CAT BUCYRUS 110-RB EXCAVATOR CARE AND MAINTENANCE INSTRUCTIONS MANUAL – PDF DOWNLOAD

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RUSTON-BUCYRUS 1l0-RB EXCAVATORS

RUSTON-BUCYRUS 110-RB EXCAVATOR

(Machines with Serial Number later than 32117)

INDEX TO DRAWINGS AND DIAGRAMS

Plan Arrangement - Full/Electric Shovel with Non-Convertible Small Crowd

Generator

Plan Arrangement - Full/Electric Shovel with Convertible Crowd Generator

Plan Arrangement - Diesel/Electric Convertible Shovel

General Arrangement of Shovel - Standard Range Equipment

General Arrangement of Shovel - Long Range Equipment

Plan Arrangement - Full/Electric Dragline with Convertible Hoist Generator

Plan Arrangement = Diesel/Electric Convertible Dragline

General Arrangement of Standard Dragline

Operator's Control Console - Key Diagram

Schematic Arrangement - Magnet Air Valve Control

Arrangement - Lower Works

Arrangement - Lower Works - Long and Wide Cats

Arrangement - Swing Machinery

Section Through Centre Pintle and Upper Propel Shaft

Arrangement of Shovel Front End Equipment

Reeving - Hoist Rope

General Arrangement of Dipper Handle

General Arrangement of Dipper Trip

Arrangement L.H. Side Piping

Arrangement R.H. Side Piping

General Arrangement of Magnet Valve Piping

Arrangement - Triple Swivel

General Arrangement of Truck Frame Air Piping

Schematic Diagram of Air Piping

Tools and Instructions for Assembly of Swivel Joint Through Centre Line of Rotation

General Arrangement of Hoist and Propel Motor Shaft

Air Compressor

Compressor Valve Assembly

'Oilmatic' Unloader

Magnet Valve Type I

Magnet Valve Type II

Motor Brake - Main Machinery

Motor Brake - Swing and Crowd

General Arrangement of Crowd Machinery

Arrangement Steering Machinery

Intermediate Shaft - Main Machinery

Arrangement Hydraulic Take Up - Caterpillars

General Arrangement of Collector Gear

Arrangement Padlock

Snubber - 4Y2 cu.yd. Dipper Door

Dipper Teeth Assembly

Lower Works Lubrication

Upper Works Lubrication

Lubrication Diagram for Dragline Front End Equipment

Section Through Hoist Shaft - Dragline

Arrangement Boom Hoist Machinery

General Arrangement of Fairlead

Arrangement Boom Suspension and Mast

Arrangement Boom Point Sheaves

Adjustment of Pressure Switch

Boom Limit Switch

Hoist or Propel Clutch

Crowd Clutch

Crowd Rope Reeving

Lubrication Diagram for Shovel Front End Equipment

Crowd Equalizer with Spring Cushion

OPERATING SUGGESTIONS

A. INSPECT MACHINE BEFORE STARTING SHIFT

Before beginning to operate the machine at the start of a shift, make a general inspection of the machine to make sure it is ready for operation:

1. Look under the cats. and around the machinery to see if there is any evidence of lubricating oil leaks. Correct any major leaks and refill to required level. Make a note of minor leaks and correct at first opportunity possible.

2. Look over the electrical accessories to make sure all units are securely mounted and properly adjusted.

3. LUbricate all twice-a-shift \4- h our) and once-a-shift (8-hour) points as covered in the Lubrication Section of this Instruction Book.

4. Consul t the lubrication record for the machine and service all points which have gone the specified length of time since the last previous servicing.

5. Check operation of all hand levers and foot pedals to see that they 'WOrk freely without binding, yet with no lost motion.

6. Check main line air pressure which must be a least no lb./sq. in., and see that crowd clutch pressure falls within range on the instruction plate mounted near crowd clutch air gauge.

7. Engage the hoist and propel clutches to check operation of each motion.

B. POINTS TO WATCH DURING SHIFT

During the shift, watch for any signs of improper operation or adjustment. The following i terns are of particular importance:

1. Check generator, motors and gear for any tmusual noise, loss of power or failure to respond.

2. Check the hoist; propel and crowd air clutches inunediately if they should start to slip excessibely during normal operation.

3. Watch the cables to see that they do not become crossed on the drums.

4. When propelling check the tracking of the drive tumblers on the cat. links and, if necessary, readjust the belts to correct improper operation.

