechanical Maintenance Manual – PDF DOWNLOAD

Description

CAT Electric Rope 495B Electric Mining Shovel Mechanical Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

CAT Electric Rope 495B Electric Mining Shovel Mechanical Maintenance Manual – PDF DOWNLOAD

FOREWORD

• The purpose of this manual is to provide information concerning the general maintenance of the 495-B electric mining shovel. The Model 495-B consists of three major units, the lower works, the rotating deck and the front end equipment.
• The lower works provides a foundation for the revolving frame and contains the necessary equipment to propel the shovel. 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 Aframe, dipper, dipper handle, boom, running ropes, and boom structural strands.
• This manual consists of four 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 bold face type. CAUTION is preceded by the safety alert symbol A 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 CAUTION’s and WARNING’s 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 BucyrusErie Company to 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.

TABLE OF CONTENTS:

CAT Electric Rope 495B Electric Mining Shovel Mechanical Maintenance Manual – PDF DOWNLOAD

COVER PAGE.................................................................  1
TABLE OF CONTENTS..........................................................  2
FOREWORD...................................................................  6
MECHANICAL MAINTENANCE.....................................................  7
	MAINTENANCE PROCEDURE..................................................  7
		GENERAL............................................................  7
		MAINTENANCE SCHEDULES AND REPORTS..................................  7
		SAFETY.............................................................  8
			GENERAL........................................................  8
			IN-OPERATION MAINTENANCE.......................................  8
			PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK.................  8
	LOWER WORKS............................................................ 10
		CRAWLER BELTS...................................................... 10
		TAKE-UP TUMBLER.................................................... 13
		UPPER ROLLERS...................................................... 14
		LOWER ROLLERS...................................................... 15
		DRIVE TUMBLER...................................................... 15
		TUMBLER DRIVE SHAFT & GEAR......................................... 17
		TRANSVERSE SHAFT................................................... 18
		PROPEL CLUTCHES.................................................... 19
		PROPEL BRAKES...................................................... 21
		PROPEL MOTOR....................................................... 24
		PROPEL TACH ASSEMBLY............................................... 26
		PROPEL MACHINERY................................................... 27
		CRAWLER FRAMES AND TRUCK FRAMES.................................... 31
		SWING RACK......................................................... 32
		ROLLER CIRCLE...................................................... 33
		CENTER PINTLE...................................................... 34
		COLLECTOR RINGS.................................................... 37
		CABLE REEL......................................................... 38
	ROTATING DECK.......................................................... 45
		REVOLVING FRAME.................................................... 45
		DECK MACHINERY..................................................... 46
		HOIST MACHINERY.................................................... 46
			GEAR TRAIN..................................................... 46
			HOIST GEAR AND DRUM............................................ 48
			HOIST BRAKES................................................... 50
			HOIST LIMIT SWITCH............................................. 52
			HOIST MOTOR.................................................... 52
		CROWD MACHINERY.................................................... 53
			GEAR TRAIN..................................................... 53
			CROWD MOTOR.................................................... 56
			CROWD BRAKE.................................................... 57
			CROWD GEAR AND DRUM............................................ 59
			CROWD AND RETRACT LIMIT SWITCH................................. 59
		SWING MACHINERY.................................................... 60
			GEAR TRAIN..................................................... 60
			SWING MOTOR.................................................... 66
			SWING BRAKE.................................................... 67
		MACHINERY HOUSE.................................................... 68
		HOUSE FANS......................................................... 69
		DYNAVANE AIR CLEANER............................................... 70
		WALKWAYS........................................................... 70
		OPERATOR'S CAB..................................................... 71
			SEAT........................................................... 71
			WINDSHIELD WIPERS.............................................. 71
			WINDSHIELD WASHER.............................................. 73
			RETRACTABLE BOARDING LADDER.................................... 74
