CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM020701 – PDF DOWNLOAD
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CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM020701 – PDF DOWNLOAD
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CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM020701 – PDF DOWNLOAD
Safety symbols
- 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.
PRECAUTIONS
• The employment of qualified maintenance personnel, through a scheduled maintenance program, is the best way to minimize machine downtime and maximize productivity of equipment.
• Keep hands, feet and clothing away from rotating parts.
• Wear a hard hat, safety shoes and protective lenses at all times.
• Replace any and all safety and warning placards if they are defaced or removed from the
machine.
• Think before you act. Carelessness is one luxury the service person cannot afford.
• Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In
case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the
suggested method of cleanup.
• Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip
off of the hook if they are not functioning properly.
• If a heavy item begins to fall, let it fall, don’t try to catch it.
• Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep
tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.
• Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure
all spillage is cleaned up.
• Electrical cords and wet metal floors make a dangerous combination.
• Regularly inspect for any loose bolts or locking devices and properly secure them.
• Use extreme caution while working near any electrical lines or equipment whether it be high
or low voltage. Never attempt electrical repairs unless you are qualified.
• Check limit switches for proper operation.
• After servicing, be sure all tools, parts or servicing equipment are removed from the machine
and secured in an appropriate storage area.
• Mechanical Brakes are designed for use as static holding brakes only. Use as a motion
(dynamic) brake in emergency situations only.
• Use proper interior and exterior lighting.
• Install and maintain proper grounding and ground fault protection systems.
• Allow electrical inspection and maintenance to be performed only by a qualified electrician.
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TABLE OF CONTENTS:
CAT BUCYRUS 495 HR MINING SHOVEL MAINTENANCE & OPERATION MANUAL EM020701 – PDF DOWNLOAD
Safety Precautions........................................................ 4 General Precautions................................................... 5 Maintenance Precautions............................................... 6 Operating Precautions................................................. 7 Fire Prevention....................................................... 8 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......................................................... 39 Deck Extensions....................................................... 41 Ballast Box........................................................... 41 Machinery House....................................................... 41 Boarding Stairs................................................... 42 Vertical Boarding Ladder.......................................... 43 A-Frame............................................................... 44 Hoist Machinery....................................................... 45 Swing Machinery....................................................... 46 Crowd Machinery....................................................... 47 OPERATOR’S CAB........................................................ 48 Compressed Air System................................................. 49 Automatic Lubrication System.......................................... 50 Lube Reservoir fill / Overflow Plumbing............................... 51 Front End Equipment....................................................... 52 Suspension Strands.................................................... 52 Boom.................................................................. 53 Running Ropes......................................................... 54 Saddle Block.......................................................... 55 Dipper Handle......................................................... 55 Dipper................................................................ 56 Padlocks.............................................................. 57 Dipper Trip........................................................... 58 Typical Machine Specifications............................................ 59 General Estimated Component Weights....................................... 61 Lower Works........................................................... 61 Upper Works........................................................... 62 Front End............................................................. 64 Side View................................................................. 67 Deck Plan................................................................. 68 Operation................................................................. 73 General Information....................................................... 73 Operation Near Electrical Lines....................................... 73 Controls.................................................................. 74 Primary Operating Controls................................................ 75 Controls On The Left Console.......................................... 76 Left Joystick..................................................... 77 Dipper Trip....................................................... 77 Signal Horn....................................................... 77 Start Pushbutton.................................................. 78 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 Brake....................................................... 78 Swing Brake....................................................... 78 Propel Brake...................................................... 78 HVAC Unit Selector................................................ 78 Temperature....................................................... 78 HVAC System Control............................................... 78 HVAC Fan Speed.................................................... 79 Cabin Lights...................................................... 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..................................................... 84 Radio/cassette/cd................................................. 84 Operator’s Display........................................................ 85 Display Area and Indicators........................................... 86 Display Screens....................................................... 86 Lubrication Control Panel............................................. 94 Fire Suppression System............................................... 94 Pre-start Checks.......................................................... 94 Walk-around Ground Level Inspection................................... 95 On-board Inspection................................................... 97 Start-up, Operation And Shutdown.......................................... 97 Machine Start-up...................................................... 97 Restarting After An Electrical Fault.................................. 99 Machine Operation..................................................... 