Cat Electric Rope Shovel 495HD Mining Shovel Maintenance And Operation Manual – PDF DOWNLOAD

Description

Cat Electric Rope Shovel 495HD Mining Shovel Maintenance And Operation Manual – PDF DOWNLOAD

DESCRIPTION:

Cat Electric Rope Shovel 495HD Mining Shovel Maintenance And 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.

TABLE OF CONTENTS:

Cat Electric Rope Shovel 495HD Mining Shovel Maintenance And 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...................................................... 25
General Information............................................... 25
	SWINGING RESTRAINT & BALLAST BOX SUPPORT...................... 26
		Ballast Box Support....................................... 26
		Swinging Restraint........................................ 27
Machine Overview.................................................. 29
Lower Works....................................................... 30
	Crawlers...................................................... 31
	Truck Frame................................................... 33
	Swing Rack.................................................... 34
	Roller Circle................................................. 35
	Propel Machinery.............................................. 36
	Collector Rings............................................... 37
Rotating Deck..................................................... 38
	Revolving Frame............................................... 38
	Center Pintle................................................. 38
	Deck Extensions............................................... 40
	Ballast Box................................................... 40
	Machinery House............................................... 40
		Vertical Boarding Ladder, Left............................ 41
	Boarding Stairs............................................... 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
Front End Equipment............................................... 51
	Suspension Strands............................................ 51
	Boom.......................................................... 52
	Running Ropes................................................. 53
	Saddle Block.................................................. 54
	Dipper Handle................................................. 55
	Dipper........................................................ 56
	Padlocks...................................................... 57
	Dipper Trip................................................... 58
Typical Machine Specifications.................................... 59
General Estimated Component Weights............................... 61
	Lower Works................................................... 61
	Upper Works................................................... 63
	Front End..................................................... 65
Operation......................................................... 71
General Information............................................... 71
	Operation Near Electrical Lines............................... 71
Controls.......................................................... 73
	Primary Operating Controls.................................... 74
		Controls On The Left Console.............................. 75
			Left Joystick......................................... 76
			Dipper Trip........................................... 76
			Signal Horn........................................... 76
			Radio................................................. 76
			Hoist Brake........................................... 76
			Crowd Brake........................................... 76
			Swing Brake........................................... 77
			Propel Brake.......................................... 77
			Climate Control Panel................................. 77
			Windshield Wiper Switch............................... 77
			Windshield Washer Switch.............................. 77
		Controls On The Right Console............................. 78
			Right Joystick........................................ 79
			Control Stop Pushbutton............................... 79
			Control Reset Pushbutton.............................. 80
			Dig/propel Transfer Switch............................ 80
			Emergency Stop Pushbutton............................. 80
			Main Power Off Pushbutton............................. 81
			Earth Continuity Lockout Pushbutton................... 81
			Telephone............................................. 81
		Heated Mirrors............................................ 81
Operator’s Seat................................................... 82
Operator’s Display................................................ 83
	Display Area and Indicators................................... 85
	Display Screens............................................... 86
Auxiliary Controls................................................ 94
	Remote Start Panel............................................ 94
		Phase Sequence Light...................................... 94
		Drive Cabinets Temperature Light.......................... 94
		PLC Power On Light........................................ 94
		System Ready Light........................................ 95
		Auxiliary Ground Fault Light.............................. 95
		Incomplete Sequence Light................................. 95
		System Run Pushbutton..................................... 95
		Air Compressor Start/Stop Pushbuttons..................... 95
		House Light Circuit Breakers.............................. 95
		Lighting Transfer Switch.................................. 96
	Lubrication Control Panel..................................... 96
	Windshield Wipers............................................. 96
	Windshield Washer............................................. 97
Pre-start Checks.................................................. 97
	Walk-around Ground Level Inspection........................... 98
	On-board Inspection........................................... 99
Start-up, Operation And Shutdown..................................100
	Machine Start-up..............................................100
	Restarting After An Electrical Fault..........................102
	Machine Operation.............................................102
	Machinery Motions.............................................103
		Hoist Motion..............................................103
		Crowd Motion..............................................104
		Propel Motion.............................................105
		Swing Motion..............................................106
			Proper Swing Motion...................................107
