Cat Electric Rope Shovel 495HF Mining Shovel Maintenance And Operation Manual – PDF DOWNLOAD
DESCRIPTION:
Cat Electric Rope Shovel 495HF 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 495HF Mining Shovel Maintenance And Operation Manual – PDF DOWNLOAD
Safety Precautions......................................................................................................................................................................................................................................................... 4
General Precautions.................................................................................................................................................................................................................................................... 5
Maintenance Precautions................................................................................................................................................................................................................................................ 6
Operating Precautions.................................................................................................................................................................................................................................................. 7
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 Overview............................................................................................................................................................................................................................................... 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 - Hydraulic Crowd........................................................................................................................................................................................................................................ 56
Dipper................................................................................................................................................................................................................................................................. 57
Padlocks............................................................................................................................................................................................................................................................... 58
Dipper Trip............................................................................................................................................................................................................................................................ 59
Typical Machine with HydraCrowd Specifications............................................................................................................................................................................................................................. 60
General Estimated Component Weights........................................................................................................................................................................................................................................ 62
Lower Works............................................................................................................................................................................................................................................................ 62
Upper Works............................................................................................................................................................................................................................................................ 63
Front End.............................................................................................................................................................................................................................................................. 65
Operation.................................................................................................................................................................................................................................................................. 71
General Information........................................................................................................................................................................................................................................................ 71
Operation Near Electrical Lines........................................................................................................................................................................................................................................ 71
Operator’s Seat............................................................................................................................................................................................................................................................ 73
Adjustable Armrest..................................................................................................................................................................................................................................................... 73
Adjustable Footrest.................................................................................................................................................................................................................................................... 74
Controls................................................................................................................................................................................................................................................................... 75
Primary Operating Controls............................................................................................................................................................................................................................................. 75
Controls On The Left Console........................................................................................................................................................................................................................................... 76
Left Joystick...................................................................................................................................................................................................................................................... 77
Dipper Trip........................................................................................................................................................................................................................................................ 77
Signal Horn........................................................................................................................................................................................................................................................ 77
Start Pushbutton................................................................................................................................................................................................................................................... 77
PLC Power On....................................................................................................................................................................................................................................................... 78
Drive Cabinet Temperature.......................................................................................................................................................................................................................................... 78
Incomplete Sequence................................................................................................................................................................................................................................................ 78
System Ready....................................................................................................................................................................................................................................................... 78
Phase Sequence..................................................................................................................................................................................................................................................... 78
Auxiliary Ground Fault............................................................................................................................................................................................................................................. 78
Hoist Brake........................................................................................................................................................................................................................................................ 78
Crowd CONTROL...................................................................................................................................................................................................................................................... 78
Swing Brake........................................................................................................................................................................................................................................................ 78
Propel Brake....................................................................................................................................................................................................................................................... 78
HVAC Unit Selector................................................................................................................................................................................................................................................. 78
Temperature........................................................................................................................................................................................................................................................ 78
HVAC System Control................................................................................................................................................................................................................................................ 78
HVAC Fan Speed..................................................................................................................................................................................................................................................... 78
Cabin Lights....................................................................................................................................................................................................................................................... 78
Auxiliary Heater................................................................................................................................................................................................................................................... 79
Controls On The Right Console.......................................................................................................................................................................................................................................... 80
Right Joystick..................................................................................................................................................................................................................................................... 81
Emergency Stop Pushbutton.......................................................................................................................................................................................................................................... 82
Windshield Wiper Switches.......................................................................................................................................................................................................................................... 82
Control Stop Pushbutton............................................................................................................................................................................................................................................ 82
Control Reset Pushbutton........................................................................................................................................................................................................................................... 82
Air Compressor..................................................................................................................................................................................................................................................... 83
Dig/propel Transfer Switch......................................................................................................................................................................................................................................... 83
Main Power Off Pushbutton.......................................................................................................................................................................................................................................... 83
Earth Continuity Lockout Pushbutton................................................................................................................................................................................................................................ 83
Seat Position...................................................................................................................................................................................................................................................... 83
Radio Receiver with CD Changer..................................................................................................................................................................................................................................... 84
Heated Mirrors..................................................................................................................................................................................................................................................... 84
Man On Ground...................................................................................................................................................................................................................................................... 84
