CAT Bucyrus 495HD Mining Shovel Maintenance & Operation Manual 10769 PDF DOWNOAD
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CAT Bucyrus 495HD Mining Shovel Maintenance & Operation Manual 10769 PDF DOWNOAD
Language : English
Pages : 498
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
CAT Bucyrus 495HD Mining Shovel Maintenance & Operation Manual 10769 PDF DOWNOAD
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Safety Precautions................................................ 4 General Precautions........................................... 5 Maintenance Precautions....................................... 6 Operating Precautions......................................... 7 Fire Prevention............................................... 8 Warning Signs And Decals...................................... 9 Introduction...................................................... 25 General Information............................................... 25 SWINGING RESTRAINT & BALLAST BOX SUPPORT...................... 26 Ballast Box Support....................................... 26 Swinging Restraint........................................ 27 Machine Overview.................................................. 29 Lower Works....................................................... 30 Crawlers...................................................... 31 Truck Frame................................................... 33 Swing Rack.................................................... 34 Roller Circle................................................. 35 Propel Machinery.............................................. 36 Collector Rings............................................... 37 Rotating Deck..................................................... 37 Revolving Frame............................................... 38 Center Pintle................................................. 38 Deck Extensions............................................... 40 Ballast Box................................................... 40 Machinery House............................................... 40 Vertical Boarding Ladder, Left............................ 41 Boarding Stairs............................................... 43 A-Frame....................................................... 44 Hoist Machinery............................................... 45 Swing Machinery............................................... 46 Crowd Machinery............................................... 47 Operator’s Cab................................................ 48 Compressed Air System......................................... 49 Automatic Lubrication System.................................. 50 Front End Equipment............................................... 51 Suspension Strands............................................ 51 Boom.......................................................... 52 Running Ropes................................................. 53 Saddle Block.................................................. 54 Dipper Handle................................................. 55 Dipper........................................................ 56 Padlocks...................................................... 57 Dipper Trip................................................... 58 Typical Machine Specifications.................................... 59 General Estimated Component Weights............................... 61 Lower Works................................................... 61 Upper Works................................................... 62 Front End..................................................... 64 Operation......................................................... 71 General Information............................................... 71 Operation Near Electrical Lines............................... 71 Controls.......................................................... 73 Primary Operating Controls.................................... 74 Controls On The Left Console.............................. 75 Left Joystick......................................... 76 Dipper Trip........................................... 76 Signal Horn........................................... 76 Radio................................................. 76 Hoist Brake........................................... 76 Crowd Brake........................................... 76 Swing Brake........................................... 77 Propel Brake.......................................... 77 Climate Control Panel................................. 77 Windshield Wiper Switch............................... 77 Windshield Washer Switch.............................. 77 Controls On The Right Console............................. 78 Right Joystick........................................ 79 Control Stop Pushbutton............................... 79 Control Reset Pushbutton.............................. 80 Dig/propel Transfer Switch............................ 80 Emergency Stop Pushbutton............................. 80 Main Power Off Pushbutton............................. 81 Earth Continuity Lockout Pushbutton................... 81 Telephone............................................. 81 Operator’s Seat................................................... 82 Operator’s Display................................................ 83 Display Area and Indicators................................... 85 Display Screens............................................... 86 Auxiliary Controls................................................ 94 Remote Start Panel............................................ 94 Phase Sequence Light...................................... 94 Drive Cabinets Temperature Light.......................... 94 PLC Power On Light........................................ 94 System Ready Light........................................ 95 Auxiliary Ground Fault Light.............................. 95 Incomplete Sequence Light................................. 95 System Run Pushbutton..................................... 95 Air Compressor Start/Stop Pushbuttons..................... 95 House Light Circuit Breakers.............................. 95 Lighting Transfer Switch.................................. 96 Lubrication Control Panel..................................... 96 Windshield Wipers............................................. 96 Windshield Washer............................................. 97 Pre-start Checks.................................................. 97 Walk-around Ground Level Inspection........................... 98 On-board Inspection........................................... 