CAT BUCYRUS 495 BI MINING SHOVEL MAINTENANCE & OPERATION MANUAL 141090

BI616793

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI616793

BI616793

BI616793

Bucyrus International, Inc. 495BI Mining Shovel

495BI Mining Shovel Maintenance and Operation Manual Manual No. 10028 sn: 141090 –Table of Contents– This manual is divided into major sections covering the various serviceable components and systems of the 495B Mining Shovel. These sections and their contents are organized as shown below.

Section 1 - INTRODUCTION Section 2 - OPERATION Section 3 - LUBRICATION Section 4 - SCHEDULED MAINTENANCE Section 5 - MAJOR MAINTENANCE Section 6 - BRAKES AND COUPLINGS Section 7 - COMPRESSED AIR SYSTEM Section 8 - HEATING, VENTILATION AND AIR CONDITIONING

IMPORTANT NOTE This document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability.

© 1999 Bucyrus International, Inc. All Rights Reserved.

April 1999

Manual No. 10028

BI616793

Bucyrus International, Inc. 495BI Mining Shovel

BI616793

Bucyrus International, Inc. 495BI Mining Shovel

DANGER: THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED

BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.

DANGER: DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY. The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.

THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between the machine and the ground. The portable trail cable and power lines supplying electric energy to the machine must have a ground wire, ample in capacity, running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult your local electrical supplier for details.

DANGER: DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.

BI616793

Bucyrus International, Inc. 495BI Mining Shovel

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

SECTION 1 - INTRODUCTION FORWARD .................................................................................................................................... 2 SAFETY PRECAUTIONS/HAZARDS ........................................................................................... 3 GENERAL SAFETY CONSIDERATIONS ......................................................................... 3 FIRE PREVENTION .......................................................................................................... 7 SAFETY SYMBOLOGY ................................................................................................................ 9 MACHINE PLACARDS ............................................................................................................... 10 MACHINE OVERVIEW ............................................................................................................... 13 SPECIFICATIONS OF THE TYPICAL 495B1 ................................................................. 13 INTRODUCTION ........................................................................................................................ 19 LOWER WORKS ............................................................................................................ 20 CRAWLERS .................................................................................................................... 21 TRUCK FRAME .............................................................................................................. 22 SWING RACK ................................................................................................................. 23 ROLLER CIRCLE ............................................................................................................ 24 PROPEL MACHINERY ................................................................................................... 25 COLLECTOR RINGS ...................................................................................................... 26 ROTATING DECK ........................................................................................................... 27 REVOLVING FRAME ...................................................................................................... 27 CENTER PINTLE ............................................................................................................ 28 DECK EXTENSIONS ...................................................................................................... 29 BALLAST BOX ................................................................................................................ 29 MACHINERY HOUSE ..................................................................................................... 30 A-FRAME ........................................................................................................................ 31 HOIST MACHINERY ....................................................................................................... 32 SWING MACHINERY ..................................................................................................... 33 CROWD MACHINERY .................................................................................................... 34 FRONT END EQUIPMENT ............................................................................................. 35 BOOM ............................................................................................................................. 35 SADDLE BLOCK ............................................................................................................. 36 DIPPER HANDLE ........................................................................................................... 36 DIPPER ........................................................................................................................... 36 PADLOCK ....................................................................................................................... 36 DIPPER TRIP .................................................................................................................. 36 RUNNING ROPES .......................................................................................................... 37 OPERATOR’S CAB ......................................................................................................... 38 COMPRESSED AIR SYSTEM ........................................................................................ 39 AUTOMATIC LUBRICATION SYSTEM ........................................................................... 39 WEIGHT LISTING OF SELECTED COMPONENTS.................................................................41

Manual No. 10028, April 99

Section 1, Introduction - 1

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

FORWARD This manual is designed to assist the owner in the operation and preventive 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. It is important to remember that when a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and reliable more operation will result.

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. Please carefully read the instructions in it. All parts are listed by group and/or product code numbers with the associated item/part numbers for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed. RIGHT HAND (RH) and LEFT-HAND (LH) parts correspond to the operator’s hands at the controls as seated when operating the machine. Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments. Records on each machine are filed by serial number and when given this number, your machine’s specific design and original equipment is accessed quickly by the Bucyrus International’s parts representative.

Periodic additions or revisions may be made to this manual. These can be ordered and will be mailed direct to you from the factory. Should you require additional information or factory service assistance contact your regional service representative or:

Bucyrus International Inc. 1100 Milwaukee Avenue P.O. Box 500 South Milwaukee, Wisconsin, USA

53172-0500

Telephone (414)-768-4000 Fax: (414) 768-4210 It is Bucyrus International’s policy to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to it’s 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.

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SAFETY PRECAUTIONS/HAZARDS

4 9 5 B I

RightView

GENERAL SAFETY CONSIDERATIONS The employment of qualified maintenance personnel, through a scheduled maintenance program, is the best way to minimize machine downtime and maximize productivity of equipment. ⇒

All personnel should be familiar with the location, usage, and operation of all onboard First-Aid kits, fire extinguishers, and other safety/emergency equipment.

⇒

Wear hearing protection when exposed to the following noise levels in excess of the period indicated: 8 hours at 90 dBa 4 hours at 95 dBa 2 hours at 100 dBa 1 hour at 105 dBa 30 minutes at 110 dBa 15 minutes at 115 dBa

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

⇒

When in doubt about the noise level, wear protection.

⇒

Before doing any work on the machine, a qualified electrician must lock out or remove the electric power supply from the machine and tag it so personnel are aware that someone is working on the machine.

⇒

Do not attempt to get on or off the shovel while it is in operation. Notify the operator of any intentions to board/exit the machine.

⇒

Keep hands, feet, and clothing away from rotating parts.

⇒

Do not wear rings, wristwatches or loose fitting clothing when working on machinery.

They could get caught on moving parts causing serious injury.

⇒

Wear a hardhat, safety shoes and protective lenses at all times.

⇒

Do not move or operate the machine without knowing the location and purpose of all personnel, test or support equipment, in or near the machine.

⇒

Always wear a safety belt or harness when the danger of falling exists.

⇒

Always have a second person to monitor the lifeline when working in confined spaces.

⇒

Replace any and all safety and warning placards if they are defaced or removed from the machine.

⇒

Do not start an engine indoors unless adequate exhaust ventilators are provided and in operation.

⇒

Think before you act. Carelessness is one luxury the service man cannot afford.

⇒

Excessive or repeated skin contact with sealant or solvents may cause skin irritation.

In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material for the suggested method of cleanup.

⇒

Never utilize the machine air or hydraulic tubing for support when working on the machine. Deactivate or isolate the system prior to performing maintenance.

⇒

Equipment should be parked on level ground at all times during machine servicing and periods of idleness.

⇒

Cranes and hoists must be of sufficient capacity to lift the heavier components (gearcases, bucket, boom, etc.) and have an ample safety margin remaining.

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⇒

Be sure heavy items are properly supported from cranes or hoists before removing supporting members from machine.

⇒

Utilize guide lines or ropes to minimize the swing of suspended heavy components.

⇒

Have sufficient service personnel available when removing or installing large heavy items to maintain control at all times.

⇒

Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load, they could fail.

⇒

Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip off of the hook if not utilized.

⇒

If a heavy item begins to fall, let it fall, don’t try to catch it.

⇒

When disassembling a machine, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.

⇒

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.

⇒

Floors, walkways and stairways must be clean and dry. After draining operations be sure all spillage is cleaned up.

⇒

Electrical cords and wet metal floors make a dangerous combination.

⇒

Check all wire ropes for telltale signs of early wear or failure.

⇒

Look for and secure any loose bolts or locking devices.

⇒

Use extreme caution while working near any electrical lines or equipment whether it be high or low voltage. Never attempt electrical repairs unless qualified.

⇒

Check limit switches for proper operation.

⇒

When using an oxy/acetylene torch, always wear welding goggles and gloves. Keep a “charged” fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart. Do not weld or heat areas near transformers or electrical cabinets. Utilize proper shielding around lubrication lines.

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Section 1, Introduction - 5

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

⇒

Use a puller to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary.

Then, be sure to wear safety glasses.

⇒

Be careful when using compressed air to dry parts. Use approved air blowguns, do not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding to protect everyone in the work area.

⇒

Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

⇒

After servicing, be sure all tools, parts or servicing equipment are removed from the machine, and secured in an appropriate storage area.

⇒

Protective eye goggles should be worn at all times when working on the airconditioning system. Work on the air conditioning system only in a well ventilated area.

⇒

Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.

⇒

Do not swing dipper over people or equipment. Injury or equipment damage may result from contact. Use audible signals to warn of unusual movements.

⇒

Identify loose rock or unusual strata conditions that might cause dangerous slides and result in injuries. Examine the surface for faulted formations prior to dragline operations and movements.

⇒ ⇒

Never leave the shovel’s dipper suspended in the air when not actually in use.

Prevent the dragging of long lengths of trail cable.

⇒

Ensure the trail cable is not in the path of trucks and bulldozers.

⇒

Check the grounding system to ensure the protection of workers from electrical faults within the trail cables.

⇒

Always handle power cables with rubber gloves and insulated hooks. If a defective cable is found: vulcanize the damaged area instead of taping it.

⇒

Operate machine on level ground and be constantly aware of swing clearance.

⇒

Never hold a load longer than needed in the dump cycle.

⇒

Mechanical Brakes are used only for holding and emergency braking.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

FIRE PREVENTION ⇒

Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate.

⇒

DO NOT smoke while handling flammables or when near batteries.

⇒

Inspect all lines, tubes, and hoses carefully. Tighten all connections to the recommended torque. See Chapter 4 of this manual for the Scheduled Maintenance recommendations and the walk around inspection procedure.

C

L

S1_001

FIRE EXTINGUISHER LOCATIONS ABOARD YOUR SHOVEL ⇒

Repair or replace loose or damaged lines, tubes, and hoses as soon as possible.

⇒

Make certain that all clamps, guards, and shields are replaced correctly so as to prevent vibration and the chafing of parts during operation.

⇒

DO NOT carry flammable fluids such as gasoline or solvents on board the machine.

⇒

DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged lines, tubes, or hoses. Replace them immediately.

⇒

DO NOT start the machine or move any of the controls if a warning tag is attached to the controls or the start panel.

⇒

Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.

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Section 1, Introduction - 7

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

⇒

Keep all structural frame compartments, walkways, and work areas clean and free of lubricant residue.

⇒

NEVER weld, burn, or perform service on the machine alone.

⇒

If a motor or other component is running hot, shutdown the machine until it has cooled and the cause determined and repaired.

Section 1, - Introduction - 8

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

SAFETY SYMBOLOGY

The safety alert symbol displayed here, and throughout this manual, is used to call your attention to instructions concerning your 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 anyone servicing this machine is aware of these SAFETY SYMBOLS and their definition.

In the event you question your ability 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.

NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken.

CAUTION: This signal word serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to.

DANGER: This signal word denotes an imminently dangerous hazard which will result in death, grievous bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

DANGER: This signal word denotes an imminently dangerous electrical hazard which will result in death, grievous bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that and that all the methods used are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit, and free from the influence of alcohol, drugs, or any medications that might impair his eyesight, hearing or reactions.

Safety must always be paramount! Consult your supervisor when safety is in doubt.

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Section 1, Introduction - 9

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

MACHINE PLACARDS The placards depicted below are mounted on your machine as delivered from Bucyrus International.

These hazard warning placards convey information to operator’s, maintenance personnel, and anyone who will be on, or near, the machine. The information is designed to help prevent situations which will terminate in injury or damage to personnel, or the machine.

Please ensure that these placards remain undamaged and intact!

Section 1, - Introduction - 10

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

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Section 1, Introduction - 11

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Section 1, - Introduction - 12

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

MACHINE OVERVIEW The 495B1 electric mining shovel is designed and constructed to provide efficient service under the most severe conditions. The machine is built to the highest possible standards and should provide trouble free operation if properly maintained. Section 1 of this manual will introduce you to the machine and it’s functional capabilities/limitations. The remainder of this publication will be primarily focused on the operation and maintenance of the 495B1 Electric Mining Shovel.

SPECIFICATIONS OF THE TYPICAL 495B1

Weights (pounds)

(kilograms)

Working Weight (w/dipper)

2,456,000

1,113,800

Dipper (55 yd3, 42 m3)

135,000

61,200

Ballast

608,000

275,700

Shipping Weight

1,896,000

859,000

Front End Equipment Boom

Welded, Impact Resistant Steel

Boom Point Sheaves

Twin Grooved, Flame Hardened

Boom Point Sheave Diameter

96"

Shipper Shaft Sheaves

Twin Grooved, Flame Hardened

Shipper Shaft Sheave Diameter

72"

182.88cm

Dipper Handle Diameter

34"

86.36cm

Dipper Handle Wall Thickness

2 1/2" (nominal)

5.71cm

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182.88cm

Section 1, Introduction - 13

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Rope Data # Ropes

Diameter

Type

Constr.

Hoist

2

2 3/4" 69.88mm

Twin Dual

6X37

Crowd

1

2 1/2" 63.5mm

Single Dual 6X37

Retract

1

2 3/8" 60.3mm

Single Dual 6X37

Dipper Trip

1

5/8"

Single

6X37

Boom Suspension

4

3 1/4" 82.6mm

Equalized

Structural

15.9mm

Dimensions and Working Ranges US

Metric

Dipper Capacity (nominal)

55 yd3

42.05 m3

Dipper Capacities (range)

40-83 yd3

30.6-61.2 m3

Length of Boom

64'

19.51m

Boom Angle

43 degrees

Effective Length of Dipper Handle

35’10"

10.92 m

Overall Length of Dipper Handle

47'

14.32 m

Dumping Height (A)

31’4"

9.55 m

Dumping Height at Maximum Radius (B)

25’3"

7.69 m

Dumping Radius at Maximum Height (C)

66’1"

20.14 m

Maximum Dumping Radius (D)

66’9"

20.34 m

Maximum Cutting Height (E)

55’3"

16.84 m

Maximum Cutting Radius (F)

78’2"

23.82 m

Radius of Level Floor (G)

50"6

15.39 m

Maximum Depth Below Ground Level (H)

10’6"

3.20 m

Clearance Height @ Boom Point Sheaves (I)

62’6"

19.05 m

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Clearance Radius @ Revolving Frame (J)

29’7"

9.01 m

Clearance Radius (Rev. Frame to Ground) (K)

11’4"

3.45 m

Clearance Height (Top of Operator Cab) (L)

33’11"

10.28 m

Height of A-Frame (M)

43’8"

13.30 m

Clearance Height (Top of Mach. House) (N)

36’2"

9.34 m

Boom Foot Height (above ground level) (P)

16'

4.87 m

Overall Machine Width (Q)

42’8"

13.00 m

Clearance Width (Operator’s Cab to machine C/L

20’2"

6.14 m

Clearance Width (Mach. House to machine C/L

24’2"

6.35 m

Ground Clearance (Lowest point of Truck Frame)

22"

0.55 m

Operator’s Cab Eye Level

28’4"

8.63 m

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

TYPICAL 495B1 DIMENSIONS (1 OF 2)

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TYPICAL 495B1 DIMENSIONS (2 OF 2)

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

TYPICAL 495B1 FLOORPLAN

Section 1, - Introduction - 18

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

MODEL 495B1 GTO ELECTRIC MINING SHOVEL STANDARD MECHANICAL DESCRIPTION INTRODUCTION This specification describes the principal mechanical features of a standard Bucyrus International, Inc. 495BI GTO Acutrol controlled frequency AC shovel. The shovel is fully revolving, crawler mounted and equipped to operate from an alternating current power source.

TYPICAL 495B1 - RIGHT SIDE VIEW

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LOWER WORKS The lower works is comprised of the truck frame, right and left crawler frames, crawler belts, propel machinery, swing rack, roller circle and collector ring system.

495B1 - LOWER WORKS OVERVIEW

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

CRAWLERS The machine is provided with a crawler type mounting composed of two belts, one on each side of the truck frame. Each belt consists of links driven by a sprocket type drive tumbler. Individual crawler links are heavy alloy steel castings connected by heat treated pins.

Innovative drive tumblers made from large diameter steel castings have lugs extending beyond the tumbler rims. They are mounted on forged alloy steel shafts which turn on large anti-friction bearings mounted within the crawler frame. The sprocket type lugs provide a large area of contact against the crawler links, extending the life of both links and tumblers.

Upper and lower rollers rotate on forged steel shafts cantilever mounted from the crawler side frames for ease of maintenance and inspection. Four (4) 55" (1.39m) diameter lower rollers per frame are specially suited to withstand the periodic single point ground reaction caused by uneven pit floors. Tepee style dirt deflectors combined with vee-ring face seals prevent dirt entry into lower roller bushings. Five upper rollers on each frame support the upper crawler belt, reducing propel friction and drag. These side frames are stress relieved weldments comprised of steel castings and cold weather steel plates.

The hook surface on the inner lower corner of the crawler frame engages a rail on the bottom of the truck frame. Both parts are factory machined to insure metal-to-metal contact.

CRAWLER RELATIONSHIP TO TRUCK FRAME

Cast take-up tumblers are mounted on each end of the take-up axle. These tumblers are fitted with manganese-bronze bushings protected by a sealed hubcap. A vee-ring face seal protects the take-up bushing from dirt contamination.

A square take-up axle fits into rectangular slots in the crawler frame which permits the axle to be moved forward and backward for belt adjustment. Shims are inserted fore and aft of the axle in these slots to position, tension and locate the tumbler and crawler belt.

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Section 1, Introduction - 21

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CRAWLER / TRUCK FRAME CUTAWAY VIEW

TRUCK FRAME The truck frame is a stress relieved welded cellular box structure which utilizes impact resistant steel in the major load carrying members. The low temperature toughness of the steel assures adequate strength and durability across a wide range of temperatures frequently encountered in shovel applications. A fabricated support structure welded integrally into the truck frame supports the center pintle hub area.

The inner diameter of the hub is machined to accept the center pintle bushing. Truck frame surfaces which mate to crawler side frames and swing rack are shop machined to assure proper alignment and solid foundation.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

SWING RACK The swing rack is a large diameter external tooth gear mounted on the top of the truck frame concentric with the center pintle bore. The rack is constructed of a one-piece forged steel rim welded to a cast support core, and welded to the truck frame during erection.

SWING RACK AND ROLLER CIRCLE DETAILS

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

ROLLER CIRCLE The roller circle is comprised of upper and lower rails, (56) tapered rollers, and inner/outer roller frames. Lower rail segments are secured to the top surface of the swing rack forming a continuous rolling path for the rollers. Upper rails attach to the bottom of the revolving frame, fore and aft of the center pintle. Upper rail ends are tapered to provide a smooth approach for the rollers. Rollers are tapered to insure non-skid contact with rails. The rollers are spaced and aligned with pins and low maintenance polyurethane bushings.

ROLLER CIRCLE OVERVIEW

Section 1, - Introduction - 24

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

PROPEL MACHINERY The propel machinery is driven by two AC motors, each horizontally mounted to a shelf cantilevered off the truck frame. The motors are coupled to twin planetary gearcases high up off the pit floor for protection from water and rock damage. The planetary gearcases bolt to the crawler frames. Low inertia spring set, air released plate disc type air brakes are mounted to each of the two motors.

The dual planetary configuration with separate drive motors permits straight ahead or reverse propel as well as counter rotation steering.

PROPEL MACHINERY ORIENTATION

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COLLECTOR RINGS High voltage collector rings on bottom of revolving frame transfer electric power from the truck frame to the rotating deck. Electric power enters the truck frame just below the propel motor, and is transferred by means of collector ring shoes to the collector rings. The shoes are mounted between the cast center pintle hub and the swing rack.

COLLECTOR RINGS - HIGH AND LOW VOLTAGE

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ROTATING DECK The rotating deck consists of revolving frame, center pintle, right and left deck extensions, operator’s cab, and the machinery house. Also included are the electrical system components, operating controls, air system, A-frame, and hoist, swing and crowd machinery units.

495B1 ROTATING DECK AND REVOLVING FRAME

REVOLVING FRAME The revolving frame is the main structural member of the rotating deck. It is a welded, stress relieved structure with integral lugs for mounting the A-frame, crowd machinery and boom.

Provisions are made for mounting deck extensions, operator’s cab, ballast box and swing gearcases.

Machined pads on the deck locate hoist drive motor and machinery frames. The revolving frame is connected to the truck frame by the center pintle.

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Section 1, Introduction - 27

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

CENTER PINTLE The center pintle, is a large diameter, hollow cylindrical forging, threaded at both ends. A bronze coated steel core spherical thrust washer between the lower adjusting nut and the bottom surface of the truck frame provides a wear surface for pintle loads. The top center pintle nut is doweled and bolted to the revolving frame.

CENTER PINTLE DETAILS

The hollow pintle provides passage for air and grease lines, and electrical cables by means of a swivel and collector ring assembly, from the revolving frame to the lower works.

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DECK EXTENSIONS Right and left side deck extensions are bolted to each side of the revolving frame. They provide a mounting area for the electrical transformers and accessory machinery as well as supporting the machinery house walls.

DECK EXTENSION AND BALLAST BOX LOCATION

BALLAST BOX The ballast box is an all welded steel fabrication located at the rear of the main revolving frame. A series of vertical plates in the box form compartments for holding ballast.

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MACHINERY HOUSE

MACHIINERY HOUSE LOCATION

The machinery house encloses the revolving frame, ballast box and deck extensions. It is constructed of self-supporting steel panels with built-in framing. Removable roof sections are provided over the swing machinery and to the side and rear of the A-frame. The house also provides mounting for the air ventilation and pressurization system. A separate electrical room is located over the ballast box. Platforms and stairs facilitate access to the sides and tops of the house for inspection and maintenance purposes. A RH pivoting boarding stairs permits easy access onto the machine.

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A-FRAME An A-frame with seamless tubular alloy steel front legs provides ample space for the retracted dipper handle end. The rear legs are cold weather steel fabricated beams. Both front and rear legs are pin connected to lugs integral with revolving frame. The A-frame supports the boom via structural strands.

A- FRAME AND FRONT END SUPPORT COMPONENTS OVERVIEW

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HOIST MACHINERY The hoist machinery consists of a motor coupled to two gear reductions which drive the hoist drum. A spring set, air released plate disc type brake is mounted to the motor. A hoist rotary encoder limits hoist travel. The hoist motor is connected to the motor pinion shaft by a gear tooth coupling.

HOIST, SWING AND CROWD MACHINERY LOCATIONS

The first reduction gear set is mounted in an oil lubricated, totally enclosed gearcase. The second reduction gears are drip lubricated with open gear lubricant from the automatic lubrication system.

All shafts run on anti-friction bearings. The hoist bull gear is bolted to a spider on the left hand side of the drum.

The hoist drum is manufactured with machined, flame hardened rope grooves. Drum spider stub shafts turn on an anti-friction bearings supported by side frames which are bolted to the rotating deck.

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SWING MACHINERY Two planetary swing gearboxes, each driven by a vertically mounted motor, are mounted on either side of the revolving frame. Dual output shafts from each gearbox are splined to pinions which engage the swing rack.

SWING COMPONENTS - OVERVIEW

Bolt-on mounting permits easy field exchange or replacement of either the planetary gearboxes or the splined pinions.

The four pinions result in lower shared tooth loads for longer pinion and rack life. A spring set air released plate disc brake is mounted on each of the two swing motors.

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CROWD MACHINERY The crowd machinery, located at the front center of the revolving frame, consists of motor, brake, drum and gearing. A crowd rotary encoder prevents overtravel of the dipper handle. Locating the crowd machinery on the revolving frame, instead of the boom, substantially reduces front end weight resulting in lower swing inertia and reduced required swing effort. The entire machinery unit can be removed from the machine should maintenance or overhaul become necessary.

CROWD MACHINERY COMPONENTS - OVERVIEW

The crowd drum drives the crowd and retract rope system. Rope grooves are machined and flame hardened. The crowd and retract ropes are attached to the drum by ferrule-becket anchors which greatly simplifies rope changes.

A spring set, air released plate disc type crowd brake is mounted on the electric drive motor.

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FRONT END EQUIPMENT The front end equipment consists of the boom, boom point sheaves, padlock, saddle block, dipper handle, dipper, dipper trip mechanisms, running ropes, and boom suspension strands.

495B1 FRONT END EQUIPMENT

BOOM The boom is a welded steel structure consisting of twin box girders integrally connected at the boom point and in the lower section between the shipper shaft and boom feet. Impact resistant steel is utilized, coupled with 100% penetration, and UT quality welds on all main splice joints.

Design optimization has resulted in heavier outside skin plates, minimizing the need for internal diaphragms. This reduction in weld related stress concentrations further enhances structural life.

Open manholes have been incorporated in the boom as a standard feature permitting periodic structural inspection. Integral “ladders” within the upper boom sections permit internal access without lowering the boom.

The boom is supported by four pre-stressed suspension (structural) strands attached to equalizer links on the A-frame. These inherent long life structural strands carry the working loads of the front end equipment. When structural fatigue finally does begin, it starts first in the outside layer of wires easily detected by visual inspection, permitting planned maintenance change outs.

A boom limit switch with soft setdown prevents boom jacking shock loads.

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SADDLE BLOCK The saddle block, positioned between the boom side girders and pivoting on manganese-bronze bushings about the shipper shaft, acts as a guide for the longitudinal movement of the dipper handle. The free floating design of the handle in the saddle block eliminates handle torsion.

DIPPER HANDLE The tubular dipper handles antiquated the rack and pinion crowd system in the early 1950’s. One end of the 34" (0.86m) diameter handle connects to the dipper. The crowd rope equalizer sheave attaches to the other end. A hydraulic adjustable take-up mechanism at the dipper end is used to remove slack from the crowd/retract rope system. The dipper handle moves in and out within the saddle block.

An electrical rate reduction circuit, along with the crowd ropes, absorb digging shock loads encountered when the dipper is crowded into the bank.

DIPPER A general purpose dipper is usually constructed as a casting and plate weldment. The dipper lip and lower front are alloy heat treated castings. The dipper body, back, upper sides and door are made of steel plate. Removable Whistler type tooth adapters, and replaceable tooth points are attached to the lip casting to penetrate the bank material.

The door is hinged and latched to the dipper body. A dipper trip mechanism controls the release of the latch bar, allowing the door to swing open. The latch bar holds the door shut during digging.

Spring loaded snubbers dampen the door’s swinging action.

PADLOCK Padlocks connect the hoist ropes to the outer edges of the dipper while still permitting fore and aft, and sideways movement.

DIPPER TRIP The dipper trip is a wire rope activated dipper door trip mechanism driven by an electric motor through gear reduction mounted on the boom near the boom foot.

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RUNNING ROPES Hoist, crowd, retract and dipper trip ropes are all plastic impregnated for increased life and for sheave and drum grooving life enhancement. The double twin hoist ropes are attached to the center of the hoist drum using ferrule-becket anchoring for faster rope change out. Each rope passes over a boom point sheave through the padlock and back over the boom point sheave to the hoist drum. The dual twin hoist rope configuration stabilizes the dipper while digging by attachment to the outer edges of the dipper body.

ROPES - GENERAL ARRANGEMENT

Crowd and retract ropes are attached to the crowd drum and work as an integral system. As the crowd rope is wound on to the drum, the retract rope is reeled off.

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OPERATOR’S CAB The isolated and elevated operator’s cab at the right hand front of the machinery house provides a comfortable, safe and efficient working environment for the operator. Sufficient space is provided for the fully adjustable operator’s seat, a helper’s seat, the standard panel view display, two storage lockers, and a small table.

TYPICAL 495B1 OPERATOR’S CAB

All operating controls are incorporated into the arms of the seat.

The cab is sound and heat insulated with interior walls made of a sound deadening steel-plasticsteel composite. Electric powered windshield wipers are provided for quiet, dependable operation.

A one-piece front window is supplied in a rugged, easy-to-change frame. A forward front window slant with over hanging roof helps keep the window clean. Transparent sun shades are provided in front and side windows.

Visibility through both side and front windows is excellent giving the operator the best view in the industry of the digging face and for truck spotting. This view is enhanced by the streamlined sides and top surfaces of the boom, unencumbered by crowd machinery or dipper handles on the outside of the boom.

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A roof mounted Sigma heater, air conditioner and pressurizing unit utilizes environmentally friendly 134a refrigerant in the cooling system. Interior ducting distributes the airflow to best suit the comfort of the operator.

COMPRESSED AIR SYSTEM The compressed air system consists of a rotary screw type air compressor, air receiver, controls, and center pintle air swivel. Aeroquip high pressure hose is used throughout for commonality with lube system componentry.

AUTOMATIC LUBRICATION SYSTEM A Lincoln type automatic lubrication system applies open gear lubricant (OGL) and grease via a programmable logic controller (PLC). The system has six lube pumps (four for OGL and two for grease), each feeding individual PLC controlled circuits. Lincoln Powermaster Four (75) to (1 ) air powered pumps are mounted on two reservoirs; one 100 gallon, and one 200 gallon. Aeroquip high pressure hoses with reusable fittings are utilized.

The six separately controlled lube circuits provide selective distribution frequency and quantity resulting in reduced lubricant usage and cost.

The lube system is located in an insulated, double wall, lube room which can be heated for cold weather operation. A one ton (907 kg) monorail mounted electric chain hoist is provided to be used to raise supplies from the ground onto the LH house platform and into the lube room. Lube points on the electric motors, suspension rope pins, and some dipper pins are manually accessed.

All other lube points are fed from the automatic system or by oil bath.