5. When functions such as the steering clutches etc., note any tendency of the controls to "hang up" or jam 'Which 'WOuld indicate improper operation. Correct the adjustment at the earliest possible opportunity.

6. Watch the air gauge in the operators cab and investigate iJmnediately should there be a sudden drop in air pressuxe.

C. CHECK MACHINE AT END OF SHIFT

At the end of the shift go over the machine again for evidence of excessive wear or damage which may have occurred during the shift.

1. Examine all cables carefully for broken strands or other evidence of weakness.

2.

3.

Arrange to replace weakened cables before starting another shift.

Clean out carefully any grease or dirt which may have accumulated around the machinery during the shift.

Clean out excessive mud or dirt in the cat. belts. This is particularly important in freeZing weather. Put planks, brush or dry material under cats. before shutting down machine if it is likely to freeze.

If the machine is to be idle for several hours, move it away from a high bank where it might be damaged by a slide or falling rocks. Do not leave the machine in a low spot where there is any danger of flooding.

5. Let the dipper down to the ground, be sure all brakes are set and place all controls in neutral position.

6. Close the windows at the operators position and lock all cab doors.

D. SHOVEL OPERATING HINTS

digging operations with a shovel require combLning the hoist. and swing motion into a fast, smooth operating cycle which cannot be described in any step by step procedure, as actual movement of the levers and pedals depends on actual digging conditions. There are many little operating tricks 1Nhich will come from experience. Some of these are as follows:

1. Keep the shovel as near the face of the bank as safety will permit and always move up before it is necessary to "reach out" with the dipper to get material.

2. Spot trucks so that the swing is kept as short as possible.

Take up a shallow cut in the bank so that the dipper will just be full when the top of cut is reached.

4. Crowd out only just enough to keep a uniform depth of the dipper in the bank.

Hoist the dipper only just high enough to provide clearance for the door when the dipper is tripped.

6. Keep dipper teeth sharp.

Move up while waiting for trucks whenever possible.

8. Loosen material by cutting with open dipper while waiting.

RUSTON-BUCYRUS 110-RB EXCAVATORS

OPERATING INSTRUCTIONS.

OPERATORtS CONTROLS

To enable the operator to be fully familiar with the equipment and controls on the machine, deck layouts are given:

Fig. l/Rl Full-electric shovel with non-convertible small crowd generator.

lA/Rl Full-electric shovel with convertible crowd generator.

lB Diesel electric shovel.

2/Rl Full-electric dragline with convertible hoist generator.

2A/Rl Diesel electric dragline.

The levers, pedals, and of the operatorts console are illustrated in Fig. 4.

STARTING UP PROCEDURE FULL ELECTRIC MACHINES

The auxiliary transformer circuit breaker and the control cubicle isolator should be in the tONt position. The emergency stop button should be in the pulledout position and the controller handles should be in neutral. All brake switches should be set to tONto

The main M.G. set is then run up by operating the main motor starter. (See later note re direction of rotation of set). Press tstart t button on console, thus running up exciter set and all auxiliary motors, including the compressor motor, (if receiver pressure is inadequate).

Before startin.§l to operate the machine, check that the main air line pressure is at least 110 lbs/sq. in.

STARTING UP PROCEDURE DIESEL ELECTRIC MACHINES

The emergency stop button should be in the pulled-out position and the controller handles should be in neutral. All brake switches should be set to tONto

The control cubicle isolators should be in the 'ON' position.

Depressing the tFuel Supply Re-set t button on the control cubicle allows the engine governor to control the fuel to the engine.

The engine and the generator unit are then run up. For procedure relating to engine refer to engine manual. The exciter set, engine radiator fans and generator chain oil pump run up with the engine and generator unit.

Press the t Start t button on the console, thus running up the main motor blowers and the compressor motor (if receiver pressure is inadequate).

Before startin.§l to operate the machine, check that the main air line pressure is at least 110 lbs/sq. in.

DIGGING

The appropriate side of the Dig/Propel switch should be selected; this automatically releases the propel clutch and ensures that the propel brake cannot be released during digging, and it automatically sets the shovel hoist clutch (or dragline drag clutch) and permits of the digging brake being controlled at will by means of the swing provided. (See Schematic arrangementFig. 5).

The hois t, swing and crowl brakes on the shovel (or the drag, swing and hoist brakes on the dragline) should be released by setting the appropriate switches on the console to the 'OFF' position. The propel brake should be placed in the 'ON' position corresponding to the automatic setting.