99 Hoist Motion......................................................100 Crowd Motion......................................................101 Propel Motion.....................................................102 Swing Motion......................................................103 Proper Swing Motion...........................................104 Steering..........................................................105 Counter-rotation Turns........................................107 Positioning the Machine...........................................108 Back-up Method................................................108 Drive-by Method...............................................109 Start Of The Dig Cycle............................................110 Engaging The Bank.................................................113 Slope Limitations.................................................115 Excavated Material....................................................117 Operation Checks......................................................117 Operating Hints.......................................................118 Stopping the Machine..................................................119 Shutdown..............................................................119 Lubrication...............................................................123 Lubrication Principles....................................................123 Greasing Main A.C. Drive Motors...........................................124 1. Type of Grease.....................................................124 2. Initial Commissioning..............................................124 3. Maintenance........................................................124 4. Regreasing Intervals...............................................125 Lubricant Selection.......................................................125 Oil Fill Capacities.......................................................127 Types Of Lubricants And Capacities Guidelines.........................127 Quantities for First Fill of Lubricants...........................127 Automatic Lubrication System..............................................128 Lube Room.............................................................129 Lube Reservoir fill / Overflow Plumbing...............................130 Auto Lube Control Panel...........................................131 Lower Works Lubrication...............................................131 Propel Machinery Lubrication..........................................132 Lubricant Replacement/sampling....................................133 Lubricant Change Cycle........................................133 Revolving Frame Lubrication...........................................134 Hoist Machinery Lubrication...........................................135 Hoist Oil Cooler..................................................136 Filter Element Cleaning...........................................139 Hoist Rope Rollers Lubrication........................................140 Oil Pump..........................................................141 Crowd Machinery Lubrication...........................................142 Swing Machinery Lubrication...........................................143 Air Compressor Lubrication............................................144 Crowd Rope Take-Up Mechanism Lubrication..............................145 Front End Lubrication.................................................145 Lincoln Type SL-1 Lubricant Injectors.................................147 SL-1 Lubricant Injector Operation.................................149 Injector Advantages...............................................151 Air Compressor Lubricant..............................................151 MPO - Multipurpose OIL................................................152 RWRL - Running Wire Rope Lubricant....................................153 EGL - Enclosed Gearcase Lubricant.....................................154 MPG - Multipurpose Grease.............................................157 OGL - Open Gear Lubricant.............................................161 Certified Lubricants Listing..........................................165 Schematics - Automatic Lubrication........................................170 OGL System A & B Schematic................................................173 Grease System C Schematic.................................................174 Preventive Maintenance....................................................177 Introduction..............................................................177 Preventive Maintenance Program........................................177 Elements of an Effective Maintenance Program..........................178 Scheduled Preventive Maintenance Program..............................179 General Safety Considerations.........................................179 Maintenance During Machine Operation......................................180 Maintenance Precautions...............................................181 Preventive Maintenance for Lubrication....................................182 Lubricant Cleanliness.................................................183 Frequency of Inspection and Maintenance...................................184 Maintenance Schedules.....................................................184 Maintenance Inspection Check Points...................................184 Daily.............................................................185 Every 100 Hours or Weekly.........................................188 Every 500 Hours Or Monthly........................................189 Every 1250 Hours or Quarterly.....................................192 Every 2500 Hours or Semi-Annually.................................195 5000 Hours or Annually............................................197 Major Component Locations.................................................199 Service Procedures........................................................227 Lower Works...............................................................227 Truck Frame Assembly..................................................227 Swing Rack Assembly...................................................228 Roller Circle Rail Replacement - Lower............................228 Roller Circle Rail Replacement - Upper............................229 Roller Circle Assembly................................................231 Roller Circle Adjustment..........................................233 Adjustment Procedure..............................................233 Run-in Procedure for the Roller Circle............................233 Roller Circle Segment Removal.....................................234 Roller Circle - Roller Replacement................................235 Crawler Belts.............................................................236 Crawler Belt Maintenance..............................................236 Crawler Belt Tension Adjustment...................................237 Crawler Shoe Replacement..........................................239 Crawler Belt Replacement..........................................240 Crawler Side Frame Assembly...........................................241 Crawler Side Frame Maintenance....................................242 Slide Bar Replacement.............................................243 Crawler Front Idler Roller Assembly...............................244 Load and Idler Rollers............................................247 Roller Removal or Replacement.................................247 Propel Assembly...........................................................250 Installation Notes....................................................252 Main Propel Drive Shaft Removal.......................................253 Main Propel Shaft - Disassembly...................................256 Tumbler Rebuild Procedure.........................................257 Propel Machinery......................................................259 Propel Gearcase Removal...........................................260 Propel Gearcase Installation......................................261 Propel Planetary Gearcase.........................................263 Propel Motors.....................................................264 Propel Motor Removal..........................................264 Propel Motor