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WEIGHT LISTING OF SELECTED COMPONENTS LOCATION

COMPONENT

QUANTITY WEIGHT (US POUNDS)

Crawler Link pads Revolving Frame Truck Frame Crawler Frame Lower Roller Swing Rack Axle, Lower Roller Front Leg, A-Frame Take-Up Axle Drive Tumbler Take-Up Tumbler Tumbler Drive Shaft Center Pintle Sleeve Roller Upper Roller Axle, Upper Roller Bearing, Drive Tumbler Hub Cap, Lower Roller Bushing, Lower Roller Split Collar, Lower Roller Propel Disc Brake Asembly Center Pintle, Lower Locknut Take-Up Axle Thrust Plate Roller Frame Bar Air Swivel Support Roller Frame Bar Center Pintle, Upper Locknut Adapter, Propel Brake Take-Up Axle Shim Roller Frame Bar Center Pintle, Thrust Washer

74 1 1 1 2 8 1 8 2 1 2 2 2 1 56 8 8 2 8 8 16 2 1 2 8 1 8 1 2 16 16 1

(total) 226,588 (each) 3,062 133,400 126,426 67,500 61,200 44,302 33,424 23,000 22,650 13,852 12,788 11,520 7,433 5,768 4,960 3,144 2,660 2,176 1,904 1,657 1,300 1,080 999 970 923 868 780 730 688 541 397

Ballast Ballast Box Swing Planetary Gearcase Drum, Hoist Gear Box, Swing, Split Power Control Power Skid Hoist Gearcase Main Power Transformer Motor, Hoist (??? Hp) Deck Extensions Hoist Spider Assembly Swing Planetary Gearcase Support Drum, Crowd Crwd Frame

1 1 2 1 2 1 1 1 1 2 1 2 1 1

607,570 76,000 34,200 24,860 17,200 16,400 16,050 16,000 16,000 14,605 13,700 13,104 12,800 11,444

Lower Works

Revolving Frame

Section 1, - Introduction - 40

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Motor, Propel (700 hp) Hoist Frame (RH) Cable Reel Swing Shaft Support, Operator’s Cab Lubricants, 1st Fill Hoist Bearing Housing Crowd Drum Gear Motor, Crowd (700 hp) Motor, Swing (505 hp) Pinion, Hoist 2nd Reduction House Filters Crowd 2nd Intermediate Gear Dual Winch Assembly Hoist Gear Guard - Bottom Air Compressor Crowd Gearcase Cover Swing Pinion Shaft, Crowd 2nd Intermediate Hoist Disc Brake Assembly Fan, House Tenkay Hoist Gear Guard - Rear UPS, Uninterruptible Power Supply Crowd 1st Intermediate Reduction Gear Hoist Frame Bearing Cap Pin, Boom Foot Swing Pinion Carrier Bearing Pin, A-Frame retaining Hoist Gear Guard - Forward Swing Disc Brake Assembly Hoist Bearing Pin Motor, Reeveing Winch Air Conditioner Hoist Drum Bearing Fan, House Tenkay Swing Shaft Upper Bearing Hoist Rope Roller (complete) Blower, Hoist Motor Heater, 25KW Adapter, Swing Brake Assembly Adapter, Hoist Brake assembly Blower, Swing Motor Automatic Lubrication Pump

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2 1 1 4 1 1 1 1 2 1 2 1 1 1 2 1 4 1 1 2 1 1 1 1 4 4 4 1 2 2 2 1 2 2 4 1 1 4 2 1 2 6

9,000 8,600 7,900 7,780 7,200 6,000 5,980 4,870 4,500 4,500 3,492 2,650 2,638 2,339 2,244 2,200 2,115 2,096 1,995 1,744 1,640 1,543 1,500 1,360 1,225 1,220 1,216 1,172 1,107 980 960 960 880 840 820 780 738 700 608 534 500 500 384

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Front End Motor Coupling, Swing Growd Gear Guard Blower, Propel Motor Blower, Crowd Motor Dipper Assembly (complete) Boom, 64 ft Dipper Handle Saddle Block Wire Rope, Hoist Sheave, Boom Point Boom Bumper Assembly (complete) Shipper Shaft Wire Rope, Crowd/Retract Half Sheave, Fixed Saddle Block Liner Dipper Door Snubber Frame, Padlock Shaft, Boom Point Sheave Spreader, Retract Suspension Starnd Sheave, Padlock Nut, Take-Up (2.375 Rope) Link, Padlock Bearing, Boom Point Sheave Sleeve, Boom Point Sheave Bearing Bushing, Padlock Pin Pin, Padlock Crowd Sheave Bearing Retract Take-Up Guide Saddle Block Sheave Retainer Split Collar, Boom Pont Sheave Take-Up Cylinder, Hydraulic Dipper Door Latch Mechanism

Section 1, - Introduction - 42

2 1 2 1 1 1 1 1 1 2 1 1 2 1 2 2 2 2 1 2 2 1 2 2 2 8 4 2 1 4 4 2 1

368 340 300 210 231,964 128,000 42,542 13,700 10,006 8,460 7,044 4,875 4,000 3,956 3,850 3,658 2,956 2,066 2,037 1,820 1,228 1,120 905 840 838 732 724 700 500 480 480 290 2.968

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SECTION 2 - OPERATION GENERAL SAFETY ...................................................................................................................... 4 SPECIFIC SAFETY RULES .......................................................................................................... 4 OPERATION NEAR ELECTRICAL DISTRIBUTION AND TRANSMISSION LINES ................... 5 PRE-START CHECKS .................................................................................................................. 6 GROUND LEVEL WALK-AROUND INSPECTION. .......................................................... 6 ON-BOARD INSPECTION ................................................................................................ 8 CONTROLS - FUNCTION AND LOCATION ............................................................................... 11 INTRODUCTION ............................................................................................................. 11 MACHINE ORIENTATION ............................................................................................... 12 PRIMARY OPERATING CONTROLS ......................................................................................... 14 HOIST/SWING/PROPEL MASTER SWITCH (LEVER) .................................................. 14 SIGNAL HORN LEVER ................................................................................................... 15 CROWD/HORN/DIPPER TRIP/PROPEL MASTER SWITCH (LEVER) ......................... 15 DIPPER TRIP .................................................................................................................. 15 HOIST BRAKE SWITCH ................................................................................................. 15 CROWD BRAKE SWITCH .............................................................................................. 16 SWING BRAKE SWITCH ............................................................................................... 16 PROPEL BRAKE SWITCH ............................................................................................. 16 EARTH CONTINUITY LOCKOUT PUSHBUTTON (IF EQUIPPED) ............................... 16 AIR PRESSURE GAUGE ................................................................................................ 16 CONTROL RESET PUSHBUTTON ................................................................................ 17 PROPEL TRANSFER SWITCH ...................................................................................... 17 CONTROL STOP PUSHBUTTON .................................................................................. 17 MACHINE STOP/EMERGENCY STOP PUSHBUTTON ................................................ 18 MAIN POWER OFF PUSHBUTTON ............................................................................... 18 PANELVIEW MONITOR.............................................................................................................. 19 WINDSHIELD WIPER SWITCH ..................................................................................... 20 WINDSHIELD WASHER SWITCH ................................................................................. 20 CAB LIGHT DIMMER SWITCH ...................................................................................... 20 OPERATOR’S SEAT ....................................................................................................... 21 AIR CONDITIONER SWITCHES .................................................................................... 21 WINDOW FAN SWITCH ................................................................................................. 21 SECONDARY OPERATING CONTROLS ....................................................................... 21 PLC CABINET ............................................................................................................................. 22 CONTROL STOP PUSHBUTTON .................................................................................. 22 EMERGENCY STOP/POWER OFF PUSHBUTTON ...................................................... 22 AC CONTROL CABINET ................................................................................................ 23 MOTOR CONTROL CENTER CABINET ........................................................................ 24 REMOTE START CONSOLE ...................................................................................................... 25 EMERGENCY STOP/POWER OFF PUSHBUTTON ...................................................... 25 AIR COMPRESSOR RUN SWITCH ............................................................................... 26 AIR COMPRESSOR START/STOP PUSHBUTTONS (OPTIONAL) .............................. 26 MACHINE STOP PUSHBUTTON ................................................................................... 26 SYSTEM RUN PUSHBUTTON ....................................................................................... 26 UNINTERRUPTABLE POWER SUPPLY OFF PUSHBUTTON ...................................... 26 UNINTERRUPTABLE POWER SUPPLY START PUSHBUTTON .................................. 26

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INCOMPLETE SEQUENCE LIGHT...............................................................................26 AUXILIARY GROUND FAULT LIGHT............................................................................27 PHASE SEQUENCE LIGHT..........................................................................................27 PLC CABINET TEMPERATURE LIGHT........................................................................27 DRIVE CABINET TEMPERATURE LIGHT....................................................................27 PLC POWER ON LIGHT...............................................................................................27 SYSTEM READY LIGHT..............................................................................................27 UPS CONTROL BOX....................................................................................................28 LIGHTING TRANSFER SWITCH (OPTIONAL).............................................................29 CABLE REEL START/STOP PUSHBUTTONS..............................................................29 LUBRICATION CONTROL PANEL................................................................................30 START UP, OPERATION, AND SHUT DOWN..........................................................................31 START UP.................................................................................................................................31 RESTARTING AFTER AN ELECTRICAL FAULT......................................................................34 OPERATION............................................................................................................................35 HOIST MOTION............................................................................................................36 CROWD MOTION.......................................................................................................37 SWING MOTION..........................................................................................................38 PROPEL MOTION.........................................................................................................39 STEERING...................................................................................................................40 CABLE REEL OPERATION..........................................................................................42 POSITIONING MACHINE AT BANK..............................................................................44 BACK-UP METHOD.....................................................................................................44 DRIVE-BY METHOD.....................................................................................................45 START OF DIG CYCLE................................................................................................46 ENGAGING THE BANK...........................................................................................................49 PROPER SWING MOTION......................................................................................................51 EXCAVATED MATERIAL ..........................................................................................................53 OPERATING HINTS:...............................................................................................................54 DURING OPERATION CHECKS.............................................................................................56 STOPPING THE MACHINE......................................................................................................57 SHUTDOWN............................................................................................................................57 PANELVIEW.............................................................................................................................58 THEORY OF OPERATION............................................................................................58 DESCRIPTION.............................................................................................................58 FAULT CONDITIONS....................................................................................................58 MAJOR FAULTS...........................................................................................................58 MINOR FAULTS............................................................................................................59 POWER-UP FUNCTIONS............................................................................................59 BATTERY FAILURE......................................................................................................59 COMMUNICATION........................................................................................................59 WATCHDOG..................................................................................................................59 ON-LINE DIAGNOSTIC TESTING.................................................................................59 PLC COMMUNICATION TIMEOUT................................................................................60 SYSTEM EEPROM CHECKSUM..................................................................................60 APPLICATION DATA CHECKSUM................................................................................60 CONFIGURATION MODE SET-UP................................................................................60 DOWNLOADING/UPLOADING AN APPLICATION FILE..............................................61 CONFIGURING THE SERIAL COMMUNICATION PORT..............................................61 Section 2, Operation - 2

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VIEWING RACK ASSIGNMENTS ................................................................................... 62 ACCESS CODES (SECURITY) ...................................................................................... 62 AUDIO RESPONSE ........................................................................................................ 63 ALARM RELAY................................................................................................................ 63 PRESET OPERATIONS .................................................................................................. 64 SCREEN SAVER ............................................................................................................ 64 ALIGN SCREEN .............................................................................................................. 64 STUCK BUTTON/CELL TIMEOUT ................................................................................. 65 CONFIGURATING TIME AND DATE .............................................................................. 65 UNIT TESTS ................................................................................................................... 66 EEPROM INSTALLATION ......................................................................................................... 67 PANELVIEW DESCRIPTION ...................................................................................................... 68 OVERVIEW ..................................................................................................................... 68 NUMERIC KEYPAD ........................................................................................................ 68 CURSOR CONTROL AND SPECIAL KEYS ................................................................... 68 OPERATING MODES ..................................................................................................... 69 FAULT CONDITIONS ...................................................................................................... 69 POWER-UP FUNCTIONS .............................................................................................. 69 BATTERY FAILURE ........................................................................................................ 69

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GENERAL SAFETY Safe operation of the shovel minimizes production delays and costly damage to equipment.

Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to prevent accidents from occurring and are provided in the interest of all mine personnel.

Overall safety depends upon the use of good judgment and the alertness of the entire mining crew.

SPECIFIC SAFETY RULES The following is a listing of some important safety rules relating to pre-start and operation of the shovel. The safety instructions given in the manual cover normal daily operations of the machine.

Additional precautions may be necessary to cover unusual circumstances. Be constantly alert for any potentially hazardous conditions and report them immediately to your supervisor.

Wear hard hat, safety shoes and safety glasses at all times.

Use audible signals to warn of special movements. A signal horn lever is provided for this purpose. Do not commence machine operation until it has been verified that personnel and obstructions are clear of the machine. A signalman or helper, if available, should be used for this verification.

Ensure that all personnel are clear of the machine and that the pit floor surface is free of obstructions before propelling the machine. A signalman or helper, if available, should be used for this verification.

Do not swing the machine until it has been verified that all personnel are clear of the area. A signalman or helper, if available, should be used for this verification. Injury or death will result if anyone is hit by falling material or by the dipper itself.

Familiarize yourself with the various safety equipment, such as fire extinguishers, on board the shovel.

Keep the operator’s cab, ladders, walkways and steps free of substances which cause slippery conditions or obstacles which create tripping hazards.

Use proper interior and exterior lighting.

Do not allow unauthorized personnel on board the shovel when it is in operation.

Do not leave the dipper suspended in the air if the equipment is to be left idle. Place the dipper on the ground, set all brakes, and de-energize the controls before leaving the operator seat.

Avoid improper loading of haulage units. Load material should not spill or hang over the side of the box.

Allow electrical inspection and maintenance to be handled only by a qualified electrician.

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Prevent trail cable from being dragged on the ground for long continuous periods or at high speeds.

Report all broken hand rails, ladders, etc. on daily machine report.

OPERATION NEAR ELECTRICAL DISTRIBUTION AND TRANSMISSION LINES DANGER: The following precautions shall be complied with whenever operating around or near electrical distribution and transmission lines.

Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be taken. For purposes of this manual we are considering the entire machine or its load, in any position, that can reach to within the minimum distance specified by local, state and federal regulations.

Safe operating practices require that you maintain the maximum possible distance from the lines and never violate the minimum clearances.

Before working in the vicinity of power lines, always take the following precautions: Always contact the owners of the power lines or the nearest electric utility before beginning work.

You and the electrical utility representative must jointly determine what specific precautions must be taken to insure safety.

It is the responsibility of the user and the electric utility to see that necessary precautions are taken.

Consider all lines to be power lines, and treat all power lines as energized even though it is known that the power is shut off and the line is visibly grounded.

Slow down the operating cycle. Reaction time may be too slow and distances may be misjudged.

Caution all ground personnel to stand clear of the machine at all times.

Use a signal person to guide the machine into close quarters. The sole responsibility of the signal person is to observe the approach of the machine to the power line. The signal person must be in direct communication with the operator and the operator must pay close attention to the signals.

DANGER: Death or injury could result should any part of the shovel come within the minimum distance of an energized power line specified by local, state, and federal regulations.

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PRE-START CHECKS Before starting the shovel, inspect the machine to ensure it is ready to be put into operation.

Failure to make such a routine check could result in unnecessary downtime. For example: an undetected oil leak could result in a dry gearcase, eventually leading to excessive gear wear or destruction, seized bearings or other mechanical problems. Broken strands in the hoist ropes, crowd rope, retract rope or structural strands could, if undetected, result in serious injury or damage to the machine or haulage unit. A few minutes spent inspecting the machine often results in considerable savings in time and machine efficiency.

GROUND LEVEL WALK-AROUND INSPECTION.

GROUND LEVEL WALK-AROUND INSPECTION SEQUENCE

1.

Check the areas under and around the crawlers for signs of oil leaks. If single droplets are noticed, leakage is minimal. Determine the point of leakage, and make a note of it on the log sheet. If pooling of oil is noticed, determine the source and take remedial action immediately. Determine if loose hardware, a defective gasket, a combination of both, or a similar problem is responsible. Tighten hardware or replace defective gaskets.

2.

Inspect the crawler belts for missing links or lock pins, excessive belt sag, cracked shoes or other deterioration. Check the oil level in the propel planetary gearcase. Add oil as required.

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3.

Check the swing rack and pinion guards for rocks, dirt and other debris that will interfere with the operation of the shovel. Inspect the swing rack gear and rollers for the proper lubricant film.

DANGER: The machine trail cable carries a lethal voltage. Handle the cable in an approved manner with appropriate rubber gloves and insulated hooks or tongs.

4.

Visually inspect the trail cable for cuts, abrasions and other damage.

5.

At the cable reel, if equipped, check the hydraulic fluid reservoir for proper fluid level. Add fluid if required.

6.

Visually check the cable reel hydraulic system for leaks. Tighten, repair or replace as necessary.

7.

Visually inspect exterior of machinery house for damage or evidence of internal leakage.

8.

Inspect the dipper trip mechanism, rope, latch bar and associated hardware for damage, adjustment and wear.

9.

Inspect the dipper door, hardware and bumpers for damage and excessive wear.

10.

Inspect fulcrum attachment points, take up cylinders and spacers, and dipper handle for damage, excessive wear and evidence of adequate lubrication.

11.

Inspect boom bumper for security and damage.

12.

Inspect the dipper and teeth adapters for security and excessive wear.

13.

Inspect padlocks for damage, wear and evidence of adequate lubrication.

14.

Check both the running ropes and the boom structural strands for broken strands and loose sockets.

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ON-BOARD INSPECTION

ON-BOARD PRE-START INSPECTION SEQUENCE

1.

Visually inspect the swing, crowd and hoist gearcases for oil levels and leaks. Repair or service as required.

2.

Visually inspect all machinery for loose bolts, nuts, clamps or unusual deterioration. Repair as required.

3.

Visually inspect the open gears of the swing, crowd, and hoist machinery for proper lubricant film and evidence of adequate lubrication from the automatic lubricant dispensing system.

4.

Visually inspect hoist and crowd ropes for wear, lubrication and evidence of birdcaging near the drum attachment beckets.

5.

Check the oil level in the air compressor. Add oil if required.

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6.

Check lubricant supply level in the air system lubricator and lube system lubricators.

7.

Inspect the automatic lubrication central pumping stations for any signs of malfunctioning.

Check the lubricant supply and refill tanks if required.

8.

Visually inspect swing brake assemblies for damage, wear, and evidence of an overheated condition.

9.

Visually inspect the crowd brake assembly for damage, wear, and evidence of an overheated condition.

10.

Visually inspect the hoist brake assembly for damage, wear, and evidence of an overheated condition.

11.

Check the operator’s cab for cleanliness and visual condition of controls and location of special equipment that may be required by the mine site. Check all operating controls for freedom of movement. Controls should move freely without binding.

12.

Clean windows of operator’s cab.

13.

Inspect all walkways and stairways to ensure there are no obstructions or fluids creating a safety hazard.

14.

Ensure ladder(s), steps and/or man basket are raised and properly stowed.

15.

Perform manual lubrication of points listed in table on the following page.

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Section 2, Operation - 9

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MANUALLLY GREASES ITEMS - TO BE ACCOMPLISHED DAILY

NOTE: Detailed information on the proper servicing of these components can be found in Sections 3 and 4 of this publication.

Section 2, Operation - 10

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

CONTROLS - FUNCTION AND LOCATION INTRODUCTION Regardless of previous experience, an operator must become familiar with the machine and its operating controls. The figure below depicts the general location of the controls on the typical 495B1 shovel.

For the purposes of this manual, the operating controls will be grouped as primary and secondary controls depending upon their location. The primary controls are the controls located in the operator’s cab and the secondary controls are the controls located in the machinery house.

TYPICAL 495B1 CONTROLS ORIENTATION

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

MACHINE ORIENTATION The descriptions within this manual are written to familiarize you with the controls locations and functional use. The terms left, right, forward and reverse will be utilized. These terms will depict a direction as if seated in the operator’s cab facing forward with the boom extending over the takeup axle of the crawlers.

OPERATOR’S CAB ORIENTATION

1. Hoist/Swing/Propel Master Switch 2. Signal Horn Lever 3. Crowd/Horn/Dipper Trip/Propel Master Switch 4. Dipper Trip Lever 5. Hoist Brake Switch 6. Crowd Brake Switch 7. Swing Brake Switch 8. Propel Brake Switch 9. Earth Continuity Lockout 10. Air Pressure Gauge 11. Control Reset Pushbutton 12. Propel Transfer Switch 13. Control Stop Pushbutton 14. Emergency Stop Pushbutton

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15. Main Power OFFPushbutton 16. Panelview Monitor 17. Windshield Wiper Switch 18. Windshield Washer Switch 19. Cab Dimmer Light 20. Operator’s Seat 21. Air Conditioner Switches 22. Cab Light/Electrical Outlet 23. Upper Windshield Wiper 24. Lower Windshield Wiper 25. Cigar Lighter 26. Oiler’s Seat 27. Fire Extinguisher 28. Windshield Washers

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

OPERATOR’S SEAT LEFT HAND (LH) AND RIGHT HAND (RH) CONSOLE DETAILS

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

PRIMARY OPERATING CONTROLS HOIST/SWING/PROPEL MASTER SWITCH (LEVER) The hoist/swing/propel master switch is a joystick mounted on the right hand console of the operator’s seat. The joystick is used to control the hoist, swing and RH crawler motions of the machine. The position of the propel transfer switch will determine whether this switch controls the hoist motion or the crawler motion.

With the propel transfer switch in the dig position, pushing the lever forward will lower the dipper.

Pulling the joystick to the rear will hoist the dipper. The neutral position between the hoist and lower functions is defined by a detent that is easily felt. The speed of moving the dipper is controlled by varying the distance the joystick is moved from the neutral position. Full forward or full rearward position provides maximum speed to the dipper. Moving the joystick to neutral will cause a braking action slowing the hoisting or lowering motion. Reversing the joystick will cause the motion to stop and if the joystick is held in this position, it will change the direction of the motion.

NOTE: When the hoist/swing master switch is used in the hoist/lower mode the switch is a spring returned switch. That is, it will return to the neutral position when it is released.

Moving the joystick to the left from the neutral position will cause the machine to swing to the left.

Moving the joystick to the right will cause the machine to rotate to the right. The swing motion is operational throughout the entire movement range of hoisting or lowering the dipper. The swing rate of acceleration is controlled by varying the distance the joystick is moved from the neutral position. Moving the joystick to the neutral position will not stop the swing motion but will allow the machine to coast. To stop or change direction the control joystick is moved past the neutral point in the opposite direction. The rate of deceleration is controlled by varying the distance the joystick is moved from the neutral position in the opposite direction.

With the propel transfer switch in the propel position, pushing the lever forward will cause the RH crawler to move forward. Pulling the lever to the rear will cause the RH crawler to move in the reverse direction. The hoist motion is locked out electrically when the machine is in the propel mode.

NOTE: When the hoist/swing master switch is used in the swing mode the switch is a spring returned switch. That is, it will return to the neutral position when it is released.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

SIGNAL HORN LEVER The signal horn lever is part of the crowd joystick function. Refer to crowd/horn/dipper trip/propel master switch for horn operation.

CROWD/HORN/DIPPER TRIP/PROPEL MASTER SWITCH (LEVER) The crowd/horn/dipper trip/propel master switch is a joystick switch mounted on the left-hand console of the operator’s seat. The switch will spring return to neutral when released.

Pushing the joystick forward will extend the dipper handle and dipper. Pulling the joystick rearward will retract the dipper handle and dipper toward the machine. The neutral position between the crowd and retract functions is defined by a detent that is easily felt. The speed of moving the handle is controlled by varying the distance the joystick is moved from the neutral position. Full forward or full rearward position provides maximum speed to the handle. Moving the joystick to neutral will cause a braking action slowing the crowding or retracting of the handle. Reversing the joystick will cause the motion to stop and if the joystick is held in this position, it will change the direction of the motion.

Moving the joystick to the right will activate the dipper trip mechanism which releases the dipper door latch. The dipper trip is operational throughout the entire range of the crowd motion.

Moving the joystick to the left will activate the signal horn. The signal horn is operational throughout the entire movement range of the crowd motion.

With the propel transfer switch in the propel position, pushing the joystick forward will cause the LH crawler to move forward. Pulling the joystick to the rear will cause the LH crawler to move in the reverse direction. The crowd/retract motion is locked out electrically when the machine is in the propel mode.

DIPPER TRIP The dipper trip is part of the crowd joystick function. Refer to crowd/horn/dipper trip/propel master switch for dipper trip operation.

HOIST BRAKE SWITCH The hoist brake switch is a two-position switch located on the left operator’s console. This switch is used to set and release the hoist brake. The switch positions are identified on the switch face.

NOTE: The hoist brake is not to be used as a braking device, except as a holding brake or with an electrical fault or in an emergency. The primary function of the brake is to prevent motor rotation while the machine is shut down.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

CROWD BRAKE SWITCH The crowd brake switch is a two-position switch located on the left operator’s console. This switch is used to set and release the crowd motor brake. The switch positions are identified on the switch face.

NOTE: The crowd motor brake is not to be used as a braking device, except with an electrical fault or as a holding brake or in an emergency. The primary function of the brake is to prevent motor rotation while the machine is shut down.

SWING BRAKE SWITCH The swing brake switch is a two-position switch located on the left operator’s console. This switch is used to set or release the swing motor brakes. The switch positions are identified on the switch face.

NOTE: The swing motor brake is not to be used as a braking device, except with an electrical fault or as a holding brake or in an emergency. The primary function of the brake is to prevent motor rotation while the machine is shut down.

PROPEL BRAKE SWITCH The propel brake switch is a two-position switch located on the left operator’s console. This switch is used to set or release the propel brakes. The switch positions are identified on the switch face.

NOTE: Unlike the other brakes on the machine, the propel brakes are intended as operational brakes and are used in the operation of the machine.

EARTH CONTINUITY LOCKOUT PUSHBUTTON (IF EQUIPPED) The earth continuity lockout pushbutton is used to trip the breaker that supplies power to the machine. When the machine is operating, this pushbutton should be used to shutdown the machine only when removal of power to the machine is required.

AIR PRESSURE GAUGE The air pressure gauge is located on the upper or lower portion of the panelview console at the left of the operator’s seat depending on your specific machine. It indicates the regulated air pressure available in the air system.

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CONTROL RESET PUSHBUTTON CAUTION: This is not an automatic reset system. All controls must be returned to neutral before the control reset button is pushed.

The control reset pushbutton is a pushbutton located on the right operator’s console. The reset pushbutton restores control to all motions if no additional faults exist. This pushbutton is inoperative until the main power start control has been actuated.

If a control fault occurs that shuts down a motion, all motions will automatically be shut down together. At this time the operator should set all brakes. If the fault clears, the motion may be reset by pressing this pushbutton. If the fault does not clear, the unfaulted motions can be restarted by pressing this pushbutton to enable these motions to re-position themselves.

PROPEL TRANSFER SWITCH The propel transfer switch is a two-position switch mounted on the right operator’s console. The switch is used to activate either the propel mode or dig mode circuits. When one circuit is activated, the other is blocked.

The recommended procedure to transfer from hoist to propel is to bring all motions to a controlled stop by the operator. Turn the hoist brake switch to the SET position and then press the control stop pushbutton. Then turn the transfer switch from DIG to PROPEL. Turn the transfer switch from dig to propel. When the indicating lights on the panelview screen indicates that the transfer has been completed, turn the propel brake switch to release.

CONTROL STOP PUSHBUTTON The control stop pushbutton is a pushbutton located on the right operator’s console. Normally it is used to de-energize controls after the machine has been safely stopped by placing motion controls in neutral.

Actuation of this pushbutton when motions are running will cause all motions to automatically electrically brake to a stop and, when the motion speed has reached less than 5% speed, set all mechanical brakes. If the motions are already stopped, the brakes will be set and power is removed immediately. A similar switch is located on the front panel of the PLC control cabinet that can be used during testing of the machine.

DANGER : The operator should never leave their seat unless they have first pressed the control stop pushbutton. Setting only the mechanical brakes with individual switches in not a sufficient safeguard to prevent machine damage and/or personnel hazards.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

MACHINE STOP/EMERGENCY STOP PUSHBUTTON The machine stop/emergency stop pushbutton is located on the right operator’s console. It is used to remove power from the machine motions after the motions have been stopped in the normal manner. A second purpose of the pushbutton is to stop the machine under operational emergency conditions. Pushing this button will provide electrical and immediate mechanical braking simultaneously. Therefore, this button should only be used if the operator intends the harshest braking of all motions. If the machine is in motion, power will remain on the motions in order to provide electrical braking for a few seconds. If the machine is in motion or stopped, this button will power the DC bus to approximately zero voltage quickly after the time delay.

A second pushbutton that also provides the functions as described above is located in the remote start console and is labeled “machine stop.”

MAIN POWER OFF PUSHBUTTON The main power off pushbutton is located on the right operator’s console. It is used only to immediately remove power from the drives in case of an electrical emergency involving component failure or fire.

CAUTION: Pushing the “power off” pushbutton while in motion will immediately set the mechanical brakes and remove incoming high voltage from the drives. This action may result in component damage. It will also result in the inability to power the DC bus voltage down to a low value. This voltage will decay slowly, taking several minutes.

Pushbuttons performing these identical functions are located on the PLC control cabinet and the operator’s remote start console. Here the buttons are labeled “EMERGENCY STOP/POWER OFF” since the likely emergency situation in these locations will be as a result of component failure.

All of these pushbuttons will latch in the off position and must be pulled out before the machine can be run.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

PANELVIEW MONITOR The panelview monitor is a video display which consists of a viewing screen (CRT) and associated key pads. The monitor allows a large number of messages to be sent to the operator from all parts of the control system.

PANELVIEW PEDESTAL DETAILS

These messages fit into four basic categories: 1.

Normal routine operational messages

2.

Alarms only

3.

Delayed shutdown messages

4.

Immediate faults and shutdowns

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The monitor also allows machine personnel to set certain operational parameters by means of the operator’s key pad on the monitor.

There are two audible alarms used with the monitor. An internal beeping sound is used to alert the operator that a message exists for his attention. A second audible alarm mounted to the monitor console is used to alert the operator that a delayed shutdown is about to occur.

NOTE: Refer to a later portion of this section for further operational procedures and details pertaining to the the panelview monitor.

WINDSHIELD WIPER SWITCH The windshield wiper switch is located on the panelview monitor console at the left of the left operator’s console. It controls the speed of the wipers, as well as the starting and stopping of the wipers.

WINDSHIELD WASHER SWITCH The windshield washer switch is located with the windshield wiper switch on the panelview monitor console. It controls the supply to the washer reservoir which powers the washers.

CAB LIGHT DIMMER SWITCH The cab light dimmer switch is located on the panelview monitor console and is used to dim the lights of the operator’s cab.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

OPERATOR’S SEAT The operator’s seat is equipped with various adjustments to position the seat for maximum operator’s comfort. Periodically lubricate the adjustable areas of the seat.

OPERATOR’S SEAT ADJUSTMENT CAPABILITIES

1.

Weight Compensation

2.

Horizontal Slide Ajustment

3.

Seat Slope Adjustment

4.

Seat Horizontal Adustment

5.

Console Adjustment

AIR CONDITIONER SWITCHES The air conditioning control unit is located on the back wall of the operator’s cab and contains a selector switch, thermostat and fan speed switch.

WINDOW FAN SWITCH (if equipped) The window fan switch is located on the panelview monitor console and is used to operate the front window fan.

SECONDARY OPERATING CONTROLS Secondary operating controls which are located in the machinery house are as follows:

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

PLC CABINET The PLC cabinet is located in the electrical control room at the rear of the machine. Located on the front panel of the cabinet are the following pushbuttons:

TYPICAL PLC CABINET

CONTROL STOP PUSHBUTTON The control stop pushbutton is the right pushbutton located on the left hand door of the cabinet. It is used to stop the machine in testing situations. The button on this cabinet is typically only used when electrical tests are being done. Actuation of this pushbutton will normally cause all motions to automatically electrically brake to a stop and when the motion speed has reached less than 5% speed, set all mechanical brakes. If motions are already stopped, the brakes will be set and reference power removed immediately. A like pushbutton is also located on the right operator’s console.