HOIST MOTION (SHOVEL AND DRAGLINE)

To hoist - push the controller handle forward.

To lower - pull the controller handle back.

The speed of hoist and lowering is controlled by varying the distance the controller handle is pushed forward or pulled back from the neutral position.

To brake the dipper or bucket during lowering, the controller handle is reversed from 'Lower' to 'Hoist', the degree of braking being dependent on the dis tance the controller handle is pushed for rard. (This method of braking is termed 'Plugging').

In shovel operation the bucket is held suspended during slewing by selecting a suitable position on the 'hoist' side of the controller. At any other time the bucket can be held suspended by applying the air brake provided. This air brake, like all the other brakes on the various motions, is in the nature of a 'parking' or for emergency application.

S-,.v'ING MOTION (SHOVEL AND DRAGLINE)

To swing left - depress the left pedal.

To swing right - depress the right pedal.

The speed of swing is controlled by the amount either pedal is depressed. The motion is stopped by 'plugging'.

CROWD MarION - SHOVEL

To crowd - push the controller handle forward.

To retract - pull the controller handle back.

The speed of crowding and retracting is controlled by varying the distance the controller handle is pushed forward or pulled back from the neutral position. The motion is stopped by 'plugging'.

DRAG MOTION - DRAGLINE

To drag - pull the controller handle back.

To payout - push the controller handle forward.

Speeds are controlled by varying the distance the controller handle is moved from neutral.

RUSTON=BUCYRUS ll0=RB EXCAVATORS

The bucket is maintained in the desired carrying position during hoisting by the drag rope pull, which is dependent on the distance the drag controller handle is pulled back.

DIPPER Till P (SHOVEL)

The dipper trip is operated by the latch handle on the shovel hoist controller. Depress the latch handle to dump dipper. The dipper door will la tch as th e di pper is lowered.

PROPELLIm

The appropriate side of the Dig-Propel switch is selected. This automatically releases the digging clutch (hoist clutch - shovel or drag clutch- dragline) and ensures that the digging brake cannot be released during propelling; it automatically sets the propel clutch and permits of the propel brake being controlled at will by means of the switch provided.

The propel brake should be released by setting the propel brake switch to the 'OFF' position.' The controller normally used for controlling the hoist motion on a shovel or the controller used for controlling the drag motion on a dragline is the one used for propelling and before operating it, make sure that the hoist, swing and crowd brake switches (shovel) or the drag, swing and hoist brake switches, (dragline) are set to the 'ON' position.

Machines are fitted with either standard side frames and caterpillars (see Fig. 6) or long side frames and caterpillars (see Fig. 6A).

The following instructions are based on travelling with the driving tumblers to the rear of the machine:

Machines with standard side frames and caterpillars (see Fig. 6'):

To move forward - pull controller handle back

To move backward - push controller handle forward.

On machines with long side frames and caterpillars (see Fig.6A):

To move forward - push controller handle forward.

To move backward - pull controller handle back.

The motion can be stopped by 'plugging' and returning the controller handle to the neutral pos1tion.

To move straight ahead or astern set the track steer switch in the 'straight' position. To turn to left or right select the appropriate posi tion of the track steer switch.

SHUTTING DOWN

At any time it is desired to shut down the machine, see that all brake switches are placed to the 'ON' position. This instruction also applies if the machine is shut down due to external causes.

Complete shut down is effected by depressing the emergency stop button which should be left depressed until it is desired to start up the machinery. It should then be re-set by pulling it out. If it is desired to close down the machine for short periods W:i.thout stopping the main generating set, the auxiliaries stop button on the operator's console should be depressed.

ROTATION OF MOTOR GENERATOR SET

When first putting the machine into commission, and every time after any changes or alterations have been made to any of the main A.C. equipment, (such as M.G. set motor or starter), or the associated cables including trailing cable connexions, it is essential to see that the direction of rotation of the M.G. set is correct as indicated by an arrow on one of the units. Serious damage may result if an attempt is made to run the set up to speed in the wrong direction. As an added precaution, the armature circuit connexions on all motions may be broken temporarily until the correct rotation has been established.

COLLECTOR GEAR

Inspect collector shoes and see that the vertical play is sufficient. A very little Vaseline smeared on the collector gear bearing surfaces assists in preventing rusting. Keep insulators clear of any accumulation of dirt.