	FRONT END EQUIPTMENT................................................... 75
		BOOM............................................................... 75
			BOON POINT SHEAVES............................................. 75
			BOOM BUMPERS................................................... 76
			SADDLE BLOCK................................................... 76
		DIPPER HANDLE...................................................... 78
			DIPPER HANDLE REMOVAL.......................................... 78
		RETRACT TAKE-UP MECHANISM REMOVAL.................................. 78
			FRONT STOP & SPREADER REMOVAL.................................. 78
			CROWN CUSHION (WITH PRE-ASSEMBLED CUSHION STACK)............... 80
			DIPPER......................................................... 82
			DIPPER PADLOCK................................................. 83
		DIPPER TRIP ASSEMBLY............................................... 85
		A-FRAME............................................................ 86
		BOOM STRUCTURAL STANDS............................................. 86
		WIRE RUNNING ROPES................................................. 87
			INSPECTION..................................................... 87
		HOIST ROPE REEVING................................................. 87
		RETRACT ROPE REEVING............................................... 90
		CROWD ROPE REEVING................................................. 91
		DIPPER TRIP ROPE REEVING........................................... 93
AIR SYSTEM................................................................. 94
	GENERAL MAINTENANCE.................................................... 94
		SAFETY............................................................. 94
		GENERAL............................................................ 94
		AIR COMPRESSOR (QUINCY QSB20)...................................... 96
		AIR LINES.......................................................... 97
		AIR TANK........................................................... 97
		AIR LINE LUBRICAOTR................................................ 97
		AIR LINE FILTER.................................................... 97
		AIR LINE REGULATOR................................................. 97
		AIR DRYER (OPTIONAL)............................................... 97
		AIR/LUBE SWIVEL ASSEMBLY........................................... 98
		PRESSURE SWITCHES.................................................. 98
		SOLENOID VALVES.................................................... 98
	COMPONENT MAINTENANCE.................................................. 99
		AIR COMPRESSOR (QUINCY QSB20)...................................... 99
		COMPRESSOR OPERATION...............................................102
		STARTING THE COMPRESSOR............................................103
		STOPPING THE COMPRESSOR............................................103
		PREPARING FOR MAINTENANCE OR SERVICE...............................103
		SERVICING..........................................................103
		ASSEMBLY AND DISASSEMBLY OF COMMON WEARING PARTS...................105
		DRIVE BELT REPLACEMENT.............................................107
		AIR/LUBE SWIVEL ASSEMBLY...........................................109
			REPAIR.........................................................109
		AIR DRYER..........................................................110
LUBRICATION................................................................123
	GENERAL LUBRICATION....................................................123
		LOWER WORKS........................................................124
		ROTATING DECK......................................................124
		FRONT END..........................................................125
		LUBRICATION BENCHMARKS.............................................125
			MULTI-PURPOSE TYPE GREASE (MPG)................................125
			AIR COMPRESSOR (PISTON TYPE) LUBRICANT (ACPL)..................126
			MULTI-PURPOSE OIL (MPO)........................................128
			OPEN GEAR LUBRICANT (OGL)......................................128
			REGULAR TYPE GEAR LUBRICANT (RGL)..............................129
			ROLLER CIRCLE RAIL LUBRICANT (RCRL)............................131
			RUNNING WIRE ROPE LUBRICANT (RWRL).............................133
			STRUCTURAL STRAND AND STATIONARY WIRE ROPE LUBRICANT (SWRL)....135
		LUBRICATION CHARTS.................................................136
	AUTOMATIC LUBRICATION SYSTEMS..........................................140
		INSPECTION.........................................................140
		LUBE SYSTEM........................................................140
		AIR PUMP SERVICE...................................................141
		LINES AND CONTROL SERVICE..........................................141
		INJECTORS AND SPRAY NOZZLES........................................142
		STARTUP OF AUTOMATIC LUBRICATION SYSTEMS...........................143
TROUBLESHOOTING............................................................146
	LOWER WORKS............................................................146
		CRAWLER............................................................146
		THIRD INTERMEDIATE PROPEL SHAFT....................................152
		SECOND INTERMEDIATE PROPEL SHAFT...................................153