Operator’s Display......................................................................................................................................................................................................................................................... 84
Display Area and Indicators............................................................................................................................................................................................................................................ 85
Display Screens........................................................................................................................................................................................................................................................ 85
Lubrication Control Panel.............................................................................................................................................................................................................................................. 92
Fire Suppression System................................................................................................................................................................................................................................................ 93
Pre-start Checks........................................................................................................................................................................................................................................................... 93
Walk-around Ground Level Inspection.................................................................................................................................................................................................................................... 94
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..................................................................................................................................................................................................................................................112
Slope Limitations..................................................................................................................................................................................................................................................114
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
Hydraulic Crowd Machinery Lubrication..................................................................................................................................................................................................................................139
Pump Drive Transmission (Pdt)..........................................................................................................................................................................................................................................140
Swing Machinery Lubrication............................................................................................................................................................................................................................................141
Air Compressor Lubrication.............................................................................................................................................................................................................................................142
Front End Lubrication..................................................................................................................................................................................................................................................143
Lincoln Type SL-1 Lubricant Injectors..................................................................................................................................................................................................................................144
SL-1 Lubricant Injector Operation..................................................................................................................................................................................................................................146
Injector Advantages................................................................................................................................................................................................................................................148
Air Compressor Lubricant...............................................................................................................................................................................................................................................148
Hydraulic Cleanliness......................................................................................................................................................................................................................................................149
Contamination Control..................................................................................................................................................................................................................................................149
Filters................................................................................................................................................................................................................................................................150
Moisture Removal.......................................................................................................................................................................................................................................................150
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......................................................................................................................................................................................................................................187
Every 2500 Hours or Semi-Annually..................................................................................................................................................................................................................................190
5000 Hours or Annually.............................................................................................................................................................................................................................................193
10,000 Hours Or Every 2 Years......................................................................................................................................................................................................................................195
20,000 Hours Or Every 4 Years......................................................................................................................................................................................................................................195
Hydraulic Crowd Service Schedule.......................................................................................................................................................................................................................................196
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................................................................................................................................................................................................................................233
Crawler Shoe Replacement.......................................................................................................................................................................................................................................235
Crawler Belt Replacement.......................................................................................................................................................................................................................................236
Crawler Side Frame Assembly............................................................................................................................................................................................................................................237
Crawler Side Frame Maintenance.....................................................................................................................................................................................................................................238
Slide Bar Replacement..............................................................................................................................................................................................................................................239
Load and Idler Rollers.............................................................................................................................................................................................................................................243
Roller Removal or Replacement..................................................................................................................................................................................................................................243
Propel Assembly............................................................................................................................................................................................................................................................246
Installation Notes.....................................................................................................................................................................................................................................................248
Main Propel Drive Shaft Removal........................................................................................................................................................................................................................................249
Main Propel Shaft - Disassembly....................................................................................................................................................................................................................................252
Tumbler Rebuild Procedure..........................................................................................................................................................................................................................................253
Propel Machinery.......................................................................................................................................................................................................................................................255
Propel Gearcase Removal............................................................................................................................................................................................................................................256
Propel Gearcase Installation.......................................................................................................................................................................................................................................257
Propel Planetary Gearcase..........................................................................................................................................................................................................................................259
Propel Motors......................................................................................................................................................................................................................................................260
Propel Motor Removal...........................................................................................................................................................................................................................................260
Propel Motor Installation......................................................................................................................................................................................................................................262
Revolving Frame........................................................................................................................................................................................................................................................263
Center Pintle..........................................................................................................................................................................................................................................................264
Center Pintle Adjustment...........................................................................................................................................................................................................................................269
Center Pintle Sleeve Removal.......................................................................................................................................................................................................................................269
Collector Rings........................................................................................................................................................................................................................................................271
Collector Ring Inspection..........................................................................................................................................................................................................................................272
Collector Ring Repair..............................................................................................................................................................................................................................................272
Rotating Deck..............................................................................................................................................................................................................................................................272
Swing Machinery........................................................................................................................................................................................................................................................273
Swing Support Mounting Bolts.......................................................................................................................................................................................................................................275