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RUSTON-BUCYRUS 1l00RB EXCAVATORS ---- --

flFCRllTION OF MACHINERY

TRUCK AND PROPELLING MACHINERY

CAT. MOUNTING

See Drawing Arrangement of Lower Works Fig. 6.

The truck frame is of all-welded steel construction. The truck frame is supported by cast-steel side frames having a heavy box section. These side frames are secured to the truck frame by hook connections at the bottom and fit bolts at the top.

The cat belts, made up of closely fitting treads, connected by specially heat-treated steel pins, run around the driving and idler tumblers of the side frames. The idler tumblers run on short extra large diameter shafts rigidly secured to the side frames. The driving tumblers, of cast alloy steel, are mounted on the keyed section of forged-steel shafts turning in bronze-bushed bearings in the side frames. These shafts also carry, on splined sections, the driving gears which mesh with the pinions on the transverse shaft. Both the gear culd pillion are enclosed an oil tight case.

On the upper surface of the truck frame is a large, circular, swing-rack casting Which carries the roller track bars held by set screws in a machined groove in the swing-rack. Gears, shafts and clutches for steering and propelling are also contained in the truck frame.

MULTIPLE JAW CLUTCHES FOR STEERING

The transverse shaft on the driving tumbler end of the truck is made up of three sections. The centre section is carried on bronze-bushed bearings in the cast gear case bolted and chocked to the truck frame. On a splined portion of this section is a bevel gear meshing with the bevel pinion on the longitudinal propelling shaft. The two ends sections of the transverse shaft are connected to the centre section by multiple jaw clutches used for steering and acting as flexible couplings when propelling. The clutch female jaws are shifted by a collar sliding on guide bars.

FULL CIRCLE ROLLER FRAME

The turntable, composed of a complete ring of rollers which roll against both the revolving frame and truck frame tracks, provides wide distribution oft,he load of the revolving frame on the truck frame. The bushed steel rollers are mounted on large diameter pins, each of which is separately lubricated through pressure grease fittings tapped in the end pins. Brass thrust washers are fitted between the rollers and the outer frame member.

PROPEL BRAKE

The propel brake on the truck frame is at the take-up tumbler end an accesible position for easy adjustment. The propel brake housing is connected to the longitudinal propelling shaft by a spur gear reduction. The brake is spring-set and air-released. The brake is controlled from the operators cab by the switch. 6.

llO-RB EXCAVATORS

marked "Propel Brake". This switch is normaJJ.y left in the "OFF" pos:L't1on, power being furnished for the magnet valve when the "Dig Propei'switch is placed in the propel position. Thus the brake' is automaticaJJ.y placed in the released position when propelling but it may be set at any time by placing the propel brake switch to the "ON" position.

In case of power failure when proPelling, the brake sets inunediatelYe

UPPER WORKS

The revolving frame consists of a mai&"'1 fr&116 Ci:iStirAg with a. wp.l dad-steel, rear baJJ.ast section on which is mounted the main motor generator set. The main frame has lugs cast in it for the boom feet and A-frame front and rear leg cormections. On the under side of the main frame the rails of the roller circle are held in place by setscrews. The baJJ.ast section is held securely to the main frame by shear plugs at both top and bottom and by a wedge being driven between shear plates welded to the front plate of the ballast container and the rear web of the casting. This wedge is finally welded in position during erection in the field. The operator's cab is built as an extension of the revolving frame fOI'lllard S!-.,.d to the right to B!!1ple room Slid a clear viel-l for the operator.

SWING MACHINERY

See drawing - General Arrangement of Swing Machinery Fig. 70

The vertical swing motor and gear case are noun ted as an independent unit at the left front of the revolv.in.g frame. The t:hree spur-gear reduction from the motor to the vertical swing shaft is totally enclosed and lubricated by a. splash system.

The swing motor has a brake on its extended armature sha.ft, this brake being spring-set and air-released. It is applied automaticaJJ.y in case of power failure or may be applied by the operator by opening a switch controlled solenoid valve. The brake is to be used only to hold the machine against swinging, and is not a service brake to retard the swing when operating.