Installation.....................................267 Center Pintle.........................................................268 Center Pintle Adjustment..........................................273 Center Pintle Sleeve Removal......................................274 Collector Rings.......................................................276 Collector Ring Inspection.........................................277 Collector Ring Repair.............................................278 Rotating Deck.............................................................278 Swing Machinery...........................................................279 Swing Support Mounting Bolts..........................................281 Swing Motor...........................................................281 Swing Blower......................................................281 Swing Motor Removal...............................................282 Swing Motor Installation..........................................283 Swing Planetary Gearcase..............................................283 Swing Gearcase Removal............................................284 Gearcase Inspection...............................................285 Swing Pinion Shafts...............................................286 Swing Pinion Shaft Removal....................................287 Swing Pinion Shaft Disassembly................................288 Swing Pinion Shaft Assembly...................................289 Swing Pinion Shaft Installation...............................290 Hoist Machinery.......................................................291 Hoist Motor Removal...............................................292 Motor Coupling Shaft..............................................295 Hoist Gearcase Assembly...........................................296 Hoist Gearcase Repair.............................................298 Hoist Drum Assembly...............................................301 Hoist Gear Replacement........................................303 Bearing Removal...............................................305 Bearing Installation..........................................306 Hoist Oil Cooler..................................................307 Hoist Mounting Bolts..................................................308 Hoist Limit Switch....................................................309 Crowd Machinery...........................................................310 Crowd Gearcase Disassembly............................................312 Crowd Gearcase Assembly...............................................315 Crowd Motor...............................................................316 Crowd Gear and Drum...................................................318 Crowd Drum Removal....................................................318 Operator’s Cab Mounting...............................................320 Machinery House...........................................................321 Walkways, Stairways, and Handrails....................................322 Boarding Stairs.......................................................322 Vertical Boarding Ladder, left........................................325 Boom Assembly.........................................................328 Boom Repair.......................................................329 Boom Limit Switch Installation........................................330 Boom Point Sheaves................................................332 Boom Point Sheave Removal and Disassembly.........................333 Boom Point Sheave Reassembly and Installation.....................335 Boom Bumper...........................................................336 Saddle Block..........................................................337 Saddle Block Repair...............................................337 Saddle Block Removal..........................................338 Dipper Handle.........................................................340 Dipper Handle Removal.............................................342 Crowd Rope Take-Up Mechanism......................................344 Crowd Rope Take-Up Mechanism Disassembly......................345 Crowd Rope Take-Up Mechanism Assembly.........................347 Retract Rope Take-up Mechanism....................................349 Spreader Repair...................................................351 Dipper Assembly...........................................................352 Latch Bar Adjusting...................................................355 Dipper Door bumpers...................................................356 Dipper Removal & Installation.....................................357 Dipper Door Snubbers..............................................362 Snubber Adjustment............................................363 Allowable Wear................................................363 Dipper Pitch Brace....................................................364 Dipper Padlock........................................................365 Dipper Trip Assembly..................................................368 A-Frame...............................................................369 Auxiliary Winch.......................................................371 Hoist Rope Support Roller.............................................372 Boom Support Ropes....................................................373 Wire Ropes............................................................374 Wire Rope Inspection..............................................375 Crowd Rope Take-up Hydraulic Unit.........................................376 Hoist Rope Reeving & Replacement......................................378 Crowd Rope Reeving & Replacement..................................382 Retract Rope Reeving & Replacement........................................385 Crowd Rope Tightening.................................................388 Retract Rope Tightening...............................................391 Dipper Trip Rope Reeving & Replacement................................392 Hoist and Crowd Limit Systems.........................................392 Setting Limits In The Hoist & Crowd System........................393 Crowd Slowdown/Stop Limits....................................395 Retract Slowdown/Stop Limits..................................396 Lower Slowdown/Stop Limits....................................397 Hoist Slowdown/Stop Limits....................................398 Brakes and Couplings......................................................401 Brakes....................................................................401 Disc Brake Operation..................................................402 Maintenance...........................................................402 Brake Adjustment Specifications.......................................402 Hoist Brake...........................................................403 Hoist Brake Adjustment............................................405 Hoist Brake Installation..........................................407 Hoist Brake Wear & Release Switches...............................407 Crowd Brake...........................................................408 Crowd Brake Installation..........................................410 Crowd Brake Wear & Release Switches...............................411 Propel Brake..........................................................412 Propel Brake Adjustment...........................................414 Propel Brake Installation.........................................416 Tachometer Mounting & Alignment...................................417 Swing Brake...........................................................420 Swing Brake Installation..........................................422 Swing Brake Wear & Release Switches...............................423 Swing Brake Burnishing............................................424 Spring Replacement — All Brakes.......................................424 Friction Disc Replacement — All Brakes................................426 O-Ring Replacement — All Brakes.......................................427 Brake Wear & Release Switches — Single Disc Brakes....................429 Brake Wear & Release Switches — Multiple Disc Brakes..................430 Couplings.................................................................431 Grid Couplings........................................................431 Lubrication.......................................................431 Coupling Disassembly and Grid Removal.............................432 Grid Coupling Installation........................................433 Seal Replacement without Hub Removal..............................436 Grid Coupling Alignment...........................................438 Gear Couplings........................................................439 Coupling Installation.............................................439 Gear Coupling Alignment...........................................441 Hoist Coupling Shaft Alignment....................................442 Compressed Air System.....................................................445 Air Compressor............................................................445 Lockout Valves........................................................447 Safety Warnings.......................................................449 Air Schematic.............................................................451 Air Filtration............................................................455 House Filter Fans.........................................................455 Lubrication...........................................................456 Dynavane Air Cleaner..................................................457 Air Conditioner.......................................................458 Specifications........................................................459 Engineering Data..........................................................465 Capscrew (Bolt) Grade.....................................................465 Bolt Tightening.......................................................466 Torque Wrench Method..............................................466 Turn-of-nut Method................................................468 Measurement Systems.......................................................470 Linear Measurements...................................................470 Area Measurements.....................................................470 Volume Measurements...................................................471 Torque Measurements...................................................472 Weight Measurements - Conventional................................473 Split Flange Assembly Procedure...........................................474 Wire Locking Capscrews....................................................476 Torque Nut Installation...................................................477 Tightening Procedure for 1.25-Inch Torque Nut.........................478 Tightening Procedure for 2-Inch Torque Nut............................479 Tightening Procedure for 2-Inch Torque Nut............................480 Tightening Procedure for 2.5-Inch Torque Nut..........................481 Tightening Procedure for 3-Inch Torque Nut............................482 Tightening Procedure for 3.5-Inch Torque Nut..........................483 Procedure for Use of Mechanical Tensioner on Crawler Rods.............484 Initial Tensioning................................................484 Final Tensioning..................................................484 Expansion Bolt Installation...............................................486 Tightening Procedures - Expansion Bolts...............................486 Hoist Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut............486 Rack & Roller Torque Rod, Tapered Sleeve & 1.5 Inch Torque Nut....487 Swing Torque Rod & Tapered Sleeve & 3.5 Inch Torque Nut...........489 Torque Nut Removal Procedure..............................................491 Thread Lubrication....................................................491 Torque Nut Helpful Hints..................................................492 Locking Assemblies........................................................493 Locking Assembly Removal..............................................495 Pinion and Hub Installation...........................................496 Removal from a Shaft..................................................496 Mounting a Pinion or Hub on a Shaft...................................496 Hub Adapter Pre-heat Advance Requirements.........................499 Motor Coupling Pre-Heat Advance Requirements......................499 Maintenance Welding.......................................................500 Welding Electrodes....................................................501 Repair Welding of Cracks..............................................502 Preheat...........................................................503 Welding Technique.................................................503 Repair Welding of Broken Parts........................................504 Repair Welding Swing Rack Teeth.......................................505 Preparation.......................................................505 Swing Rack Welding Electrodes.....................................505 Preheat...........................................................505 Welding Procedure.................................................507 Welding and Cutting Equipment.........................................509 Stress Relieving & Temperature Measuring Equipment....................510 Storage...............................................................511 Checking Diameter.....................................................511 Handling Wire Rope....................................................512 Seizing Wire Rope.....................................................513 End Preparations/Terminations.........................................515 Wire Rope Clips.......................................................515 Wire Rope Clip Application........................................515 Wedge Sockets.....................................................517 Inspection of Sheaves and Drums.......................................518 Breaking In a New Wire Rope...........................................519 Inspection Data.......................................................520 Guideline to Inspections and Reports..................................521 Wire Rope Inspection Criteria.....................................522 Reduction in Rope Diameter....................................522 Rope Stretch..................................................523 Abrasion......................................................524 Corrosion.....................................................524 Kinks.........................................................524 Bird Caging...................................................524 Localized Conditions..........................................524 Heat Damage...................................................524 Protruding Core...............................................524 Damaged End Attachments.......................................525 Peening.......................................................525 Scrubbing.....................................................525 Fatigue Fracture..............................................525 Broken Wires..................................................525 Electric Arc..................................................526 Seals.....................................................................526 Seal Installation.....................................................527 Gearcase Sealing......................................................528
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