Swing Motor........................................................................................................................................................................................................................................................275
Swing Blower...................................................................................................................................................................................................................................................275
Swing Motor Removal............................................................................................................................................................................................................................................276
Swing Motor Installation.......................................................................................................................................................................................................................................277
Swing Planetary Gearcase...........................................................................................................................................................................................................................................277
Swing Gearcase Removal.........................................................................................................................................................................................................................................278
Gearcase Inspection............................................................................................................................................................................................................................................279
Swing Pinion Shafts................................................................................................................................................................................................................................................280
Swing Pinion Shaft Removal.....................................................................................................................................................................................................................................281
Swing Pinion Shaft Disassembly.................................................................................................................................................................................................................................282
Swing Pinion Shaft Assembly....................................................................................................................................................................................................................................283
Swing Pinion Shaft Installation................................................................................................................................................................................................................................284
Hoist Machinery........................................................................................................................................................................................................................................................285
Hoist Motor Removal................................................................................................................................................................................................................................................286
Motor Coupling Shaft...............................................................................................................................................................................................................................................289
Hoist Gearcase Assembly............................................................................................................................................................................................................................................290
Hoist Gearcase Repair..............................................................................................................................................................................................................................................294
Hoist Drum Assembly................................................................................................................................................................................................................................................297
Hoist Gear Replacement.........................................................................................................................................................................................................................................299
Bearing Removal................................................................................................................................................................................................................................................301
Bearing Installation...........................................................................................................................................................................................................................................302
Hoist Oil Cooler...................................................................................................................................................................................................................................................304
Hoist Mounting Bolts...............................................................................................................................................................................................................................................305
Hoist Limit Switch.................................................................................................................................................................................................................................................306
Crowd Machinery Overview...............................................................................................................................................................................................................................................307
Power Module/Lower Hydraulic Tank..................................................................................................................................................................................................................................308
Main Pump Removal..................................................................................................................................................................................................................................................309
Pdt Removal........................................................................................................................................................................................................................................................312
Pump Timing & Installation.........................................................................................................................................................................................................................................316
Crowd Motor Removal & Installation.................................................................................................................................................................................................................................318
Tuning Set-up Procedure............................................................................................................................................................................................................................................322
Tachometer Removal & Installation..................................................................................................................................................................................................................................325
Boom Tube Removal & Replacement....................................................................................................................................................................................................................................326
Power Module Removal...............................................................................................................................................................................................................................................330
Oil Circulation Pump REMOVAL & replacement.........................................................................................................................................................................................................................334
Flushing/PDT Lube Motor Disassembly & Replacement..................................................................................................................................................................................................................337
Operator’s Cab Mounting................................................................................................................................................................................................................................................340
Operator’s Seat Installation...........................................................................................................................................................................................................................................341
Footrest Installation..................................................................................................................................................................................................................................................343
Machinery House........................................................................................................................................................................................................................................................344
Walkways, Stairways, and Handrails.................................................................................................................................................................................................................................345
Boarding Stairs....................................................................................................................................................................................................................................................345
Vertical Boarding Ladder, left.....................................................................................................................................................................................................................................348
Boom Assembly..........................................................................................................................................................................................................................................................351
Boom Repair............................................................................................................................................................................................................................................................352
Boom Limit Switch Installation.........................................................................................................................................................................................................................................353
Boom Point Sheaves.....................................................................................................................................................................................................................................................355
Boom Point Sheave Removal and Disassembly..........................................................................................................................................................................................................................356
Boom Point Sheave Reassembly and Installation......................................................................................................................................................................................................................358
Boom Bumper............................................................................................................................................................................................................................................................359
Saddle Block...........................................................................................................................................................................................................................................................360
saddle Block Hose Guides & Guards..................................................................................................................................................................................................................................360
Saddle Block Repair................................................................................................................................................................................................................................................361
Saddle Block Removal...............................................................................................................................................................................................................................................362
Dipper Handle - Hydraulic Crowd........................................................................................................................................................................................................................................362
Dipper Handle Guide Bushing Replacement............................................................................................................................................................................................................................363
Dipper Handle Removal..............................................................................................................................................................................................................................................364
Dipper Handle Installation.........................................................................................................................................................................................................................................365
Linear Encoder Removal & Installation..............................................................................................................................................................................................................................366