CENTRE PINTLE WITH SPHERICAL THRUST WASHER (SEE FIG. a)

The vertical digging reactions as well as the horizontal loads due to swinging and digging are carried by a centre pintle <>f simple yet rugged construction. A cast steel sleeve is locked in the revolving frame and bronze-bushed in the truck frame. The lower end of the sleeve is threaded for a large diameter lock nut which bears on the spherical tlu.-uat washer giv-L."1g even distribution of tipping l.oads over the entire area of the thrust washer. The vertical proPelling shaft runs in bronze bushings pressed in the centre pintle sleeve. Thrust washers, at top and bottom, take the bevel gear thrust.

MAIN MACHINERY

See drawing - General Arrangement of Main Machinery - Plan View Fig. 1.

The shovel hoist drum shaft is forged steel. and runs in babbitt lined bronze bearings supported by cast-steel side frames. The hoist gear is keyed to the hoist shaft and the left nange of the split hoist drum, grooved for the double twin hoist. 7.

ropes, is bolted to the hoist gear. The hoist gear meshes with the hoist pinion, on the right end of the intermediate shaft. The intermediate shaft is a steel forging and runs in antifriction bearings.

The hoist intermediate gear meshes with the hoist motor" pinion and shaft 1I\Ihi.ch, in turn, is coupled to the motor by the Airflex: clutch. (Fig. 52). In addition to the pinion and clutch, the hoist brake is also mounted on the shaft. The en tire assembly runs free on anti-friction bearings.

On the right em of the hois t motor the propel Airflex: clutch (Fig. 53) is mounted. The clutch housing and propel' sprocket shaft is mounted in anti-fric ti on bearings. The propel power flO# is from the motor through the air clutch to a sprocket on which a roller chain connects it to the first intermediate shaft of propelling machinery. A spur pinion on the opposite end drives the gear on the second intermediate propel shaft. This shaft drives the vertical propel shaft \'hich drives the longitudinal propel shaft am the centre drive shaft at the rear of the truck frame.

RUSTON-BUCYRUS EXCAVATORS

FRONT END EQUIPMENT

SHOVEL BOOM

Refer to General Arrangement Drawing of Shovel Front End Equipment Fig. 9/R2.

The shovel boom is comprised of two main parts. The lower section consists of a one-piece box section, supporting the shipper shaft and provided with lugs at the upper end, to which the upper section of the boom is pin-connected. Two supporting struts extend from the shipper shaft to the head of the A-frame, to support the lower section, whilst four bridge strand cables, also attached to the head of the A-frame, support the upper section at the boom point.

CROWD MACHINERY

Refer to Drawing of Crowl Machinery Fig. 29/Rl, and Reeving Drawings Fig. 12 and 54/R2.

The crowd motor and machinery are mounted on the front of the revolving frame. The dipper handle is forced outward and pulled inward by the crowd and retract ropes respectively.

The rope crowd provides a cushion for the shock compression loads plus additional cushioning provided in the crowd Airflex clutch.

The crowd motor drives the crowd rope drum through an Airflex slipping clutch (Figs. 29/Rl and 53) three gear reductions.

The boom point sheaves are bronze bushed to rotate on the ends of the boom point sheave shaft which is mounted at an angle to provide better off-lead for the hoist ropes.

The shipper shaft which carries and also forms the pivot for the saddle block, is mo"wnted in the shaft bearings at the upper end of the lower boom section.

The saddle block is a steel casting, the main function of which is to provide a pivoted guide through which the dipper handle slides outwards and inwards to 'Crowd' or 'Retract' the dipper, respectively. Concentric with the pivot point there are hubs on both sides of the saddle block, on which the crowd rope sheaves rotate. Additionally the saddle block carries the dipper handle stabilising device.

DIPPER HANDLE

Refer to General Arrangement Drawing of Dipper Handle Fig. 13/R2.

The dipper handle consists of a single, tubular member supported in the saddle block. The tubular dipper handle minimizes weight, eliminates torsion since it is free to rotate initially within a small range and subsequently retarded by means of a patented friction stabilising device. This feature, together with the rope crowd eases off the shock compression loads in the handle.

The dipper handle is held in the saddle block by replaceable front and rear liners, both made in four segments for assembly purposes. The bottom segments each have keyways appreciably wider than the long key on the lower part of the dipper handle. The clearance between the key and keyway thus permits the dipper handle to rotate slightly before it has any tendency to rotate the liners. Integral with three segments of the front liner are external gear teeth which mesh with the snubber pinion. Movement of the snubber pinion is retarded by friction discs on both sides, which are in permanent engagement with it by means of compression plates and powerful compression springs, adjusted by a rod bolt.

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