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

Description

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

DESCRIPTION:

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

SN: 141322
Bucyrus International, Inc.
SN: 141425
SN: 141440
SN: 141449
Manual No. 10940

Introduction

GENERAL INFORMATION

• This manual is designed to assist the owner in the operation and maintenance of this machine. By following easy to understand step-by-step procedures the operators and maintenance personnel can perform all tasks in a safe manner.
• When a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.
• Throughout this section, and the remainder of the manual, the use of the terms “LEFT, RIGHT, FRONT, and REAR” refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.
• THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied for this purpose. Periodic additions or revisions may be made to this manual. Should you require additional information or factory service assistance contact your regional service representative or:

Bucyrus International, Inc.
1100 Milwaukee Avenue
P.O. Box 500
South Milwaukee, Wisconsin, USA 53172-0500
Telephone (414)-768-4000

It is the policy of Bucyrus International, Inc. to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations to install such changes on machines sold previously. Due to this ongoing program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve our machines

TABLE OF CONTENTS:

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

SAFETY
SAFETY PRECAUTIONS s-ii
GENERAL PRECAUTIONS s-iii
MAINTENANCE PRECAUTIONS s-iv
OPERATING PRECAUTIONS s-v
FIRE PREVENTION s-vi
WARNING SIGNS AND DECALS s-vii
SECTION 1 – INTRODUCTION
GENERAL INFORMATION 1-3
SWINGING RESTRAINT & BALLAST BOX SUPPORT 1-4
BALLAST BOX SUPPORT 1-4
SWINGING RESTRAINT 1-5
MACHINE OVERVIEW 1-7
LOWER WORKS 1-8
CRAWLERS 1-9
TRUCK FRAME 1-10
SWING RACK 1-11
ROLLER CIRCLE 1-12
PROPEL MACHINERY 1-13
COLLECTOR RINGS 1-14
ROTATING DECK 1-15
REVOLVING FRAME 1-15
CENTER PINTLE 1-15
DECK EXTENSIONS 1-17
BALLAST BOX 1-17
EM021121
Bucyrus International, Inc
495HR Electric Mining Shovel
Manual No 10940 T – II August 2010
MACHINERY HOUSE 1-17
BOARDING STAIRS 1-18
A-FRAME 1-20
HOIST MACHINERY 1-21
SWING MACHINERY 1-22
CROWD MACHINERY 1-23
OPERATOR’S CAB 1-24
COMPRESSED AIR SYSTEM 1-25
AUTOMATIC LUBRICATION SYSTEM 1-26
LUBE RESERVOIR FILL / OVERFLOW PLUMBING 1-27
FRONT END EQUIPMENT 1-28
SUSPENSION STRANDS 1-28
BOOM 1-29
RUNNING ROPES 1-30
SADDLE BLOCK 1-31