Hydraulic Crowd Component Weights & Weight Distribution............................................................................................................................................................................................................367
Sleeve & Cylinder Removal..........................................................................................................................................................................................................................................368
Sleeve & Cylinder Installation.....................................................................................................................................................................................................................................374
Hydraulic Crowd Cylinder Removal...................................................................................................................................................................................................................................377
Rod End Relief Valve Replacement...................................................................................................................................................................................................................................382
Sleeve Tube Removal & Replacement..................................................................................................................................................................................................................................383
Static Rod Seal Installation.......................................................................................................................................................................................................................................385
Guide Bushing Wear & Rotation......................................................................................................................................................................................................................................387
LatchFreeTM Dipper Assembly............................................................................................................................................................................................................................................391
Dipper Assembly........................................................................................................................................................................................................................................................391
Latch Bar Adjusting................................................................................................................................................................................................................................................393
Dipper Door bumpers................................................................................................................................................................................................................................................394
Dipper Removal & Installation..............................................................................................................................................................................................................................................395
Dipper Door Snubbers...................................................................................................................................................................................................................................................402
Snubber Adjustment.................................................................................................................................................................................................................................................403
Dipper Pitch Brace.....................................................................................................................................................................................................................................................404
Dipper Padlock.........................................................................................................................................................................................................................................................405
Dipper Trip Assembly...................................................................................................................................................................................................................................................408
A-Frame................................................................................................................................................................................................................................................................409
Auxiliary Winch........................................................................................................................................................................................................................................................411
Hoist Rope Support Roller..............................................................................................................................................................................................................................................412
Boom Support Ropes.....................................................................................................................................................................................................................................................413
Wire Ropes.............................................................................................................................................................................................................................................................414
Wire Rope Inspection...............................................................................................................................................................................................................................................415
Hoist Rope Reeving & Replacement.......................................................................................................................................................................................................................................415
Dipper Trip Rope Reeving & Replacement.................................................................................................................................................................................................................................419
Hoist and Crowd Limit Systems..........................................................................................................................................................................................................................................420
Setting Limits In The Hoist & Crowd System.........................................................................................................................................................................................................................421
Crowd Slowdown/Stop Limits.....................................................................................................................................................................................................................................423
Retract Slowdown/Stop Limits...................................................................................................................................................................................................................................425
Lower Slowdown/Stop Limits.....................................................................................................................................................................................................................................427
Hoist Slowdown/Stop Limits.....................................................................................................................................................................................................................................428
Brakes and Couplings.......................................................................................................................................................................................................................................................431
Brakes.....................................................................................................................................................................................................................................................................431
Disc Brake Operation...................................................................................................................................................................................................................................................432
Maintenance............................................................................................................................................................................................................................................................432
Brake Adjustment Specifications........................................................................................................................................................................................................................................432
Hoist Brake............................................................................................................................................................................................................................................................433
Hoist Brake Adjustment.............................................................................................................................................................................................................................................435
Hoist Brake Installation...........................................................................................................................................................................................................................................437
Hoist Brake Wear & Release Switches................................................................................................................................................................................................................................437
Propel Brake...........................................................................................................................................................................................................................................................438
Propel Brake Adjustment............................................................................................................................................................................................................................................440
Propel Brake Installation..........................................................................................................................................................................................................................................442
Tachometer Mounting & Alignment....................................................................................................................................................................................................................................444
Swing Brake............................................................................................................................................................................................................................................................446
Swing Brake Installation...........................................................................................................................................................................................................................................448
Swing Brake Wear & Release Switches................................................................................................................................................................................................................................449
Swing Brake Burnishing.............................................................................................................................................................................................................................................450
Spring Replacement — All Brakes........................................................................................................................................................................................................................................450
Friction Disc Replacement — All Brakes.................................................................................................................................................................................................................................452
O-Ring Replacement — All Brakes........................................................................................................................................................................................................................................453
Brake Wear & Release Switches — Single Disc Brakes.....................................................................................................................................................................................................................455
Brake Wear & Release Switches — Multiple Disc Brakes...................................................................................................................................................................................................................456
Couplings..................................................................................................................................................................................................................................................................457
Grid Couplings.........................................................................................................................................................................................................................................................457
Lubrication........................................................................................................................................................................................................................................................457
Coupling Disassembly and Grid Removal..............................................................................................................................................................................................................................458
Grid Coupling Installation.........................................................................................................................................................................................................................................459