EMERGENCY STOP/POWER OFF PUSHBUTTON This pushbutton, like the power off pushbutton on the operator’s right console, will provide immediate mechanical braking only and remove power from the motions.

CAUTION: Depressing this button when any drive is in motion may result in component damage.

For the complete description of the operation of this pushbutton see machine power off pushbutton under operator’s cab controls.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

AC CONTROL CABINET The AC control cabinet is located next to the PLC cabinet in the electrical control room at the rear of the machine. Located on the front panel of the cabinet is an hourmeter and the uninterruptable power supply breaker.

1.

2.

Hourmeter Uninterruptable Power Supply Breaker

The breaker must be in the ON position in order to operate the machine.

TYPICAL AC CONTROL CABINET

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

MOTOR CONTROL CENTER CABINET The typical motor control center cabinet contains the breakers for the auxiliary equipment on the shovel. Because of the variations of equipment supplied on a particular shovel, a list of typical controls which might appear on the cabinet is shown in the figure shown below.

TYPICAL MOTOR CONTROL CABINET

1. Auxiliary Power Breaker 12. Front Intake Fan #1 Breaker 2. Dipper Trip Breaker 13. Drive Cabinet Fans - Low Speed Breaker 3. Control Room Heater #2 Breaker 14. Drive Cabinet Fans - High Speed Breaker 4. Control Room Heater #1 Breaker 15. Uninterruptable Power Supply Breaker 5. Rear Intake Fan Breaker 16. Welder Breaker 6. Lighting Transformer Breaker 17. Front Intake Fan #2 Breaker 7. Operator’s Cab Ventilator Breaker 18. Propel Blower Breaker 8. Crowd Blower Breaker 19. Air Compressor Breaker 9. Hoist Blower Breaker 20. Reeving Winch #1 Breaker 10. Swing Blower #2 Breaker 21. Reeving Winch #2 Breaker 11. Swing Blower #1 Breaker

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

REMOTE START CONSOLE The remote start panel is located just inside the machinery house right hand door. The panel

contains switches and indicator lights. This panel is used to initially start the machine.

REMOTE START CONSOLES FOR SINGLE/DUAL AIR COMPRESSOR MACHINES

1. Emergency Stop/Main Power Off Pushbutton 2. Air Compressor Run Switch 2a. Air Compressor Run Switch (1 of 2) 2b. Air Compressor Run Switch (2 of 2) 3. Machine Stop Pushbutton 4. System Run Pushbutton 5. Uninterruptable Power Supply Off Pushbutton 6. Uninterruptable Power Supply On Pushbutton 7. Incomplete Sequence Light

8. Auxiliary Ground Fault Light 9. Phase Sequence Light 10. PLC Cabinet Temperature Light 11. Drive Cabinets Temperature Light 12. PLC Power On Light 13. System Ready Light

EMERGENCY STOP/POWER OFF PUSHBUTTON This pushbutton, like the power off pushbutton on the operator’s right console, will provide immediate mechanical braking only and remove power from the motions.

CAUTION: Depressing this button when any drive is in motion may result in component damage.

For the complete description of the operation of this pushbutton see machine power off pushbutton under “operator’s cab controls.”

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

AIR COMPRESSOR RUN SWITCH This switch is normally in the run position at all times so that the compressor runs continuously.

The compressor is equipped with an unloader system to maintain prescribed air pressure.

If this switch is in the run position when the machine is started, an audible alarm will sound.

This switch is not used when the console is equipped with start and stop pushbuttons (optional) to operate the air compressor.

AIR COMPRESSOR START/STOP PUSHBUTTONS (OPTIONAL) The air compressor start and stop pushbuttons are used to control the auxiliary air compressor.

The stop pushbutton is only used for complete machine shutdown or when maintenance is being performed on the air compressor.

MACHINE STOP PUSHBUTTON This button provides the same functions as the machine stop/emergency stop pushbutton in the operator’s cab. For the operation of this pushbutton see the description for the machine stop/ emergency stop pushbutton on the right operator’s console.

SYSTEM RUN PUSHBUTTON This pushbutton will energize the drive system when pressed if the system ready light is on.

UNINTERRUPTABLE POWER SUPPLY OFF PUSHBUTTON This button is used to shutdown the UPS motor. A like button is located on the UPS control box door.

UNINTERRUPTABLE POWER SUPPLY START PUSHBUTTON This button is used to start the UPS motor. The phase sequence light must be on before this button can start the motor. A like button is located on the UPS control box door.

INCOMPLETE SEQUENCE LIGHT This red indicator light, when lit, indicates automatic start-up sequence did not complete in a preset time period. Have an electrician troubleshoot the sequence. If this indicator does not light up, then the sequence so far is correct and the start-up of the machine can continue.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

AUXILIARY GROUND FAULT LIGHT This green indicator light, when lit, indicates that no auxiliary power ground fault exists. If the light is off, alert an electrician as soon as possible.

PHASE SEQUENCE LIGHT This green indicator light, when lit, indicates that incoming power sequence is correct. If the light is off, have electrical maintenance change trail cable phase sequence.

PLC CABINET TEMPERATURE LIGHT This green indicator light, when lit, indicates that the PLC cabinet is at the correct operating temperature. Too low or too high cabinet temperature will not allow the machine to start.

DRIVE CABINET TEMPERATURE LIGHT This green indicator light, when lit, indicates that the drive electronic cabinets are at the correct operating temperature. Too low or too high cabinet temperatures will not allow the machine to start.

PLC POWER ON LIGHT This green indicator light, when lit, indicates that PLC and drive control power is on. This light should be lit about 20 seconds after the UPS mg set is started.

SYSTEM READY LIGHT This green indicator light, when lit, indicates the system is ready to start. When the system run pushbutton is pressed and the system successfully started, this light will go out.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

UPS CONTROL BOX The UPS control box is mounted to the top of the UPS mg set and contains the controls as shown.

TYPICAL UNINTERRUPTIBLE POWER SUPPLY AND CONTROL BOX

1. Motor ON Light 2. Generator ON Light 3. Overvoltage Indicator Light 4. Ammeter 5. Voltmeter 6. AM-VM Selector Switch

7. Overvoltage Reset Button 8. Auto Voltage Adjustment 9. Start Button 10. Stop Button 11. Output Circuit Breaker

HOUSE LIGHT CIRCUIT BREAKERS The house light circuit breakers are located on the right side wall of the machinery house next to the remote start console. A main light circuit breaker is located on the auxiliary control cabinet. The breakers protect the lights from over-current loads.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

LIGHTING TRANSFER SWITCH (OPTIONAL) The lighting transfer switch is located on the right side wall of the machinery house near the lighting control center. This switch is used to transfer power for lighting from on machine source to off machine source.

LIGHTING POWER TRANSFER SWITCH

CABLE REEL START/STOP PUSHBUTTONS The cable reel start/stop pushbuttons are located on the right side of the cable reel frame. These pushbuttons are used to start and stop the hydraulic pump drive motor. The on/off switch in the operator’s cab (if equipped) must be in the on position before these pushbuttons are energized.

CABLE REEL CONTROL LOCATIONS - EXTERNAL

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

LUBRICATION CONTROL PANEL The top row on this panel consists of a group of indicating lights. A red light indicating that the system has a fault and a green light indicating that power for the system is provided for each independent lubricating system (A, B & C). Isolating switches are used to provide power to each system and a means of isolating each system from electrical power. They are also used to reset lubrication faults. These switches are normally on. Manual lube buttons are also provided.

LUBRICATION CONTROL PANEL

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

START UP, OPERATION, AND SHUT DOWN START UP Whether starting the shovel for the first time, or starting after the machine has been in service for some time, the procedures are essentially the same.

1.

Perform all pre-start checks listed earlier in this section of the manual.

2.

Raise the boarding stair, making sure it is secured in the raised position. The limit switch at the top of the stair will not close and the controls will not energize if the stair is not in the full raised position.

TYPICAL START-UP CONTROL LOCATIONS

3.

In the operator’s cab check that all brake switches are in the set position and that the control joysticks are in the neutral position. Then go to the electrical room at the rear of the machinery house.

4.

At the AC control cabinet verify that the uninterruptable breaker is in the on position. At the motor control cabinet, verify that all breakers are in the on position.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

5.

Go to the remote starting console in the machinery house and use the following sequence to start the machine. a.

Verify that the auxiliary ground fault light, which is a green light, is lit.

CAUTION: If the light is off, alert an electrician as soon as possible. The machine may be operated with one such a fault but a second fault could cause damage to the machine and/or become a safety hazard. The fault should be cleared as soon as possible. b.

Verify that the phase sequence light, which is a green light, is lit. This indicates that the incoming power sequence is correct. If it is not correct, the light will be out and the machine will not start. The electrical maintenance personnel must correct the sequence.

NOTE: This light also indicates auxiliary power phase unbalance, phase loss or under voltage.

If any of these faults occurs, when the machine is running, an alarm will also sound. In event of such an alarm, the electrician should be notified but machine may be operated. c.

Verify that the PLC and drive cabinets temperature lights, which are green lights, are lit. If the cabinet temperature is too low or too high, the machine cannot be started.

d.

Press the uninterruptable power supply on pushbutton. A second start pushbutton is located on the UPS control cabinet.

e.

Verify that the PLC power on light, which is a green light, is lit. This light should be lit about 20 seconds after the UPS motor is started.

f.

Turn the air compressor run switch to the run position, if console is so equipped. (for machines with pushbuttons instead of a switch to control the air compressor, depress the start pushbutton)

g.

Verify that the system ready light, which is a green light, is lit.

h.

Press the system run pushbutton. When this button is pressed, the system ready light will go out and the drive system will automatically power up.

i.

Verify that the incomplete sequence light, which is a red light, is out. If the light is lit, call the electrician to troubleshoot the sequence.

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6.

At this point return to the operator’s cab and position yourself in the operator’s seat. Check the air pressure gauge for correct air pressure. The machine cannot be operated until the air pressure is at the specified rating.

7.

Again verify that the brake switches are in the set position, the joysticks are in the neutral position, and the air pressure is at the correct pressure. Sound the signal horn and be sure all personnel are clear of machine.

8.

Turn the propel transfer switch to the dig position. When the panelview lights indicate that the process is complete, press the control reset pushbutton to activate the controls.

9.

Turn the hoist, crowd, swing and propel brake switches to the released position.

10.

Briefly actuate swing, crowd, hoist and propel controls to make sure each motion is operational.

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RESTARTING AFTER AN ELECTRICAL FAULT To restart the machine after the electrical control system has gone into a fault condition, proceed as follows:

NOTE: Before any or all motions can be reset, the following conditions must be met: a.

No operator’s monitor special screens are activated.

b.

For hoist/propel motion the hoist/propel transfer switch is in the position called f or by the operator’s mode selector switch.

c.

The master switch for the motion being reset must be in the neutral position.

d.

The motion mechanical brake selector switch must be in the released position.

1.

For hoist or crowd travel limit faults, the motion will first slow down and then will stop, but the controls will remain active. Reversing the master switch will remove the fault and allow continued operation.

2.

For a boom jacking fault, the motion will stop but the controls will remain active. Reversing the crowd master switch will remove the fault and allow continued operation.

3.

If the boarding ladder is pulled down while the machine is in operation, an alarm message will be sent to the operator and swing and propel motions will be shut down. The hoist and crowd motions will remain active.

Once the ladder is back in position, the motions may be restarted by pressing the control reset pushbutton.

4.

For most other faults, the machine will be shut down and brakes set. In these situations, the controls cannot be reset until the fault has been corrected by an electrician.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

OPERATION Efficient operation is essentially the result of understanding and applying the basic techniques related to each shovel motion, to achieve fast, smooth and safe load cycles. The interrelated coordination of the hoist, swing and crowd motions results in efficient shovel operation.

Each motion is described in the following paragraphs. The operator should thoroughly learn each motion, its purpose and how this knowledge can be applied in becoming a better operator.

When learning to handle the controls, be sure that all personnel are clear of the machine and that there is ample clearance with no danger spots around the machine, such as culverts, ditches, embankments, and that the machine is not too close to the digging face or overhanging ledge and large rocks.

Use the panelview monitor in the operator’s cab to assist in the operation of the machine. The monitor allows a large number of messages to be sent to the operator from all portions of the control system. These messages fit into four basic categories: 1. Normal routine operational messages.

2. Alarm only.

3. Delayed shutdown messages.

4. Immediate faults and shutdowns.

This monitor also allows the setting of certain operating parameters for the machine. Refer to separate manual for the operation of the panelview monitor as the proper use of the monitor messages is essential for the operation of the machine.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

HOIST MOTION The Hoist motion is controlled by a single joystick control at the operator’s right. Set the propel transfer switch in the dig mode. Move the control joystick between the hoist and lower until a “feel” is developed for the height, depth range and speed at which the dipper moves. Practice the hoist function until movement can be stopped smoothly. The crawlers should be positioned so that the digging is done over the front of the crawlers.

CAUTION: This joystick also controls the swing motion.

HOISTING AND LOWERING OPERATIONS

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CROWD MOTION The crowd motion is controlled by a single joystick control at the operator’s left. Move the control joystick to crowd and retract the dipper handle until a “feel” is developed for the limits and speed of the motion.

CAUTION: This joystick also controls the signal horn and dipper trip.

CROWD AND RETRACT OPERATIONS

Practice the crowd and retract functions until the movement can be stopped smoothly.

Combine the crowd and hoist functions and practice until smooth coordinated motions and subsequent maximum machine effectiveness are achieved.

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SWING MOTION The swing motion is controlled by a single control joystick to the right of the operator. To swing in either direction, move the joystick lever in the direction you want to swing . Practice swinging in each direction until a “feel” is developed for start-up and stopping.

NOTE: The joy stick also controls the hoisting and lowering of the dipper. Remember moving the joystick forward or backwards from the neutral point will lower or hoist the dipper. Moving the joystick from side to side will swing the machine.

DANGER: Be sure you are fully aware of the movements of this lever before attempting to use it, as each motion - hoist or swing - is fully operational throughout the complete movement of the other motion.

NOTE: When this joystick is used for propelling the machine, the hoist motion is electrically locked out.

SWING OPERATIONS

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PROPEL MOTION The propel motion is controlled by placing the propel transfer switch in the propel mode, and actuating the hoist master switch control and/or crowd master switch control. To propel in a straight forward direction, push forward on the hoist and crowd master switches at the same time . The speed is increased as the levers are displaced farther from neutral. To propel straight in reverse, pull both joysticks to the rear equally.

NOTE: The control stop pushbutton should be depressed before the propel transfer switch can be activated.

DANGER: The hoist brake must be set whenever in the propel mode.

PROPEL - STRAIGHT FORWARD/REVERSE

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STEERING To make a gradual forward right turn, leave the hoist joystick in neutral and operate the crowd joystick forward.

To make a gradual forward left turn, leave the crowd joystick in neutral and operate the hoist joystick forward.

Whenever possible, gradual turns should be made in short increments of 15 to 20 degrees maximum.

Propel straight for a short distance (usually 1/2 the length of the crawler belts) to clear the crawler belts of stone and other debris; then make another 15 to 20 degree turn. Until the turn is completed.

MAKING GRADUAL TURNS IS EASIER ON COMPONENTS

NOTE: When steering in soft material such as sand, clay, etc. Increments of less than 15° to 20° might be used to minimize material build up on the crawler belt roller path.

A single sharp turn should be avoided to minimize material build up on the crawler belt roller path and subsequent high loading of crawler belt and associated propel components.

To make a sharp right turn, push the crowd joystick forward and pull the hoist joystick to the rear.

To make a sharp left turn, push the hoist joystick forward and pull the crowd joystick to the rear.

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CAUTION: When using the counter-rotation method for turning, have a helper available who can watch that the trail cable does not get fouled and/or torn from the machine.

NOTE: The ability of the machine to turn sharply is dependent on the surface on which the machine is setting. A soft surface will cause the crawlers to dig-in and machine to bog-down.

CAUTION: The propel brakes are released whenever either joystick is moved from the neutral detent. The propel brakes are set when both joysticks are returned to their neutral detent.

When straight propelling, propel forward, which is in the direction of the take-up axle, instead of reverse, to reduce strain on the crawler belts and propel mechanism. However, it is not always possible to propel only forward. When propelling to the rear, make sure the trail cable is clear of the machine, and follow the signals given by the signal man. The machine should be swung so the operator is facing the direction of travel.

NOTE: Turning when propelling to the rear requires that the master control be positioned in a direction opposite the actual direction in which the turn takes place.

The shovel should be moved close to the bank in short and frequent moves, to maintain digging efficiency. Movement should occur between the loading of haulage units.

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CABLE REEL OPERATION The cable reel is designed to pick up trail cable as the shovel moves toward its power source. It is not designed to drag the trail cable over the ground.

The “line pull” of the cable is proportional to operating pressure. The correct line pull is when there is sufficient pull on the cable to wind it on the reel but not too great to put unnecessary strain on the trail cable.

The “line speed” is dependent on the volume of hydraulic oil flowing through the system. The correct line speed is slightly faster than the travel speed of the shovel.

CABLE REEL OPERATION

To operate the cable reel proceed as follows: 1. If the machine is so equipped, verify that the cable reel on/off switch in the operator’s cab is in the on position.

2. Jog the start/stop pushbutton at the cable reel to check for proper rotation of the pump.

3. Start the pump and allow oil to circulate for five minutes.

4. The cable reel, if properly adjusted, will then automatically wind or unwind the trail cable as the shovel is propelled.

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DANGER: For maximum safety when manually operating the cable reel, the cable reel operator must be in view of the shovel operator at all times. This is accomplished by extending the boom mounted to the right side of the cable reel.

5. To operate the cable reel manually, close the needle valve mounted on the RH end of the reel frame. When the valve is closed, the hydraulic system can be operated without the propel clutch air being applied.

6. Manual control of the cable reel is then controlled by the 4-way valve mounted to the swing out boom of the cable reel.

Manual No. 10028, April 99

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POSITIONING MACHINE AT BANK There are two basic methods for positioning an excavator at a bank working face. The first method is the “back-up method”. The second method is the “drive-by method”. Both methods are acceptable and effective when set up correctly.

BACK-UP METHOD When using the back-up method, the excavator is placed in the bank with the front of the machine turned directly toward the digging face. The haulage units are spotted on both sides of the machine.

The bank is worked until a 180° semicircle has been excavated. When the point is reached where a 90° swing to either side is required to load haulage units, the excavator is moved to a new cut.

BACK-UP METHOD OF BANK REPOSITIONING

Move the shovel right to left along the bank. The operator should set the left brake first. In increments, back the shovel until the crawlers are at a 45° angle to the original digging path. Then, back the machine straight until the right crawler crosses the corner of the excavated semicircle.

Lock the left track, propel forward turning the crawler in increments. When the right crawler is in line with the corner of the semicircle, move forward and proceed to load the haulage units.

The back-up method will minimize the swing arc and reduce moving time. Other advantages are less bank toe area clean up and simplified handling of the trail cable, cable standard and trail cable boat.

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DRIVE-BY METHOD NOTE: If the machine and haulage units cannot be set up as described below, the drive-by method should be avoided.

Position the shovel crawlers parallel to the bank with the inside edge of the outer set of crawler tracks directly in line with the bank toe.

The trucks must approach the shovel from the front making a turn away from the shovel as the front wheel approaches the outside crawler. The truck should stop in a position to allow backing toward the point of the bank for loading.

DRIVE-BY METHOD OF MACHINE REPOSITIONING

During the load cycle, the swing arc should not exceed 90°. The time between finishing one truck to the first digging cycle of the next should not exceed that of any cycle during a load.

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START OF DIG CYCLE The crowd motion forces the dipper lip into the bank at the start of the digging cycle. It is the crowd thrust which enables the dipper lip and front opening to get into a column of material of sufficient cross section to fill the dipper rapidly.

FORCE THE DIPPER LIP INTO THE BANK AT THE START OF THE CYCLE

There is a direct relationship between crowd depth of bank penetration and the distance the dipper must rise in the bank to fill the dipper. The deeper the “bite” the quicker the dipper will be filled, providing the hoist force is sufficient to cut the column of material. Do not attempt to lift the entire bank with each pass. As soon as the dipper is full, retract it from the bank and swing the truck.

Crowd penetration should be rapid just at the arc of entry and rise as the dipper enters the bank.

This will permit as much digging as possible near the base of the bank. This is of particular advantage when digging loose or blasted material. The greater the hoist force and crowd thrust, the faster the dipper filling time of the dig cycle. The crowd thrust should be maintained to hold the dipper in the bank while it is being hoisted. An added benefit of proper crowd thrust and hoist force is that the opposing vertical resistance of the bank material tends to have a “ramming” effect in the dipper front opening, minimizing voids and producing larger dipper loads.

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It is important that the full cutting surface of the dipper contact the bank on each pass. A full face cut combined with deep bank penetration will result in a full dipper for the least amount of hoist. A partial cut, even with deep bank penetration, requires a greater rise, and tends to leave voids in the dipper. This could necessitate additional passes to fill the haulage unit.

A DEEPER BITE OF THE BANK = QUICKER FILL TIMES

Shallow bank penetration of the arc of entry and rise is ineffective and inefficient. A shaving cut dribbles material into the dipper resulting in voids and making additional passes necessary while accelerating dipper lip wear.

VARIATIONS ON DIPPER PENETRATION Manual No. 10028, April 99

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Digging should take place under the boom point for maximum shovel effectiveness. If necessary, the machine should be moved closer to the bank face, rather than extending the dipper handle.

Reaching for material results in a partially filled dipper and excessive crowd and retract time. Use caution not to damage the boom point sheaves when operating close to the high wall.

DIGGING UNDER THE BOOM POINT TO MAXIMIZE PRODUCTION

Overcrowding with the dipper lowered can result in lifting the boom. This jacking action can result in damaged components.

Overcrowding the dipper in the bank slows up the dipper loading process, thereby reducing machine efficiency.

THE NEGATIVE EFFECTS OF OVERCROWDING

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ENGAGING THE BANK To make maximum use of the hoist rope pull, the dipper rise should be as close to vertical as possible. The dipper should enter the bank approximately under and behind the boom point. The actual cut should start a few degrees behind an imaginary vertical line from the front of the boom point sheaves. Proper bank engagement results in maximum hoisting force in line with the cut.

When the dipper is too far forward, bank penetration will be minimal, and the hoist and crowd forces will oppose each other rather than working together.

ALWAYS MAKE EFFECTIVE USE OF THE HOIST EFFORT

An excavator dipper capacity rating is the struck measure cubic yard capacity. When digging, a load greater or less than the rated capacity may be obtained, depending on the type of material.

An efficient operation can be measured by the number of dipper loads required to load a haulage unit. When the dipper capacity is efficiently sized to the truck capacity, not less than three or more than five dippers full should be required to load a unit. Other factors such as improper sizing of haulage units to dipper, improper material fragmentation, etc., also must be considered.

AVOID INEFFICIENT HOIST USAGE - HOIST FORCE IS OPPOSING CROWD FORCE

In all types of digging the skilled operator must carefully control the desired depth of cut, and control the hoist power requirements. Often, digging situations are encountered which require hoist and crowd motions to maneuver around oversize or lodged obstructions in the bank, rather than attempting to lift the entire bank.

ALWAYS ENGAGE THE BANK UNDER THE BOOM POINT

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DANGER: Maintain a digging face which avoids any major slides which could cause an accident. Examine the digging face for large boulders, large rocks, or frozen material which could slide and cause an accident. Avoid overhanging material.

The experienced operator does not repeatedly stall the dipper in the bank, nor maintain a stall condition. The life expectancy of the hoist machinery and hoist ropes is directly related to the operator’s skill in avoiding stalling. Whenever stall conditions are encountered, back off on the hoist motion, retract the dipper, or do both. Avoid stall conditions at all times.

MINIMIZE THE DISTANCE BETWEEN THE BANK AND THE BOOM POINT

DANGER: Do not suspend a loaded or empty dipper in the air with the brakes set for long time periods. Lower the dipper to the ground if the machine is to be idle or unattended for any length of time. Failure to comply can result in personal injury or death of anyone beneath the dipper.

AVOID STALL CONDITIONS

For most efficient production, the dipper should be loaded from the most remote point while waiting for a truck. When the truck is positioned, excavating should begin close to the haulage unit, progressively working away from the unit.

This technique saves time by allowing smooth, short dig cycles, and eliminates excessive swing, crowd and retract motions.

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CONTROL THE DEPTH OF THE CUT FOR PROPER HOIST CONTROL

PROPER SWING MOTION Proper swing motion means smooth control and an efficient swing cycle. The swing motion is begun toward the haulage unit when the dipper is filled and is clear of the bank.

DANGER: Extensive damage to the dipper handle and dipper can occur if the machine is swung before the dipper clears the bank.

The swing motion begins with acceleration to an optimum point at which the excavator is brought to a stop over the haulage unit. Maximum efficiency and minimum swing machinery wear are direct results of mastering the swing motion.

NOTE: Improper swing motion results in erratic control, and an inefficient swing cycle.

DANGER: The dipper should never be swung over personnel, trail cables, related electrical equipment or other equipment. When the dipper is loaded, accidental tripping of the dipper door could result in death or serious injury to personnel, and extensive damage to equipment. Empty dippers may contain small fragments of material that can be extremely dangerous when dropped from a considerable height. On long moves it’s best to have the door open on an empty dipper and the dipper lowered to a point that permits moving without striking the ground.

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Time is required to accelerate any motion from zero to working speed, and also to decelerate from working speed back to zero. The time expended for accelerating and decelerating the swing represents the major part of the entire dig cycle. Therefore, the swing arcs must be kept to a minimum to obtain maximum operating efficiency. As an example: assuming that a 90° swing results in 100 percent of the maximum output, increasing the swing arc to 180° reduces output to 70 percent, while decreasing the swing arc to 45° increased the output to 126 percent. Therefore, a swing arc of 90° or less should usually be used.

Haulage units should be positioned so their center line is approximately under or not more than slightly outside the swing path of the boom point . This substantially reduces the amount of dipper maneuvering required of the operator when positioning the dipper for dumping. Positioning of the haulage unit inside or outside the boom point makes it necessary to retract or crowd the dipper handle and dipper, which breaks the operator’s natural rhythm .

A clean, level pit floor must be maintained. A good operator will always clean the floor before moving into the bank. A clean and level floor grade is a requisite to safe and stable machine operation, and reduces damage to crawler links and related components.

DANGER: “Sweeping” should never be attempted with the machine.

Sweeping consists of lowering the dipper to the ground and using the swing motion of the machine to move the dipper from side-to-side and “sweep” the pit floor. The dipper, dipper handle and boom structures can be damaged by this tactic. A bulldozer or loader should be used to help the shovel operator maintain a clean pit floor in conjunction with the shovel.

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EXCAVATED MATERIAL It is important that the operator not only know the controls but recognize other aspects of the mining operation. Chief among these is the type of material to be excavated. It plays a great part in the overall efficiency of the machine.

Materials can be roughly divided into four categories.

1.

Easy digging. This category includes all loose, free-flowing materials, such as sand and gravel deposits, stock pile materials such as finely crushed stone, ore fines, coal fines and any other similar materials. The dipper will usually obtain a heaped load.

2.

Medium digging. This category includes only materials which can be excavated from their natural beds without blasting, and which break up in bulk with some voids. Such material includes clay, dry earth, clay-gravel mixtures, gravel with some boulders, certain types of ores, and coal. The dipper will usually obtain a full load, with filling augmented by the material’s natural tendency to break apart when it encounters the dipper lip and teeth.

3.

Hard digging. Included in this category are materials that require blasting, resulting in good fragmentation, but leaving large chunks which develop voids. Limestone, gypsum shale, cemented gravel, wet earth, clay and certain types of ore and overburden all fall within this category. The dipper will average less than a full load because of the resistance of the material against flow and voids due to blocky material

4.

Very hard digging. This category includes all materials that require heavy blasting and give irregular fragmentation. Taconite, granite, laminar shale, certain types of limestone, and conglomerate overburden fall into this category. The dipper will average considerably less than a full load, because of the large chunks and interlocking action of the material which block fill.

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OPERATING HINTS: The following hints are primarily reminders of the do’s and don’ts related to excavator operation.

Engage the bank properly.

Load with the successive pass technique.

Maintain a clean pit floor.

Use proper hoist control.

Make effective use of the hoist pull.

Use proper crowd control.

Force the dipper lip into the bank at the arc of entry.

Crowd the dipper into the bank for deep penetration.

Make full face cuts for faster loading cycles.

Dig under the boom point.

Make smooth, safe swing cycles.

Keep swing arcs within 90 degrees.

“Spot” the haulage units properly.

Keep the working faces free of projections.

Propel forward whenever possible rather than backward.

Move up to the bank frequently.

Dig over the take-up axle end of the crawlers whenever possible.

Make gradual turns when propelling.

Do not suspend a loaded dipper for an extended time.

Do not operate too close to material.

Do not operate with missing dipper teeth.

Do not stall hoist or crowd motions.

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Do not reach for material.

Do not reach for haulage units.

Do not overcrowd and jack the boom or machine.

Do not make partial face cuts.

Do not make shallow bank penetration.

Do not make erratic swings.

Do not swing until dipper is clear of the bank.

Do not swing loaded or unloaded dippers over personnel or equipment.

Do not “sweep” pit floor.

Do not make sharp turns when propelling.

Do not make long inefficient moves.

Do not exceed swing arc of 90 degrees.

Do not spot haulage units inside or outside the boom point swing arc.

Maintain adequate clearance between digging face and point sheaves.

Do not allow the dipper to contact the crawler belts.

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DURING OPERATION CHECKS During machine operation there are several things to consider relative to safe, efficient machine operation.

1.

Check the motors for unusual noise, loss of power or failure to respond to controls.

2.

Check hoist, crowd, swing and propel machinery for unusual sounds and overheating of bearings.

3.

Avoid slack hoist ropes which could allow the ropes to become crossed on the drum, or skip a groove.

4.

Check the air gauge frequently and investigate immediately if there is a drop in air pressure.

Correct all air leaks.

5.

When propelling, check the engagement of the drive tumblers on the crawler belt links, and adjust the belts to correct any improper alignment.

6.

When operating auxiliary functions, such as steering, note any tendency of the controls to jam or hang up. Check and correct any problems at the earliest opportunity.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

STOPPING THE MACHINE 1.

Return hoist control joystick and crowd control joystick to their center positions and set all brake switches.

2.

After all motions are stopped, and brakes set, depress the control stop pushbutton. This action will remove power to the control units and set the brakes. The controls will become inoperative.

3.

To stop the machine completely and remove power from the drives, depress the MachineStop Pushbutton on the right operator’s console.

SHUTDOWN When shutting down the machine at the end of a shift proceed as follows: 1.