DIPPER HANDLE 1-32
DIPPER 1-33
PADLOCKS 1-34
DIPPER TRIP 1-35
TYPICAL MACHINE SPECIFICATIONS 1-36
GENERAL ESTIMATED COMPONENT WEIGHTS 1-38
LOWER WORKS 1-38
UPPER WORKS 1-39
FRONT END 1-41
SECTION 2 – OPERATION
GENERAL INFORMATION 2-5
OPERATION NEAR ELECTRICAL LINES 2-5
OPERATOR’S SEAT 2-7
ADJUSTABLE ARMREST 2-7
ADJUSTABLE FOOTREST 2-8
CONTROLS 2-9
PRIMARY OPERATING CONTROLS 2-9
CONTROLS ON THE LEFT CONSOLE 2-10
LEFT JOYSTICK 2-11
DIPPER TRIP 2-11
SIGNAL HORN 2-11
START PUSHBUTTON 2-11
PLC POWER ON 2-12
DRIVE CABINET TEMPERATURE 2-12
INCOMPLETE SEQUENCE 2-12
SYSTEM READY 2-12
PHASE SEQUENCE 2-12
AUXILIARY GROUND FAULT 2-12
HOIST BRAKE 2-12
CROWD BRAKE 2-12
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Bucyrus International, Inc
495HR Electric Mining Shovel
August 2010 T – III Manual No 10940
SWING BRAKE 2-12
PROPEL BRAKE 2-12
HVAC UNIT SELECTOR 2-12
TEMPERATURE 2-12
HVAC SYSTEM CONTROL 2-12
HVAC FAN SPEED 2-12
CABIN LIGHTS 2-12
CONTROLS ON THE RIGHT CONSOLE 2-13
RIGHT JOYSTICK 2-14
EMERGENCY STOP PUSHBUTTON 2-15
WINDSHIELD WIPER SWITCHES 2-15
CONTROL STOP PUSHBUTTON 2-15
CONTROL RESET PUSHBUTTON 2-15
AIR COMPRESSOR 2-16
DIG/PROPEL TRANSFER SWITCH 2-16
MAIN POWER OFF PUSHBUTTON 2-16
EARTH CONTINUITY LOCKOUT PUSHBUTTON 2-16
SEAT POSITION 2-16
RADIO RECEIVER WITH CD CHANGER 2-17
OPERATOR’S DISPLAY 2-17
DISPLAY AREA AND INDICATORS 2-18
DISPLAY SCREENS 2-18
LUBRICATION CONTROL PANEL 2-25
FIRE SUPPRESSION SYSTEM 2-26
PRE-START CHECKS 2-26
WALK-AROUND GROUND LEVEL INSPECTION 2-27
ON-BOARD INSPECTION 2-28
START-UP, OPERATION AND SHUTDOWN 2-29
MACHINE START-UP 2-29
RESTARTING AFTER AN ELECTRICAL FAULT 2-30
MACHINE OPERATION 2-30
MACHINERY MOTIONS 2-31
HOIST MOTION 2-31
CROWD MOTION 2-32
PROPEL MOTION 2-33
SWING MOTION 2-34
PROPER SWING MOTION 2-35
STEERING 2-36
COUNTER-ROTATION TURNS 2-38
POSITIONING THE MACHINE 2-39
BACK-UP METHOD 2-39
DRIVE-BY METHOD 2-40
START OF THE DIG CYCLE 2-41
ENGAGING THE BANK 2-43
SLOPE LIMITATIONS 2-45
EXCAVATED MATERIAL 2-48
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Bucyrus International, Inc
495HR Electric Mining Shovel
Manual No 10940 T – IV August 2010
OPERATION CHECKS 2-48
OPERATING HINTS 2-49
STOPPING THE MACHINE 2-50
SHUTDOWN 2-50
SECTION 3 – LUBRICATION
LUBRICATION PRINCIPLES 3-3
GREASING MAIN A C DRIVE MOTORS 3-4
1 TYPE OF GREASE 3-4
2 INITIAL COMMISSIONING 3-4
3 MAINTENANCE 3-4
4 REGREASING INTERVALS 3-5
LUBRICANT SELECTION 3-5
OIL FILL CAPACITIES 3-7
TYPES OF LUBRICANTS AND CAPACITIES GUIDELINES 3-7