		Steering..................................................109
			Counter-rotation Turns................................110
		Positioning the Machine...................................111
			Back-up Method........................................111
			Drive-by Method.......................................112
		Start Of The Dig Cycle....................................113
		Engaging The Bank.........................................116
		Slope Limitations.........................................118
	Excavated Material............................................120
	Operation Checks..............................................120
	Operating Hints...............................................121
	Stopping the Machine..........................................122
	Shutdown......................................................122
Lubrication.......................................................125
Lubrication Principles............................................125
Greasing Main A.C. Drive Motors...................................126
	1. Type of Grease.............................................126
	2. Initial Commissioning......................................126
	3. Maintenance................................................126
	4. Regreasing Intervals.......................................127
Lubricant Selection...............................................127
Oil Fill Capacities...............................................129
	Types Of Lubricants And Capacities Guidelines.................129
		Quantities for First Fill of Lubricants...................129
Automatic Lubrication System......................................130
	Lube Room.....................................................131
	Lube Reservoir fill / Overflow Plumbing.......................132
		Auto Lube Control Panel...................................133
	Lower Works Lubrication.......................................133
	Propel Machinery Lubrication..................................137
		Lubricant Replacement/sampling............................138
			Lubricant Change Cycle................................138
	Revolving Frame Lubrication...................................139
	Hoist Machinery Lubrication...................................140
		Hoist Gearcase Oil Cooler.................................141
	Crowd Machinery Lubrication...................................143
	SWING MACHINERY LUBRICATION...................................144
	Air Compressor Lubrication....................................145
	Front End Lubrication.........................................145
	Lincoln Type SL-1 Lubricant Injectors.........................146
		SL-1 Lubricant Injector Operation.........................148
		Injector Advantages.......................................150
Lubrication Benchmarks............................................151
	Air Compressor Lubricant......................................151
	MPO - Multipurpose OIL........................................151
	RWRL - Running Wire Rope Lubricant............................153
	EGL - Enclosed Gearcase Lubricant.............................154
	MPG - Multipurpose Grease.....................................157
	OGL - Open Gear Lubricant.....................................161
	Certified Lubricants Listing..................................165
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....................................194
Major Component Locations.........................................196
Service Procedures................................................221
Lower Works.......................................................221
	Propel Machinery..............................................221
	Crawler Frames and Truck Frame................................222
		Crawler Belts.............................................224
			Belt Adjustment.......................................225
			Belt Replacement......................................228
		Crawler Links.............................................230
			Take-up Tumbler & Axle................................231
			Tumbler Repair........................................232
		Upper Rollers.............................................233
			Upper Roller Repair...................................234
		Lower Rollers.............................................235
			Lower Roller Repair...................................236
		Drive Tumbler.............................................237
			Drive Tumbler Repair..................................237
			Drive Tumbler Rebuild.................................238
		Tumbler Drive Shaft.......................................241
			Shaft Repair..........................................242
	Propel Motor..................................................243
	Propel Planetary Gearcase.....................................244
	Swing Rack....................................................246
	Roller Circle.................................................247
		Roller Circle Repair......................................249
	Swing Rack Dust Curtains......................................252
	Center Pintle.................................................253
		Center Pintle Adjustment..................................258
		Center Pintle Sleeve Removal..............................258
	Collector Rings...............................................260
		Collector Ring Inspection.................................261
		Collector Ring Repair.....................................261
	Swing Machinery...............................................262
	Swing Blower..................................................264
		Swing Motor...............................................264
		Swing Motor Removal.......................................265
			Swing Motor Installation..............................265
		Swing Planetary Gearcase..................................266
			Gearcase Inspection...................................267
	Swing Shafts and Pinions......................................268
		Swing Pinion Removal......................................269
	Swing Pinion Installation.....................................270
	Swing Shaft Removal...........................................270
		Swing Shaft Installation..................................271
Hoist Machinery...................................................273
	Hoist Motor...................................................275
	Hoist Gearcase Assembly.......................................278
		Hoist Gearcase Installation...............................279
		Hoist Gearcase Repair.....................................281
		Motor Coupling Shaft......................................281