Park the machine on firm ground in a position where it cannot be damaged by a slide, falling rocks or flooding. In cold climates, be sure the crawler belts will not freeze into the ground.

2.

Place the dipper firmly on the ground.

3.

Make sure hoist control joystick and crowd control joystick are in their center positions.

4.

Make sure all brake switches are in the set position.

5.

Depress the control stop pushbutton. All primary controls should be de-energized.

6.

To de-energize the DC bus, depress the machine stop pushbutton on the remote start console or the machine stop/emergency stop pushbutton on the operator’s console.

7.

Place the air compressor switch on the remote start console in the stop position.

8.

Press the uninterruptable power supply off pushbutton on the remote start console.

9.

Close all windows in the cab and lock all cab doors.

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PANELVIEW THEORY OF OPERATION DESCRIPTION The Panelview is an operator’s CRT (Cathode Ray Tube) display and input terminal which is located in the machine operator’s cab. This unit provides the operator with enhanced status and fault information. Additionally, this unit includes custom defined pushbuttons and a numeric keypad which allows tasks, such as lube system timing adjustments and head position limit calibrations, to be easily initiated from within the operator’s cab.

The Panelview unit provides operator information directly from the PLC (Programmable Logic Controller.) The unit operates as a remote PLC card rack with communications controlled by the PLC. All connections and adjustments are accessed via the rear of the panelview terminal. The items mounted on the back cover are shown in the figure. All programming level changes are made via the front panel keypads. Once the panelview is mounted in the operator’s console, access to the mode select keyswitch is limited. Therefore, a remote keyswitch is used which mounts on the side of the console and extends both the connection point and the keyswitch function to an accessible area in the operator’s cab. The remote keyswitch is housed inside a circular shaped cover and is the normal connection point for panelview communications on the actual final installation.

The Panelview terminal has two basic modes of operation: CONFIGURATION mode and RUN mode. In CONFIGURATION mode you set up the terminal; in RUN mode you run an application file. The Panelview terminal communicates with the PLC only when it is in RUN mode. You must be in RUN mode to monitor and control the PLC. FAULT CONDITIONS When a Panelview terminal is switched ON, it performs a series of power-up tests. In RUN mode, the Panelview terminal performs an on-going series of on-line tests. If the Panelview terminal detects any internal faults, it displays a message in the fault window on the display.

There are two types of faults: Major Faults and Minor Faults.

MAJOR FAULTS If the Panelview terminal detects major faults, it enters MAJOR FAULT mode, and displays a message in the fault window. The Panelview terminal will be unable to control or monitor PLC functions while the terminal is in MAJOR FAULT mode. The operator must correct the problem and restart the terminal or switch modes.

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MINOR FAULTS If the Panelview terminal detects any minor faults, it displays a message in the fault window. The operator must press the CLEAR key to resume operation. This key temporarily overrides the function that was previously assigned to the associated function key. Minor faults do not affect PLC communications.

POWER-UP FUNCTIONS When you power up the Panelview terminal, it performs a number of tests for major or minor faults to determine if there are any problems that will affect its operation.

Once all the tests are successfully completed, the panelview terminal will go into CONFIGURATION or RUN mode, depending on the MODE SELECT key setting.

BATTERY FAILURE The battery should last the life of the Panelview terminal. However, since the battery backed RAM plays such an important role in the Panelview terminal, the battery is constantly monitored.

If the battery has failed and you power up the Panelview terminal, you may not be able to go into RUN mode. Since EEPROMs are used to store the application file, the terminal will reload the application file into RAM. You will see a minor fault message telling you of the battery fault. Press the CLEAR key and you will be able to proceed. You will have lost, however, any retained values for the retentive functions. Operator adjusted values (lube timing, etc.) will be lost.

If the battery fails when you are in RUN mode, you’ll see a warning message displayed in the fault message window in the bottom of the screen. Press the CLEAR key to continue.

COMMUNICATION The PLC Communication test verifies that the communication card is installed and functioning. If not, a minor fault occurs.

WATCHDOG The “watchdog” test indicates that the watchdog circuit is unable to reset the machine. If the Panelview terminal fails this test, it enters MAJOR FAULT mode, and will require servicing.

ON-LINE DIAGNOSTIC TESTING The Panelview terminal performs continuous fault detection tests while on-line with the PLC.

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PLC COMMUNICATION TIMEOUT The PLC communication timeout test determines if communication between the PLC and Panelview terminal has been interrupted.

Panelview terminal functions will continue to operate, and screens can be selected and displayed.

This condition is reflected in a special, blinking PLC Communication Lost status window on the top line of the display.

SYSTEM EEPROM CHECKSUM The system EEPROM checksum test determines if the EEPROM on which the resident software is stored is corrupted.

The panelview terminal enters major fault mode if it fails this test, and will require servicing.

APPLICATION DATA CHECKSUM The application data checksum continuously checks the integrity of your application file in RAM. If the Panelview terminal fails this test, it likely indicates that the configuration file has not been successfully downloaded to the terminal. If the test finds that the application file is not present, then the Panelview terminal enters major fault mode. You will need to repeat the downloading procedure to correct this problem. Contact the Bucyrus Service Department for assistance.

CONFIGURATION MODE SET-UP To start up your Panelview terminal in CONFIGURATION mode, set the Remote Mode Select Key to CONFIGURE and apply power to the unit. You can also change from CONFIGURE to RUN with the same key.

In CONFIGURATION mode your Panelview terminal will appear as a faulted rack to your PLC and the terminal will display the Configuration Mode Menu screen. This screen displays: •

The name of the application file, bytes used and free.

•

Version and date identification for the Panelview terminal resident software.

•

A menu to define the operational characteristics of the terminal.

•

UP CURSOR, DOWN CURSOR, and ENTER function key definitions for moving through the list of menu options and choosing the desired operation.

•

The current time and date.

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From the Configuration Mode Menu, the desired operation can be selected by following the screen prompts, as needed.

DOWNLOADING/UPLOADING AN APPLICATION FILE The process of transferring an application file to a Panelview terminal is called downloading, and transferring it back to the development computer is called uploading. As supplied, the terminal includes preloaded software stored in an EEPROM. If software changes are required, requests should be made via normal Bucyrus parts channels.

CONFIGURING THE SERIAL COMMUNICATION PORT The Panelview terminal has a serial communication port which is used to connect the terminal for downloading/uploading application files, or for printing out alarm messages. Uploading and downloading share communications settings (baud rate, etc.), but the printer setting may be different.

1.

Choose SERIAL PORT from the Panelview terminal’s Configuration Mode Menu.

2.

Using the CHOOSE LIST key, select between:

3.

•

Upload/download to configure the port for downloading or uploading your application file.

•

Printer to configure the port for printing alarm messages on a serial printer.

Using the CHANGE DATA key, set the desired baud rate, number of bits, parity, etc.

The standard settings should be as follows: UPLOAD/DOWNLOAD BAUD RATE PARITY TYPE DATE BITS 8 STOP BITS 1 HANDSHAKE TYPE AUTO LINE FEED

PRINTER* 9600 9600 NONE 8 1 HARDWARE OFF ON

NONE

SOFTWARE

* Printer settings may vary as a function of connected device.

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VIEWING RACK ASSIGNMENTS Use this option to view the rack assignment and block transfer file definitions that were defined in the Panelview development software.

When you choose RACK ASSIGNMENTS from the configuration mode menu, you’ll see a screen showing the rack assignments for up to eight racks, the PLC type and the baud rate. A key on this screen allows you to view the block transfer file definition.

ACCESS CODES (SECURITY) For each screen, Panelview software allows you to specify any of 8 operators (users) that will be allowed access to that screen. Each operator (identified 1-8) can have a unique access code.

Access codes are assigned in the Panelview terminal’s configuration mode menu.

If a user attempts to access a restricted Panelview screen, it will first be necessary to enter the proper access code. If the entered access code is not valid, the requested screen will not be displayed. The user will instead be informed which operator(s) (1-8) were specified to have access to that screen. A supervisor with a mode select key can view or change each user’s access code in the Panelview terminal’s configuration mode menu.

To assign access codes, choose ACCESS CODES. When the terminal displays the security access codes, use the NEXT OPERATOR key to view the access codes for each user. Use the numeric keypad to change the selected operator’s access code. Access codes must be numeric and range from 0-99999.

If a screen is triggered by the PLC controlled screen option or the power-up screen, then that screen will be displayed and no access code will be requested. Security codes can be totally disabled by turning the security option off.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

AUDIO RESPONSE The Panelview terminal will normally sound a tone whenever you press an active keypad. The PLC can also trigger this audio indicator either directly with the PLC controlled audio or through an alarm message.

Choose AUDIO RESPONSE to set: •

Button audio ON or OFF. The default setting is on. With the setting on, the Panelview terminal provides audio feedback each time you press a button.

•

The alarm audio ON or OFF. With the default setting of ON, both the PLC controlled audio bit and alarm messages will cause the Panelview terminal’s built-in audio indicator to sound.

•

The volume level to HIGH or LOW. The default setting is high.

ALARM RELAY The Panelview terminal has an alarm relay that is wired to an external alarm. The alarm relay option from the configuration menu allows you to enable or disable the alarm relay.

Use the Alarm Relay option to: •

Enable the alarm relay so that an alarm message or the PLC controlled alarm relay bit can activate it.

•

Disable the alarm relay.

•

Test the operation of the alarm relay by manually activating or disactivating it.

NOTE: This function should be left enabled or an important operator’s aid will be defeated.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

PRESET OPERATIONS Panelview software allows you to preset the initial states or values of certain retentive objects (lube timers, etc.) These PLC inputs are initially transferred to the PLC and remain until changed by an operator.

The preset operation screen in the Panelview terminal’s configuration mode menu allows you to set the way in which retentive objects will operate.

Power-up values can be set to PRESETS or LAST STATES. If preset is chosen, the initial presets as configured in Panelview software will be loaded when the terminal is powered up. If last states is chosen, all retentive objects will retain the state that they had when the terminal was powered down.

LAST STATES is the default setting. This selection should be used or all operator adjustments (lube, etc.) will be lost.

The initial presets, as configured in Panelview software can be loaded into all retentive objects at any time by pressing the LOAD PRESETS key.

This operation modifies all values previously loaded by the operator.

SCREEN SAVER The screen saver function preserves the life of the Panelview terminal’s display panel by blanking the screen when the terminal has not been used for a period of time.

Choose SCREEN SAVER from the configuration Menu to enable this function and set the amount of time which should pass before the screen blanks.

You can set the elapsed time from 1 to 999 minutes. A setting of 0 (zero) disables the screen saver.

A setting of 10 is normally recommended. When the screen blanks, a message appears: “Press Any Key To Activate.” Pressing any key causes the last screen to re-appear. A PLC generated alarm message, a PLC generated information message, the appearance of the status window, or a major or minor fault message will also cause the last screen to re-appear, along with the message.

ALIGN SCREEN Screens are normally centered on the terminal display. To change the alignment of a screen, use the key labels to visually align the screen. Use the UP, DOWN, LEFT and RIGHT keys to move the screen. Press EXIT to return to the configuration mode menu.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

STUCK BUTTON/CELL TIMEOUT The stuck button timeout option causes a major fault condition to occur when a key is continuously pressed for longer than a specified time. In other words, if the Panelview terminal detects that a key has been pressed longer than the specified time, it will assume that the key is stuck and will shut down the Panelview terminal.

Choose STUCK BUTTON TIMEOUT from the configuration menu to enable this function and set the amount of time a key may be pressed before the terminal enters fault mode.

Use the keypad to set the amount of time from 0 to 60 seconds. A setting of 0 disables the function.

Normally, it is recommended that this function be disabled.

CONFIGURATIONG TIME AND DATE The Panelview terminal has a battery-operated clock. Screens created with Panelview software can include a time or date display anywhere on the screen.

The date is displayed in the format: mm/dd/yy.

The time is displayed in the format: hh:mm:ss; in either 12 hour or 24 hour (Military) format.

Use the time and date option from the configuration menu to set the correct time and date.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

UNIT TESTS Unit tests in the Configuration Mode menu allows checking the operation of various components of a Panelview terminal.

Choosing UNIT TESTS displays a menu of test options from which you choose the required test.

Alongside the menu are the results of the most recent set of diagnostic tests performed. Each test provides an EXIT button to return to the configuration menu.

•

User RAM performs a read/write test on random access memory (RAM) to determine if the battery-backed RAM is corrupted. The results are displayed on the terminal’s display panel. If the RAM is corrupted, the terminal will enter major fault mode. You will need to download a new configuration file to the terminal to correct this problem if it occurs. Contact Bucyrus service for assistance.

•

System RAM test performs a read/write test to a portion of the random access memory (RAM.) This test is similar to the user RAM memory option, except that it does not test the battery-backed RAM. Thus, your data will not be corrupted even if the power is accidentally cut midway through this test.

•

Memory checksum performs a checksum test of all memory and displays the results.

If the user EEPROM option is not installed, then the test will indicate a failure at memory location 5000:0000. This is normal.

•

Function keys identifies function keys that are difficult to activate and those that are inoperable. This test applies to all terminal keys. During this test, you’ll see a display of all the keys. Test each key by pressing it. If the key is working, the corresponding picture of the key will be highlighted. Press the key a second time to turn off the highlighting.

•

Display tests the terminal’s display functions. The terminal shows samples of the different sizes and attributes.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

EEPROM INSTALLATION The Panelview application file is stored on an EEPROM which is supplied pre-programmed by Bucyrus. In the event that a new EEPROM must be installed (either due to device failure or application software modification) the following installation procedure must be carefully followed: CAUTION: It is strongly recommended that proper installation and removal tools be used in the procedure. Contact the Bucyrus Service Department for assistance.

To install PROM chips: 1.

De-energize the Panelview terminal and remove the unit and necessary cables from the console.

CAUTION: Take the necessary precautions against electrostatic discharge.

Ideally, you should use an anti-static mat or wear a grounding wrist strap whenever you work with any electronic components sensitive to electrostatic discharges.

If you’re not using an anti-static mat or wrist strap, follow these precautions before you touch any components inside your Panelview terminal: •

Assume your body is always carrying an electrostatic charge.

•

Touch any grounded metal surface to discharge yourself. Do this frequently.

•

Wear cotton clothes, not wool or synthetic fabrics.

•

Don’t move too much or scuff your feet if walking on a carpeted surface.

•

Be extra careful in low-humidity environments.

2.

Open up the Panelview terminal. You must remove the three screws at the back of the unit to drop the tray containing the board.

3.

Socket U52 is labeled User Mem High Byte and socket U53 is labeled User Mem Low Byte. Make sure you install the EEPROM chips into the correct sockets.

4.

Ensure that jumpers JP6 to JP8 are all set to the left-most pins.

5.

Gently ease the chip’s pins into the socket.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

CAUTION: The notch on the chip MUST match up with the notch on the socket.

When you’re sure you have all the pins properly positioned in their holes and the notch on the correct side, gently press the chip into the socket. It will go in easily if the pins are properly positioned.

CAUTION: If you break or severely bend a pin, the chip will be unusable.

PANELVIEW DESCRIPTION OVERVIEW The panelview is an operator CRT (Cathode Ray Tube) display and input terminal which is located in the operator’s cab. This unit provides the operator with enhanced status and fault information directly from the PLC (Programmable Logic Controller). Custom defined pushbuttons (keys) and a numeric keypad are provided to allow the operator or programmer to communicate with the PLC. Using the panelview keys, the operator can easily choose between different screen displays and perform tasks, such as lube system timing adjustments or head position limit calibrations. Likewise, all programming level changes can be made using the keys.

NUMERIC KEYPAD In addition to the number keys (0-9), the numeric input keypad also includes ENTER, BACKSPACE, - (negative) and . (decimal) keys. Use the numeric keypad to enter values into the panelview window or pop-up box.

CURSOR CONTROL AND SPECIAL KEYS In addition to the “ARROW” keys, the cursor control and special keys area on the keypad also includes HOME, SELECT, CANCEL, RAISE, and LOWER keys. These keys are used for positioning the cursor or selecting a menu choice on the screen.

PANELVIEW TERMINAL REAR CONNECTIONS AND ADJUSTMENTS All connections and adjustments are made at the rear of the panelview terminal.

NOTE: After the panelview is mounted in the operator’s console, access to the mode select keyswitch and serial port is limited. Therefore, a remote keyswitch is used which mounts on the side of the console and extends both the serial port and the keyswitch functions to an accessible area in the operator’s cab. The remote keyswitch is housed inside a circular shaped cover and is the normal connection point for panelview communications on the final installation.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

OPERATING MODES The panelview terminal has two modes of operation: CONFIGURATION mode is used to set up the terminal.

RUN mode is used to run an application file. This is the normal mode of operation and the only mode in which the panelview terminal can communicate with the PLC controller.

FAULT CONDITIONS Whenever the panelview terminal is ON and it detects an internal fault, a message will be displayed in a fault window on the panelview display . If the fault is a MINOR FAULT, the operator must press the CLEAR key to resume operation. This key temporarily overrides the function that was previously assigned to the associated function key. Minor faults do not affect PLC communications.

If a major fault is detected while the panelview terminal is ON, it enters the MAJOR FAULT mode.

The panelview terminal will be unable to control or monitor PLC functions while the terminal is in MAJOR FAULT mode. The operator must correct the problem and restart the terminal or switch modes.

POWER-UP FUNCTIONS When you power up the panelview terminal, it performs a number of tests for major or minor faults to determine if there are any problems that will affect its operation refer to the topic “Fault Conditions”, above.

Once all the tests are successfully completed, the panelview terminal will go into CONFIGURATION or RUN mode, depending on the MODE SELECT key setting.

BATTERY FAILURE The battery should last the life of the panelview terminal. However, since the battery backed RAM plays such an important role in the panelview terminal, the battery is constantly monitored.

If the battery has failed and you power up the panelview terminal, you may not be able to go into RUN mode. Since EEPROMs are used to store the application file, the terminal will reload the application file into RAM. You will see a minor fault message telling you of the battery fault. Press the CLEAR key and you will be able to proceed. You will have lost, however, any retained values for the retentive functions. Operator adjusted values (lube timing, etc.) will be lost.

If the battery fails when you are in RUN mode, you’ll see a warning message displayed in the fault message window in the bottom of the screen. Press the CLEAR key to continue.

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Bucyrus International, Inc. 495B Mining Shovel

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

SECTION 3 - LUBRICATION GENERAL LUBRICATION PRINCIPLES ...................................................................................... 2 LUBRICANT SELECTION ............................................................................................................ 4 AUTOMATIC LUBRICATION SYSTEM ........................................................................................ 6 LINCOLN TYPE SL-1 LUBRICANT INJECTORS ......................................................................... 8 LUBRICANT INJECTOR OPERATION ....................................................................................... 10 INJECTOR ADVANTAGES ............................................................................................. 12 LUBE ROOM ............................................................................................................................... 15 LUBRICANT SYSTEMS ..............................................................................................................17 OGL SYSTEM “A” BLOCK DIAGRAM ............................................................................ 18 OGL SYSTEM “B” BLOCK DIAGRAM ............................................................................ 19 GREASE SYSTEM “C” BLOCK DIAGRAM ..................................................................... 20 AUTOMATIC LUBRICATION SYSTEM CONTROL PANEL ....................................................... 21 LOWER WORKS ........................................................................................................................ 22 PROPEL MACHINERY ............................................................................................................... 25 REVOLVING FRAME .................................................................................................................. 26 HOIST ......................................................................................................................................... 27 CROWD ...................................................................................................................................... 28 SWING ........................................................................................................................................ 29 AIR COMPRESSOR ................................................................................................................... 30 FRONT END ............................................................................................................................... 31 BOOM FOOT PINS ..................................................................................................................... 31 SADDLE BLOCK ......................................................................................................................... 32 SHEAVES ................................................................................................................................... 32 DIPPER TRIP .............................................................................................................................. 32 WIRE ROPES ............................................................................................................................. 32 LUBRICATION BENCHMARKS .................................................................................................. 33 MPG - Multi-Purpose Grease ...................................................................................................... 33 TABLE OF SPECIFIC REQUIREMENTS FOR MPG LUBRICANTS .............................. 34 ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT ...................................................... 35 MPO - MULTI-PURPOSE OIL ..................................................................................................... 36 OGL - OPEN GEAR LUBRICANT............................................................................................... 37 RGL - REGULAR GEAR LUBRICANT ........................................................................................ 40 RWL - RUNNING WIRE ROPE LUBRICANT ............................................................................. 44

Manual No. 10028, April 99

Section 3, Lubrication - 1

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

GENERAL LUBRICATION PRINCIPLES The proper lubrication of this machine is vital to its successful, continued operation. Application of the CORRECT lubricant in the CORRECT amount at the CORRECT place as part of a PROVEN maintenance program is required to keep the machine operating at a level of productivity that will make your mining operation profitable. Proper lubrication will provide better component service life with a reduction of repairs and downtime. When not properly lubricated, moving parts wear quicker and fail sooner.

The primary wear items of this machine are lubricated by an automatic system that dispenses lube to selected points at pre-selected, timed intervals during machine operation. This system is covered in more detail further on in this section. It is important to the operation of this automatic lube system that you become familiar with it and understand its operation in order to properly maintain and service it, thus keeping it operable. It is also necessary that you inspect on a regular basis the points for automatic lubricant application to insure the system is performing its job adequately.

Some components, due to their location and function, can not be readily covered by the automatic lube system. You should become familiar with these points so you can service them properly at the intervals listed. A listing of the parts covered by the automatic lubrication system is included later in this section.

The standard lubrication fittings used for manual service are the hydraulic type, push-on fittings, having 1/8 inch or 1/4 inch NPT threads.

Bushings and Bearings operating in a highly contaminated atmosphere (dust, grit, etc.) should be lubed until clean grease seeps out around the journal or seal, or comes out the purge fitting if one is provided. New bushings sometimes overheat because they are excessively tight and will not allow proper distribution of the lubricant. Older bushings may overheat because they are excessively worn and will no longer retain the lubricant until the next lubrication cycle. New bushings may require more frequent lubrication until the component has been worked in. The same may be necessary for an older, worn bushing until it can be replaced. The loss of short amounts of time on a shift for the application of extra lubricant may seriously outweigh the effort to run a bearing, or component, until the end of any given shift.

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Overfilling an anti-friction bearing can cause it to run excessively warm. After lubricating antifriction bearings, especially those that are sealed such as in electric motors, remove the pressure fitting, or the relief plug when provided, allowing the bearing to purge itself of any excess lube during the first 10-15 minutes of operation. Replace the fitting or plug after that time.

Most wearing parts respond best to lubricant application that is accomplished regularly, in small quantities, instead of large quantities applied less often. Make regular inspections of the machine and be vigilant for signs of incorrect lubrication such as build-up of excess lubricant. If build-up is encountered, make sure it is not the result of a broken or disconnect pipe or lubrication line.

Grease in a bearing generally deteriorates gradually, not suddenly. Only a small amount needs to be added to it at regular intervals to maintain the proper lubricant level. Adding a small quantity of grease to the bearing every 600 operating hours, unless otherwise specified, is adequate.

Open Gears and Pinions require a constant coating of high grade lubricant which is specified for operation. Inspect all open gear sets at least once daily (every 24 hours) to ensure they are coated with OGL.

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Section 3, Lubrication - 3

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

LUBRICANT SELECTION The selection of the proper lubricants for use on this machine is critical to its reliability. Improperly lubricated bearings, gears, couplings, and other precision parts quickly fail. For this reason, lubricants selected in accordance with the “American Standards Testing Material” (ASTM) standards are recommended. These standards were compiled in cooperation with major petroleum suppliers to insure the consumer of an exact supply to specific requirements, regardless of source.

We recommend you advise your petroleum supplier of the following information to assist him in selecting the proper product for each application of this machine.

Final acceptance of all lubricants supplied to this standard will be based upon their satisfactory performance in the intended application, and does not relieve the supplier of performance responsibility for brand name products.

Operation of this machine in extreme temperatures (below -20oF/-29oC or above 110oF/44oC) requires special lubrication. Note the temperature ranges on the following lubricant specification sheets. Contact your local supplier, your Bucyrus representative, or the Service Department of you local Bucyrus International office for recommendations if you require additional information or advice.

Store lubrication drums on their side, with the opening toward the top.

PROPER LUBRICANT STORAGE IS CRITICAL!

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Some points to remember ⇒

STORE ALL LUBRICANTS IN TIGHTLY COVERED CONTAINERS!

⇒

WIPE OFF COVERS AND LIDS PRIOR TO OPENING CONTAINERS!

⇒

STORE FUNNELS, CANS AND GREASE GUNS IN A CLEAN PLACE AND CLEAN BEFORE USE!

⇒

WIPE OFF GREASE GUN AND FITTINGS BEFORE SERVICING!

⇒

WIPE OFF FILLER CAPS AND SURROUNDING AREA BEFORE OPENING!

⇒

FILTER ALL OIL BEFORE ADDING IT TO THE SYSTEM!

⇒

USE ONLY CLEAN and PROPER LUBRICANTS - KEEP IT CLEAN!

⇒

DO NOT MIX TYPES or BRANDS of LUBRICANTS!

NOTE: Accumulated excess lubricant can constitute a serious safety and fire hazard. Practice good housekeeping!

REMEMBER: Even the best lubricants are useless in preventing wear if it has become contaminated by dirt or water due to careless handling or storage.

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Section 3, Lubrication - 5

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

AUTOMATIC LUBRICATION SYSTEM THE AUTOMATIC LUBRICATION SYSTEM IS NOT DESIGNED TO PROVIDE INITIAL COVERAGE. New parts installed or those cleaned during maintenance procedures must be fully lubricated before commencing machine operation. Anti-friction bearings and bushings must be hand packed or thoroughly coated with the correct lubricant. Open gearing and moving contact surfaces must be completely covered with their lubricant. Do not permit the lack of lubricant at start-up cause you to redo a repair job!

NOTE: The greatest amount of wear to be experienced by any moving part will take place during the first few cycles, or operating hours. A lack of proper lubrication can destroy a new part at a dramatically increased rate over the normal wear patterns experienced.

Enclosed gear cases must have their recommended lubricant level maintained at the prescribed level. Check the lubricant level at the oil level plug or with the dipstick at least once weekly (every 150 hours). Inspect them daily (every 24 hours) for leaks. Change the oil in the gearcase at their recommended intervals while flushing each case with a light lube oil before adding the new gear oil. ALWAYS STORE THE USED OIL IN A SAFE CONTAINER UNTIL PROPERLY DISPOSED OF. DO NOT POLLUTE THE ENVIRONMENT!

Bucyrus International recommends that scheduled oil samplings from the enclosed gear cases and air compressor crankcase on this machine be taken and tested by an authorized, reputable lab to determine the contamination level of the sump oil. These samples should be obtained and tested every 30 operating days (600 hours). They should be taken when the oil is at its normal operating temperature and is well mixed in the case so the samples are representative of actual conditions. This diagnostic maintenance procedure will permit you to determine the condition of internal components within the operating gear cases. Increases in the presence of certain metallic types can be analyzed with the Bucyrus International Service personnel to determine the best time to change the oil, thus obtaining its best service life. This will simultaneously allow you to monitor the condition of the components and address situations in their infancy instead of after a catastrophic breakdown.. This program will pay you dividends in the long run.

If a sample diagnostic system is undertaken it is imperative that adequate records be maintained of the maintenance and component history of the items in question. Without theses record there will be no adequate date by which to compare any changes or occurrences and make realistic determinations.

Section 3, Lubrication - 6

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Wire Rope Lubrication dislodges with the movement of one strand against another. Moisture can then enter the stranding and cause deterioration of the wire rope. The areas where the greatest deflection occurs are most susceptible to this contamination and early failure. On pendants, it is at or near the sockets. On other wire rope applications, such as the hoist rope, it is at the sheaves or lagging. To increase the service life of any wire rope, apply the proper wire rope lubricant (WRL) to the areas of its greatest deflection at periodic intervals.

Lubricant Service Life is adversely affected by unusually dusty or dirty environments and atmospheres where extreme high humidity or temperatures exist. It shall, therefore, be the responsibility of the owner/operator of this machine to determine the most effective lubricant and lubrication interval for all the components according to the environmental conditions that prevail.

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Section 3, Lubrication - 7

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Lincoln Type SL-1 Lubricant Injectors These are pressure operative, spring reset, series installed injectors which are supplied in banks mounted on manifolds. Each injector will expel a maximum of .08 cu. inch of lubricant from its outlet port each cycle. Dual outlet ports on each injector permit the injectors to be piped in series for increased lube supply to a common point. The quantity of lubrication provided to each point on this machine has been carefully designed by our engineers for proper coverage. Each injector output can be adjusted. Bucyrus recommends they be set and used at their maximum setting initially and monitored for evidence of excessive lubrication. If it is determined that the initial amount of lubrication is excessive the output of the individual injectors can be reduced at that time.

NOTE:

Maximum Operating Pressure————————----———-—3500 psi Recommended Operating Pressure———————————2500 psi Minimum Operating Pressure—————————----————850 psi Maximum Recharge Pressure——————————-----——-600 psi

To set an injector for maximum output: 1.

Loosen lock nut.

2.

Turn adjusting nut until there is a small gap at the top of the stem.

3.

Orient the adjusting nut so that the opening is toward the front of the injector.

4.

Tighten the lock nut.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

To reduce injector output: 1.

Loosen lock nut.

2.

Turn adjusting nut clockwise (CW) until desired discharge rate is obtained. This will force stem into body, retarding its movement.

3.

Set the lock nut.

CAUTION: Do not turn adjusting nut down clockwise more than 5 full turns from maximum discharge setting. Check output flow from injector then to insure it is still operating. If not, back off adjusting nut until injector does consistently operate. Inspect adjusted injector for operation for 3 or 4 cycles after returning machine to work to make sure it is functioning.

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Section 3, Lubrication - 9

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

LUBRICANT INJECTOR OPERATION

STAGE 1: The injector piston is i it’s normal or reset position.

The discharge chamber is filled with lubricant from the previous cycle. Under pressure of the incoming lubricant, the slide valve is about to open the passgae leading to the piston.

STAGE 2: When the slide valve uncovers the passage, lubricant is admitted to the top of the piston, forcing the piston down. The piston forces lubricant from the discharge chamber through the outlet port to the bearing.

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

STAGE 3: As the piston completes its stroke, it pushes the slide valve past the passage, cutting off further admission of lubricant to the passage. The piston and slide valve remain in this position until lubricant pressure in the supply line is vented (relieved) at the pump.

STAGE 4: After the pressure is relieved, the compressed spring moves the slide valve to the closed position. This opens the port from the measuring chamber and permits the lubricant to be transferred from the top of the piston to the discharge chamber.

NOTE: The injectors may be mounted individually, or grouped in a manifold at one location.