QUANTITIES FOR FIRST FILL OF LUBRICANTS 3-7
AUTOMATIC LUBRICATION SYSTEM 3-8
LUBE ROOM 3-9
LUBE RESERVOIR FILL / OVERFLOW PLUMBING 3-10
AUTO LUBE CONTROL PANEL 3-11
LOWER WORKS LUBRICATION 3-11
PROPEL MACHINERY LUBRICATION 3-12
LUBRICANT REPLACEMENT/SAMPLING 3-13
LUBRICANT CHANGE CYCLE 3-13
REVOLVING FRAME LUBRICATION 3-14
HOIST MACHINERY LUBRICATION 3-15
HOIST OIL COOLER 3-16
FILTER ELEMENT CLEANING 3-19
HOIST ROPE ROLLERS LUBRICATION 3-20
OIL PUMP 3-21
CROWD MACHINERY LUBRICATION 3-22
SWING MACHINERY LUBRICATION 3-23
AIR COMPRESSOR LUBRICATION 3-24
CROWD ROPE TAKE-UP MECHANISM LUBRICATION 3-25
FRONT END LUBRICATION 3-25
LINCOLN TYPE SL-1 LUBRICANT INJECTORS 3-27
SL-1 LUBRICANT INJECTOR OPERATION 3-29
INJECTOR ADVANTAGES 3-31
ACSL – AIR COMPRESSOR (SCREW-TYPE) LUBRICANT 3-32
MPO – MULTIPURPOSE OIL 3-33
RWRL – RUNNING WIRE ROPE LUBRICANT 3-34
EGL – ENCLOSED GEARCASE LUBRICANT 3-35
MPG – MULTIPURPOSE GREASE 3-38
OGL – OPEN GEAR LUBRICANT 3-42
CERTIFIED LUBRICANTS LISTING 3-46
EM021121
Bucyrus International, Inc
495HR Electric Mining Shovel
August 2010 T – V Manual No 10940
SECTION 4 – PREVENTIVE MAINTENANCE
INTRODUCTION 4-3
PREVENTIVE MAINTENANCE PROGRAM 4-3
ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM 4-4
SCHEDULED PREVENTIVE MAINTENANCE PROGRAM 4-5
GENERAL SAFETY CONSIDERATIONS 4-5
MAINTENANCE DURING MACHINE OPERATION 4-6
MAINTENANCE PRECAUTIONS 4-7
PREVENTIVE MAINTENANCE FOR LUBRICATION 4-8
LUBRICANT CLEANLINESS 4-9
FREQUENCY OF INSPECTION AND MAINTENANCE 4-10
MAINTENANCE SCHEDULES 4-10
MAINTENANCE INSPECTION CHECK POINTS 4-10
DAILY 4-11
EVERY 100 HOURS OR WEEKLY 4-14
EVERY 500 HOURS OR MONTHLY 4-15
EVERY 1250 HOURS OR QUARTERLY 4-18
EVERY 2500 HOURS OR SEMI-ANNUALLY 4-21
5000 HOURS OR ANNUALLY 4-23
MAJOR COMPONENT LOCATIONS 4-25
SECTION 5 – SERVICE PROCEDURES
LOWER WORKS 5-7
TRUCK FRAME ASSEMBLY 5-7
SWING RACK ASSEMBLY 5-8
ROLLER CIRCLE RAIL REPLACEMENT – LOWER 5-8
ROLLER CIRCLE RAIL REPLACEMENT – UPPER 5-9
ROLLER CIRCLE ASSEMBLY 5-11
ROLLER CIRCLE ADJUSTMENT 5-13
ADJUSTMENT PROCEDURE 5-13
RUN-IN PROCEDURE FOR THE ROLLER CIRCLE 5-13
ROLLER CIRCLE SEGMENT REMOVAL 5-14
ROLLER CIRCLE – ROLLER REPLACEMENT 5-15
CRAWLER BELTS 5-16
CRAWLER BELT MAINTENANCE 5-16
CRAWLER BELT TENSION ADJUSTMENT 5-18
CRAWLER SHOE REPLACEMENT 5-20
CRAWLER BELT REPLACEMENT 5-21
CRAWLER SIDE FRAME ASSEMBLY 5-22
CRAWLER SIDE FRAME MAINTENANCE 5-23
SLIDE BAR REPLACEMENT 5-24
CRAWLER FRONT IDLER ROLLER ASSEMBLY 5-25
LOAD AND IDLER ROLLERS 5-28