99 Start-up, Operation And Shutdown..................................100 Machine Start-up..............................................100 Restarting After An Electrical Fault..........................102 Machine Operation.............................................102 Machinery Motions.............................................103 Hoist Motion..............................................103 Crowd Motion..............................................104 Propel Motion.............................................105 Swing Motion..............................................106 Proper Swing Motion...................................107 Steering..................................................109 Counter-rotation Turns................................110 Positioning the Machine...................................111 Back-up Method........................................111 Drive-by Method.......................................112 Start Of The Dig Cycle....................................113 Engaging The Bank.........................................116 Slope Limitations.........................................118 Excavated Material............................................120 Operation Checks..............................................120 Operating Hints...............................................121 Stopping the Machine..........................................122 Shutdown......................................................122 Lubrication.......................................................125 Lubrication Principles............................................125 Greasing Main A.C. Drive Motors...................................126 1. Type of Grease.............................................126 2. Initial Commissioning......................................126 3. Maintenance................................................126 4. Regreasing Intervals.......................................127 Lubricant Selection...............................................127 Oil Fill Capacities...............................................129 Types Of Lubricants And Capacities Guidelines.................129 Quantities for First Fill of Lubricants...................129 Automatic Lubrication System......................................130 Lube Room.....................................................131 Lube Reservoir fill / Overflow Plumbing.......................132 Auto Lube Control Panel...................................133 Lower Works Lubrication.......................................133 Propel Machinery Lubrication..................................137 Lubricant Replacement/sampling............................138 Lubricant Change Cycle................................138 Revolving Frame Lubrication...................................139 Hoist Machinery Lubrication...................................140 Hoist Gearcase Oil Cooler.................................141 Crowd Machinery Lubrication...................................143 SWING MACHINERY LUBRICATION...................................144 Air Compressor Lubrication....................................145 Front End Lubrication.........................................145 Lincoln Type SL-1 Lubricant Injectors.........................146 SL-1 Lubricant Injector Operation.........................148 Injector Advantages.......................................150 Lubrication Benchmarks............................................151 Air Compressor Lubricant......................................151 MPO - Multipurpose OIL........................................151 RWRL - Running Wire Rope Lubricant............................153 EGL - Enclosed Gearcase Lubricant.............................154 MPG - Multipurpose Grease.....................................157 OGL - Open Gear Lubricant.....................................161 Certified Lubricants Listing..................................165 Preventive Maintenance............................................173 Introduction......................................................173 Preventive Maintenance Program................................173 Elements of an Effective Maintenance Program..................174 Scheduled Preventive Maintenance Program......................175 General Safety Considerations.................................175 Maintenance During Machine Operation..............................176 Maintenance Precautions.......................................177 Preventive Maintenance for Lubrication............................178 Lubricant Cleanliness.........................................179 Frequency of Inspection and Maintenance...........................180 Maintenance Schedules.............................................180 Maintenance Inspection Check Points...........................180 Daily.....................................................181 Every 100 Hours or Weekly.................................184 Every 500 Hours Or Monthly................................185 Every 1250 Hours or Quarterly.............................188 Every 2500 Hours or Semi-Annually.........................191 5000 Hours or Annually....................................194 Major Component Locations.........................................196 Service Procedures................................................221 Lower Works.......................................................221 Propel Machinery..............................................221 Crawler Frames and Truck Frame................................222 Crawler Belts.............................................224 Belt Adjustment.......................................225 Belt Replacement......................................228 Crawler Links.............................................230 Take-up Tumbler & Axle................................231 Tumbler Repair........................................232 Upper Rollers.............................................233 Upper Roller Repair...................................234 Lower Rollers.............................................235 Lower Roller Repair...................................236 Drive Tumbler.............................................237 Drive Tumbler Repair..................................237 Drive Tumbler Rebuild.................................238 Tumbler Drive Shaft.......................................241 Shaft Repair..........................................242 Propel Motor..................................................243 Propel Planetary Gearcase.....................................244 Swing Rack....................................................246 Roller Circle.................................................247 Roller Circle Repair......................................249 Swing Rack Dust Curtains......................................252 Center Pintle.................................................253 Center Pintle Adjustment..................................258 Center Pintle Sleeve Removal..............................259 Collector Rings...............................................260 Collector Ring Inspection.................................261 Collector Ring Repair.....................................261 Swing Machinery...................................................262 Swing Blower..................................................264 