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Section 3, Lubrication - 11

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

INJECTOR ADVANTAGES Simplicity This system is simpler and less expensive to install than other systems - it is also much easier to understand. Your maintenance personnel will appreciate the ease with which they can learn the operation and service features.

External Adjustment A micrometer-type adjustment makes each injector (metering device) adjustable externally, without special tools. The system permits lubricant adjustments to meet actual bearing requirements - not just an approximation, as with other systems.

Section 3, Lubrication - 12

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Built –In Grease Fitting This system incorporates a capped grease fitting on the injector. This permits easy filling of lines when the system is installed. It also allows hand lubrication of the machine in the event of a pump or power failure, damage to the supply line, or even a malfunction in the air system. The built-in grease fitting can also be used as an inspection system. When the cap is removed, the lubricant normally metered to a bearing will come out of the grease fitting head.

Extreme Pumping Distance Single-line design and powerful pumping unit permit installations at long distances from original refinery containers of bulk tanks to point of application. And if you plan to expand your operation, this system has the designed – in capacity that lets you do it - normally without adding booster pumps and controls.

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Section 3, Lubrication - 13

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Ease of Injector Replacement Should an injector ever need replacing, it can be done quickly and easily without disturbing adjacent injectors or removing the supply line connections - does not require machine shutdown as do all other systems. As a matter of fact, injector replacement usually can be done between lubricating cycles, thus preventing lubricant loss or machine downtime.

Section 3, Lubrication - 14

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

LUBE ROOM The lubrication room aboard the typical 495B1 is located at the left front corner of the machinery house. The lube room can be accessed from the walkways external to the machinery house. The lube room contains the pumps, tanks, transducers and the basic componentry associated with the automatic lubrication system of the shovel.

Lubrication Room

S3_14

MAJOR LUBRICATION ROOM COMPONENTS - (LOOKING REARWARD)

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

LUBRICATION ROOM DETAILS - (LLOKING REARWARD)

Section 3, Lubrication - 16

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

LUBRICANT SYSTEMS The following pages contain a series of block diagrams depicting the schematic layout of the automatic lubrication systems of your mining shovel Systems “A” and “B” automatically disperse Open Gear Lubricant (OGL) to critical portions of the machine.

System “C” is a grease system that lubricates items rewuiring a lubricant of slightly different characteristcs.

Later within this section you will find a breakdown of the requirements for all of the lubricants required in the maintenance of your machine.

SCHEMATIC LEGEND

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Section 3, Lubrication - 17

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

OGL SYSTEM “A” Block Diagram

Section 3, Lubrication - 18

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

OGL SYSTEM “B” Block Diagram

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Section 3, Lubrication - 19

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

GREASE SYSTEM “C” Block Diagram

Section 3, Lubrication - 20

Manual No. 10028, April 99

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Automatic Lubrication System Control Panel The Automatic Lubrication Control Panel is mounted on the inboard most wall of the lubrication room. The panel provides the switches and override functions required to activate, reset, and override the automatic functions, POWER ON - Allows electrical power to energize the system LUBE FAULT - When depressed will reset the fault message that appeared on the PLC in the operator’s cab.

MANUAL LUBE - Will disperse (on command) 1 measured quantity of lubricant to the injectors on that system.

ON /OFF - Energizes the system for normal operation.

AUTOMATIC LUBRICATION SYSTEM CONTROL PANEL

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Section 3, Lubrication - 21

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LOWER WORKS Although this machine does not spend very much time being propelled between digging sites there are considerable forces exerted on the lower works of the machine. The severe loads and oscillations created during the constant cycles of the digging process tend to squeeze the lubricant out of bushings creating a circumstance for wear if proper lubrication habits are neglected.

LOWER WORKS OGL PIPING DIAGRAM

1 - Take Up Axle, LH 2 - Upper Roller, front LH 3 - Upper Roller, 2nd from front LH 4 - Upper Roller, center LH 5 - Center Pintle Bushing, RH 6 - Upper Roller, center RH 7 - Upper Roller, 2nd from font RH 8 - Upper Roller, front RH 9 - Take Up Axle, RH 10 - Lower Roller Axle, front RH 11 - Lower Roller Axle, 2nd from front LH

12 - Lower Roller Axle, 2nd from front LH 13 - Lower Roller Axle, front LH 14 - Upper Roller, rear LH 15 - Lower Roller Axle, rear LH 16 - Upper Roller, 2nd from rear LH 17 - Lower Roller Axle, 2nd from rear LH 18 - Center Pintle Bushing, LH 19 - Upper Roller, rear RH 20 - Lower Roller Axle, rear RH 21 - Upper Roller 2nd from rear RH 22 - Lower Roller Axle, 2nd from rear RH

With the high possibility of operation while submersed in water the applied lubricant should have properties which allow for protection under theses circumstances.

Section 3, Lubrication - 22

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When propelling over any long distances the machine should be lubricated at least every 1500 feet of travel, or every ½ hour. Bearings and bushings should be carefully watched and force lubricated until they run cool if evidence of heat build-up is apparent.

Under extremely harsh conditions such as propelling up a hill, frequent turns, or through deep water and mud the lubrication frequency should be increased.

LOWER WORKS OGL MANIFOLD DETAILS

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Section 3, Lubrication - 23

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LOWER WORKS GREASE PIPING DIAGRAM

Section 3, Lubrication - 24

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PROPEL MACHINERY Propel planetary gearcases should be checked every 48 hours. Inspect the lubricant level with the machine on level ground and add the required amount of the recommended lubricant if necessary.

If water has accumulated within the gearcases remove the drain plug and drain into a container for waste removal and refill with clean lubricant.

When radical changes in temperature, or at the recommendation of a testing facility, make it necessary to change the lubricant within a gearcase, it is advised to drain the box immediately after propelling the machine. This will allow for a more thorough removal of contaminants and foreign material due to the elevated temperature and suspension of particles within the lubricant.

Drive tumbler bearings and the center pintle receive lubricant in the form of grease from System “C”.

ROLLER POSITIONING FOR PROPER LUBRICATION

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Section 3, Lubrication - 25

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REVOLVING FRAME Always keep the swing rack and roller path coated liberally with the proper lubricant and check daily. In the event of severe accumulations, remove accumulated material and re-lubricate the area before placing the machine back into service.

Although the machinery contained within the house is not exposed to the extreme conditions of some other machine components the loading and stresses exerted on this equipment are severe.

Longevity of these components is largely dependant upon proper lubrication.

REVOLVING FRAME LUBE COMPONENTS - OVERVIEW

Section 3, Lubrication - 26

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HOIST The hoist machinery drive is comprised of 2 stages of gear reduction. The first stage gear reduction is an enclosed system running submersed in lubricant. The gear case housing is equipped with lubricant level check plugs on the RH side of the case. A filter breather is provided to allow for air entry to equalize pressure differentials created by the warming and cooling of the gear case, allows moisture to escape, and prevents contaminants from entering.

The second stage of gear reduction is operating as a semi-enclosed system lubricated by OGL. The drum shaft bearings are grease lubricated by System “C” along with the intermediate shafts of the hoist gearing. The motor pinion shaft bearings are splash lubricated from the 1st stage gear case.

HOIST MACHINERY LUBRICATION POINTS - OVERVIEW

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Section 3, Lubrication - 27

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CROWD The crowd first and second stages of gear reduction totally enclosed systems submerged in gear lubricant. The gearcase is provided with it’s own level plug to check for adequate lubrication and a filter breather. The third stage of gear reduction, the crowd drum gear, is lubricated by OGL from system “B”. The bearings of the crowd drum, along with the shafts of the crowd reduction system are lubricated by grease from system “C”

CROWD MACHINERY OVERVIEW

Section 3, Lubrication - 28

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SWING The swing machinery is primarily composed of an enclosed planetary gear case on either side of the machine’s swing rack. The gear cases are self contained units with their own individual pump, filtering system and lubricant reservoir. Lubricant levels should be checked at least every 48 hours with a visual inspection for leakage at the start of each shift.

A filter breather is provided on each planetary gearcase to allow for air entry to equalize pressure differentials created by the warming and cooling of the gear case, allows moisture to escape, and prevents contaminants from entering.

The swing pinions and lower swing shaft bearings are lubricated with open gear lubricant from System “B”.

SWING MACHINERY SPRAY NOZZLES

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Section 3, Lubrication - 29

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AIR COMPRESSOR The air compressor supplied with your machine has very specific lubrication needs. For the details of servicing this equipment you should refer to the manufacturer’s instructions. And the specific lubricant recommendations made later within this section.

AIR COMPRESSOR - SHOWN WITHOUT AIR TANK

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FRONT END The front end equipment is exposed to the most extreme working environment of any part of the machine. Proper lubrication quantity and quality is imperative to achieving a substantial service life from these components. Daily inspection and monitoring of the lubrication system will reap huge rewards in both durability and reduction of downtime.

FRONT END LUBE LOCATIONS - OVERVIEW

BOOM FOOT PINS Although not under constant movement during the operation of the shovel, the boom point feet are subjected to high loads and oscillations in a variety of directions. Virtually all movement of the front end equipment will exert a load on the pins as a result of their location. OGL is introduced from system “A” to reduce the wear induced by these forces.

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SADDLE BLOCK The saddle block bears the brunt of movement from the entire weight of the dipper tube, attached equipment, and any material being moved. The location of this components creates a situation where it travel a large distance with a substantial load factor. The saddle block lube points need to be checked at least before each shift to avoid dry spots and accumulations of foreign material.

Although the saddle block and shipper shaft bearings is incorporated into the scheme of automatic lubrication by system “B”, constant vigilance is required to ensure proper adjustment of the system.

SHEAVES Sheaves, both fixed and rotating, are subjected to loads introduced by the ropes as they move the larger components of the machine. The sheave bearings on the boom point and crowd sheaves are lubricated by system “A”. The connection points of the structural strands are also protected by the same circuit of system “A”.

DIPPER TRIP The dipper trip mechanisms are another example of components that are constantly in motion under the most severe environmental conditions. The gears and bearings of the system are lubricated by system “C” with grease lubrication to ensure durability and reduce problems.

WIRE ROPES Wire ropes, running and structural, have very specific requirements for lubrication in order to survive the difficult conditions they are forced to operate within. Without proper lubrication and maintenance the expected life from costly wire roped will be seriously degraded. Refer to appendix 495LB for lubrication specifics and appendix 495WR for care and maintenance of these components.

Section 3, Lubrication - 32

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LUBRICATION BENCHMARKS MPG - MULTI-PURPOSE GREASE Scope: Performance requirements for Multi-Purpose Type Grease.

Application: For heavy duty ball, roller and plain bearings.

General Requirements: 1.

Heat Resistance - Shall be thermally stable.

2.

Retention - Shall not exhibit high leakage.

3.

Stability - Shall work continuously with a minimum change in consistency.

4.

Water Resistance - Shall withstand water washout or leaching.

5.

Reversibility - Shall be stable with repeated heating and cooling.

6.

Pressure Separation - Shall resist oil-soap separation.

7.

Dispensability - Shall have the ability to be pumped through automatic lubrication systems without the aid of heat tracing on the lube lines at the designated ambient temperatures.

8.

Extreme Pressure - Shall withstand heavy shock loading.

9.

Compatibility - Low temperature greases shall be compatible with mineral oil base greases and their oil seal material.

Compounding: Suitable for producing the extreme pressure characteristics (without inert fillers) required for heavy duty ball, roller and plain bearing lubrication.

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Section 3, Lubrication - 33

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TABLE OF SPECIFIC REQUIREMENTS FOR MPG LUBRICANTS See Ambient Temperature Note #1 PROPERTY

REFERENCE

NGLI Consistency #

ASTM D-217

Typical Penetration

+30° to +110°F

0° to + 40°F

+10° to -50°F

2

1

Note #2

ASTM D-217

265-295

310-340

Note #2

Dropping Point (°F-min.)

ASTM D-2265

325

325

Note #2

Timken O.K.(load-lbs min.)

ASTM D-2509

40

40

40

Shell Four Ball EP

ASTM D-2596

Load wear index (kg –min.) ASTM D-2596

40

40

35

Load Weld (kg-min.)

ASTM D-2596

200

200

200

Shell Four Ball Wear

ASTM D-2266

Wear Scar (mm max.)

ASTM D-2266

0.60

0.60

0.60

Copper Strip Corrosion

ASTM D-130

Pass

Pass

Pass

Rust Test

ASTM D-1743

Pass

Pass

Pass

Notes: 1.

2.

3.

4.

Ambient Temperature - The ambient temperature shall be the temperature at the point of lubricant application.

Low Temperature Grease - For extended use in low temperature (+10ø to -50øF) areas, this product should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing. In order to minimize compatibility problems, it is desirable that the thickener and additive system be the same as NLGI #1 and #2 greases.

Pumpability Tests - major manufacturers of automatic lubrication systems for pumpability tests at the designated ambient temperatures. The results of these tests should be sent to the Bucyrus International Service Department for review.

Seal and Packing - If a vendor should recommend a multi-purpose grease which would require a special type of material for seals and packing, he should contact the Bucyrus International Service Department and discuss these requirements with them.

NOTE: These performance requirements are benchmarks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

Section 3, Lubrication - 34

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ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT Scope:

Lubrication performance requirements and recommendations for Air Compressor (Screw-type) Lubricants.

Application: IMPORTANT: These lubricant performance requirements for screw-type air compressors are only good for A-C Compressor Corporation screw compressors. If your machine is equipped with air compresors manufactured by other than A-C you must refer to the vendor’s maintenance information provided with your machine and Section 7 of this manual.

LUBRICANT RECOMMENDATIONS: The following lubricants are recommended: 1.

If the ambient temperature is expected to always be above -26øC (-15øF), use either: Automatic Transmission Fluid (ATF) - General Motors Dexron III or Ford Type F. or Synthesized Hydrocarbon Fluid - Mobil Rarus SHC 924.

2.

If the ambient temperature is expected to drop to -40øC (-40øF), use Mobil Rarus SHC 1024 or Phillips Philesco ISO32 or equivalent.

NOTE: If the ambient temperature drops below -26øC (-15øF), it may cause the lubricant to thicken in the oil cooler and could result in unit shutdown after a short run. If this happens often and the compressor is being lubricated with ATF, it is recommended that a synthesized hydrocarbon lubricant be used, instead.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

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Section 3, Lubrication - 35

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MPO - MULTI-PURPOSE OIL Scope:

Lubricant performance requirements for Multi-Purpose Oil.

Application:

The addition of a lubricant to the compressed air system (not for screw-type air compressor systems - see ACSL), hand oil cans, etc.

General Requirements: 1.

Must be fluid at temperature applied.

2.

Should contain rust inhibitor.

3.

Motor oil - API service classification “MS.”

Viscosity Recommendations 1.

Air Line Lubricant AMBIENT TEMPERATURE SAE NUMBER

2.

Below 10øF

5W

Above 10øF

10W

Hand Oil Can - Viscosity suitable for application and temperature.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

Section 3, Lubrication - 36

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OGL - OPEN GEAR LUBRICANT Scope: Lubricant performance requirements for the lubrication of open gearing.

Application: Lubrication between mating teeth in an open gear drive.

Methods of Application: 1.

Heated and poured, or hand sprayed on the gear teeth.

2.

Sprayed or dripped on the gear teeth by means of an automatic lubrication system.

3.

Applied by means of a cartridge gun.

General Requirements: The following are the requirements of the lubricant at the ambient temperature of the open gear drive.

1.

Adhesive - Maintain film lubricity and be highly resistance to squeeze at contact points of mating surfaces.

2.

Flexible - The coating on the surface of the gear teeth must remain pliable.

3.

Extreme Pressure - Must withstand the high rolling and sliding contact pressure and have the ability to flow under loads.

4.

Consistency - Should maintain consistency.

5.

Water Resistance - Ability to resist water washout.

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Type of Lubricants: 1.

Petroleum Resin and Asphaltic Types a. Hot Melt Type CAUTION: Since this type must be heated and melted before it is applied to the gears, safety codes should be checked before it is used. b. Diluted Type: This should contain a fast drying diluter such as or equivalent to trichloroethylene. The diluted viscosity must be such that the lubricant can be applied by either spraying or dripping at the ambient temperature of the open gear drive.

2.

Semi-Synthetic Type

Diluted Type: This should contain a fast drying diluter such as or equivalent to trichlorethylene.

The diluted viscosity must be such that the lubricant can be applied by either spraying or dripping at the ambient temperature of the open gear drive.

3.

Special Greases

These generally contain a soap type base, E.P. compounds and adhesive agents. Some contain molybdenum disulfide, graphite or other solid lubricants.

The consistency should be such that the lubricant can be applied by either spraying, dripping or cartridge gun at the ambient temperature of the open gear drive.

Compounding: Suitable for producing extreme pressure lubrication between the mating teeth in an open gear drive.

Section 3, Lubrication - 38

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Specific Requirements For All Types of OGL Lubricants: 1.

Must pass the United States Steel Retention Test Using Timken Tester.

2.

Shell Four Ball E.P. - (ASTM D-2596)

3.

Load wear index, kg., min.

40

Load weld kg., min.

250

Shell Four Ball Wear - (ASTM D-2266) Wear scar diameter mm., max.

0.60

4.

Timken O.K. Load lbs., min. - (ASTM D-2782)

45

5.

Copper Strip Corrosion - (ASTM D-130),

pass

6.

Suggested Application Temperature Range: There should be a lubricant for each of the following temperature ranges: 30ø to 110øF 0ø to 40øF 10ø to -50øF

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

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Section 3, Lubrication - 39

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RGL - REGULAR GEAR LUBRICANT Scope:

Lubricant performance requirements for Regular Gear Lubricant.

Application:

For enclosed helical, worm, bevel, spiral bevel and other gears or gear assemblies subjected to severe shock loads.

Table of General Requirements for RGL Lubricants PROPERTY

REFERENCE

ACCEPTANCE

Oxidation Stability should not

ASTM D-2893

Increase in Kinematic viscosity @ 210°F exceed 8%

Rust Protection water

ASTM D-665

No rust after 24 immersion in synthetic sea

Corrosion Protection

ASTMD-130

#1b strip after 3 hours @ 250dF

Foam Suppression

ASTM D-892

Test

Limits (max. volume of foam – ml after:

Sequence

Demulsibility

Section 3, Lubrication - 40

Temperature 5 min. blow

10 min. rest

I

75°F

75

10

II

200°F

75

10

II

75°F

75

10

ASTM D-2711-86

(per par. 3.2) AGMA* Grades 2EP-6EP

7EP and up

Max. % water in oil

1%

1%

Max. Cuff

2.0 ml

4.0 ml

Min. Free Water

60 ml

50 ml

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Timken O.K. Load

ASTM D-2782

Typical Pass of # 55

EP Test –4 Ball

ASTM D-2783

1) Load wear index min. – kg = 40 2) Load Weld min – kg = 250

Wear Test –4 Ball

ASTM-2266

Wear Scar diameter – mm max. = .6 1 hr. @ 130°F @1800RPM @ 20kg

FZG Test

Min. 11 stages passed

Separation Resistance

Should not separate in storage and should maintain extreme pressure characteristics when subjected to centrifugal forces while in use.

* American Gear Manufacturer’s Association

Compounding:

Should contain mild EP, agents of the leaded, sulfur-phosphorus or equivalent type.

Synthesized hydrocarbon fluids are not excluded as Regular Gear Lubricants.

Viscosity And Viscosity Index: For the maximum gear life the heaviest viscosity gear oil should be used, limited by the gearcase ambient temperature and duty cycle. The gear oil used must have a viscosity index equal to or greater than the required minimum of this specification.

The AGMA (American Gear Manufacturer’s Association) grade is SUS (Saybolt Universal Seconds) as specified in this standard for gear oil viscosity. This tends to overcome the confusion of selecting a grade of oil based on SAE numbers (motor oil & gear oil, viscosity at what temperature, etc.).

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Section 3, Lubrication - 41

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Notes: 1.

Ambient Temperature: The ambient temperature is defined as the air temperature in the immediate vicinity of the gearcase. Refer to the following in determining the ambient temperature: - Use atmospheric temperature for gearcases in an extreme exposed location.

- Use machinery house temperature for gearcases inside of the house. Some ma chines are equipped with house heaters.

- Use oil temperature for gearcases having either strip heaters or immersion heaters.

- Gearcases exposed to the direct rays of the sun will run hotter and must therefore be given special attention.

2.

Requirements For Selecting Gear Lubricant - Lubrication of the gears and anti-friction bearings with the same gearcase oil.

- Lubrication for the gears only whenever the bearings are sealed and lubricated separately.

- Duty Cycle Semi-continuous operations such as: dragline hoist, drag and swing; shovel hoist, swing and crowd; drill rotary drive.

Intermittent operation such as propelling.

3.

Guidelines For Selecting Temperature Range For Any Gear Oil - Minimum Ambient Temperature Use oil pour point temperature when gears only are to be lubricated.

Use a temperature 10øF above pour point when gears and bearings are to be lubricated.

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- Maximum Ambient Temperature when oil viscosity is 2000 SUS At many locations, a winter and summer grade of Regular Gear Oil will be used.

Use ASTM standard viscosity - temperature chart to plot temperature range.

Notes: 1.

AGMA standard gear oil specification does not include pour point temperature pour point as specified is an additional Bucyrus requirement.

2.

If ambient starting temperature approaches lubricant pour point, external heaters may be required to facilitate starting and insure proper lubrication.

CAUTION: If oil recommendation requires special seal or packing material, oil supplier should inform the Bucyrus Engineering Department of the need in time to obtain suitable seals or packings.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

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Section 3, Lubrication - 43

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RWL - RUNNING WIRE ROPE LUBRICANT Scope:

Lubrication performance requirements for hoist rope lubricant.

Application:

Primarily for hoist ropes or any other running ropes where fatigue and not wear is of prime concern.

General Requirements: 1.

Penetrate between adjacent wires in order to lubricate and protect them against wear and to keep the rope core from drying out and deteriorating.

2.

Provide a lubricant between sheaves and wire rope.

3.

Resist being washed off.

4.

Protect against rusting or corrosion.

5.

Form a non-sticky film so that dust and dirt will not build up on the wires.

6.

Remain pliable and resist stripping at the lowest temperatures to which the rope will be exposed.

7.

Preferably, it should form a light colored transparent film so that wear, corrosion or broken wires can be readily detected by inspection.

8.

Be capable of easy application, both manually and by devices without being heated.

Section 3, Lubrication - 44

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Compounding Suitable for penetrating between the adjacent wires of a rope in order to lubricate them and also to replenish the lubricant in the core.

Special Requirements: 1.

Must pass United States Steel Retention Test Using a Timken Tester

2.

Shell Four Ball E.P. - (ASTM D-2596) Load wear index, kg., min.:

40

Load weld kg., min.: 250 3.

Shell Four Ball Wear - (ASTM D-2266) Wear scar diameter, mm., max.:

0.60

4.

Timken O.K. Load lbs., min. - (ASTM D-2782):

5.

Copper Strip Corrosion - (ASTM D-130): pass

6.

Suggested Application Temperature Ranges

45

There should be a lubricant for each of the following temperature ranges: 110øF to 30øF 40øF to 9øF 10øF to -50øF NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

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Section 3, Lubrication - 45

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

SECTION 4 - SCHEDULED MAINTENANCE ABOUT THIS SECTION ............................................................................................................... 2 GENERAL SAFETY CONSIDERATIONS ..................................................................................... 2 IN-OPERATION MAINTENANCE ................................................................................................. 2 PRECAUTIONS BEFORE AND DURING MAINTENANCE.......................................................... 3 LUBRICATION GUIDELINES ....................................................................................................... 5 LUBRICANT CLEANLINESS ........................................................................................................ 6 LUBRICATION POINTS AND SERVICE AREAS .......................................................................... 7 INSPECTION SCHEDULES ....................................................................................................... 11 DAILY MAINTENANCE SCHEDULE..............................................................................13 MASTER MAINTENENCE SCHEDULE........................................................................15

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Section 4, Scheduled Maintenance - 1

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ABOUT THIS SECTION This section of the manual describes those aspects of preventive maintenance such as inspection, adjustment and routine repetitive tasks of the Model 495B1 electric mining shovel. Information related to lubrication techniques, frequency, and service points is also partially included. Further detailed information can be found in Sections 3 and 5 of this manual.

At the end of this section you will find reproducable maintenance schedules that may assist in your record keeping and maintenance schedualling.

GENERAL SAFETY CONSIDERATIONS The importance of overall safety in the maintenance of a mobile shovel should always be emphasized; excavating operations may involve a variety of hazardous conditions. Many critical shovel components are subject to wear and other deterioration which limits their useful life; thus making them expendable. When new, all such parts have a built in reserve strength against unknown factors and reasonable loss of durability from gradual wear. If however; inspection and adjustment are neglected, these parts eventually reach a condition where they become a potential problem. Similarly, failure to replace various mechanisms to ensure proper performance of the shovel could constitute a problem. Study this manual carefully to avoid unsafe conditions. Review the manual periodically to refresh your knowledge of these procedures. Supervisors, operators, and maintenance men should continuously follow safe practices.

IN-OPERATION MAINTENANCE Safety requirements dictate that all shovels in active service be inspected at regular intervals for proper adjustment of operating mechanisms, excessive wear of components, system cleanliness and any other defects. In-operation deficiencies should be carefully investigated. It should be determined if a safety problem exists. Remember, maintenance is vital to safe operation! It should be performed systematically by competent personnel.

From an economic standpoint, it is advisable to perform as much of the upkeep as can be safely accomplished while the shovel is running. Obviously, there are some maintenance procedures, such as gear tooth inspections and replacement which require machine shut down. However; many support duties can be effectively handled at shift change when the shovel is still activated.

Automatic lubrication systems function throughout the operational cycles of the machine. These systems release pre-measured lubricant which extends the wear life of the machinery units. Other parts of the machine may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the operator’s hands at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.

A repair or maintenance job on shovel equipment is not complete until all guards, plates and other safety devices have been replaced before the equipment is restored to operation.

Section 4, Scheduled Maintenance - 2

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PRECAUTIONS BEFORE AND DURING MAINTENANCE The operator must be sure that the shovel equipment is in a safe position before repairs or adjustments are made. The machine should not be endangered by falling rock or a possibly yielding support surface. Before beginning repair or adjustment, the operator shall: 1.

Set the dipper on the ground.

2.

Set all brakes.

3.

De-energize control functions.

4.

Do whatever else is necessary to prevent accidental movement of the machine.

DANGER: If power is essential to the repair, it should only be energized when all personnel are clear of electrical and mechanical hazards. The power should only be energized during the required period and not when repair work is being done.

Prior to undertaking any work, maintenance personnel should notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the starting controls should be locked in the OFF position and tagged. The lock and tag should be removed only by the maintenance people who installed them, or other authorized personnel. During all phases of maintenance, use extreme caution when working near electrical equipment. Never work near exposed, energized high voltage connections.

Approved protective equipment such as gloves and insulated hooks or tongs should always be used when high voltage electrical cables are handled.

DANGER: Only qualified electricians are permitted to directly maintain electrical equipment such as motors, transformers, and switches.

While performing maintenance, the awkward positions assumed, and the handling of heavy parts often increases the possibility of injuries. As a precautionary measure, use mechanical handling equipment whenever possible. The mining foreman can facilitate safer and easier maintenance work by providing blocking materials. Service crews should have a fundamental knowledge of lifting practices so their knees and legs are used rather than their backs.

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Section 4, Scheduled Maintenance - 3

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DANGER: Many of the components comprising the 495B1 electric mining shovel are heavy, bulky items. Extreme caution should be used when lifting these items. Personnel should be certain of the weights of components before attempting to lift them, either manually or with a lifting device. All applicable safety rules should be followed when using a crane or other lifting device. Be aware of the load rating, lifting height and swing radius of the lifting device before lifting a load. Failure to follow all applicable safety rules when performing maintenance could result in serious injury, or death.

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LUBRICATION GUIDELINES Lubrication may well be the most important portion of a preventative maintenance program. Do not allow anything to interfere with the lubrication of the machine. It will require some study to adjust the amount of lubricant to use at each servicing, however; the extra effort will result in a smooth running machine with less wear and breakdowns.

There is no way to predict how much lubricant should be applied to a particular bearing. It is dependant upon on how hard the machine is being worked, how much the bearing has previously worn, and the grade of lubricant being used. Watch all the bearings closely until you are sure the lubricant added at one servicing is enough to last until the next .

Most wearing parts require that lubricant be applied regularly in small quantities as accomplished by the automatic lubrication system instead of large amounts applied occasionally. Make regular inspections of the machine and watch for signs of improper lubrication such as accumulation of excess lubricant or discolored lubricant. Ensure that the lubricant has not come from a broken or disconnected line or lubricant pipe. Usually, it is a waste to pump more lubricant into a plain bearing after the lubricant starts to come out. However, certain bearings, in locations which may collect dirt (such as the lower works and dipper padlocks) should have extra lubricant added to purge all of the old lubricant which may have collected abrasive dirt.

New bushings sometimes overheat because they are too tight to allow normal distribution of lubricant.

Old bushings may overheat because they are so worn that lubricant will not stay in until the next time of servicing. In the case of the new bushing, it may be necessary to give it more frequent lubrication until it is worked in. It may be necessary to do the same for the old bushing, until it can be replaced. It is much better to lose a little time on a shift to give some extra lubricant to a point which needs it rather than trying to run it to the end of the shift.

The most common cause of overheating of an anti-friction bearing is churning of the lubricant.

This happens when the bearing is packed excessively full. If lubricant leaks out of an anti-friction bearing, it is almost a sure sign that too much lubricant was added to the bearing. Continue to lubricate it as often as before, but use less lubricant.

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LUBRICANT CLEANLINESS Even the best lubricant is a useless wear preventative if it has become contaminated by careless handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep it clean. It is the responsibility of the person performing the machine lubrication to be sure that no dirt gets into the lubricant.

Follow these points of good lubrication practice: • Keep all oil and other lubricants in tightly covered containers.

• Wipe off covers before opening containers.

• Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off with a clean lint-free cloth before using.

• Wipe off each fitting before attaching the lubricant gun.

• Wipe off oil filler caps or covers and the surrounding area before removing them.

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LUBRICATION POINTS AND SERVICE AREAS The next portion of this manual describes and illustrates the principal points or areas which require lubrication and maintenance. Refer to the topic “Lubricant Benchmarks” in Section 3 of this manual for an explanation of each type of lubricant required for servicing this machine.

The frequency of lubrication given in each chart is intended as a guide only. Under unusual operating conditions, some points may require more frequent lubrication or other special attention.

Use good judgement in lubricating the machine. If a bearing is showing signs of trouble, such as overheating or unusual noise, give it immediate attention. Make sure the lubricant was not dirty or of improper viscosity. When the machine is operated for more than one shift each day, all crews must cooperate on checking lubrication. This is to ensure that no lubrication point will be missed, or over-lubricated. It is usually best to do this at the beginning of each shift. Reproducible service schedules are provided for recording service information.