ROLLER REMOVAL OR REPLACEMENT 5-28
PROPEL ASSEMBLY 5-31
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Bucyrus International, Inc
495HR Electric Mining Shovel
Manual No 10940 T – VI August 2010
INSTALLATION NOTES 5-33
MAIN PROPEL DRIVE SHAFT REMOVAL 5-34
MAIN PROPEL SHAFT – DISASSEMBLY 5-37
TUMBLER REBUILD PROCEDURE 5-38
PROPEL MACHINERY 5-40
PROPEL GEARCASE REMOVAL 5-41
PROPEL GEARCASE INSTALLATION 5-42
PROPEL PLANETARY GEARCASE 5-44
PROPEL MOTORS 5-45
PROPEL MOTOR REMOVAL 5-45
PROPEL MOTOR INSTALLATION 5-47
REVOLVING FRAME 5-48
CENTER PINTLE 5-48
CENTER PINTLE ADJUSTMENT 5-54
CENTER PINTLE SLEEVE REMOVAL 5-54
COLLECTOR RINGS 5-56
COLLECTOR RING INSPECTION 5-57
COLLECTOR RING REPAIR 5-57
ROTATING DECK 5-57
SWING MACHINERY 5-58
SWING SUPPORT MOUNTING BOLTS 5-60
SWING MOTOR 5-60
SWING BLOWER 5-60
SWING MOTOR REMOVAL 5-61
SWING MOTOR INSTALLATION 5-61
SWING PLANETARY GEARCASE 5-62
SWING GEARCASE REMOVAL 5-63
GEARCASE INSPECTION 5-64
SWING PINION SHAFTS 5-65
SWING PINION SHAFT REMOVAL 5-66
SWING PINION SHAFT DISASSEMBLY 5-67
SWING PINION SHAFT ASSEMBLY 5-68
SWING PINION SHAFT INSTALLATION 5-69
HOIST MACHINERY 5-70
HOIST MOTOR REMOVAL 5-71
MOTOR COUPLING SHAFT 5-74
HOIST GEARCASE ASSEMBLY 5-75
HOIST GEARCASE REPAIR 5-79
HOIST DRUM ASSEMBLY 5-82
HOIST GEAR REPLACEMENT 5-84
BEARING REMOVAL 5-86
BEARING INSTALLATION 5-87
HOIST OIL COOLER 5-89
HOIST MOUNTING BOLTS 5-90
HOIST LIMIT SWITCH 5-91
CROWD MACHINERY 5-92
EM021121
Bucyrus International, Inc
495HR Electric Mining Shovel
August 2010 T – VII Manual No 10940
GEARCASE REPAIR 5-94
CROWD GEARCASE DISASSEMBLY 5-94
CROWD GEARCASE ASSEMBLY 5-97
CROWD MOTOR 5-98
CROWD GEAR AND DRUM 5-100
CROWD DRUM REMOVAL 5-100
OPERATOR’S CAB MOUNTING 5-102
OPERATOR’S SEAT INSTALLATION 5-103
FOOTREST INSTALLATION 5-105
MACHINERY HOUSE 5-106
WALKWAYS, STAIRWAYS, AND HANDRAILS 5-107
BOARDING STAIRS 5-108
FRONT END EQUIPMENT 5-111
BOOM ASSEMBLY 5-112
BOOM REPAIR 5-113
BOOM LIMIT SWITCH INSTALLATION 5-114
BOOM POINT SHEAVES 5-116
BOOM POINT SHEAVE REMOVAL AND DISASSEMBLY 5-117
BOOM POINT SHEAVE REASSEMBLY AND INSTALLATION 5-119
BOOM BUMPER 5-120
SADDLE BLOCK 5-121
SADDLE BLOCK REPAIR 5-121
SADDLE BLOCK REMOVAL 5-122
DIPPER HANDLE 5-124
DIPPER HANDLE REMOVAL 5-126
CROWD ROPE TAKE-UP MECHANISM 5-128
CROWD ROPE TAKE-UP MECHANISM DISASSEMBLY 5-129
CROWD ROPE TAKE-UP MECHANISM ASSEMBLY 5-131
RETRACT ROPE TAKE-UP MECHANISM 5-133
SPREADER REPAIR 5-135
DIPPER ASSEMBLY 5-136
LATCH BAR ADJUSTING 5-139
DIPPER DOOR BUMPERS 5-140
DIPPER REMOVAL & INSTALLATION 5-141