		FIRST INTERMEDIATE PROPEL SHAFT....................................153
		PROPEL MOTOR SHAFT.................................................154
		PROPEL CLUTCH......................................................156
		PROPEL BRAKE.......................................................156
		PROPEL MOTOR, BLOWER AND GEAR CASE.................................158
		SWING RACK TEETH...................................................158
		HOUSE ROLLER RAILS.................................................159
		HOUSE ROLLERS......................................................159
		CENTER PINTLE......................................................160
	ROTATING DECK..........................................................161
		HOIST MACHINERY....................................................161
		HOIST MOTOR PINION SHAFT...........................................161
		HOIST INTERMEDIATE SHAFT ASSEMBLY..................................162
		HOIST DRUM ASSEMBLY................................................163
		CROWD MACHINERY....................................................164
		CROWD DRUM GEAR AND PINION LUBRICATION.............................165
		CROWD DISC TYPE BRAKE..............................................166
		A-FRAME............................................................166
		SWING MACHINERY....................................................167
	FRONT END EQUIPMENT....................................................170
		BOOM...............................................................170
		DIPPER-PIN CONNECTED...............................................173
		DIPPER DOOR SNUBBERS...............................................174
		DIPPER HANDLE......................................................175
		AIR/LUBE SWIVEL....................................................176
	AIR STSTEM.............................................................178
		QUINCY QSB20 SCREW COMPRESSOR......................................178
APPENDICES.................................................................184
	APPENDIX A1-GEAR INSPECTION............................................184
	APPENDIX A2-BOLT TORQUING..............................................186
		TORQUE WRENCH METHOD...............................................186
		TURN-OF-THE-NUT METHOD.............................................187
	APPENDIX A3-MAINTENANCE WELDING........................................190
		PRINCIPAL STRUCTURES...............................................190
			GENERAL........................................................190
		MAINTENANCE WELDING................................................190
			STRUCTURAL MATERIALS...........................................191
			WELDING ELECTRODES.............................................191
			PREHEAT REQUIREMENTS...........................................194
			REMOVAL OF CRACKS..............................................195
			WELD GROOVE PREPARATION........................................195
		BUTTER WELDING.....................................................195
			WELDING TECHNIQUE..............................................195
			WELD INSPECTION................................................195
			REPAIR OF BROKEN PARTS.........................................197
		DIPPER HANDLES.....................................................197
			MAINTENANCE WELDING............................................197
			FLAME STRAIGHTENING BENT TUBE..................................197
		WELDING TUBE WITHOUT BACKING RING..................................199
			WELDING TUBE USING BACKING RING................................202
			HANDLE END CASTING REPLACEMENT.................................203
			TUBE REPLACEMENT...............................................204
			STRESS RELIEVING WELDED TUBE...................................204
		REPAIR WELDING OF SWING RACKS......................................204
			CRACK REPAIR WELDING...........................................204
			BROKEN TOOTH REPAIR WELDING....................................206
		CRAWLER FRAME TO TRUCK FRAME WELDING...............................207
		SWING RACK TO TRUCK FRAME WELDING..................................208
	APPENDIX A4-PINION, BRAKE DRUM AND COUPLING INSTALLATION...............210
	APPENDIX A5-PREVENTIVE MAINTENANCE CHECKLISTS..........................213
		VISUAL WEEKLY CHECKLIST............................................213
		VISUAL MONTHLY CHECKLIST...........................................219
		VISUAL SEMI-ANNUAL CHECKLIST.......................................223
	APPENDIX A6-ROLLER REPLACEMENT.........................................227
	APPENDIX A7-BRAKE OR CLUTCH MAINTENANCE CHECKLIST......................229
	APPENDIX A8-ROLLER CIRCLE REPAIR MODIFICATION..........................230
	APPENDIX A9-SHIMMING INSTRUCTIONS......................................232
	APPENDIX A10-DRIVE TUMBLER REBUILD PROCEDURE...........................233
	APPENDIX A11-ELECTRIC MINING SHOVEL "BREAK-IN" INSTRUCTIONS............235
	APPENDIX A12-MOTOR COUPLING ALIGNMENT..................................237
	APPENDIX A13-FIGURE TO G.A. DRAWING CROSS REFERENCE....................238

CAT ELECTRIC ROPE 495B ELECTRIC MINING SHOVEL MECHANICAL MAINTENANCE MANUAL – PDF DOWNLOAD:

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• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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