		Hoist Drum Assembly.......................................284
			Hoist Gear Replacement................................286
			Bearing Replacement...................................287
		Hoist Mounting Bolts......................................288
		Hoist Limit Switch........................................289
	Hoist Motor...................................................290
	Crowd Machinery...............................................292
	Gearcase Repair...............................................294
		Crowd Motor...............................................299
			Crowd Gear and Drum...................................301
			Crowd Drum Removal....................................302
	Machinery House...............................................304
	Walkways, Stairways, and Handrails............................305
		Vertical Boarding Ladder, left............................306
	Boarding Stairs...............................................308
Front End Equipment...............................................310
	Boom Assembly.................................................311
		Boom Repair...............................................311
	Boom Limit Switch.............................................312
		Limit Switch Inspection...................................315
		Limit Switch Adjustment...................................315
	Boom Point Sheaves............................................316
		Boom Point Sheave Removal and Disassembly.................317
		Boom Point Sheave Reassembly and Installation.............319
	Boom Bumper...................................................320
	Saddle Block..................................................321
		Saddle Block Repair.......................................321
		Saddle Block Removal......................................322
	Dipper Handle.................................................324
		Dipper Handle Removal.....................................325
		Retract Rope Take-up Mechanism............................326
		Spreader Repair...........................................328
Dipper Assembly...................................................329
	Latch Bar Adjusting...........................................332
	Dipper Door bumpers...........................................333
	Dipper Door Snubbers..........................................334
		Snubber Adjustment........................................335
		Allowable Wear............................................335
	Dipper Padlock................................................335
	Dipper Pitch Brace............................................338
	Dipper Trip Assembly..........................................339
	A-Frame.......................................................340
	Auxiliary Winch...............................................343
	Hoist Rope Support Roller.....................................344
	Boom Support Ropes............................................345
	Wire Ropes....................................................346
		Wire Rope Inspection......................................347
	Hoist Rope Reeving & Replacement..............................347
		Crowd Rope Reeving & Replacement..........................351
	Retract Rope Reeving & Replacement............................354
	Retract Rope Tightening.......................................357
	Dipper Trip Rope Reeving & Replacement........................358
	Hoist and Crowd Limit Systems.................................358
		Setting Limits In The Hoist & Crowd System................359
			Crowd Slowdown/Stop Limits............................361
			Retract Slowdown/Stop Limits..........................362
			Lower Slowdown/Stop Limits............................363
			Hoist Slowdown/Stop Limits............................364
Brakes and Couplings..............................................367
Brakes............................................................367
	Disc Brake Operation..........................................368
	Maintenance...................................................368
	Brake Adjustment Specifications...............................368
	Hoist Brake...................................................369
		Hoist Brake Adjustment....................................371
		Hoist Brake Installation..................................373
		Hoist Brake Wear & Release Switches.......................373
	Crowd Brake...................................................374
		Crowd Brake Installation..................................376
		Crowd Brake Wear & Release Switches.......................377
	Propel Brake..................................................378
		Propel Brake Adjustment...................................380
		Propel Brake Installation.................................382
		Tachometer Mounting & Alignment...........................383
	Swing Brake...................................................385
		Swing Brake Installation..................................387
		Swing Brake Wear & Release Switches.......................388
		Swing Brake Burnishing....................................389
	Spring Replacement — All Brakes...............................389
	Friction Disc Replacement — All Brakes........................391
	O-Ring Replacement — All Brakes...............................392
	Brake Wear & Release Switches — Single Disc Brakes............395
	Brake Wear & Release Switches — Multiple Disc Brakes..........396
Couplings.........................................................397
	Grid Couplings................................................397
		Lubrication...............................................397
		Coupling Disassembly and Grid Removal.....................398
		Grid Coupling Installation................................399
		Seal Replacement without Hub Removal......................402
		Grid Coupling Alignment...................................404
	Gear Couplings................................................405
		Coupling Installation.....................................405
		Gear Coupling Alignment...................................408
		Hoist Coupling Shaft Alignment............................408
Compressed Air System.............................................413
Air Compressor....................................................413
	Compressor Maintenance........................................416
	Pressure Switch...............................................416
	Lockout Valves................................................417
	Safety Warnings...............................................419
Air Filtration....................................................423