NOTE: Lubrication instructions provided by any vendor for a vendor supplied item have priority over Bucyrus International, Inc. lubrication intervals and procedures.

CAUTION: Do not climb on the machine to perform maintenance procedures.

Use a “cherry picker” or “man basket” when inspecting or servicing elevated areas. A slip or fall can result in severe personal injury or death.

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INSPECTION SCHEDULES

On the following pages will be found reproducable maintenance schedules that may be utilized as an aid in your systematic approach to machine maintenance.

These are to be considered minimal requirements forthe proper upkeep of your electricmining shovel!

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SECTION 5 - MAJOR MAINTENANCE LOWER WORKS .......................................................................................................................... 4 PROPEL MACHINERY ..................................................................................................... 4 GENERAL ...................................................................................................................... 4 CRAWLER FRAMES AND TRUCK FRAME ..................................................................... 5 INSPECTION ................................................................................................................. 5 REPAIR .......................................................................................................................... 6 CRAWLER BELTS ............................................................................................................ 7 INSPECTION ................................................................................................................. 7 CRAWLER LINKS ........................................................................................................... 13 REPLACEMENT .......................................................................................................... 13 TAKE-UP TUMBLER ....................................................................................................... 14 INSPECTION ............................................................................................................... 14 REPAIR ........................................................................................................................ 15 UPPER ROLLERS .......................................................................................................... 17 INSPECTION ............................................................................................................... 17 REPAIR ........................................................................................................................ 17 LOWER ROLLERS ......................................................................................................... 19 INSPECTION ............................................................................................................... 19 REPAIR ........................................................................................................................ 19 DRIVE TUMBLER ........................................................................................................... 22 INSPECTION ............................................................................................................... 22 REPAIR ........................................................................................................................ 23 INSPECT THE CRAWLER LINK ..................................................................................... 25 TUMBLER DRIVE SHAFT .............................................................................................. 27 INSPECTION ............................................................................................................... 27 REPAIR ........................................................................................................................ 28 PROPEL MOTOR ........................................................................................................... 30 PLANETARY GEARCASE .............................................................................................. 31 REPLACE ..................................................................................................................... 31 SWING RACK ................................................................................................................. 33 INSPECTION ............................................................................................................... 33 ROLLER CIRCLE ............................................................................................................ 34 INSPECTION ............................................................................................................... 34 REPAIR ........................................................................................................................ 35 CENTER PINTLE ............................................................................................................ 38 INSPECTION ............................................................................................................... 39 ADJUSTMENT ............................................................................................................. 40 REPAIR ........................................................................................................................ 42 COLLECTOR RINGS ...................................................................................................... 44 GENERAL .................................................................................................................... 44 INSPECTION ............................................................................................................... 44 REPAIR ........................................................................................................................ 45 CABLE REEL .................................................................................................................. 46 INSPECTION ............................................................................................................... 46

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FRONT END EQUIPMENT ......................................................................................................47 BOOM..........................................................................................................................47 GENERAL....................................................................................................................47 REPAIR.........................................................................................................................48 BOOM LIMIT SWITCH................................................................................................49 GENERAL...................................................................................................................49 INSPECTION.............................................................................................................49 ADJUSTMENT...............................................................................................................50 BOOM POINT SHEAVES.............................................................................................51 INSPECTION.................................................................................................................51 DISASSEMBLY.............................................................................................................51 ASSEMBLY...............................................................................................................53 BOOM BUMPER........................................................................................................54 INSPECTION...........................................................................................................54 SADDLE BLOCK........................................................................................................55 INSPECTION..............................................................................................................55 REPAIR...................................................................................................................55 REMOVAL OF SADDLE BLOCK...................................................................................56 DIPPER HANDLE....................................................................................................58 REMOVAL.....................................................................................................................58 RETRACT TAKE-UP MECHANISM ..............................................................................60 FRONT STOP & SPREADER .......................................................................................63 DIPPER....................................................................................................................64 INSPECTION..............................................................................................................64 DOOR BUMPERS.....................................................................................................66 ADJUSTMENT......................................................................................................66 DOOR SNUBBERS..................................................................................................68 ADJUSTMENT.......................................................................................................68 DIPPER PADLOCK..................................................................................................70 INSPECTION..........................................................................................................70 DISASSEMBLY......................................................................................................70 DIPPER TRIP ASSEMBLY..........................................................................................72 REPAIR....................................................................................................................72 A-FRAME................................................................................................................73 INSPECTION............................................................................................................73 REMOVAL................................................................................................................74 AUXILIARY WINCH..................................................................................................74 INSPECTION..........................................................................................................74 HOIST ROPE SUPPORT ROLLER.............................................................................75 INSPECTION.............................................................................................................75 BOOM STRUCTURAL STRANDS..............................................................................76 INSPECTION..........................................................................................................76 RUNNING WIRE ROPES..........................................................................................77 INSPECTION.............................................................................................................78 HOIST ROPE REEVING/REPLACEMENT................................................................79 RETRACT ROPE REEVING/REPLACEMENT..........................................................84 CROWD ROPE REEVING/REPLACEMENT............................................................87 DIPPER TRIP ROPE REEVING/REPLACEMENT.......................................................91

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DESCRIPTION OF HOIST AND CROWD LIMIT SYSTEMS ..................................................... 92 ENCODER CALIBRATION DESCRIPTION .................................................................... 92 SETTING ROPE LIMITS ................................................................................................. 93 SETTING ROPE LIMITS ................................................................................................. 97 SWING MACHINERY ................................................................................................................. 97 GENERAL ....................................................................................................................... 97 INSPECTION .................................................................................................................. 97 SWING BLOWER ........................................................................................................... 98 SWING MOTOR .............................................................................................................. 99 INSPECTION ............................................................................................................... 99 REMOVAL .................................................................................................................... 99 INSTALLATION .......................................................................................................... 100 PLANETARY GEARCASE ............................................................................................ 101 GENERAL INFORMATION ........................................................................................... 101 INSPECTION ............................................................................................................. 101 SWING SHAFT PINIONS ............................................................................................. 104 REMOVAL .................................................................................................................. 104 INSTALLATION .......................................................................................................... 105 SWING SHAFT ............................................................................................................. 106 REMOVAL .................................................................................................................. 106 INSTALLATION .......................................................................................................... 107 SWING MACHINERY BEARING TEMPERATURE MONITOR SYSTEM ..................... 109 HOIST MACHINERY ..................................................................................................... 110 GEAR TRAIN INSPECTION ......................................................................................... 110 HOIST MOTOR PINION ............................................................................................... 112 REPAIR ...................................................................................................................... 112 HOIST GEAR AND DRUM ............................................................................................ 116 INSPECTION ............................................................................................................. 116 REPAIR ..................................................................................................................... 117 HOIST MACHINERY BEARING TEMPERATURE MONITOR SYSTEM ...................... 119 HOIST LIMIT SWITCH .................................................................................................. 120 HOIST MOTOR ............................................................................................................. 121 CROWD MACHINERY .................................................................................................. 123 GEAR TRAIN ................................................................................................................ 124 INSPECTION ............................................................................................................. 124 REPAIR ...................................................................................................................... 124 CROWD MACHINERY BEARING TEMPERATURE MONITOR SYSTEM ................... 128 CROWD MOTOR .......................................................................................................... 129 CROWD GEAR AND DRUM ......................................................................................... 131 INSPECTION ............................................................................................................. 131 REPAIR ...................................................................................................................... 132 MACHINERY HOUSE ................................................................................................... 133 INSPECTION ............................................................................................................. 133 WALKWAYS .................................................................................................................. 134 OPERATOR’S CAB ....................................................................................................... 135 WINDSHIELD WIPERS ................................................................................................ 135 WINDSHIELD WASHER ............................................................................................... 136

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SUPERBOLT APPLICATIONS .................................................................................................. 137 INSTALLATION PROCESS ........................................................................................... 137 PREPARATION ............................................................................................................. 137 TIGHTENING PROCEDURE ........................................................................................ 137 REMOVAL PROCEDURE ............................................................................................. 138 LUBRICATION .............................................................................................................. 139 HELPFUL HINTS: ......................................................................................................... 139 WIRE ROPE CARE AND MAINTENANCE ............................................................................... 141 STORAGE ..................................................................................................................... 141 CHECKING DIAMETER ................................................................................................ 141 HANDLING WIRE ROPE ............................................................................................. 142 SEIZING WIRE ROPE ................................................................................................. 144 END PREPARATIONS/TERMINATIONS ..................................................................... 146 WIRE ROPE CLIPS ..................................................................................................... 147 WIRE ROPE CLIP APPLICATION ............................................................................... 147 WEDGE SOCKETS ...................................................................................................... 149 INSPECTION OF SHEAVES AND DRUMS .................................................................. 151 BREAKING IN A NEW WIRE ROPE ............................................................................ 153 INSPECTION DATA ...................................................................................................... 153 GUIDELINE TO INSPECTIONS AND REPORTS ......................................................... 154 WIRE ROPE INSPECTION CRITERIA ........................................................................ 156 ABRASION: ................................................................................................................... 156 REDUCTION IN ROPE DIAMETER: ............................................................................ 156 ROPE STRETCH: ......................................................................................................... 158 CORROSION: ............................................................................................................... 159 KINKS: ........................................................................................................................... 159 BIRD CAGING: ............................................................................................................. 159 LOCALIZED CONDITIONS: .......................................................................................... 159 HEAT DAMAGE: ........................................................................................................... 159 PROTRUDING CORE: .................................................................................................. 160 DAMAGED END ATTACHMENTS: ............................................................................... 160 PEENING: ..................................................................................................................... 160 SCRUBBING: ................................................................................................................ 160 FATIGUE FRACTURE: ................................................................................................. 160 BROKEN WIRES: ......................................................................................................... 161 ELECTRIC ARC: ........................................................................................................... 162 TORQUE APPLICATION .......................................................................................................... 163 TORQUE WRENCH METHOD ..................................................................................... 163 TURN OF THE NUT METHOD ..................................................................................... 165

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LOWER WORKS PROPEL MACHINERY GENERAL The propel machinery consists of two separate units; one to drive the right crawler and one to drive the left. Each unit consists of a motor coupled to a planetary gearcase which in turn drives the drive tumbler of the crawler. A disc-type brake is mounted to each motor. A common blower supplies air to both motors. Each motor is independently controlled allowing for sharper turns due to counter-rotation of the tracks.

Controlled from the operator’s cab, the electrical propel mechanisms allow for repositioning of the machine in a quick and easy fashion.

CRAWLER AND TRUCK FRAME RELATIONSHIP - TOP VIEW

The propel machinery should be inspected on a daily basis in order to maintain machine productivity by reducing unexpected breakdowns.

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CRAWLER FRAMES AND TRUCK FRAME INSPECTION Once a month inspect the crawler frames and truck frame for cracks and structural defects. Pay particular attention to the weld between the crawler frames and the truck frame along with the internal diaphragms in the front corners of the truck frame.

CRAWLER FRAME/TRUCK FRAME WELD LOCATIONS

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DANGER: Do not attempt to enter the truck frame compartments via access covers without first disconnecting all electrical power to the machine by deenergizing the trail cable. Failure to do so could result in electrocution causing death or serious injury.

Every six months, disconnect power to the machine and inspect the inside of the truck frame for cracks. Pay particular attention to the center pintle area of the truck frame.

Check the center pintle by way of access covers in the bottom and the plate on top. At this time the electrician should inspect the propel and high voltage collector rings.

If cracks or other defects are found, contact the Bucyrus International Service Department before attempting any repair REPAIR Questions concerning repair welding of the crawler frames and truck frame should be referred to the Bucyrus International Service Department.

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CRAWLER BELTS INSPECTION The crawler belts and individual links should be inspected frequently to prevent an unexpected break down.

CRAWLER LINK ASSEMBY DETAILS

Check the links for cracks, worn lugs, elongated link pin bores or other damage. For optional bushed crawler links, check for bushing wear. Links with broken or severely worn drive lugs can cause the belts to ride off the rollers or tumblers and should be replaced at the earliest convenient time. Bent, broken or badly worn link pins should be replaced.

Section 5, Major Maintenance - 8

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ADJUSTMENT When properly adjusted, the crawler belts will sag approximately 1 to 1-1/2 inches at the center points between the upper rollers. The belts need adjusting if any of the following conditions exists:

CHECKING OF CRAWLER BELT TENSION

1.

The amount of sag is greater than 1 to 1-1/2 inches.

2.

When propelling forward: a. Excessive peaking occurs as the links leave the drive tumbler. or b. Links are forced away from the tumbler at the top and are being driven by the ends of thedrive tumbler lugs.

3.

When propelling in reverse, excessive link buckling occurs between the raised drive tum bler and the nearest lower roller.

CAUTION: The crawler belts should not be allowed to become so loose that excessive crawler belt buckling occurs. Link, link pin, and roller can be damaged if the lower roller travels over the buckled belt.

If the action of the crawler belt system is smooth and quiet while propelling forward or in reverse, the system is working correctly. If it looks jerky and is noisy, it most likely needs to be adjusted.

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Adjustment of the crawler belts is accomplished at the take-up tumbler end of the belts. The takeup tumblers are bushing mounted on a single forged axle which extends through elongated guides in the side frames. Spacers placed ahead of or behind the axle in the guides position the axle to obtain the desired belt tension.

1.

Propel the machine forward on firm level ground, a distance sufficient to remove the slack in both crawler belts at ground level. All belt slack should now be on the top side of the crawler frame. The links on the bottom side of the crawler frame should be taut.

CRAWLER BELT TENSION ADJUSTMENT DETAILS

2.

Remove the spacer retainer from the crawler frame.

3.

Securely attach a 150-ton jack to the take-up axle on one side of the machine and move the axle forward minimally to allow clearance.

4.

Remove several spacers from in front of the axle.

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5.

With the jack and support, push on the axle until the crawler belt is properly tensioned. The sum total of sag at the points between the upper rollers, the upper roller and take-up tumbler, and the upper roller and drive tumbler should be 4 to 6 inches.

6.

Insert sufficient spacers behind the axle to hold the adjustment. Several different thick ness spacers are provided.

7.

Release pressure from the jack and install the remaining spacers in front of the axle.

Install the spacer retainer.

CAUTION: Axle must be shimmed tight, both fore AND aft, using all shims originally provided with machine. Failure to do so allows axle movement during machine operation which can lead to crawler frame damage and expensive repair procedures.

8.

Move the jack to the other side of the machine and adjust the belt on that side. Be sure the spacers are the same thickness as installed on the opposite side.

9.

When both crawler belts have been correctly adjusted, remove the jack and clear all tools and equipment from the crawler track area.

10.

Check the performance of the crawler belts by propelling the machine forward on a rela tively flat surface.

11.

When correct tension can no longer be achieved by moving spacers to the front of the axle a link must be removed from the belt on each side of the machine. Following link removal, and re-pinning of the links, adjust belt tension as previously described.

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BELT REPLACEMENT

Although belt replacement is required infrequently, there are times when it is necessary.

To replace a belt, first propel the machine to flat, firm, level ground.

NOTE: For this operation the machine will need to be positioned where adequate space is available for assembly of a complete replacement belt in front of the machine, and enough room to propel the machine forward an equal distance.

1.

Remove tension from the belt by removing the tensioning spacers from behind the take-up axle. Use a jack to relieve tension for spacer removal. Remove link pins.

2.

Remove pin from a link in front of the take up roller but below the centerline of the roller.

3.

Assemble the new track to the lower end of the remaining track by positioning the links, inserting the link pins directly on to the end of the old track now laying under the machine..

4.

When assembled, the new belt will be in a straight line forward of the machine, and at tached to the old belt.

NOTE: Due to the elevated drive tumbler design of the 495B1 pressure must be applied at all times to the end of the track being removed. The use of a bulldozer, road grader or other vehicle will accomplish this task.

5.

Position a vehicle, of adequate size and strength to drag the track assembly, over the newly assembled track in a straddling type position. Move the vehicle along the track until it is close enough to attach it to the remaining end of track on the tumbler.

DANGER: Positive communication between the operator’s of the shovel and the vehicle are critical. DO NOT PROCEED UNTIL IT IS MADE AVAILABLE. The vehicles will move in a synchronous direction and speed while the track will be pulled into position. If not carefully planned and executed the shovel may override the tow vehicle causing severe vehicle damage and possible injury or death!

5.

Attach chains or strapping to the free end of the track assembly which is currently hanging down over the top of the take-up tumbler and fix to vehicle.

6.

Ensuring positive voice communications between the operators of the machines apply tension to the track end by pulling forward with the pulling vehicle.

7.

Propel the machines slowly to move the 495B1 off the old belt and onto the new belt. The new track will have to remain under tension from the tow vehicle until completely repositioned and the two ends are able to be rejoined.

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7.

Once the two ends of the new track are positions so they may be joined, stop the propel motion and shut down the machine. Remove link pins between the new and old sections of track and pull away the old section of track.

8.

Using a crane, come-a-long, or other suitable lifting device, lift and drag the lower free end of the new belt into position on the take-up tumbler and rollers and install the pin and keepers.

9.

Adjust belt tension as described in the topic covered earlier.

SUPPORTING THE CRAWLER BELT WITH A LIFTING DEVICE

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CRAWLER LINKS REPLACEMENT 1.

Propel the machine to position the defective link in an accessible position.

2.

Remove tension from the belt by removing the tensioning spacers from behind the take-up axle. Use jack to relieve tension for spacer removal.

3.

Attach the lifting device to the belt link.

4.

Remove the pins from the link and remove the link. Use the lifting device to remove the link

CRAWLER LINK SECTIONAL VIEW

5.

Position the replacement link and insert new link pins after applying a liberal coating of MolyKote Type G.

6.

Adjust belt tension as described in the topic Crawler Belt - Adjustment.

Section 5, Major Maintenance - 14

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TAKE-UP TUMBLER INSPECTION Inspect the take-up tumbler for cracks and damage that can impair normal tracking of the crawler belts.

TAKE UPTUMBER ARRANGEMENT

Remove the take-up tumbler hub caps every three months. Also make sure the cap is filled with lubricant. At the same time, check the tumbler clamp collars, to make sure they are secured on the take-up axle. Tighten the clamp collar bolts if loose.

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Every six months, relieve weight of the machine at the take-up axle, remove the take-up tumbler hub cap and tumbler clamp collar and check the take-up tumbler bushing for bore elongation and wear.

REPAIR If bushing replacement is needed, the tumbler must be removed from the machine. To accomplish this: 1.

Place blocking in front of the crawler belt which requires repair on the related take-up tumbler. Propel the machine up onto the blocks so that the take-up tumbler will be out of contact with the ground once the track is removed.

2.

Separate the crawler belt as described in the topic covered earlier in this section. Separa tion of the belt should take place at a point near the take-up tumbler, and the links laid back out of the way.

3.

Remove the take-up tumbler hub cap and the tumbler clamp collar. Remove the O-ring from the hub cap.

4.

Attach a suitable lifting device to the tumbler and slide the tumbler from the axle.

5.

The tumbler bushings are press-fit into the tumbler and must be removed with appropriate tooling,

NOTE: Bushings that have an interference fit can be difficult, if not impossible to replace in the field locations of this equipment. The use of liquid nitrogen will, in most cases, allow sufficient size reduction for the installation of interference fit bushing. It is advisable to work quickly and efficiently as heat will transfer quickly due to the material utilized in bushing construction.

CAUTION: Components that have been cryogenically treated to reduce their temperatures are extremely dangerous to handle. Always wear appropriate eye protection and gloves to avoid any possible skin contact with frozen components.

6.

After the bushing is removed, check the tumbler bushing bore for defects. Remove any burrs. Check the bore for out-of-round condition. Replace or rebuild the tumbler if bore is out-of-round. Check take-up axle for wear.

7.

Inspect the dirt seal and thrust plate on the take-up axle. Replace the thrust plate if it is badly worn. Replace the dirt seal if it is worn or damaged.

8.

Install new bushings in the take-up tumbler after adequate temperature reduction and apply light lubrication of the bushing bore.

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9.

Lubricate the bushing bore and the axle mating surface. Use a hoist and slide the take-up tumbler onto the axle. Install the tumbler clamp and hub cap. Be sure to install a replace ment hub cap O-ring.

10.

Join the crawler belt links and adjust belt tension as described in topic related to belt tension adjustment. Thoroughly lubricate the take-up tumbler bushings. Propel the ma chine carefully and remove the installed blocking

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UPPER ROLLERS INSPECTION Inspect the upper rollers for cracks and damage that can impair normal tracking of the crawler belts.

Every six months remove the upper roller collar and check the roller bushing for bore elongation and wear. Replace the bushing if badly worn.

UPPER ROLLER DETAILS

REPAIR If bushing replacement is necessary, the upper roller must be removed from the machine. To remove the roller: 1.

Relieve crawler belt tension as described in topic related to belt tension adjustment.

2.

Raise the belt with a suitable lifting device until it clears the upper portion of the roller.

Block belt in raised position.

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3.

Remove the nut and capscrew securing the roller collar and remove the collar. Slide the roller from the shaft.

4.

Remove the bushing from the roller. Check the roller bore and the shaft for damage and elongation. Remove any burrs with a file. Check the roller bore for an out-of-round condi tion. Replace the roller if the bore is out-of-round. Check roller shaft for wear.

NOTE: Bushings that have an interference fit can be difficult, if not impossible to replace in the field locations of this equipment. The use of liquid nitrogen will, in most cases, allow sufficient size reduction for the installation of interference fit bushing. It is advisable to work quickly and efficiently as heat will transfer quickly due to the material utilized in bushing construction.

CAUTION: Components that have been cryogenically treated to reduce their temperatures are extremely dangerous to handle. Always wear appropriate eye protection and gloves to avoid any possible skin contact with frozen components.

5.

Install new bushing into the roller bore. Make sure bushing is flush with, or slightly below the surface of the roller. Ensure groove in bushing is facing to the outside when roller is mounted to crawler frame.

6.

Lubricate the bushing bore and the shaft mating surface. Slide the roller onto the shaft and secure with the collar, capscrew and nut.

7.

Lower the belt until it contacts the upper rollers. Adjust belt tension as described in the topic covered earlier.

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LOWER ROLLERS INSPECTION Inspect the lower roller for cracks and damage that can impair normal tracking of the crawler belts.

Every six months remove the roller hub cap and clamp collar and check the roller bushings for bore elongation and wear. Replace bushings if badly worn.

LOWER ROLLER DETAILS

REPAIR The most common problem encountered is bushing wear. However, over a long period of time it is possible for the rollers to develop cracks and wear. If cracks do occur, they can be repaired by gouging out the metal on both sides of the crack and welding the crack. Contact the Bucyrus International Service Department for specific instructions concerning the repair welding of these structures.

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If bushing replacement is necessary the roller must be removed from the machine.

NOTE: In order to allow accessibility to the lower rollers the machine must be propelled to a location which will allow lower roller exposure with the track disengaged. The easiest method is usually to dig a hole of adequate size for the maintenance to be performed and then to propel over it.

1.

Relieve crawler belt tension as described in the topic related to belt adjustment.

2.

Position the shovel in such a manner as to allow the lower portion of the roller clears the lugs of the crawler belt by allowing the belt to sag into a hole or depression.

CAUTION: Always keep the overall stability of the machine in mind. Unstable strata may lead to catastrophic results if not considered adequate before propelling over inadequate terrain.

3.

Remove the lower roller hub cap and clamp collar. Remove the O-ring from the hub cap.

4.

Attach a suitable lifting device to the roller and slide the roller from the shaft.

5.

The lower roller bushings are press-fit into the rollers.

6.

After removing the bushings, check the roller bushing bore and the shaft for defects.

Remove any burrs with a file. Check the bore for out-of-round condition. Replace the roller if the bore is found to be out-of-round. Check roller shaft for wear.

7.

Inspect the rubber face seal and thrust washer. Replace the thrust washer if it is badly worn. Replace the the seal if it is worn or damaged.

NOTE: Bushings that have an interference fit can be difficult, if not impossible to replace in the field locations of this equipment. The use of liquid nitrogen will, in most cases, allow sufficient size reduction for the installation of interference fit bushing. It is advisable to work quickly and efficiently as heat will transfer quickly due to the material utilized in bushing construction.

CAUTION: Components that have been cryogenically treated to reduce their temperatures are extremely dangerous to handle. Always wear appropriate eye protection and gloves to avoid any possible skin contact with frozen components.

8.

Install new bushings in the roller after adequate temperature reduction and apply light lubrication of the bushing bore

9.

Lubricate the bushing bore and the shaft mating surface. Slide the roller onto the shaft.

Install the clamp collar and hub cap. Be sure the replacement hub cap O-ring is in place.

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10.

Lower the crawler assembly, and adjust belt tension as described in the topic shown earlier in this section.

12.

Thoroughly lubricate the lower roller bushing.

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DRIVE TUMBLER INSPECTION Inspect the drive tumbler for cracked or broken lugs, lug wear, and other defects which can impair tumbler function and belt tracking. Check the tumbler retainer bolts and tighten if loose. Every six months remove the drive tumbler and check the bearing and duo-cone seal for wear. Replace worn or damaged seal or bearing.

DRIVE TUMBLER DETAILS

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REPAIR The drive tumbler is splined to the drive shaft and is held securely to the shaft with a retaining plate. If repair of the tumbler is deemed necessary, consult with the Bucyrus International Service Department for repair instructions.

To replace the drive tumbler: 1.

Relieve crawler belt tension and separate the belt as described earlier. Separation of the belt should take place at a point near the drive tumbler and the links laid back out of the way.

2.

Remove the bolts securing the retaining plate to the drive shaft and remove the plate.

Remove the O-ring from the plate.

3.

Attach a suitable lifting device to the drive tumbler and slide the tumbler from the drive shaft.

4.

Inspect the bearing and duo-cone seal on the drive shaft for defects and damage. Re move any burrs from the splines of the shaft.

5.

Examine the exposed end of the drive shaft for defects and damage. Remove any burrs from the splines of the shaft.

6.

If the duo-cone seal was removed, re-install it as per the section on Duo-Cone Seal Installation found later within this section.

7.

Lightly lubricate the tumbler bore and the splines of the drive shaft with Molykote Type G.

8.

Slide the new tumbler on to the shaft. Install the retaining plate and shim to obtain a gap of 0.002 to 0.005 inches and tighten the bolts securely. Ensure you have installed a new “O” ring onto the retaining plate prior to installation.

9.

Join the crawler belt links and adjust belt tension as previously described.

Inspect the drive tumblers for evidence of an out of pitch condition. If such a condition is found a sampling of link pitches must be taken

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REBUILD OF THE DRIVE TUMBLER 1.

Bucyrus crawler systems are designed to acomodate a limited amount of component wear in the drive tumbler/link system.

2.

The tumbler/link engagement results in clearances “A” and “B” as shown in the figure below. The sum of “A” and “B” is typically 4.08 inches (A+B=4.08 in.)

As link pin wear occurs clearance “B” will decrease unit it becomes zero, (as in figure 2) and dimension “A” will decrease accordingly.

Eventually both dimensions “A” and “B” will become zero.

At this point a component rebuild or replacement i snecessary to avoid link distress and/or breakage.

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NOTE: Wear of the individual tumbler lugs will actually increase dinensions “A” and “B”.

3.

Field inspections of the tumbler/crawler engagement should consist of actual “A” + “B” observations. If the sum of these two dimensions is approaching zero the following corrective action should be taken

NOTE: A new drive tumbler O.D. is 45.75 inches. If your drive tumbler is worn to an O.D. of 43.75 inches or less, rebuilding the O.D. should be considered. Dimension “A” + “B” will increase by 1.23 inches for each 1.00 inch the O.D. of the tumbler is increased.

INSPECT THE CRAWLER LINK Inspect the crawler link pins ehich are originally 4.50 inches in diameter. If the pins are significantly worn they may be replaced.

A new 4.50 inch diameter pin replacing a worn pin with a diameter of 3.50 inches will increase the dimension “A” + “B” by 1.55 inches.

NOTE: Oversize pins, those having a diameter greater than 4.50 inches, are genereally not practical as the holes in the link bores tend to wear unevenly and theses pins will not fit.

Refer to the figure above for the relationship of decrease in the dimension “A” + “B” as the link pitch increases. Rebuild or replace the components as required.

The figure on the following page provides details on the dimensional requirements for a drive tumbler rebuild.

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DRIVE TUMBLER REBUILD DETAILS

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TUMBLER DRIVE SHAFT INSPECTION For inspection of the bearings and other components of the drive tumbler shaft, removal of the shaft is necessary. The tumbler drive shaft can be removed without disturbing the propel planetary unit.

TAKE UP TUMBLER DRIVE SHAFT DETAILS

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REPAIR To disassemble the drive tumbler shaft proceed as follows: 1.

Remove the drive tumbler as described in the earlier topic.

2.

Remove the socket head screws securing the bearing retainer. Remove the retainer.

Separate the duo-cone seal from the retainer.

3.

Install an eyebolt in one of the tumbler retainer plate screw holes and attach a “come-along” to the eyebolt.

4.

As the shaft is removed, and the bearing clears the crawler frame, support the shaft with an additional sling in the area of the bearing retainer nut. The sling should be installed prior to the shaft exiting the guide bushing as monitored through the inspection hole in the top of the crawler frame.

5.

Remove the lockplate capscrews, lockplate, and bearing nut from the shaft. Remove the flat head screws securing the seal retainer to the bearing. Remove the seal retainer and bearing spacer from the shaft. Separate the oil seal from the retainer.

6.

The bearing has an interference fit of .0052 to .0084 to the shaft. The shaft is machined with two grooves under the bearing for hydraulic assist in bearing removal. Each groove is connected to an individual lube port at the end of the shaft.

CAUTION: When using hydraulic assist for bearing removal, take precautions to prevent grease spray as the bearing is removed.

7.

Through the inspection hole, remove the shaft guide bushing retainer capscrews, the re tainer and guide bushing.

8.

Clean and inspect all parts. Repair or replace all worn or damaged parts.

9.

Re-assemble in reverse order of disassembly noting the following: a. Heat the bearing in an oil bath to 250° F. b. Install the bearing on the shaft tightly against the shaft shoulder while ensuring holes for mounting seal retainer are facing away from the shaft shoulder. c. Install bearing spacer and retaining nut. d. Allow bearing to cool.

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e. Install oil seal and retainer on bearing with seal lip facing toward the bearing.

Install nut lockplate and lockplate capscrews. f. The nut may have to be backed-off slightly to install lockplate. g. Re-install the guide bushing and retainer in the crawler frame. Coat the bushing with lubricant prior to installing shaft to help protect the shaft splines.

NOTE: All splined surfaces should be re-coated with Molykote Type G or other suitable antiseize compound. h. To prevent damage to the planetary gearcase when installing the drive tumbler shaft, bolt and nut must be installed in the center hole of cover. This will prevent movement of the sun shafts. i. When installation is complete, the bolt and nut should be switched with plug. j.