DIPPER DOOR SNUBBERS 5-146
SNUBBER ADJUSTMENT 5-147
ALLOWABLE WEAR 5-147
DIPPER PITCH BRACE 5-148
DIPPER PADLOCK 5-149
DIPPER TRIP ASSEMBLY 5-152
A-FRAME 5-153
AUXILIARY WINCH 5-155
HOIST ROPE SUPPORT ROLLER 5-156
BOOM SUPPORT ROPES 5-157
WIRE ROPES 5-158
WIRE ROPE INSPECTION 5-159
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Bucyrus International, Inc
495HR Electric Mining Shovel
Manual No 10940 T – VIII August 2010
CROWD ROPE TAKE-UP HYDRAULIC UNIT 5-160
HOIST ROPE REEVING & REPLACEMENT 5-162
CROWD ROPE REEVING & REPLACEMENT 5-166
RETRACT ROPE REEVING & REPLACEMENT 5-168
CROWD ROPE TIGHTENING 5-172
RETRACT ROPE TIGHTENING 5-174
DIPPER TRIP ROPE REEVING & REPLACEMENT 5-175
HOIST AND CROWD LIMIT SYSTEMS 5-175
SETTING LIMITS IN THE HOIST & CROWD SYSTEM 5-176
CROWD SLOWDOWN/STOP LIMITS 5-178
RETRACT SLOWDOWN/STOP LIMITS 5-179
LOWER SLOWDOWN/STOP LIMITS 5-180
HOIST SLOWDOWN/STOP LIMITS 5-181
SECTION 6 – BRAKES AND COUPLINGS
BRAKES 6-3
DISC BRAKE OPERATION 6-4
MAINTENANCE 6-4
BRAKE ADJUSTMENT SPECIFICATIONS 6-4
HOIST BRAKE 6-5
HOIST BRAKE ADJUSTMENT 6-7
HOIST BRAKE INSTALLATION 6-9
HOIST BRAKE WEAR & RELEASE SWITCHES 6-9
CROWD BRAKE 6-10
CROWD BRAKE INSTALLATION 6-12
CROWD BRAKE WEAR & RELEASE SWITCHES 6-14
PROPEL BRAKE 6-15
PROPEL BRAKE ADJUSTMENT 6-17
PROPEL BRAKE INSTALLATION 6-19
TACHOMETER MOUNTING & ALIGNMENT 6-21
SWING BRAKE 6-23
SWING BRAKE INSTALLATION 6-25
SWING BRAKE WEAR & RELEASE SWITCHES 6-26
SWING BRAKE BURNISHING 6-27
SPRING REPLACEMENT — ALL BRAKES 6-27
FRICTION DISC REPLACEMENT — ALL BRAKES 6-29
O-RING REPLACEMENT — ALL BRAKES 6-30
BRAKE WEAR & RELEASE SWITCHES — SINGLE DISC BRAKES 6-32
BRAKE WEAR & RELEASE SWITCHES — MULTIPLE DISC BRAKES 6-33
COUPLINGS 6-34
GRID COUPLINGS 6-34
LUBRICATION 6-34
COUPLING DISASSEMBLY AND GRID REMOVAL 6-35
GRID COUPLING INSTALLATION 6-36
SEAL REPLACEMENT WITHOUT HUB REMOVAL 6-39
GRID COUPLING ALIGNMENT 6-41
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Bucyrus International, Inc
495HR Electric Mining Shovel
August 2010 T – IX Manual No 10940
GEAR COUPLINGS 6-42
COUPLING INSTALLATION 6-42
GEAR COUPLING ALIGNMENT 6-44
HOIST COUPLING SHAFT ALIGNMENT 6-45
SECTION 7 – COMPRESSED AIR SYSTEM
AIR COMPRESSOR 7-3
LOCKOUT VALVES 7-5
SAFETY WARNINGS 7-7
SECTION 8 – AIR FILTRATION
HOUSE FILTER FANS 8-3
LUBRICATION 8-4
DYNAVANE AIR CLEANER 8-5
AIR CONDITIONER 8-6
SPECIFICATIONS 8-7
SECTION 9 – ENGINEERING DATA
CAPSCREW (BOLT) GRADE 9-5
BOLT TIGHTENING 9-5
TORQUE WRENCH METHOD 9-5