House Filter Fans.................................................423
	Lubrication...................................................424
	Dynavane Air Cleaner..........................................425
Air Conditioner...................................................426
	Specifications................................................427
Engineering Data..................................................433
Capscrew (Bolt) Grade.............................................433
	Bolt Tightening...............................................433
		Torque Wrench Method......................................433
		Turn-of-nut Method........................................435
Measurement Systems...............................................437
	Linear Measurements...........................................437
	Area Measurements.............................................437
	Volume Measurements...........................................438
	Torque Measurements...........................................439
		Weight Measurements - Conventional........................440
Split Flange Assembly Procedure...................................441
Wire Locking Capscrews............................................443
Torque Nut Installation...........................................444
	Tightening Procedure for 2-Inch Torque Nut....................445
	Tightening Procedure for 2-Inch Torque Nut....................446
	Tightening Procedure for 2.5-Inch Torque Nut..................447
	Tightening Procedure for 3-Inch Torque Nut....................448
Expansion Bolt Installation.......................................449
	Tightening Procedures - Expansion Bolts.......................449
		Hoist Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut....449
Torque Nut Removal Procedure......................................451
	Thread Lubrication............................................451
Torque Nut Helpful Hints..........................................452
Locking Assemblies................................................453
	Locking Assembly Removal......................................455
Pinion and Hub Installation.......................................456
	Removal from a Shaft..........................................456
	Mounting a Pinion or Hub on a Shaft...........................456
		Hub Adapter Pre-heat Advance Requirements.................459
		Motor Coupling Pre-Heat Advance Requirements..............459
Maintenance Welding...............................................460
	Welding Electrodes............................................461
	Repair Welding of Cracks......................................462
		Preheat...................................................463
		Welding Technique.........................................463
	Repair Welding of Broken Parts................................464
	Repair Welding Swing Rack Teeth...............................465
		Preparation...............................................465
		Swing Rack Welding Electrodes.............................465
		Preheat...................................................465
		Welding Procedure.........................................467
	Welding and Cutting Equipment.................................469
	Stress Relieving & Temperature Measuring Equipment............470
Wire Rope Care and Maintenance....................................471
Wire Rope Care and Maintenance....................................472
	Storage.......................................................472
	Checking Diameter.............................................472
	Handling Wire Rope............................................473
	Seizing Wire Rope.............................................474
	End Preparations/Terminations.................................476
	Wire Rope Clips...............................................476
		Wire Rope Clip Application................................477
		Wedge Sockets.............................................479
	Inspection of Sheaves and Drums...............................480
	Breaking In a New Wire Rope...................................481
	Inspection Data...............................................482
	Guideline to Inspections and Reports..........................483
		Wire Rope Inspection Criteria.............................484
			Reduction in Rope Diameter............................484
			Rope Stretch..........................................485
			Abrasion..............................................486
			Corrosion.............................................486
			Kinks.................................................486
			Bird Caging...........................................486
			Localized Conditions..................................486
			Heat Damage...........................................486
			Protruding Core.......................................486
			Damaged End Attachments...............................487
			Peening...............................................487
			Scrubbing.............................................487
			Fatigue Fracture......................................487
			Broken Wires..........................................487
			Electric Arc..........................................488
Seals.............................................................488
	Seal Installation.............................................489
	Gearcase Sealing..............................................490
Schematics........................................................492
Schematics - Automatic Lubrication................................492
Side View.........................................................  0
Deck Plan.........................................................  0
OGL System A & B Schematic........................................  0
Grease System C Schematic.........................................  0
Air Schematic.....................................................  0
10840-10N.pdf.....................................................  0
	Side View.....................................................493
10840-10D.pdf.....................................................  0
	Deck Plan.....................................................494
10840-10L.pdf.....................................................  0
	OGL System A & B Schematic....................................495
	Grease System C Schematic.....................................496
10840-10A.pdf.....................................................  0
	Air Schematic.................................................497

CAT ELECTRIC ROPE SHOVEL 495HD MINING SHOVEL MAINTENANCE AND OPERATION MANUAL – PDF DOWNLOAD:

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