Swing Motor...................................................264 Swing Motor Removal.......................................265 Swing Motor Installation..................................265 Swing Planetary Gearcase......................................266 Gearcase Inspection.......................................267 Swing Shafts and Pinions......................................268 Swing Pinion Removal......................................269 Swing Pinion Installation.....................................270 Swing Shaft Removal...........................................270 Swing Shaft Installation..................................271 Hoist Machinery...................................................273 Hoist Motor...................................................275 Hoist Gearcase Assembly.......................................278 Hoist Gearcase Installation...............................279 Hoist Gearcase Repair.....................................281 Motor Coupling Shaft......................................281 Hoist Drum Assembly.......................................284 Hoist Gear Replacement................................286 Bearing Replacement...................................287 Hoist Mounting Bolts..........................................288 Hoist Limit Switch............................................289 Hoist Motor...................................................290 Crowd Machinery...................................................292 Gearcase Repair...............................................294 Crowd Motor.......................................................299 Crowd Gear and Drum...........................................301 Crowd Drum Removal............................................302 Machinery House...................................................304 Walkways, Stairways, and Handrails............................305 Vertical Boarding Ladder, left............................306 Boarding Stairs...............................................308 Front End Equipment...............................................310 Boom Assembly.................................................311 Boom Repair...............................................311 Boom Limit Switch.............................................312 Limit Switch Inspection...................................315 Limit Switch Adjustment...................................315 Boom Point Sheaves............................................316 Boom Point Sheave Removal and Disassembly.................317 Boom Point Sheave Reassembly and Installation.............319 Boom Bumper...................................................320 Saddle Block..................................................321 Saddle Block Repair.......................................321 Saddle Block Removal......................................322 Dipper Handle.................................................324 Dipper Handle Removal.....................................325 Retract Rope Take-up Mechanism............................326 Spreader Repair...........................................328 Dipper Assembly...................................................329 Latch Bar Adjusting...........................................332 Dipper Door bumpers...........................................333 Dipper Door Snubbers......................................334 Snubber Adjustment....................................335 Dipper Padlock................................................335 Dipper Pitch Brace............................................338 Dipper Trip Assembly..........................................339 A-Frame.......................................................340 Auxiliary Winch...............................................342 Hoist Rope Support Roller.....................................343 Boom Support Ropes............................................344 Wire Ropes....................................................345 Wire Rope Inspection......................................346 Hoist Rope Reeving & Replacement..............................346 Crowd Rope Reeving & Replacement..........................350 Retract Rope Reeving & Replacement................................353 Retract Rope Tightening.......................................356 Dipper Trip Rope Reeving & Replacement........................357 Hoist and Crowd Limit Systems.................................357 Setting Limits In The Hoist & Crowd System................358 Crowd Slowdown/Stop Limits............................360 Retract Slowdown/Stop Limits..........................361 Lower Slowdown/Stop Limits............................362 Hoist Slowdown/Stop Limits............................363 Brakes and Couplings..............................................367 Brakes............................................................367 Disc Brake Operation..........................................368 Maintenance...................................................368 Brake Adjustment Specifications...............................368 Hoist Brake...................................................369 Hoist Brake Adjustment....................................371 Hoist Brake Installation..................................373 Hoist Brake Wear & Release Switches.......................373 Crowd Brake...................................................374 Crowd Brake Installation..................................376 Crowd Brake Wear & Release Switches.......................377 Propel Brake..................................................378 Propel Brake Adjustment...................................380 Propel Brake Installation.................................382 Tachometer Mounting & Alignment...........................383 Swing Brake...................................................385 Swing Brake Installation..................................387 Swing Brake Wear & Release Switches.......................388 Swing Brake Burnishing....................................389 Spring Replacement — All Brakes...............................389 Friction Disc Replacement — All Brakes........................391 O-Ring Replacement — All Brakes...............................392 Brake Wear & Release Switches — Single Disc Brakes............395 Brake Wear & Release Switches — Multiple Disc Brakes..........396 Couplings.........................................................397 Grid Couplings................................................397 Lubrication...............................................397 Coupling Disassembly and Grid Removal.....................398 Grid Coupling Installation................................399 Seal Replacement without Hub Removal......................402 Grid Coupling Alignment...................................404 Gear Couplings................................................405 Coupling Installation.....................................405 Gear Coupling Alignment...................................407 Hoist Coupling Shaft Alignment............................408 Compressed Air System.............................................411 Air Compressor....................................................411 Lubrication...................................................413 Fluid Level Check.............................................413 Fluid Filter..................................................413 Fluid Change..................................................413 V-Belt Tension................................................413 V-Belt Removal and Replacement................................414 Pressure Switch...............................................415 Lockout Valves................................................416 Safety Warnings...............................................418 Air Filtration....................................................423 House Filter Fans.................................................423 Lubrication...................................................424 Dynavane Air Cleaner..........................................425 Air Conditioner...............................................426 Specifications................................................427 Engineering Data..................................................433 Capscrew (Bolt) Grade.............................................433 Bolt Tightening...............................................433 Torque Wrench Method......................................433 Turn-of-nut Method........................................435 Measurement Systems...............................................437 Linear Measurements...........................................437 Area Measurements.............................................437 Volume Measurements...........................................438 Torque Measurements...........................................439 Weight Measurements - Conventional........................440 Split Flange Assembly Procedure...................................441 Wire Locking Capscrews............................................443 Torque Nut Installation...........................................444 Tightening Procedure for 2-Inch Torque Nut....................445 Tightening Procedure for 2-Inch Torque Nut....................446 Tightening Procedure for 2.5-Inch Torque Nut..................447 Tightening Procedure for 3-Inch Torque Nut....................448 Expansion Bolt Installation.......................................449 Tightening Procedures - Expansion Bolts.......................449 Hoist Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut....449 Torque Nut Removal Procedure......................................451 Thread Lubrication............................................451 Torque Nut Helpful Hints..........................................452 Locking Assemblies................................................453 Locking Assembly Removal......................................455 Pinion and Hub Installation.......................................456 Removal from a Shaft..........................................456 Mounting a Pinion or Hub on a Shaft...........................456 Hub Adapter Pre-heat Advance Requirements.................459 Motor Coupling Pre-Heat Advance Requirements..............459 Maintenance Welding...............................................460 Welding Electrodes............................................461 Repair Welding of Cracks......................................462 Preheat...................................................463 Welding Technique.........................................463 Repair Welding of Broken Parts................................464 Repair Welding Swing Rack Teeth...............................465 Preparation...............................................465 Swing Rack Welding Electrodes.............................465 Preheat...................................................465 Welding Procedure.........................................467 Welding and Cutting Equipment.................................469 Stress Relieving & Temperature Measuring Equipment............470 Wire Rope Care and Maintenance....................................471 Storage.......................................................471 Checking Diameter.............................................471 Handling Wire Rope............................................472 Seizing Wire Rope.............................................473 End Preparations/Terminations.................................475 Wire Rope Clips...............................................475 Wire Rope Clip Application................................476 Wedge Sockets.............................................478 Inspection of Sheaves and Drums...............................479 Breaking In a New Wire Rope...................................480 Inspection Data...............................................481 Guideline to Inspections and Reports..........................482 Wire Rope Inspection Criteria.............................483 Reduction in Rope Diameter............................483 Rope Stretch..........................................484 Abrasion..............................................485 Corrosion.............................................485 Kinks.................................................485 Bird Caging...........................................485 Localized Conditions..................................485 Heat Damage...........................................485 Protruding Core.......................................485 Damaged End Attachments...............................486 Peening...............................................486 Scrubbing.............................................486 Fatigue Fracture......................................486 Broken Wires..........................................486 Electric Arc..........................................487 Seals.............................................................487 Seal Installation.............................................488 Gearcase Sealing..............................................489 Schematics........................................................492 Schematics - Automatic Lubrication................................492 Side View.........................................................493 Deck Plan.........................................................494 OGL System A & B Schematic........................................495 Grease System C Schematic.........................................496 Air Schematic.....................................................497
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DESCRIPTION:
CAT Bucyrus 495HD Mining Shovel Maintenance & Operation Manual 10769 PDF DOWNOAD
INRODUCTION:
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
- 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.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
G.P