Seal Replacement without Hub Removal...............................................................................................................................................................................................................................462
Grid Coupling Alignment............................................................................................................................................................................................................................................464
Gear Couplings.........................................................................................................................................................................................................................................................465
Coupling Installation..............................................................................................................................................................................................................................................465
Gear Coupling Alignment............................................................................................................................................................................................................................................467
Hoist Coupling Shaft Alignment.....................................................................................................................................................................................................................................468
Circulation Pump Coupling Alignment................................................................................................................................................................................................................................469
Flushing/pdt Lube Motor - Coupling Alignment.......................................................................................................................................................................................................................470
Hydraulic Crowd Motor To Pdt Coupling Alignment....................................................................................................................................................................................................................470
Digital Tachometer Coupling........................................................................................................................................................................................................................................473
Compressed Air System......................................................................................................................................................................................................................................................477
Air Compressor.............................................................................................................................................................................................................................................................477
Lockout Valves.........................................................................................................................................................................................................................................................479
Safety Warnings........................................................................................................................................................................................................................................................481
Air Filtration.............................................................................................................................................................................................................................................................485
House Filter Fans..........................................................................................................................................................................................................................................................485
Lubrication............................................................................................................................................................................................................................................................486
Dynavane Air Cleaner...................................................................................................................................................................................................................................................487
Air Conditioner............................................................................................................................................................................................................................................................488
Specifications.........................................................................................................................................................................................................................................................489
Engineering Data...........................................................................................................................................................................................................................................................495
Capscrew (Bolt) Grade......................................................................................................................................................................................................................................................495
Bolt Tightening........................................................................................................................................................................................................................................................495
Torque Wrench Method...............................................................................................................................................................................................................................................495
Turn-of-nut Method.................................................................................................................................................................................................................................................497
Measurement Systems........................................................................................................................................................................................................................................................499
Linear Measurements....................................................................................................................................................................................................................................................499
Area Measurements......................................................................................................................................................................................................................................................499
Volume Measurements....................................................................................................................................................................................................................................................500
Torque Measurements....................................................................................................................................................................................................................................................501
Weight Measurements - Conventional.................................................................................................................................................................................................................................502
Split Flange Assembly Procedure............................................................................................................................................................................................................................................503
Wire Locking Capscrews.....................................................................................................................................................................................................................................................505
Torque Nut Installation....................................................................................................................................................................................................................................................506
Expansion Bolt Installation................................................................................................................................................................................................................................................506
Tightening Procedure for 1.25-Inch Torque Nut..........................................................................................................................................................................................................................507
Tightening Procedure for 1.5-Inch Torque Nut...........................................................................................................................................................................................................................508
Tightening Procedure for 2-Inch Torque Nut.............................................................................................................................................................................................................................509
Tightening Procedure for 2-Inch Torque Nut.............................................................................................................................................................................................................................510
Tightening Procedure for 3.5-Inch Torque Nut...........................................................................................................................................................................................................................511
Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods.....................................................................................................................................................................................................512
Initial Tensioning.................................................................................................................................................................................................................................................512
Final Tensioning...................................................................................................................................................................................................................................................512
Tightening Procedures - Expansion Bolts................................................................................................................................................................................................................................514
Rack & Roller Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut.....................................................................................................................................................................................................514
Hoist Torque Rod, Tapered Sleeve & 1.62 Inch Torque Nut............................................................................................................................................................................................................515
Swing Torque Rod & Tapered Sleeve & 3.25 Inch Torque Nut...........................................................................................................................................................................................................517
Torque Nut Removal Procedure...............................................................................................................................................................................................................................................519
Thread Lubrication.....................................................................................................................................................................................................................................................519
Torque Nut Helpful Hints...................................................................................................................................................................................................................................................520
Locking Assemblies.........................................................................................................................................................................................................................................................520
Installation, Series B115..............................................................................................................................................................................................................................................520
Removal, Series B115...................................................................................................................................................................................................................................................521
Locking Assembly Removal...............................................................................................................................................................................................................................................522
Pinion and Hub Installation............................................................................................................................................................................................................................................523
Removal from a Shaft...................................................................................................................................................................................................................................................523
Mounting a Pinion or Hub on a Shaft....................................................................................................................................................................................................................................523
Pre-heat Advance Requirements - Pinions and Hubs...................................................................................................................................................................................................................526