TURN-OF-NUT METHOD 9-7
MEASUREMENT SYSTEMS 9-9
LINEAR MEASUREMENTS 9-9
AREA MEASUREMENTS 9-9
VOLUME MEASUREMENTS 9-10
TORQUE MEASUREMENTS 9-11
WEIGHT MEASUREMENTS – CONVENTIONAL 9-12
SPLIT FLANGE ASSEMBLY PROCEDURE 9-13
WIRE LOCKING CAPSCREWS 9-15
TORQUE NUT INSTALLATION 9-16
TIGHTENING PROCEDURE FOR 1 25-INCH TORQUE NUT 9-17
TIGHTENING PROCEDURE FOR 2-INCH TORQUE NUT 9-18
TIGHTENING PROCEDURE FOR 2-INCH TORQUE NUT 9-19
TIGHTENING PROCEDURE FOR 2 5-INCH TORQUE NUT 9-20
TIGHTENING PROCEDURE FOR 3-INCH TORQUE NUT 9-21
TIGHTENING PROCEDURE FOR 3 5-INCH TORQUE NUT 9-22
PROCEDURE FOR USE OF MECHANICAL TENSIONER ON CRAWLER RODS 9-23
INITIAL TENSIONING 9-23
FINAL TENSIONING 9-23
EXPANSION BOLT INSTALLATION 9-25
TIGHTENING PROCEDURES – EXPANSION BOLTS 9-25
HOIST TORQUE ROD, TAPERED SLEEVE & 1 0 INCH TORQUE NUT 9-25
RACK & ROLLER TORQUE ROD, TAPERED SLEEVE & 1 5 INCH TORQUE NUT 9-27
SWING TORQUE ROD & TAPERED SLEEVE & 3 5 INCH TORQUE NUT 9-28
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Bucyrus International, Inc
495HR Electric Mining Shovel
Manual No 10940 T – X August 2010
TORQUE NUT REMOVAL PROCEDURE 9-30
THREAD LUBRICATION 9-30
TORQUE NUT HELPFUL HINTS 9-31
LOCKING ASSEMBLIES 9-32
LOCKING ASSEMBLY REMOVAL 9-34
PINION AND HUB INSTALLATION 9-35
REMOVAL FROM A SHAFT 9-35
MOUNTING A PINION OR HUB ON A SHAFT 9-35
PRE-HEAT ADVANCE REQUIREMENTS – PINIONS AND HUBS 9-38
MOTOR COUPLING PRE-HEAT ADVANCE REQUIREMENTS 9-38
MAINTENANCE WELDING 9-40
WELDING ELECTRODES 9-41
REPAIR WELDING OF CRACKS 9-42
PREHEAT 9-43
WELDING TECHNIQUE 9-43
REPAIR WELDING OF BROKEN PARTS 9-44
REPAIR WELDING SWING RACK TEETH 9-45
PREPARATION 9-45
SWING RACK WELDING ELECTRODES 9-45
PREHEAT 9-45
WELDING PROCEDURE 9-47
WELDING AND CUTTING EQUIPMENT 9-49
STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT 9-50
WIRE ROPE CARE AND MAINTENANCE 9-51
STORAGE 9-51
CHECKING DIAMETER 9-51
HANDLING WIRE ROPE 9-52
SEIZING WIRE ROPE 9-53
END PREPARATIONS/TERMINATIONS 9-55
WIRE ROPE CLIPS 9-55
WIRE ROPE CLIP APPLICATION 9-55
WEDGE SOCKETS 9-57
INSPECTION OF SHEAVES AND DRUMS 9-58
BREAKING IN A NEW WIRE ROPE 9-59
INSPECTION DATA 9-60
GUIDELINE TO INSPECTIONS AND REPORTS 9-61
WIRE ROPE INSPECTION CRITERIA 9-62
REDUCTION IN ROPE DIAMETER 9-62
ROPE STRETCH 9-63
ABRASION 9-64
CORROSION 9-64
KINKS 9-64
BIRD CAGING 9-64
LOCALIZED CONDITIONS 9-64
HEAT DAMAGE 9-64
PROTRUDING CORE 9-64
EM021121
Bucyrus International, Inc
495HR Electric Mining Shovel
August 2010 T – XI Manual No 10940
DAMAGED END ATTACHMENTS 9-65