Re-install shaft assembly into crawler frame. Shaft may have to be rotated slightly to align splines of shaft and planetary unit.

k. When the bearing is tight against shoulder in crawler frame bore, install bearing retainer and duo-cone seal. Use procedure in Appendix 495DC to install seal. l.

Install the drive tumbler as described in the Appendix 495DT.

m. Thoroughly lubricate the bearing. Refer to Section 3 for more information.

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PROPEL MOTOR At least once a month, check the hardware of the motor coupling for tightness, and tighten if necessary. Check the couplings for evidence of lubricant leakage. If leakage from a coupling is noticed, the coupling should be disassembled and repaired. Refer to Appendix 495MC for coupling repair.

The couplings normally will not require lubricant. To add lubricant, remove the pipe plugs from the sleeves and fill the coupling until an overflow condition exists with the grease holes in the horizontal position. Re-install plugs firmly after lubricating couplings.

The level of lubricant in the gearcase should be checked weekly and lubricant added as required.

The daily inspection should also include checking for leaking seals or gaskets.

DANGER: Press the MAIN POWER OFF button and tag it to avoid inadvertent energizing before attempting to disconnect the propel motor leads. A voltage hazard is present and could cause electrocution resulting in death or serious injury. Do not attempt to disconnect any wires until the auxiliary power has been disconnected and the main power is OFF. Frequently check the electrical connection of the propel motor and blower motor for tightness.

Tighten the connection hardware if necessary.

PROPEL MOTOR LOCATIONS

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PLANETARY GEARCASE REPLACE Repair of the propel machinery will consist mainly of replacement of worn or damaged parts.

Proceed as follows to disassemble the gear train. Repair procedure for the brakes is listed separately. Motor repair will be found in the Electrical Vendors’ Manuals.

1.

Position the machine on level ground and swing the revolving frame so the boom foot is slightly beyond the center of the propel motor. This will allow for vertical pickup of motor.

2.

Have an electrician disconnect and tag the motor electrical connections.

PLANETART PROPEL GEARCASE ARRANGEMENT

3.

Remove all lube lines and drain the gearcase.

4.

Remove the propel motor blower ducts.

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5.

Remove coupling guard cover to expose the motor coupling and remove the coupling bolts. Remove the motor mounting bolts and lift the motor and brake from the truck frame.

6.

Secure a crane and rigging to the planetary gearcase and remove the bolts mounting the gearcase to the crawler frame. Match mark the gearcase to the crawler frame so that the input shaft will be at the correct angle to align with the motor shaft at re-assembly.

7.

Slide the gearcase out of the crawler frame. Remove the O-ring and retainer from the output end of the gearcase.

8.

If the planetary gearcase is to be disassembled, refer to topic: Planetary Gearcase.

9.

Reassemble in reverse order, noting the following:

NOTE: Recoat all spline surfaces with Molykote Type G or other suitable anti-sieze compound. a.

To prevent damage to the gearcase when assembling it to the crawler frame and drive tumbler shaft, bolt and nut as shown must be installed in the center hole of the cover. This will prevent movement of the sun shafts.

When installation is complete, the bolt and nut should be switched with plug.

b.

Lubricate and tighten gearcase mounting bolts to 2,600 ft.lbs. A hardened steel washer is used with each bolt. When properly tightened, lockwire bolts.

c.

When installing motor coupling, align per instructions in Appendix 495MC.

d.

Fill gearcase with approximately 70 gallons of ISO-VG 220 oil.

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SWING RACK INSPECTION Make sure all teeth carry a protective coating of lubricant to reduce wear. Inspect the swing rack weekly for broken teeth and unusual wear patterns. Every six months, disconnect power, remove access covers and inspect the weld between swing rack and truck frame. Also, clean and inspect swing rack teeth for pitting, abrasion, spalling and galling.

REPAIR If during inspection a broken tooth is noted, shutdown the machine immediately and do not operate the machine until the tooth has been repaired. Due to the specific materials and processes involved in the manufacture of this component a specific repair procedure cannot be stated. Contact your Bucyrus International Service representative for an appropriate repair procedure.

CAUTION: Continued operation of the machine with one or more broken teeth in the swing rack could result in additional damage to the swing rack, swing pinions and swing machinery units.

SWING RACK ORIENTATION

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ROLLER CIRCLE INSPECTION DANGER: Extreme care must be exercised at all times when performing maintenance in the center pintle area due to the presence of electrical energy.

High voltage can cause serious or fatal injury. DANGER Installation, operation and servicing of components should be performed only by qualified personnel. ALWAYS DISCONNECT THE ELECTRICAL POWER BEFORE TOUCHING ANY PART IN THE CENTER PINTLE.

Inspect the rollers and rails of the roller circle monthly for severe pitting or spalling. This will usually be an indication of non-uniform loading. Small incipient pitting is not unusual and is not harmful. If rollers are damaged to the extent that they retard the swing function, they should be replaced as soon as possible. The diameter of the replacement roller must be matched to the worn good rollers. Consult the Bucyrus International Service Department for the correct procedure.

The shovel can operate, in an emergency, with a few rollers missing, however, the missing rollers must not be adjacent, but equally spaced around the roller circle.

NOTE: Remaining rollers will be subjected to increased loading, resulting in a shorter roller life.

Inspect the inner and outer roller frame sections and the roller weekly for broken bolts. Normally the inside flange of the rollers contacts the inside edge of the lower rail. If they do not, in time, a cracking or popping noise may be heard as the machine swings. This noise is caused by the rollers aligning themselves with the rails. Excessive popping requires a close inspection of the roller frame. Also, check the lubricant being used. Consult the Bucyrus International Service Department if noise is excessive.

Check both the upper and lower rails to see that they are properly chocked and secured to the swing rack and the revolving frame. Check the rail clamp bolts and retighten as required. Also check the rail surfaces for pitting and spalling.

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REPAIR To replace a roller, roller pin, frame, or rail: 1.

Swing the machine until maximum access is available to the defective component. Defec tive rollers should not be between upper and lower rails.

2.

Remove the splice plate bolts from each end of an outer frame section.

3.

Remove the nuts securing the roller pins to the outer frame section, and remove the frame section.

4.

Remove the bolts from the roller pin and remove the defective roller with its pin.

5.

If a lower rail segment must be replaced, remove both inner and outer frame splice joints.

Remove the chocks, clamp bar, and hardware securing the rail to the rack. Install a new rail segment. If required, install shims as needed to remove any spacing between rail segments.

6.

If an upper rail segment must be replaced, remove a frame and roller section and swing the machine until the upper rail is over the gap. Remove the rail segment and install a new segment.

7.

Before replacing a new roller, contact Bucyrus International for the procedure required to size the new roller to the old roller.

8.

Install a new roller, roller pin or frame section as needed reversing the steps necessary for removal of the component. Be sure to lubricate the roller pins and bushings and the roller when installing them.

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RAIL AND ROLLER SYSTEM ARRANGEMENT

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roller circle details - cutaway

ROLLER CIRCLE ARRANGEMENT - EXPLODED VIEW

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CENTER PINTLE DANGER: Extreme care must be exercised at all times when performing maintenance in the center pintle area due to the presence of electrical energy.

High voltage can cause serious or fatal injury. Installation, operation and servicing of components should be performed only by qualified personnel.

ALWAYS DISCONNECT the electrical power BEFORE touching any part in the center pintle.

CENTER PINTLE ARRANGEMENT

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INSPECTION 1.

To inspect for worn thrust washers, rails, or rollers proceed as follows:

Every 3 months, check the amount of lift of the revolving frame at the rear of the machine. Engage the dipper in the bank at near maximum reach and apply hoist power. Measure the distance between the upper and lower roller rails at the rear of the machine. Subtract from this measurement the measured distance at the rear between the upper and the lower roller rails with the dipper on the ground. If the difference in measurement is greater than 1/2 inch, the pintle lower nut must be adjusted to limit the amount of lift to between 3/16 and 1/4 inch. See Adjustment procedure.

2.

Thrust washer, rails, or rollers may be worn sufficiently to require replacement rather than adjustment. If such a condition exists, replace thrust washer per center pintle repair proce dure and roller and/or rail per the applicable repair paragraph.

3.

Clearance for free rotation of the revolving frame must be provided between the truck frame bushing and the sleeve. Such clearance, however, cannot be excessive or prema ture wear of the truck frame bushing or sleeve will occur. To determine this clearance, proceed as follows: DANGER: Extreme care must be exercised at all times when performing maintenance in the center pintle area due to the presence of electrical energy.

High voltage can cause serious or fatal injury. Installation, operation and servicing of components should be performed only by qualified personnel.

ALWAYS DISCONNECT the electrical power BEFORE touching any part in the center pintle. a.

Disconnect the power to the machine. Enter the truck frame through the bottom access opening.

b.

Remove the cover from the top of the truck frame and gain access to the space between the pintle and the rollers. Insert a feeler gauge between the sleeve and the bushing of the truck frame. Any determination over 0.250" diametral clearance is considered excessive and replacement of the bushing and/or sleeve is necessary.

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ADJUSTMENT To secure a loose center pintle sleeve which may be due to a worn thrust washer, roller, or rail, tighten the pintle lower nut as follows: 1.

Enter the bottom compartment of the truck frame which will give access to the pintle lower nut adjusting pin.

2.

Cut the lock wires and remove capscrew attaching the lock bars to the lower nut. Remove the lock bars.

3.

Pull down on the pin handle and rotate it 90 degrees so that the pin can be moved into one of the slots in the lower pintle nut.

4.

To calculate the required rotation of the center pintle to keep lift at the rear rails within the allowable range of 0.18" to 0.25", use the following formula:

R = (M-.25)576° M = Measured lift at rear rails R = Rotation, in degrees, required at center pintle Example: If measured lift is .625", then R = (.625-.25)576° R = (.375)576° R = 216° The actual adjustments must be made in 90° increments to allow re-installation of the nut-lock bars. Therefore, the adjustment can be made only at 90°, 180°, 270°, or 360°. After determining the required rotation, select the degree of turn closest to 90°, 180°, 270°, or 360°. In the above example 216° is closest to 180°. When there is a choice of selecting a higher or lower degree turn from the formula’s result. Always use the lower degree turn to prevent over-tightening of the pintle nut.

When making the above adjustment, access the Rope Reeving/Pintle Tightening screen on the panelview monitor in the operator’s cab. Pressing the button F6 will change the swing to a speed control drive reduced to 15% of normal maximum speed. Carefully rotate the machine to the required degree of rotation.

5.

Install the lock bars and capscrews. Secure the capscrews with lock wire.

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6.

Disengage the adjusting pin. Make sure the pin handle is turned parallel to the pin and locked in the slot on the pin to prevent the pin from accidently re-engaging the pintle lower nut.

7.

Apply power to the machine and check the lift as described in Inspection. Repair adjust ment procedure if necessary.

CENTER PINTLE DETAILS - CUTAWAY

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REPAIR Remove the center pintle sleeve, and thrust washer through the bottom of the truck frame as follows: 1.

Propel the machine over a pit of sufficient depth to allow the center pintle sleeve to clear the truck frame.

2.

Disconnect electrical power to the machine.

DANGER: Extreme care must be exercised at all times when performing maintenance in the center pintle area due to the presence of electrical energy.

High voltage can cause serious or fatal injury. Installation, operation and servicing of components should be performed only by qualified personnel.

ALWAYS DISCONNECT the electrical power BEFORE touching any part in the center pintle.

3.

Remove the coupling cover, the coupling, and shaft spacer. Disconnect, plug and tag lube and air lines.

4.

Remove protector and cover. Disconnect electric leads and tag them.

5.

Remove shoes, spacers, and insulators from housing.

6.

Remove the control collector rings from the swivel shaft. Unbolt the swivel assembly re tainer and remove the retainer with swivel assembly attached. Unbolt the collector ring support and remove the support and collector rings as a unit. You now have access to the pintle sleeve upper nut.

7.

Secure the swivel support at the top so that when it is unbolted in the truck frame it will not fall. Remove the access cover from the bottom of the truck frame and enter truck frame.

Disconnect and tag the air and lube lines and the electrical cables and tie out of the way.

8.

Unbolt the swivel support base from the truck frame and lower the swivel support with base out of the truck frame.

9.

Remove the lock bars, lower nut, and thrust washer from the lower end of the pintle sleeve

10.

Bolt the lifting lug, supplied with the machine, to the top of the pintle and connect the auxiliary winch to the lifting lug.

11.

Remove the bolts, lockwashers and dowels from the upper nut. Remove the upper lock bars and upper nut from the pintle sleeve.

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NOTE: In the event the upper nut should become seized on the sleeve, the upper nut is provided with two slots at the I.D. Insert ceramic tape into the slots to protect the threads on the sleeve, and burn through the nut at the slots.

CAUTION: When using a torch to burn through the nut, take every precaution to prevent injury and avoid damage to the threaded areas..

12.

Lower the sleeve into the pit. Replace worn or damaged sleeve with a new one. Check the pintle sleeve bushing for wear or damage. Replace if required. Check the truck frame around the pintle structure for cracks. If the pintle structure area needs repair, contact the Bucyrus International Service Department.

Install the new, or repaired, center pintle sleeve in reverse order of disassembly noting the following: *If the upper nut was burned apart in order to remove it, it must be replaced with a new nut. When installing the upper nut on the pintle sleeve, tighten the nut until the top surface of the nut is flush with the top surface of the sleeve. *If the lower nut was burned apart for removal, re-assemble the nut as follows: a.

Install new O-rings on the alignment pins and insert the pins in the nut halves.

b.

Clamp the two halves of the nut together. To install the new T-bolts which have an interference fit of 0.47 to 0.53" to the nut, heat the T-bolt to 900-950°F. Do not heat the T-bolts to more than 1,000°F.

c.

When installing the heated T-bolts, be sure the chamfer is facing outward. Clamp the T-bolts in-place with the T-bolt retainers.

DANGER: Be sure the electrical lines are correctly connected and all connections are tight. Also make sure that the air and lube lines are connected to the correct outlets in the swivel assembly and that the connections do not leak.

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COLLECTOR RINGS GENERAL There are three sets of collector rings on the machine. One set consists of a series of concentric rings attached to the bottom of the revolving frame. These rings allow high voltage power transfer from the lower works to the revolving frame. The rings are mounted on porcelain insulators attached to the revolving frame. Shoes are mounted on the top of the truck frame and bear against the collector rings.

The second set of collector rings transfer power for the propel motors.

The third set are control collector rings which provide control to the propel motors and power for the propel blower motor.

CAUTION: Do not attempt to maintain the collector rings unless you are positive the machine is disconnected from its power inlet. Electrical shock from high voltage sources can be lethal. Only authorized personnel should service the collector rings.

INSPECTION Inspect the collector rings and shoes frequently for grease and contaminant accumulations on the rings, shoes, insulators and incoming wires.

Clean the collector rings and related parts with an approved solvent regularly to prevent high potential grounds. Make sure each shoe bears firmly against the collector ring. The shoes are spring loaded to maintain constant contact.

CAUTION: Solvents may be toxic or flammable. Adequate ventilation must be provided to minimize fire and health hazards caused by using solvents for cleaning. Use away from sparks, heat or flame to prevent fire or explosion.

Follow the manufacturer’s instructions.

Check the insulators for cracks or chipping and replace them promptly if damaged. A dead fault can be dangerous to life and potentially costly to accompanying equipment. Verify that the screws securing the rings to the insulators do not protrude beyond the countersunk holes of the rings.

CAUTION: A cracked or chipped insulator or excessive amount of contaminates might cause a dead fault which could result in electrocution causing death or serious injury.

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REPAIR Repair of the collector rings basically involves replacement of damaged insulators or defective shoes. The collector ring life expectancy exceeds the life expectancy of the machine. To replace the insulators or shoes: 1.

Disconnect electrical power to the machine.

2.

Remove the attaching hardware securing the insulator or shoe to the mounting. Access to the shoes mounted to the truck frame is obtained by entering the truck frame through the bottom access opening.

3.

Install new insulators or shoes. Make sure all electrical leads are securely attached to the shoes and collector rings.

CAUTION: Do not attempt to inspect the underside of the revolving frame until power to the machine is disconnected.

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CABLE REEL INSPECTION CAUTION: The cable reel handles the trail cable during propelling. The trail cable carries a high voltage which can cause serious or fatal injury. Whenever work is to be done on the cable reel, the trail cable must be disconnected from its power source.

NOTE: The cable reel described in the following paragraphs is an Industrial Welder & Machinists, Inc. cable reel. If your cable reel is of a different manufacturer, do not use the following information but refer to the manuals of that manufacturer.

The cable reel should be checked daily to assure that it is working properly and that the trail cable is being spooled on and off the reel correctly. Check that the level wind mechanism works freely.

Check that all drive chains are properly tensioned and well lubricated.

Check that the control valve lever works freely. Check the hydraulic reservoir for the proper level.

Add fluid if required. Check the hydraulic lines for leaking.

Deatiled maintenence information on this component can be found in the vendor’s proprietary data supplied with your machine.

Check all structural components for cracking.

CABLE REEL OVERVIEW

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FRONT END EQUIPMENT BOOM GENERAL Maintenance of the front end equipment requires at minimum a weekly visual check for cracks or other damage to the boom structure. It will include checking the ladders and the boom point platform. Also, check for signs of wear and cracks on the sheaves. Replace, if necessary.

Unusual problems should be referred to the Bucyrus International Service Department for solutions.

Inspect the boom foot lugs for any signs of cracking. Also check to see that the boom foot pins are being properly lubricated.

FRONT END MAJOR COMPONENTS

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REPAIR Repair of the 495B1’s boom is normally limited to very minimal additional damage sustained following the failure of an attached component. If and structural damage should be encountered on the boom assembly contact Bucyrus International’s Service Department immediately.

DANGER: Due to the high load carrying posture of the boom assembly, any questionable damage may seriously endanger human life and it must be investigated by qualified personnel before continued service can be undertaken.

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BOOM LIMIT SWITCH GENERAL The boom limit switch is used to prevent the boom from being pushed backward by the action of the dipper being forced into a bank. Located in the area of the RH boom foot, and amidst the walkway railings, the switch is mounted with common hardware.

BOOM LIMIT SWITCH LOCATION

INSPECTION A verification of the switch’s adjustment can easily be made during the operation of the machine at shift change. With the dipper on the ground, raise the boom by extending the crowd action of the dipper handle until the boom begins to raise. There should be no power allowed to the crowd machinery after the boom point has moved about 5.25 inches.

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BOOM LIMIT SWITCH ADJUSTMENT DETAILS

ADJUSTMENT 1.

Set the dipper on the ground ensuring that the boom remains tight against the suspension ropes.

2.

Adjust the push rod with set screw so that the switch roller is fully extended and there is a 1/8" (+0, -1/32") gap between the switch roller and the push rod. If the boom point is raised approximately 0°-30' (about 5 1/4"), the push rod will depress the switch roller and cut-off power.

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BOOM POINT SHEAVES INSPECTION Monthly check the boom point sheaves for unusual wear. Check that the sheave bearings are receiving proper lubrication and that the lube lines are not damaged or crimped. For detailer sheave inspection procedure refer to Appendix 495WR near the end of this manual.

BOOM POINT SHEAVE DETAILS

DISASSEMBLY If the point sheaves have to be repaired, use the following procedure for removal: 1.

Position the machine in a clear and level area for performing the repair.

2.

It is not necessary to lower the boom to accomplish this repair. It is necessary to remove the hoist ropes from the sheaves. This must be accomplished with a crane. The ropes should be moved toward the center of the boom point.

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CAUTION: The rope should be secured to the boom for safety until the repair is completed.

3.

Adequate lifting capacity is required in order to effect the required repair.

CAUTION: Adequate precautions must be taken to ensure the safety of the personnel when equipment is removed and replaced.

4.

Disconnect and plug the lubrication lines to the sheave pins.

BOOM POINT SHEAVE - CUTAWAY

5.

Remove the sheave pin clamp collars. Tack weld the sleeve spacer to the boom ensuring minimal additional damage.

6.

Support the sheave assembly with a sufficient sling or chain device while pulling the sheave pin from the sheave and boom. Remove the key from the pin.

7.

Remove sheave assembly and then remove the sleeve spacer. Separate the bearings, bearing retainers, seals, O-rings, and bearing clamps from the sheave. Take care not to damage the seals and O-rings.

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8.

Repair or replace all damaged or worn parts.

ASSEMBLY 1.

Re-assemble the bearing, sleeve, retainers, seals, O-rings, and bearing clamps to the sheave. Refer to Appendix 495SH for bearing clamp shimming instructions. Tighten the retainer and clamp capscrews. Use LocTite on the capscrews.

2.

Tack-weld the sleeve spacer to the boom in line with pin bore. Lift the sheave assembly into the boom and insert the pin while ensuring the pin key is in place. Install the clamp collar and tighten the bolts. Carefully remove tack-weld from the sleeve spacer.

3.

Re-connect the lube lines and place the hoist ropes back on the sheaves. While ensuring that you do not cross the hoist ropes.

Section 5, Major Maintenance - 54

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BOOM BUMPER INSPECTION Regularly check the condition of the boom bumper and make repairs as required. Inspections should be conducted at minimum of once per operating shift. Additional inspections may be required.

Operator’s style will affect bumper life.

BOOM BUMPER ARRANGEMENT

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SADDLE BLOCK INSPECTION The saddle block should be inspected daily for signs of excessive wear. Make certain that it is being adequately lubricated and that the injectors are functioning properly. Also check the condition of the shipper shaft sheaves for signs of unusual wear. The lubrication lines which run up the boom should be checked for any signs of damage or crimping which could impede the flow of lubricant to the saddle block.

SADDLE BLOCK BUSHING ARRANGEMENT

REPAIR The saddle block liners should be replaced when the 0.50 chamfer has been worn off, or when the measured distance of handle to lining is 0.12" with handle pushed into side of liner as shown.

Replace the liners as follows: 1.

Remove the dipper handle as described under the topic Dipper Handle Removal.

2.

Secure the rear liner with a crane and remove the liner mounting bolts. With the crane, remove the liner from the saddle block. Remove the front liner in the same way.

3.

When installing new rear liners, uniformly coat mating surfaces of liner O.D. and saddle block I.D. with Loctite(R) 680 immediately before installing liners. Use Locket 227 on liner bolts.

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4.

Replace the front liners in the same manner.

REMOVAL OF SADDLE BLOCK For any work to be done on the saddle block other than replacement of liners, the saddle block must be removed from the machine. Remove the saddle block as follows: 1.

Remove the crowd and retract ropes as described under Crowd & Retract Rope Removal.

2.

Remove the dipper handle as described under Dipper Handle Removal.

SADDLE BLOCK DETAILS - CUTAWAY

3.

Two cranes are required to remove the saddle block. One crane is used to support and remove the saddle block. The other crane is used to remove the shipper shaft.

4.

Separate and plug the lube lines to the saddle block.

5.

With a crane supporting the saddle block, remove the shipper shaft clamp collars and slide the shipper shaft from the saddle block and boom. Lower the saddle block to the ground.

6.

Check the shipper shaft bushings in the boom and replace if required. Consult Bucyrus Service Department prior to starting repair.

7.

Inspect and replace any worn sheave bearings and seals or saddle block bushings. Refer to Appendix 9 for bearing retainer shimming instructions.

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8.

Reinstall the saddle block in the boom. Reconnect the lube lines. Reinstall the dipper handle.

Reeve the crowd and retract ropes on to the machine.

SADDLE BLOCK SHEAVE DETAILS - CUTAWAY

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DIPPER HANDLE The dipper handle should be checked regularly for cracking or bending. If cracking or bending is noticed, the handle should be removed and repaired as directed by Bucyrus International’s Service Department.

Also check the handle for proper lubrication.

DIPPER HANDLE ARRANGEMENT

Check condition of the crowd sheave and retract take-up mechanism.

DIPPER HANDLE REMOVAL 1.

Lower the dipper to the ground.

2.

Remove the crowd and retract ropes.

3.

Remove the crowd half sheave.

4.

Secure a crane with adequate lifting power to the dipper handle. Chain the saddle block to the boom to limit rotation when the handle is removed from it.

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5.

While supporting the dipper handle with a crane, slowly back the machine up. The dipper handle will slide from the saddle block. Set the dipper handle on blocking and perform the required maintenance. While the handle is on the ground, the crowd half sheave (previ ously removed) and retract take-up mechanism should be inspected and repaired if re quired.

6.

Reinstall dipper handle in reverse of removal. Install the crowd cushion. Install the crowd and retract ropes.

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RETRACT TAKE-UP MECHANISM The retract take-up mechanism of this machine provides the ability to remove slack, and apply proper tensioning to the retract ropes of the mechanism.

1.

If the retract take-up mechanism must be repaired, lower the dipper so that the front of the dipper is flat on the ground.

TAKE UP MECHANISM - DETAILS

2.

Remove the shim guard bolts and rotate shim guard out of the way.

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3.

Unload retract rope using hydraulic jacks to remove shims as follows: CAUTION: Beware of oil when opening needle valves as oil is under high pressure and can cause serious injury. Stay clear of take-up nut, shims and cylinders when operating needle valve, as these items could move unexpectedly and cause injury if hands or fingers are caught between pieces of metal. a. Clean-up and grease sliding area on take-up nut, support and screw. b. Make sure needle valves RH open and LH closed. c. Extend cylinders by injecting hydraulic fluid into LH fitting d. Remove desired amount of shims from cylinder side of take-up nut and store on opposite side of nut. e. Slowly open LH valve. Stay clear of take-up nut because weight of rope may jerk take-up nut when valve is opened. Close RH valve.

4.

Release pressure from hydraulic jacks.

5.

Repair or replace all damaged parts.

6.

Retighten retract rope as follows:

NOTE: Do not overtighten ropes. Ropes are properly adjusted when a very slight curvature is noticeable on the retract rope with a tight crowd rope. a. Make sure needle valves RH open and LH closed. b. Extend cylinders by injecting hydraulic fluid into LH fitting c. Shim take-up nut at desired position.

CAUTION: Take-up nut must be shimmed tight, both fore and aft, utilizing all shims originally provided with machine. d. Slowly open LH valve (2) to release pressure on cylinders.

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CAUTION: Beware of oil when opening needle valves as oil is under high pressure and can cause serious injury. Stay clear of take-up nut, shims and cylinders when operating needle valve, as these items could move unexpectedly and cause injury if hands or fingers are caught between pieces of metal.

7.

Close and secure shim guard.

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FRONT STOP & SPREADER 1.

Lower the dipper to the ground.

2.

Back-off the retract as far as possible per step 3 of Retract Take-up Mechanism Removal.

3.

Remove the retract rope retainer bolts and retainers. Lift the retract rope out of the spreader grooves.

4.

With a torch, remove the lower splice plate. Then remove the upper splice plate.

CAUTION: When using the torch, be sure all safety precautions are followed.

5.

Attach a crane to one side of the spreader and remove the anchor bolt. Lift the spreader from the handle. Remove the other side in the same way.

6.

When re-installing the spreader, be sure it is aligned to the handle so that one side is aligned with the other side and each side is an equal distance from the handle.

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DIPPER INSPECTION The dipper should be inspected before the start of each shift. The side and front surfaces provide critical reinforcement for the dipper. Consequently, they should be checked regularly for cracks and component wear. When wear spots develop in the side and front surfaces, the metal contour can be restored by building up the affected area. Refer to welding instructions in Appendix 495RW.

DIPPER - OVERVIEW

NOTE: Do not apply hard-surfacing to steel side and front surfaces. This could promote the development of cracks. Where wear is excessive, mild steel plates can be welded in place and hardsurfacing applied to these additional plates with excellent results.

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All lubrication points should be inspected and lubricated each shift. The dipper should also be checked for missing or broken teeth or missing wedges. These items if missing or broken must be replaced before digging is started.

Check the latch bar and the latch bar keeper insert for wear and replace if required.

Check latch bar and latch lever for proper adjustment. Latch bar should be adjusted so that it enters the latch keeper pocket between 3/4 to 1 inch. Latch lever bottom bumper should be shimmed so that lever has 1/4 inch clearance from bottom of door hinge slot.

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DOOR BUMPERS ADJUSTMENT 1.

Position door to the rear (toward boom) as far as possible in order to obtain the maximum possible gap between the door and the dipperbody with the latch bar engaged.

DOOR BUMPER LOCATIONS

2.

Measure and record the gaps on both sides of the dipper between the bumper housing and the rear face of the dipper body.

3.

Assemble the bumpers so that they extend out of the housings approximately 1.00 inch.

Use the shims as necessaryu to achieve this dimension.

NOTE: It is critical that there be an equal distance on both side of the dipper when complete.

4.

Save the excess shims as they will be used in future adjustments.

5.

Check and re-adjustbumpers after one week of operation as the bumpers will develop a “memory” to that dimension.

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DOOR BUMPER ADJUSTMENT DETAILS

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DOOR SNUBBERS Check the door snubber for proper tension. When the snubber lining is new the belleville spring washers are compressed to “y” dimension as shown in figure. As these linings wear, tighten the spring bolt nut to maintain proper tension.

DOOR SNUBBER DETAILS

ADJUSTMENT Door snubber pads are stacked in a series of 4 to provide tension on the dipper door and prevent excessive speed and movement of the dipper door.

1.

Apply a thin coat of MolyKote type G to the outside of the spring diuring assembly.

2.

Apply a heavy coat of MPG to the threads of the adjustment bolt and the inside face of the adjustment nut during assembly.

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3.

Compress the snubber pads “dimension “Z” until a dimension of approx. 6.3 inches with new pads, 5.13 with used pads. This should approximate a torque value of 200 ft lbs.

4.

Observe the door closing during a drop cycle and tighten or loosen the adjusting nut accordingly to allow the dipper door gentle contact with the dipper body.

NOTE: Both snubbers must be adjusted the same!

5.

As lining wear increases, dimension “Z” will will increase with a corresponding decrease in snubbing action.

6.

Repeat as necessary to minimize dipper/door contact.

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DIPPER PADLOCK INSPECTION The padlock should be checked every shift to see that all pin retaining bolts are not loose or missing. All lubrication points should be lubricated every shift. Daily check excessive movement at the pin joints which indicate bushing wear. Replace worn bushings and pins. Check for cracking in the frames and links and make repairs when required.

DISASSEMBLY 1.

Place the dipper on the ground. Remove enough tension from the hoist ropes to remove the weight from the dipper lug pin, but not allowing enough slack to permit the weight of the padlock to rest on the pin.

PADLOCK DETAIS

2.

Remove T-bolts retaining the lug pin. Remove lug pin with suitable lifting device.

3.

Using hoist ropes, lift the padlock from the dipper padlock lug and lower padlock to the ground. Remove thrust washers and dowels from the lug.

4.

Remove T-bolt retaining the link pin. Strike the link pin foot with enough force to expose enough of the link pin head to secure to a suitable lifting device. Remove link pin from padlock frame.

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5.