Motor Coupling Pre-Heat Advance Requirements.......................................................................................................................................................................................................................526
Maintenance Welding........................................................................................................................................................................................................................................................528
Welding Electrodes.....................................................................................................................................................................................................................................................529
Repair Welding of Cracks...............................................................................................................................................................................................................................................530
Preheat............................................................................................................................................................................................................................................................531
Welding Technique..................................................................................................................................................................................................................................................531
Repair Welding of Broken Parts.........................................................................................................................................................................................................................................532
Repair Welding Swing Rack Teeth........................................................................................................................................................................................................................................533
Preparation........................................................................................................................................................................................................................................................533
Swing Rack Welding Electrodes......................................................................................................................................................................................................................................533
1. All welding is to be done using oven dry E11018-M low hydrogen electrodes. Connect an electrode drying oven as close as possible to the work area. Set the oven temperature at 300°F (149°C). As sealed containers of electrodes are opened, place th.......533
Preheat............................................................................................................................................................................................................................................................533
Welding Procedure..................................................................................................................................................................................................................................................535
Welding and Cutting Equipment..........................................................................................................................................................................................................................................537
Stress Relieving & Temperature Measuring Equipment.....................................................................................................................................................................................................................538
Wire Rope Care and Maintenance.............................................................................................................................................................................................................................................539
Storage................................................................................................................................................................................................................................................................539
Checking Diameter......................................................................................................................................................................................................................................................539
Handling Wire Rope.....................................................................................................................................................................................................................................................540
Seizing Wire Rope......................................................................................................................................................................................................................................................541
End Preparations/Terminations..........................................................................................................................................................................................................................................543
Wire Rope Clips........................................................................................................................................................................................................................................................543
Wire Rope Clip Application.........................................................................................................................................................................................................................................543
Wedge Sockets......................................................................................................................................................................................................................................................545
Inspection of Sheaves and Drums........................................................................................................................................................................................................................................546
Breaking In a New Wire Rope............................................................................................................................................................................................................................................547
Inspection Data........................................................................................................................................................................................................................................................548
Guideline to Inspections and Reports...................................................................................................................................................................................................................................549
Wire Rope Inspection Criteria......................................................................................................................................................................................................................................550
Reduction in Rope Diameter.....................................................................................................................................................................................................................................550
Rope Stretch...................................................................................................................................................................................................................................................551
Abrasion.......................................................................................................................................................................................................................................................552
Corrosion......................................................................................................................................................................................................................................................552
Kinks..........................................................................................................................................................................................................................................................552
Bird Caging....................................................................................................................................................................................................................................................552
Localized Conditions...........................................................................................................................................................................................................................................552
Heat Damage....................................................................................................................................................................................................................................................552
Protruding Core................................................................................................................................................................................................................................................552
Damaged End Attachments........................................................................................................................................................................................................................................553
Peening........................................................................................................................................................................................................................................................553
Scrubbing......................................................................................................................................................................................................................................................553
Fatigue Fracture...............................................................................................................................................................................................................................................553
Broken Wires...................................................................................................................................................................................................................................................553
Electric Arc...................................................................................................................................................................................................................................................554
Seals......................................................................................................................................................................................................................................................................554
Seal Installation......................................................................................................................................................................................................................................................555
Gearcase Sealing.......................................................................................................................................................................................................................................................556
Hydraulic Crowd Service Procedures.........................................................................................................................................................................................................................................561
Hydraulic System Cleanliness...............................................................................................................................................................................................................................................561
Hydraulic System Oil Contamination Guide...................................................................................................................................................................................................................................562
Crowd Machinery Overview...............................................................................................................................................................................................................................................563
Hydraulic Crowd Cylinder Overview..........................................................................................................................................................................................................................................564
Cylinder Control Manifold Overview.........................................................................................................................................................................................................................................565
Auxiliary Power Unit Overview..............................................................................................................................................................................................................................................568
Power Module/lower Tank Overview...........................................................................................................................................................................................................................................569
Lower Tank, Crowd Motor, Transmission & Pumps Overview.....................................................................................................................................................................................................................570
Flushing/pdt Lube Motor Overview...........................................................................................................................................................................................................................................571
Circulation Filter Overview................................................................................................................................................................................................................................................572