PEENING 9-65
SCRUBBING 9-65
FATIGUE FRACTURE 9-65
BROKEN WIRES 9-65
ELECTRIC ARC 9-66
SEALS 9-66
SEAL INSTALLATION 9-67
GEARCASE SEALING 9-68
SECTION 10 – SCHEMATICS
SCHEMATICS 10-2
SIDE VIEW 10-3
DECK PLAN 10-4
OGL SYSTEM A & B SCHEMATIC 10-5
GREASE SYSTEM C SCHEMATIC 10-6
AIR SCHEMATIC 10-7
Table of Contents
GENERAL INFORMATION 1-3
SWINGING RESTRAINT & BALLAST BOX SUPPORT 1-4
BALLAST BOX SUPPORT 1-4
SWINGING RESTRAINT 1-5
MACHINE OVERVIEW 1-7
Figure 1-1: Nomenclature 1-7
LOWER WORKS 1-8
Figure 1-2: Truck Frame and Crawlers 1-8
CRAWLERS 1-9
Figure 1-3: Right Crawler Assembly (Left Opposite) 1-9
TRUCK FRAME 1-10
SWING RACK 1-11
Figure 1-4: Swing Rack and Roller Circle 1-11
ROLLER CIRCLE 1-12
Figure 1-5: Roller Circle Assembly 1-12
PROPEL MACHINERY 1-13
COLLECTOR RINGS 1-14
ROTATING DECK 1-15
REVOLVING FRAME 1-15
CENTER PINTLE 1-15
DECK EXTENSIONS 1-17
Figure 1-6: Deck Extensions and Ballast Box 1-17
BALLAST BOX 1-17
MACHINERY HOUSE 1-17
BOARDING STAIRS 1-18
Figure 1-7: Right Hand Boarding Stairs 1-18
Figure 1-8: Left Hand Boarding Stairs 1-19
A-FRAME 1-20
Figure 1-9: A-Frame and Front End Support Components 1-20
HOIST MACHINERY 1-21
Figure 1-10: Hoist Machinery – Plan View 1-21
SWING MACHINERY 1-22
Figure 1-11: Swing Machinery Components 1-22
CROWD MACHINERY 1-23
Figure 1-12: Crowd Machinery Components 1-23
OPERATOR’S CAB 1-24
COMPRESSED AIR SYSTEM 1-25
AUTOMATIC LUBRICATION SYSTEM 1-26
Figure 1-13: Lubrication Room 1-26
LUBE RESERVOIR FILL / OVERFLOW PLUMBING 1-27
EM021121
Bucyrus International, Inc
495HR Electric Mining Shovel
Manual No 10940 1 – 2 August 2010
Figure 1-14: Lube Reservoir Fill / Overflow Plumbing 1-27
FRONT END EQUIPMENT 1-28
Figure 1-15: Front End Equipment 1-28
SUSPENSION STRANDS 1-28
BOOM 1-29
Figure 1-16: Boom Assembly 1-29
RUNNING ROPES 1-30
Figure 1-17: Ropes – General Arrangement 1-30
SADDLE BLOCK 1-31
Figure 1-18: Saddle Block Bushing Arrangement 1-31
DIPPER HANDLE 1-32
DIPPER 1-33
Figure 1-19: Dipper Assembly 1-33
PADLOCKS 1-34
Figure 1-20: Left and Right Padlocks 1-34
DIPPER TRIP 1-35
Figure 1-21: Dipper Trip Motor and Dipper Trip Sheave 1-35
TYPICAL MACHINE SPECIFICATIONS 1-36
Table 1-1: Weights 1-36
Table 1-2: Front End Equipment 1-36
Table 1-3: Rope Data 1-36
Table 1-4: Typical Dimensions and Working Ranges 1-37
GENERAL ESTIMATED COMPONENT WEIGHTS 1-38
LOWER WORKS 1-38
UPPER WORKS 1-39
FRONT END 1-41

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

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