Cat 495HD Electric Rope Shovel O&M 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

Introduction

GENERAL INFORMATION

• This manual is designed to assist the owner in the operation and preventive 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.
• It is important to remember that when a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.
• 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. Please carefully read the instructions in it.
• All parts are listed by group and/or product code numbers with the associated item/part numbers for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed.
• RIGHT and LEFT refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab. Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments.
• Records on each machine are filed by serial number and when given this number, the machine’s specific design and original equipment is accessed quickly by the Bucyrus International parts representative. 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 53172-0500, USA
Telephone (414)-768-4000 Fax: (414) 768-4210

It is Bucyrus International’s policy to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to it’s machines at any time. This will be without incurred obligation 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

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 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

TABLE OF CONTENTS:

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

GENERAL INFORMATION ………………………………………………………………………………………………3
SAFETY ………………………………………………………………………………………………………………….4
SAFETY – SWINGING RESTRAINT & BALLAST BOX SUPPORT …………………………………..5
BALLAST BOX SUPPORT……………………………………………………………………………………5
SWINGING RESTRAINT ………………………………………………………………………………………6
SAFETY PRECAUTIONS…………………………………………………………………………………………..8
FIRE PREVENTION ……………………………………………………………………………………………….. 11
WARNING SIGNS AND DECALS ……………………………………………………………………………… 12
Stored Energy Decals ………………………………………………………………………………………………….13
MACHINE OVERVIEW …………………………………………………………………………………………………. 14
LOWER WORKS ……………………………………………………………………………………………………….. 15
Truck Frame and Crawlers ……………………………………………………………………………………………15
CRAWLERS………………………………………………………………………………………………………….. 16
Right Crawler Assembly (Left Opposite) ………………………………………………………………………….16
TRUCK FRAME ……………………………………………………………………………………………………..17
SWING RACK ……………………………………………………………………………………………………….. 18
Swing Rack and Roller Circle ………………………………………………………………………………………..18
ROLLER CIRCLE ………………………………………………………………………………………………….. 19
Roller Circle Assembly …………………………………………………………………………………………………19
PROPEL MACHINERY ……………………………………………………………………………………………. 20
COLLECTOR RINGS……………………………………………………………………………………………… 21
REVOLVING FRAME ………………………………………………………………………………………………. 22
CENTER PINTLE ……………………………………………………………………………………………………22
DECK EXTENSIONS ……………………………………………………………………………………………… 23
Deck Extensions and Ballast Box ………………………………………………………………………………….23
BALLAST BOX ………………………………………………………………………………………………………. 23
MACHINERY HOUSE ……………………………………………………………………………………………… 23
BOARDING STAIRS – RIGHT …………………………………………………………………………………… 24
POWER STEP ………………………………………………………………………………………………………25
A-FRAME……………………………………………………………………………………………………………….26
A- Frame and Front End Support Components …………………………………………………………………26
HOIST MACHINERY ……………………………………………………………………………………………….. 27
Hoist Machinery – Plan View ………………………………………………………………………………………….27
SWING MACHINERY………………………………………………………………………………………………. 28
Swing Machinery Components ……………………………………………………………………………………….28
CROWD MACHINERY ……………………………………………………………………………………………. 29
Crowd Machinery Components ………………………………………………………………………………………29
OPERATOR’S CAB ………………………………………………………………………………………………..30
COMPRESSED AIR SYSTEM …………………………………………………………………………………. 31
AUTOMATIC LUBRICATION SYSTEM ………………………………………………………………………. 31
Lubrication Room ………………………………………………………………………………………………………..32
LUBE RESERVOIR FILL / OVERFLOW PLUMBING …………………………………………………… 33
Lube Reservoir Fill / Overflow Plumbing ………………………………………………………………………….33
FRONT END EQUIPMENT …………………………………………………………………………………………… 34
SUSPENSION STRANDS……………………………………………………………………………………….. 34
BOOM ………………………………………………………………………………………………………………….. 35
Boom Assembly …………………………………………………………………………………………………………35
RUNNING ROPES …………………………………………………………………………………………………. 36
Ropes – General Arrangement ……………………………………………………………………………………….36
SADDLE BLOCK …………………………………………………………………………………………………… 37
DIPPER HANDLE ………………………………………………………………………………………………….. 37
PADLOCK …………………………………………………………………………………………………………….. 38
Left and Right Padlocks ……………………………………………………………………………………………….38
DIPPER TRIP………………………………………………………………………………………………………… 39
Dipper Trip Motor and Dipper Trip Sheave ………………………………………………………………………..39
TYPICAL MACHINE SPECIFICATIONS …………………………………………………………………………… 40
GENERAL ESTIMATED COMPONENT WEIGHTS …………………………………………………………..42
495HD COLOR DECK PLAN …………………………………………………………………………… ( foldout )

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

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• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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S.M