Remove bushings from the link and from lower padlock frame. The bushings have an interference fit. See Bushing Fits Tabulation on figure.

6.

Support the padlock sleeve. Remove T-bolts retaining the padlock sheave pin. Remove sheave pin with a suitable lifting device.

7.

Using a suitable lifting device, remove the padlock sheave from padlock frame. Remove the thrust washers and dowels from the sheave.

8.

Remove the hoist rope from padlock frame. Remove the sheave pin bushings from pad lock sheave and frame. The bushings have an interference fit. See Bushing Fits Tabula tion on figure.

9.

Clean and inspect all parts. Repair or replace all damaged or worn parts.

10.

Reassemble in reverse of disassembly. Be sure all the dowels are flush with, or below, the surface of the thrust washers.

The upper and lower pins of the padlock appear to be identical. These items are identical in size only! The material of construction and part numbers are different. Ensure they are placed in the proper location during assembly.

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DIPPER TRIP ASSEMBLY The dipper trip can be disassembled in place on the machine or removed as a complete unit. In either case, the disassembly procedure is the same.

REPAIR

DIPPER TRIP ARRANGEMENT

1.

Remove the drum guard and trip rope from the drum.

2.

Unbolt and open the gear and pinion guard.

3.

Unbolt and remove the drum retainer and drum.

4.

Unbolt and remove the bearing retainer and spacer on the drum side. Then remove the cover and bearing retainer at the other end of this shaft.

5.

Support the gear and slide the shaft from the gear and base on the drum side of the base.

Remove the gear, bearings, spacers, and seals.

6.

Repair or replace all worn or damaged parts and reassemble in reverse order of disassem bly. Lubricate the bearings.

7.

If the pinion was removed from the motor, when it is reinstalled, the motor shaft should be recessed inside of the pinion 1/16 inch.

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A-FRAME INSPECTION Periodically inspect the A-frame for signs of cracking or other damage. This check should include the mounting lugs and pins, the ladders and platforms, the equalizer links holding the boom structural strands and the leg shrouds on the machinery house roof. Make certain there are good seals around the leg shrouds.

A-FRAME ARRANGEMENT

If any repair welding is required, contact the Bucyrus International Service Department for a specialized repair process. For any other unusual problems consult the Bucyrus International Service Department.

Carefully inspect the mounting lugs and pins for cracks or other signs of wear or deterioration.

Lubricate these areas occasionally to prevent rusting. Check the leg shrouds both from the inside and on the top of the machinery house to see that a tight seal is maintained and there are no leaks.

If there are any signs of leaking, re-seal around the shrouds with a suitable caulking compound.

Make certain the ladders are securely mounted in good condition. Repair any cracks as soon as they are noticed.

Check the condition of the platforms to see that they are secure and safe. At the same time inspect the equalizer links and connections of the boom structural strands.

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REMOVAL Under normal circumstances the A-Frame of the machine will most likely not be removed until disassembly of the machine is required. Please contact the Bucyrus Internatiuonal Service Representative should any unusual circumstances arise.

AUXILIARY WINCH INSPECTION The auxiliary winch is used to handle the hoist ropes during hoist machinery maintenance and change-out of hoist ropes.

AUXILIARY WINCH ARRANGEMENT

The winch can be single or double arrangement. The double arrangement is shown. The winch consists of a drum and rope mounted to an electric gear motor.

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HOIST ROPE SUPPORT ROLLER INSPECTION The hoist rope support rollers are used to guide the hoist rope as they leave the hoist drum and exits the machinery house.

HOIST ROPE SUPPORT ROLLER ARRANGEMENT

The rollers should be inspected daily for wear. The roller bushings should be lubricated once every shift.

Repair of the rope rollers will consist mainly of replacement of worn bushing and/or rollers. Refer to figure on page 77 for layout of hoist ropes.

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BOOM STRUCTURAL STRANDS INSPECTION Periodic inspection of the outer layer of wires immediately adjacent to the sockets should be made. If 30% of outer strands are broken, the strand must be replaced.

STRUCTURAL STRAND ARRANGEMENT

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RUNNING WIRE ROPES In designing excavating machinery, careful study of the size and operating speed of all sheaves and drums is conducted to determine the proper wire rope for each application. Continual contact with many machines in the field and repeated consultation with leading rope manufacturers permits the selection of the most satisfactory rope for each machine. To maintain the shovel at its highest level of efficiency, purchase new ropes which conform to Bucyrus International specifications, and thereby obtain the wire rope best suited for the particular application. Here are a few pointers relative to the proper inspection, lubrication, and replacement of wire ropes on the 495b1 shovel.

RUNNING ROPE LAYOUT

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INSPECTION 1.

It is the operator’s responsibility to maintain drums and sheaves in good condition. Use ropes of proper size and construction. Examine ropes for signs of deterioration or damage in service, replace them when necessary.

2.

It is customary to work the running ropes almost to destruction in order to reduce the machine operating cost and downtime for replacement. When loading trucks, hoppers, and the like, which would be damaged by a falling dipper, ropes should be inspected for signs of deterioration.

3.

Outer wires of the hoist ropes may be damaged or broken by falling rocks, by chafing over sharp rocks in the bank, and by the presence of stones in sheave grooves. Rope life may be prolonged if broken wires are trimmed so that they do not cross over and cause addi tional damage to adjacent unbroken wires.

4.

The operator should always observe safety precautions.

5.

For more information refer to the Wire Rope Care and Maintenance topic later within this section.

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HOIST ROPE REEVING/REPLACEMENT There are several methods of removing and installing new hoist ropes.

HOIST ROPE REEVING OVERVIEW

NOTE: The procedure outlined in this manual assumes that the old hoist ropes are not broken or severely frayed, that the machine is equipped with an auxiliary rope winch, and that all of the tools and supplies specified are on hand. This method was developed to keep the hoist rope under complete control at all times.

CAUTION: Methods which allow the rope to become uncontrolled at any time during the operation should be avoided. The hoist ropes are very heavy and death, serious injury, or serious damage to the shovel could result should a rope become uncontrolled.

1.

The machine should be in a clear, flat area with sufficient room to allow all of the steps in the procedure to be carried out. All applicable safety regulations should be followed. Only personnel directly connected with replacing the ropes should be allowed on or near the machine.

DANGER: The condition of the ropes may make it necessary to modify the procedures outlined here slightly, especially if the rope is broken or severely damaged. Be sure to always follow safety precautions when burning or climbing. Always keep the ropes under complete control.

2.

Lower the dipper to the ground. Position the dipper so that the padlocks are directly under neath of the point sheaves (the hoist ropes will be vertical and the heel of the dipper will be on the ground).

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3.

Position a signal man in the machinery house in a position to observe the hoist drum and ropes. Slowly rotate the drum in a lowering direction until all of the rope is spooled off of the drum and the rope sockets are in the bottom rear quadrant of the hoist drum.

CAUTION: Throughout this operation a signal man is necessary to communicate drum or rope positions to the operator. Make sure that a system of signals is worked out in advance and that the line of communication is unbroken.

NOTE: Throughout this procedure the terms “follow rope” and “lead rope” are used. Each hoist rope is a continuous length of rope. When describing each rope, however, the portion of rope from the hoist drum, over the outer groove of the point sheaves, and down to the back of the padlock is the “lead rope” because the socket on the hoist drum for this rope “leads” the socket for the “follow” rope. There is a lead rope on each individual hoist rope. The portion of rope from the front of the padlock, over the inner groove of the point sheaves, and back to the hoist drum is called the “follow rope.”

HOIST ROPE ATTACHMENT DETAILS

4.

Remove the follow rope ferrule retainer. Attach the auxiliary winch line to one follow rope becket.

5.

Pull the ferrule out of the socket. Lower the auxiliary winch line until the hoist rope can be tied off. Tie-off the follow rope just removed.

6.

Repeat the procedure for other follow rope.

7.

Carefully rotate the drum 180° in the lower direction to unwrap the remainder of the lead ropes from the drum.

8.

When all of the lead rope has been removed from the drum and the sockets are in the lower rear quadrant of the drum, stop the drum and remove the ferrule retainer.

9.

Attach the auxiliary winch line to one lead rope. Remove the rope ferrule from the socket.

Pay-ou t the winch line until the lead rope can be tied off. Tie-off the lead rope.

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10.

Attach the auxiliary winch line to the other lead rope. Remove the rope ferrule from the socket. Pay-out the winch line until the follow rope on that side cab be attached to the auxiliary winch line also.

11.

Attach the follow rope to the winch line. This allows both the lead and follow ropes to be lowered at the same time.

12.

Attach a sling to the hoist rope near the padlock. Attach this sling to a ground vehicle.

13.

At the same time, pay-out the auxiliary winch line and pull the rope off with the ground vehicle. Lower the cables until the winch line can be disconnected.

NOTE: The ground vehicle pulling on the hoist rope serves two purposes. First, the hoist rope will not lower itself until the amount of rope from the point sheave to the padlock is greater than the amount of rope from the point sheave to the end of the rope. The ground vehicle will pull the hoist rope over the point sheaves until it can lower itself. Second, since the rope is still through the padlock, any kinks, or bends in the rope will make it difficult to remove from the padlock. Pulling the rope with the ground vehicle will keep the rope straight, making it easier to remove from the padlock.

14.

Disconnect the winch line from the hoist rope. Attach one end (either lead or follow) of the hoist rope to the ground vehicle.

15.

Pull the hoist rope through the padlock. Once the rope is clear of the padlock, pull the hoist rope clear of the work area.

16.

Reeve the auxiliary winch line through the padlock. The winch line should go down through the rear of the padlock and come out through the front.

17.

Place the new hoist ropes approximately 10 feet in from of the dipper. If a double reel stand is used, place it in the center of the dipper. If two single reel stands are used, place them in line with each point sheave. The reels should be placed on the stands so that the cable unreels from the bottom of the reel.

DANGER: To prevent injury or death, special care must be taken when removing staples which secure the new rope to the shipping reel. Rope end(s) may forcefully uncoil in release of energy which was stored when the rope was wound to the reel.

18.

Attach the auxiliary winch line to one end of the new rope. This is now the new lead rope.

Remove the wire rope holding the rope to the reel.

19.

Hoist the auxiliary winch until the lead rope has cleared the padlock and the follow rope can be attached to the winch line.

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NOTE: Ropes supplied by Bucyrus will be wound on the reel so that both ends of the rope are on the outside of the reel. If this is not the case with the rope being installed with this procedure, it will be necessary to unreel the rope fully and proceed as normal. Having future ropes wound correctly on the reel will eliminate this extra step.

HOIST ROPE TERMINATION DETAILS

20.

Attach the follow rope to the winch line. Pull both ropes over the point sheave, being careful to keep the lead rope (rear rope in padlock) on the outside groove of the point sheave.

21.

Continue pulling the ropes into the machinery house. When the ends of the ropes reach a point where the follow rope can be tied off, stop pulling, detach the follow rope from the winch line and tie it off.

22.

Continue pulling the lead rope until it is in a position where it can be placed in its rope socket.Place the ferrule in the socket and detach the winch line.

23.

Attach the winch line to the hoist rope on the opposite side. Attach the sling to the rope near the padlock and to the ground vehicle.

24.

Disconnect the tie-offs securing the hoist rope. Follow the procedure outlined in steps 12 through 22 above.

25.

Once both lead ropes have been attached to the drum, secure the ferrule retainer.

26.

Position the signal man so that he can see the ferrule sockets. Slowly rotate the drum 180° in the hoist direction so that the follow ropes can be attached.

27.

Attach the winch line to one follow rope. Hoist the winch line until the rope can be attached to the drum. Attach the rope to thedrum, then repeat the procedure for the other follow rope. Secure the follow rope ferrule retainer.

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28.

Position the signal man so that he can see the ropes as they wind on the drum. Slowly rotate the drum in the hoist direction until the hoist ropes are tight. Make sure the ropes stay in the proper grooves.

29.

Hoist the dipper approximately 1 foot off of the ground. Check to make sure the dipper hangs straight. If not, place shims between the ferrule and the ferrule socket on either the lead or the follow ropes on the side that the dipper hangs lower. If necessary,locally manufactured shims may be placed under both ferrules.

SHIM DETAILS

30.

Hoist and lower the dipper several times to seat the ropes. Make sure the dipper hangs straight. If not, shim as in step 29. Reset the hoist and crowd limit switches.

NOTE: Certain situations may require the change out of only one hoist rope. This is permitted only so long as it is possible to shim the ferrules to keep the dipper hanging straight. If this is not possible, then both ropes must be replaced as a set.

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RETRACT ROPE REEVING/REPLACEMENT There are several methods of removing and installing a new retract rope.

NOTE: The procedure described below assumes: that the old retract rope is not broken or severely frayed, and that the new retract rope is wound to the shipping reel with the correctly. It remains understood that all tools and equipment specified are on hand. This procedure was developed with safety, as well as efficiency, in mind.

DANGER: Methods which allow the rope to fall uncontrolled are unsafe and should not be used. The retract rope is heavy and could cause death or serious injury should personnel be struck by the falling rope.

RETRACT ROPE REEVING

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With the machine positioned as described in the following procedure, the retract rope can be readily replaced.

NOTE: Should it be necessary to replace both the crowd and retract ropes, the crowd rope should be replaced first. The crowd rope has ferrules swaged onto the ends of the rope to the drum. These ferrules limit the amount of rope on the crowd drum in relationship to the handle position. Failure to install the crowd rope first may cause the ropes to be “out of time” and cause operating difficulties. Replacing both ropes simultaneously should not be attempted.

The retract rope is replaced in this manner: 1.

The machine should be in a clear, flat area with sufficient room to allow all of the steps in the procedure to be carried out. All applicable safety regulations should be followed. Only personnel directly connected with replacing the rope should be allowed on or near the machine.

CAUTION: The condition of the rope may make it necessary to modify the procedure described here, especially if the rope is broken or severely damaged. Be sure to always follow safety precautions when burning. Always maintain complete control over the rope and any burned section of rope.

2.

Crowd and lower the dipper simultaneously until the rear stop of the dipper handle en gages the saddle block, and the dipper is resting on the ground. The dipper heel should be on the ground.

3.

Back off the retract take-up adjustment to its complete limit. Remove the rope retaining bolts on the take-up nut and the rope retainers on the front spreader.

4.

Remove the retract rope from the drum.

5.

Remove the old retract rope from the machine.

6.

Position the reel of new retract rope directly under the saddle block.

DANGER: To prevent injury or death, special care must be taken when removing staples which secure the new rope to the shipping reel. Rope end(s) may forcefully uncoil in release of energy which was stored when the rope was wound to the reel.

7.

Reeve an auxiliary line under then over the crowd drum, up and over the outer groove of the saddle block sheave, through the rope guide on the front stop and around the retract take-up nut. Reeve it through the rope guide on the front stop on the opposite side of the handle, over the outer groove of the other shipper shaft sheave, down and over then under the crowd drum and secure the other end of the auxiliary line to the ground vehicle.

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NOTE: Liberally lubricate the grooves of the crowd drum and the take-up nut to help prevent damage to the new retract rope as it is pulled onto the machine.

8.

With the ground vehicle pull the new rope onto the machine until an equal amount of the retract rope is on each side of the machine. Disconnect the auxiliary line from the retract rope.

9.

Reeve the auxiliary line, still attached to the ground vehicle, under the crowd drum up through the rope socket, down under then over the drum and secure it to the retract rope becket loop. With the ground vehicle pull the retract rope onto the drum and into the rope socket. Seat the becket within the drum receptacle,

10.

Install the other end of the retract rope in the crowd drum in the same way.

11.

Be sure the retract rope is seated in the outer groove of the shipper shaft sheaves and the rope grooves of the front stops. Re-install the take-up nut rope retaining bolts and front stop rope retainers.

12.

Take up any slack in the retract rope with the retract take-up mechanism.

NOTE: The constructional stretch may be out of the crowd ropes when it becomes necessary to adjust ropes for about the third time. After the third adjustment, back-off the take-up mechanism 1/2" after tightening to prevent working with overtight ropes.

13.

Re-index the crowd limit switch.

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CROWD ROPE REEVING/REPLACEMENT There are several methods of removing and installing a new crowd rope.

NOTE: The procedure described below assumes: that the old crowd rope is not broken or severely frayed, that the new crowd rope is wound to the shipping reel with the one ferrule button-end in and one ferrule button-end out, that all tools and equipment specified are on hand.

This procedure was developed with safety, as well as efficiency, in mind.

CROWD ROPE REEVING

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DANGER: Methods which allow the rope to fall uncontrolled are unsafe and should not be used. The crowd rope is heavy and could cause death or serious injury should personnel be struck by the falling rope.

With the machine positioned as described in the following procedure, the crowd rope can be readily replaced.

NOTE: Should it be necessary to replace both the crowd and retract ropes, the crowd rope should be replaced first. The crowd rope has ferrules swaged onto the ends of the rope to the drum. These ferrules limit the amount of rope on the crowd drum in relationship to the handle position. Failure to install the crowd rope first may cause the ropes to “out of time” and cause operating difficulties. Replacing both ropes simultaneously should not be attempted.

The crowd rope is replaced in this manner: 1.

Check new rope length for correctness. Measure to inner ends of ferrule buttons.

2.

The machine should be in a clear flat area with sufficient room to allow all of the steps in the procedure to be carried out. All applicable safety regulations should be followed. Only personnel directly connected with replacing the rope should be allowed on or near the machine.

CAUTION: The condition of the rope may make it necessary to modify the procedure described here, especially if the rope is broken or severely damaged. Be sure to always follow all safety precautions when burning.

Always maintain complete control over the rope and over any burned sections of rope.

3.

Crowd and lower the dipper simultaneously until the rear stop of the dipper handle contacts the saddle block and the dipper heel is resting on the ground as shown.

4.

Set all brakes, shut the machine down, and tag and lock all controls.

5.

Back-off the retract take-up adjustment to its complete limit.

6.

While using an auxiliary line to control the becketed end of the retract rope, remove the clamp and disconnect retract rope from LH side of the crowd drum.

7.

Use an auxiliary line to pull the ferrule button-end of the retract rope sufficiently to permit the removal of the ferrule button from the ferrule socket on the RH side of the crowd drum.

8.

Secure both ends of the retract rope away from the crowd drum.

9.

Remove locks and tags from the controls and, using the crowd motor, rotate crowd drum in the retract direction to unwind the crowd rope from the drum. When the crowd rope ferrule buttons are in position for easy removal from the sockets, stop rotating the crowd drum.

Set the brakes and replace the tags and locks to the controls.

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10.

Remove the crowd rope ferrule buttons from the ferrule sockets and allow the rope ends to hang vertically from the saddle block sheaves. Inspect the drum grooves for sharp edges and grind them as necessary.

11.

Position the reel of new crowd rope under the saddle block and in-line with the LH saddle block sheave.

DANGER: To prevent injury or death, special care must be taken when removing staples which secure the new rope to the shipping reel. Rope end(s) may forcefully uncoil in release of energy which was stored when the rope was wound to the reel.

Attach end of new crowd rope to LH side end of old crowd rope and secure RH side end of old crowd rope to a ground vehicle.

OR If old crowd rope was broken and had to be removed in sections:

12.

a.

Inspect rope grooves and repair/weld as required.

b.

Reeve an auxiliary line up to and over the inner groove of the RH side saddle block sheave, around the crowd cushion sheave, back over the inner groove of the LH saddle block sheave, and down to the new reel of rope. Attach the auxiliary line to the becket loopof the new rope and the other end of the line to a ground vehicle as shown.

With the ground vehicle, pull the new crowd rope onto the machine until an equal amount of crowd rope hangs from each saddle block sheave. Secure the crowd rope and discon nect the auxiliary line.

NOTE: Liberally lubricate the grooves of the crowd drum to help prevent damage to the new crowd rope as it is pulled into position on the crowd drum.

13.

Bring the auxiliary line over the top of the crowd drum, through the crowd rope socket, around the rear of the drum and forward from the bottom of the drum to the corresponding end of the new crowd rope. Connect the auxiliary line to the corresponding end of the crowd rope. Release the corresponding end of the crowd rope from (step 12) securing means, and with the ground vehicle still attached to the other end of the auxiliary line, pull the crowd rope onto the rope ferrule socket on the drum. Secure the crowd ferrule button into the drum ferrule socket. Release the auxiliary line from the crowd rope.

14.

Connect the other end of the crowd rope to the other corresponding crowd drum ferrule socket in the same way as described in step 13.

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15.

Remove the locks and tags from the controls and using the crowd motor, rewind new crowd rope onto the crowd drum by rotating the drum in the crowd direction. Make sure rope is seating properly in drum grooves and the inner grooves of the saddle block sheaves.

Stop rotating drum when the crowd rope is tight. Set brakes and replace the tags and locks to the controls.

16.

With the ferrule button-end of the retract rope controlled by an auxiliary line to start with, reinstall the retract rope to the crowd drum by following steps 11 thru 17 of the Retract Rope Reeving Procedure.

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DIPPER TRIP ROPE REEVING/REPLACEMENT 1.

Use steps one and two from Hoist Rope Reeving. In this procedure the on-board auxiliary winch is not used.

2.

Have an electrician remove the dipper trip fuse from the DC cabinet.

3.

Crowd the dipper handle to unwind the trip rope from the reel. Lower the dipper to the ground and retract it slightly to get some slack in the trip rope. Remove worn rope from dipper door.

4.

Open the drum guard on the dipper trip and remove the rope and wedge from the drum.

Attach a work line to the trip rope. Pull the trip rope over and off of the trip rope guide sheave and lower to ground. The work rope will remain on the guide sheave and will be used to pull the new trip rope on.

NOTE: Do not use new trip rope which is longer than specified. Increasing length adds layers of rope on the drum which decreases trip torque.

5.

Reeve one end of the new trip rope under the guide roller, around the latch lever sheave and secure it to the rope socket with the rope socket wedge on the dipper door.

6.

Attach the other end of the new trip rope to the work line still in place on the guide sheave. With the work line, pull the trip rope onto the guide sheave and up to the dipper trip. Secure the trip rope to the drum with the rope wedge. Close the drum guard.

7.

Have an electrician replace the dipper trip fuse and adjust the trip for proper operation.

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DESCRIPTION OF HOIST AND CROWD LIMIT SYSTEMS All Bucyrus International mining Shovels incorporate a PLC-based limit position system that permits the setting of the Hoist/Lower and Crowd/Retract operational limits. Hoist and crowd encoders send digital signals to the PLC relative to the hoist crowd motor positions. The setup of the hoist and crowd limits is accomplished through the operator’s panelview display terminal by following the insructions provided here in this manual along with those on the panelview screen. When encoder calibration and hoist/crowd positional limits have been properly set the system will prevent the dipper handle from hitting it’s end stops and will prevent the padlocks from being pulled into the boom point sheaves.

ENCODER CALIBRATION DESCRIPTION Hoist/Crowd encoder calibration provides the limit system a reference point for tracking both the hoist and crowd positions. Performing the encoder calibration sets all the hoist and crowd limits to their previously set values in order that the actual limits do not require reset after initial commissioning.

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SETTING ROPE LIMITS

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SETTING ROPE LIMITS SWING MACHINERY GENERAL The swing machinery of the 495B1 is mounted on both the left and right sides of the rotating deck.

The machinery consists of a pair of 505 horsepower, 700V electric motors mounted vertically atop a planetary gear reduction box. The planetary gearcases on the 495B1 possess individual motor driven lubrication pumps to provide positive lubrication to the critical bearing surfaces of the gearcase.

The motors are force cooled by blowers mounted to their sides. The motors drive the planetary gear systems through a single input coupling on each side. The gearcases transmit the torque to a pair of pinion shafts for driving the 2 pinions on each side of the machine. The pinions mesh with

the swing rack of the machine and, in turn, provide rotational movement for the shovel’s swing cycle. Mounted on top of the swing motors are spring set, pneumatically released plate disc brake assemblies to prevent uncommanded movement.

SWING COMPONENT ORIENTATION

INSPECTION The swing machinery of the 495B1 should be inspected daily for proper lubricant level within the planetary gearcases. If lubricant level is found to be low it must be serviced prior to machine

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operation. The area of the mesh between the rack and pinions must be looked at with a critical eye. Proper lubrication, damage and the presence of foreign material are some of the items to look for in this area.

SWING BLOWER The blower assembly is mounted with the use of common hardware to the side of the swing motor.

The blower is essentially a complete unit and will normally be replaced as a complete assembly.

SWING COMPONENTS - OVERVIEW

DANGER: Press the MAIN POWER OFF button and tag it to avoid inadvertent energizing of the electrical circuit before attempting to disconnect any power leads. Electrocution may lead to serious injury or death if appropriate safety measures are not followed. Electrical connections should only be touched by trained electrical personnel.

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SWING MOTOR INSPECTION Inspection, lubrication and maintenance instructions for the swing motor can be found in the motor’s manufacturer’s manual. Replacement of the motor is covered below.

DANGER: Press the MAIN POWER OFF button and tag it to avoid inadvertent energizing of the electrical circuit before attempting to disconnect any power leads. Electrocution may lead to serious injury or death if appropriate safety measures are not followed. Electrical connections should only be touched by trained electrical personnel.

REMOVAL NOTE: Removal of the appropriate roof panel is required for the removal/replacement of either the left or right swing motor.

NOTE: Complete instructions for the removal and replacement of the motor coupling hub and swing brake hub may be found in Section 6, at the rear of this manual.

1.

Have a qualified electrician tag and remove the electrical leads to the motor.

2.

Remove the swing motor blower and duct assembly.

3.

Remove the swing brake from the motor as per the instructions in the Sectio 6 of this manual.

4.

Remove the bolts securing the motor drive coupling halves together as per the instructions in the Section 6 of this manual .

5.

Attach a lifting device to the motor and remove slack from sling.

6.

Remove the bolts securing the motor to the planetary gearcase housing.

7.

Remove the motor from the planetary gearcase and store in a dry location if to be rein stalled.

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INSTALLATION Installation of the swing motor is the reverse operation of the removal procedure covered above with the following exception: IMPORTANT Alignment of the motor coupling is critical to the longevity of the bearings within the motor and the planetary gearbox. Check, and adjust, the coupling alignment in accordance with the instructions found in section 6 of this manual.

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PLANETARY GEARCASE GENERAL INFORMATION The planetary gear cases supplied with the 495B1 are a self-contained segregated systems designed to provide extended service under adverse conditions. The repair of this gearbox is planned for a 5,000 hour cycle of factory maintenance. Other than the preventive measures listed below only seal replacement should be necessary within this time frame.

SWING PLANETARY GEARCASE

INSPECTION 1.

Check the magnetic plug weekly for evidence of excessive metallic deposits indicating unusual wear of the internal components of the gearbox.

NOTE: The magnetic plug equipped on this gearcase provides a check valve internally to prevent lubricant loss when the plug is removed.

Pick the metallic deposit off the plug and rub the deposit between your fingers.

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SWING PLANETARY GEARBOX - EXPLODED

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NOTE: Normal wear within the gearbox will provide a deposit that appears like “silver paint” when the substance is rubbed between the fingers. This is a collection of tiny metal particles that are produced by normal friction within the internal components of the gearbox. The amount may seem excessive during the initial break-in of the machine, but will reduce in short order.

NOTE: Abnormal wear within the gearbox will be evidenced by a “gritty” crumb type of material being found on the plug. If the material gathered is not smooth a problem may be surfacing.

When a gear tooth, or bearing begins to erode and “make metal” this process will only increase in severity until a point when severe, and costly, damage will be result.

Check the oil each time the magnetic plug is inspected, refill or change lubricant as needed.

A parts breakdown for the planetary gearcase is provided within this publication. Detailed repair items will be found in the manufacturer’s publication that accompanied this machine.

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SWING SHAFT PINIONS NOTE: Removal of the swing shaft pinions can be accomplished at nearly any location on a mine site. Removal of the swing shaft assemblies will require heavier hoist and more detailed tooling capabilities.

SWING PINION INSTALLATION OVERVIEW

REMOVAL 1.

Remove lockwire and loosen all of the retaining bolts of the swing pinion retainer. Ensure to only remove 3 of the 5 bolts at this time.

2

Place appropriate blocking, capable of supporting 600 lbs., under the pinion in such a manner to allow access to the remaining pinion retention bolts and the removal of the retainer. Remove the remaining bolts, retainer and shim pack.

CAUTION: Pinion gear weight is 524 lbs.

3. Lower pinion and repair/replace as required.

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INSTALLATION Installation of the pinion is the reverse of disassembly with the exception of shim pack determination.

This will be covered in the following topic.

SWING SHAFT AND PINION DETAILS

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SWING SHAFT REMOVAL NOTE: Removal of the swing shaft will require the prior removal of an appropriate section of: a. An appropriate section of the machinery house roof panel. b. Swing motor and Brake assembly. c. Planetary gearcase.

NOTE: The swing shaft must be removed from the top due to a taper on the inside bore of the bearing along with the interference fit of the bearing outside diameter to the swing support gearcase.

CAUTION: The swing shaft may also be removed from the bottom of the gearcase support if removed with the bearing and carrier as an assembly.

Careful attention must be paid to personnel safety if this procedure is utilized 1.

Remove Appropriate machinery house roof panel.

DANGER: Press the MAIN POWER OFF button and tag it to avoid inadvertent energizing of the electrical circuit before attempting to disconnect any power leads. Electrocution may lead to serious injury or death if appropriate safety measures are not followed. Electrical connections should only be touched by trained electrical personnel.

2.

Remove affected swing motor.

3.

Remove affected planetary gearcase.

4.

Remove swing shaft pinion.

5.

Attach crane to 2" lifting eye threaded into the top of the shaft, DO NOT LIFT

NOTE: ! Remove any slack from lifting device, but do not apply excessive force in an upward direction at this time 6.

Utilize a hydraulic hand pump, placed on blocking, to apply pressure attempting to force the shaft through the interference fit of the bearing.

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CAUTION: If shaft does not move, increase viscosity of hydraulic fluid and increase force to a maximum of 10,000 psi applied pressure.

NOTE: In the event that the shaft will still not move additional force can be applied with the hydraulic ram, or a jacking device of up to 50 ton. If this additional force is required to loosen the shaft, the bearing must be discarded.

7.

Once the shaft has been released it may be lifted clear of the machinery house and stored or transported for repair.

INSTALLATION 1.

Assemble upper seal, upper retainer, bearing and “O” rings in the gearcase support in preparation for the shaft.

2.

Apply a thin coating of MolyKote lubricant to the splined sections of the swing shaft prior to assembly.

3.

Raise the swing shaft and lower into the upper seal and bearing assembly while the lower seal and retainer is installed from beneath.

4.

Torque lower retainer retention bolts to 110 ftlbs.

Install the spacer, without shim pack, on the bottom of the shaft and then the pinion gear. Support the pinion gear and install bolts to 20 ftlbs.

5.

Through the hole in the center of the retainer, obtain a measurement of the distance be tween the bottom of the shaft and the bottom of the pinion retainer. