CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual 11000 PDF DOWNLOAD
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CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual 11000 PDF DOWNLOAD
Language : English
Pages : 480
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual 11000 PDF DOWNLOAD
SN 141460
SN 141444
Safety Precautions........................................................ 3 General Precautions................................................... 5 Maintenance Precautions............................................... 6 Operating Precautions................................................. 7 Fire Prevention....................................................... 8 Warning Signs And Decals.............................................. 9 Introduction.............................................................. 25 SWINGING RESTRAINT & BALLAST BOX SUPPORT.............................. 26 Ballast Box Support................................................... 26 Swinging Restraint.................................................... 27 Machine Overview.......................................................... 29 Lower Works............................................................... 30 Crawlers.............................................................. 31 Truck Frame........................................................... 32 Swing Rack............................................................ 33 Roller Circle......................................................... 34 Propel Machinery...................................................... 35 Collector Rings....................................................... 36 Rotating Deck............................................................. 37 Revolving Frame....................................................... 37 Center Pintle......................................................... 37 Deck Extensions....................................................... 39 Ballast Box........................................................... 39 Machinery House....................................................... 39 Boarding Stairs................................................... 40 A-Frame............................................................... 42 Hoist Machinery....................................................... 43 Swing Machinery....................................................... 43 Crowd Machinery....................................................... 45 OPERATOR’S CAB........................................................ 46 Compressed Air System................................................. 47 Automatic Lubrication System.......................................... 48 Lube Reservoir fill / Overflow Plumbing............................... 49 Front End Equipment....................................................... 50 Suspension Strands.................................................... 50 Boom.................................................................. 51 Running Ropes......................................................... 52 Saddle Block.......................................................... 53 Dipper Handle......................................................... 54 Dipper................................................................ 55 Padlocks.............................................................. 56 Dipper Trip........................................................... 57 Typical Machine Specifications............................................ 58 General Estimated Component Weights....................................... 60 Lower Works........................................................... 60 Upper Works........................................................... 61 Front End............................................................. 63 Lubrication............................................................... 67 Greasing Main A.C. Drive Motors........................................... 68 1. Type of Grease..................................................... 68 2. Initial Commissioning.............................................. 68 3. Maintenance........................................................ 68 4. Regreasing Intervals............................................... 69 Lubricant Selection....................................................... 70 Oil Fill Capacities....................................................... 71 Types Of Lubricants And Capacities Guidelines......................... 71 Quantities for First Fill of Lubricants........................... 71 Automatic Lubrication System.............................................. 72 Lube Room............................................................. 73 Lube Reservoir fill / Overflow Plumbing............................... 74 Auto Lube Control Panel........................................... 75 Lower Works Lubrication............................................... 75 Propel Machinery Lubrication.......................................... 76 Lubricant Replacement/sampling.................................... 77 Lubricant Change Cycle........................................ 77 Revolving Frame Lubrication........................................... 78 Hoist Machinery Lubrication........................................... 79 Hoist Oil Cooler.................................................. 80 Filter Element Cleaning........................................... 83 Hoist Rope Rollers Lubrication........................................ 84 Oil Pump.......................................................... 85 Crowd Machinery Lubrication........................................... 86 Swing Machinery Lubrication........................................... 87 Air Compressor Lubrication............................................ 88 Crowd Rope Take-up Mechanism Lubrication.............................. 88 Front End Lubrication................................................. 90 Lincoln Type SL-1 Lubricant Injectors................................. 91 SL-1 Lubricant Injector Operation................................. 93 Injector Advantages............................................... 95 ACSL - Air Compressor (Screw-Type) Lubricant.......................... 96 MPO - Multipurpose OIL................................................ 97 RWRL - Running Wire Rope Lubricant.................................... 98 EGL - Enclosed Gearcase Lubricant..................................... 99 MPG - Multipurpose Grease.............................................102 OGL - Open Gear Lubricant.............................................106 Certified Lubricants Listing..........................................110 Preventive Maintenance....................................................117 Preventive Maintenance Program........................................117 Elements of an Effective Maintenance Program..........................118 Scheduled Preventive Maintenance Program..............................119 General Safety Considerations.........................................119 Maintenance During Machine Operation......................................120 Maintenance Precautions...............................................121 Preventive Maintenance for Lubrication....................................122 Lubricant Cleanliness.................................................123 Frequency of Inspection and Maintenance...................................124 Maintenance Inspection Check Points...................................124 Daily.............................................................125 Every 100 Hours or Weekly.........................................128 Every 500 Hours Or Monthly........................................129 Every 1250 Hours or Quarterly.....................................132 Every 2500 Hours or Semi-Annually.................................135 5000 Hours or Annually............................................137 Major Component Locations.................................................139 Service Procedures........................................................167 Truck Frame Assembly..................................................167 Swing Rack Assembly...................................................168 Roller Circle Rail Replacement - Lower............................168 Roller Circle Rail Replacement - Upper............................169 Roller Circle Assembly................................................171 Roller Circle Adjustment..........................................173 Adjustment Procedure..............................................173 Run-in Procedure for the Roller Circle............................173 Roller Circle Segment Removal.....................................174 Roller Circle - Roller Replacement................................174 Crawler Belts.........................................................175 Crawler Belt Maintenance..........................................175 Crawler Belt Tension Adjustment...............................177 Crawler Shoe Replacement......................................179 Crawler Belt Replacement......................................179 Crawler Side Frame Assembly...........................................180 Crawler Side Frame Maintenance....................................181 Slide Bar Replacement.............................................182 Crawler Front Idler Roller Assembly...................................183 Load and Idler Rollers............................................186 Roller Removal or Replacement.................................186 Propel Assembly.......................................................189 Installation Notes................................................191 Main Propel Drive Shaft Removal...................................192 Main Propel Shaft - Disassembly...................................195 Tumbler Rebuild Procedure.........................................196 Propel Machinery......................................................198 Propel Gearcase Removal...........................................199 Propel Gearcase Installation......................................200 Propel Planetary Gearcase.........................................202 Propel Motors.....................................................203 Propel Motor Removal..........................................203 Propel Motor Installation.....................................205 Rotating Deck.............................................................207 Revolving Frame.......................................................207 Center Pintle.........................................................207 Center Pintle Adjustment..........................................212 Center Pintle Sleeve Removal......................................212 Collector Rings.......................................................214 Collector Ring Inspection.........................................215 Collector Ring Repair.............................................215 Cable Reel............................................................216 Swing Machinery.......................................................217 Swing Support Mounting Bolts......................................219 Swing Motor.......................................................219 Swing Blower..................................................219 Swing Motor Removal...........................................220 Swing Motor Installation......................................221 Swing Planetary Gearcase..........................................221 Swing Gearcase Removal........................................222 Gearcase Inspection...........................................223 Swing Pinion Shafts...............................................224 Swing Pinion Shaft Removal....................................224 Swing Pinion Shaft Disassembly................................226 Swing Pinion Shaft Assembly...................................227 Swing Pinion Shaft Installation...............................228 Hoist Machinery.......................................................229 Hoist Motor Removal...............................................230 Motor Coupling Shaft..............................................233 Hoist Gearcase Assembly...........................................234 Hoist Gearcase Repair.............................................238 Hoist Drum Assembly...............................................241 Hoist Gear Replacement........................................243 Bearing Removal...............................................245 Bearing Installation..........................................246 Hoist Oil Cooler..................................................248 Hoist Mounting Bolts..............................................249 Hoist Limit Switch................................................250 Crowd Gearcase Disassembly........................................251 Crowd Gearcase Assembly...........................................254 Crowd Motor.......................................................255 Crowd Gear and Drum...........................................257 Crowd Drum Removal............................................257 Operator’s Cab Mounting...............................................258 Joystick Replacement..................................................259 Joystick Calibration..............................................261 Wiper Arm Replacement.................................................263 Wiper Blade Replacement...........................................264 Wiper Motor Replacement...........................................265 Machinery House...........................................................269 Walkways, Stairways, and Handrails....................................270 Boarding Stairs...................................................271 Front End Equipment.......................................................274 Boom Assembly.........................................................275 Boom Repair...........................................................276 Boom Limit Switch Installation........................................276 Boom Point Sheaves....................................................278 Boom Point Sheave Removal and Disassembly.........................279 Boom Point Sheave Reassembly and Installation.....................281 Boom Bumper...........................................................282 Saddle Block..........................................................283 Saddle Block Repair...............................................283 Saddle Block Removal..............................................284 Dipper Handle.........................................................286 Dipper Handle Removal.............................................288 Crowd Rope Take-Up Mechanism......................................290 Crowd Rope Take-Up Mechanism Disassembly......................291 Crowd Rope Take-Up Mechanism Assembly.........................293 Retract Rope Take-up Mechanism....................................295 Spreader Repair...................................................297 Dipper Assembly.......................................................298 Latch Bar Adjusting...............................................300 Dipper Door bumpers...............................................301 Dipper Removal & Installation.....................................302 Dipper Door Snubbers..............................................308 Snubber Adjustment............................................309 Allowable Wear................................................309 Dipper Pitch Brace................................................310 Dipper Padlock....................................................311 Dipper Trip Assembly..............................................313 A-Frame...............................................................315 Auxiliary Winch.......................................................317 Hoist Rope Support Roller.............................................318 Boom Support Ropes....................................................319 Wire Ropes............................................................320 Wire Rope Inspection..............................................321 Crowd Rope Take-up Hydraulic Unit.....................................322 Hoist Rope Reeving & Replacement......................................324 Crowd Rope Reeving & Replacement......................................328 Retract Rope Reeving & Replacement....................................330 Crowd Rope Tightening.................................................334 Retract Rope Tightening...............................................336 Dipper Trip Rope Reeving & Replacement................................337 Hoist and Crowd Limit Systems.........................................337 Setting Limits In The Hoist & Crowd System........................338 Crowd Slowdown/Stop Limits....................................340 Retract Slowdown/Stop Limits..................................341 Lower Slowdown/Stop Limits....................................342 Hoist Slowdown/Stop Limits....................................343 Brakes and Couplings......................................................347 Disc Brake Operation..................................................348 Maintenance...........................................................348 Brake Adjustment Specifications.......................................348 Hoist Brake...........................................................349 Hoist Brake Adjustment............................................351 Hoist Brake Installation..........................................353 Hoist Brake Wear & Release Switches...............................353 Crowd Brake...........................................................354 Crowd Brake Installation..........................................356 Crowd Brake Wear & Release Switches...............................358 Propel Brake..........................................................359 Propel Brake Adjustment...........................................361 Propel Brake Installation.........................................363 Tachometer Mounting & Alignment...................................364 Swing Brake...........................................................366 Swing Brake Installation..........................................368 Swing Brake Wear & Release Switches...............................369 Swing Brake Burnishing............................................370 Spring Replacement — All Brakes.......................................370 Friction Disc Replacement — All Brakes................................372 O-Ring Replacement — All Brakes.......................................373 Brake Wear & Release Switches — Single Disc Brakes....................376 Brake Wear & Release Switches — Multiple Disc Brakes..................377 Couplings.................................................................378 Grid Couplings........................................................378 Lubrication.......................................................378 Coupling Disassembly and Grid Removal.............................379 Grid Coupling Installation........................................380 Seal Replacement without Hub Removal..............................383 Grid Coupling Alignment...........................................385 Gear Couplings........................................................386 Coupling Installation.............................................386 Gear Coupling Alignment...........................................388 Hoist Coupling Shaft Alignment....................................389 Compressed Air System.....................................................393 Lockout Valves........................................................395 Safety Warnings.......................................................397 Air Filtration............................................................401 Lubrication...........................................................402 Dynavane Air Cleaner..................................................402 Air Conditioner/heater....................................................404 Evaporator............................................................404 Condenser.............................................................404 Pressurizer...........................................................405 Cleaning The Washable Filter......................................405 Specifications........................................................406 Engineering Data..........................................................411 Bolt Tightening.......................................................411 Torque Wrench Method..............................................411 Turn-of-nut Method................................................413 Measurement Systems.......................................................415 Linear Measurements...................................................415 Area Measurements.....................................................415 Volume Measurements...................................................416 Torque Measurements...................................................417 Weight Measurements - Conventional................................418 Split Flange Assembly Procedure...........................................419 Wire Locking Capscrews....................................................421 Torque Nut Installation...................................................422 Tightening Procedure for 1.25-Inch Torque Nut.........................422 Tightening Procedure for 2-Inch Torque Nut............................423 Tightening Procedure for 2-Inch Torque Nut............................424 Tightening Procedure for 2-Inch Torque Nut............................425 Tightening Procedure for 2.5-Inch Torque Nut..........................425 Tightening Procedure for 3-Inch Torque Nut............................426 Tightening Procedure for 3.5-Inch Torque Nut..........................427 Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods....428 Initial Tensioning................................................428 Final Tensioning..................................................428 Tightening Procedures - Expansion Bolts...............................430 Rack & Roller Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut....430 Hoist Torque Rod, Tapered Sleeve & 1.62 Inch Torque Nut...........431 Swing Torque Rod & Tapered Sleeve & 3.25 Inch Torque Nut..........432 Thread Lubrication....................................................434 Locking Assemblies........................................................436 Locking Assembly Removal..............................................438 Pinion and Hub Installation...............................................439 Removal from a Shaft..................................................439 Mounting a Pinion or Hub on a Shaft...................................439 Pre-heat Advance Requirements - Pinions and Hubs..................442 Motor Coupling Pre-Heat Advance Requirements......................442 Maintenance Welding.......................................................444 Welding Electrodes....................................................445 Repair Welding of Cracks..............................................446 Preheat...........................................................447 Welding Technique.................................................447 Repair Welding of Broken Parts........................................448 Repair Welding Swing Rack Teeth.......................................449 Preparation.......................................................449 Swing Rack Welding Electrodes.....................................449 Preheat...........................................................449 Welding Procedure.................................................451 Welding and Cutting Equipment.........................................453 Stress Relieving & Temperature Measuring Equipment....................454 Wire Rope Care and Maintenance............................................455 Storage...............................................................455 Checking Diameter.....................................................455 Handling Wire Rope....................................................456 Seizing Wire Rope.....................................................457 End Preparations/Terminations.........................................459 Wire Rope Clips.......................................................459 Wire Rope Clip Application........................................459 Wedge Sockets.....................................................461 Inspection of Sheaves and Drums.......................................462 Breaking In a New Wire Rope...........................................463 Inspection Data.......................................................464 Guideline to Inspections and Reports..................................465 Wire Rope Inspection Criteria.....................................466 Reduction in Rope Diameter....................................466 Rope Stretch..................................................467 Abrasion......................................................468 Corrosion.....................................................468 Kinks.........................................................468 Bird Caging...................................................468 Localized Conditions..........................................468 Heat Damage...................................................468 Protruding Core...............................................468 Damaged End Attachments.......................................469 Peening.......................................................469 Scrubbing.....................................................469 Fatigue Fracture..............................................469 Broken Wires..................................................469 Electric Arc..................................................470 Seal Installation.....................................................471 Gearcase Sealing......................................................472 Schematics................................................................ 0 Side View................................................................. 0 Deck Plan................................................................. 0 HVAC Schematic............................................................ 0 OGL System A & B Schematic................................................ 0 Grease System C Schematic................................................. 0 Air Schematic............................................................. 0 11000-Schematics.pdf...................................................... 0 Schematics............................................................474 Side View.............................................................475 Deck Plan.............................................................476 HVAC Schematic........................................................477 OGL System A & B Schematic............................................478 Grease System C Schematic.............................................479 Air Schematic.........................................................480 11000-ServiceProcedures X30.pdf........................................... 0 Page 1................................................................190
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CAT Bucyrus 495HR2 Mining Shovel Maintenance Manual 11000 PDF DOWNLOAD
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