Manifolds Overview.........................................................................................................................................................................................................................................................573
Oil Circulation Manifold Overview..........................................................................................................................................................................................................................................574
Pump Control Manifold Overview.............................................................................................................................................................................................................................................575
Upper Hydraulic Tank Overview..............................................................................................................................................................................................................................................576
Oil Circulation Pump Overview..............................................................................................................................................................................................................................................578
Isolator Tank Overview.....................................................................................................................................................................................................................................................579
Oil Cooler & Plumbing Overview.............................................................................................................................................................................................................................................580
Hydraulic Crowd Sensor Locations...........................................................................................................................................................................................................................................581
Cylinder Sensors.......................................................................................................................................................................................................................................................581
Power Module Sensors...................................................................................................................................................................................................................................................582
Upper Hydraulic Tank Sensors...........................................................................................................................................................................................................................................586
Pump Control Manifold Sensor...........................................................................................................................................................................................................................................587
Auxiliary Power Unit Sensor............................................................................................................................................................................................................................................588
Inspection.................................................................................................................................................................................................................................................................589
Pdt Leak Inspection........................................................................................................................................................................................................................................................589
Circulation Plumbing Inspection............................................................................................................................................................................................................................................590
Oil Circulation Pump Inspection............................................................................................................................................................................................................................................592
Isolator Troubleshooting...................................................................................................................................................................................................................................................592
Isolator Tank Inspection...................................................................................................................................................................................................................................................593
Isolator Manifold Inspection...............................................................................................................................................................................................................................................594
Vacuum Breaker Inspection..................................................................................................................................................................................................................................................595
Isolator Plumbing Inspection...............................................................................................................................................................................................................................................596
Service Procedures.........................................................................................................................................................................................................................................................597
Hydraulic Crowd Start-up Procedure.........................................................................................................................................................................................................................................597
Standard System Flushing & Filtration......................................................................................................................................................................................................................................598
Complete System Flushing & Filtration......................................................................................................................................................................................................................................600
Initial System Oil Fill....................................................................................................................................................................................................................................................602
System Top Off.............................................................................................................................................................................................................................................................604
System Oil Drain - Partial.................................................................................................................................................................................................................................................606
System Oil Drain - Complete................................................................................................................................................................................................................................................607
Auxiliary Power Unit Fill & Filter Replacement.............................................................................................................................................................................................................................610
Pdt - Initial Oil Fill.....................................................................................................................................................................................................................................................612
Pdt - Oil Top Off..........................................................................................................................................................................................................................................................613
Pdt - Oil Level Check......................................................................................................................................................................................................................................................614
Pdt - Oil Drain............................................................................................................................................................................................................................................................615
Hydraulic Crowd Cooler Cleaning............................................................................................................................................................................................................................................616
Purging The Main Pumps.....................................................................................................................................................................................................................................................617
Hydraulic System Prefill Filter Replacement................................................................................................................................................................................................................................618
Upper Tank Return Filter Cleaning & Replacement............................................................................................................................................................................................................................619
Isolator Removal And Replacement...........................................................................................................................................................................................................................................621
Isolator Draining..........................................................................................................................................................................................................................................................622
Circulation Filter Replacement.............................................................................................................................................................................................................................................623
Boom Pressure Hose Removal & Installation..................................................................................................................................................................................................................................624
Pressure Hose Positioning..................................................................................................................................................................................................................................................627
Boom Return Hose Removal & Installation....................................................................................................................................................................................................................................628
Return Hose Positioning....................................................................................................................................................................................................................................................631
Main Pump Pressure Hose Removal & Installation.............................................................................................................................................................................................................................632
Hydraulic Crowd Service Schedule.......................................................................................................................................................................................................................................635
Schematics.................................................................................................................................................................................................................................................................638
Schematics.................................................................................................................................................................................................................................................................638
Side View..................................................................................................................................................................................................................................................................639
Deck Plan..................................................................................................................................................................................................................................................................640
OGL System A & B Schematic.................................................................................................................................................................................................................................................641
Grease System C Schematic..................................................................................................................................................................................................................................................642
Air Schematic..............................................................................................................................................................................................................................................................643
Hydraulic Crowd Troubleshooting Schematics.................................................................................................................................................................................................................................644
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CAT ELECTRIC ROPE SHOVEL 495HF MINING SHOVEL MAINTENANCE AND OPERATION MANUAL – PDF DOWNLOAD:
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Cat Electric Rope Shovel 495HF Mining Shovel Maintenance And Operation Manual – PDF DOWNLOAD
Cat Electric Rope Shovel 495HF Mining Shovel Maintenance And Operation Manual – PDF DOWNLOAD
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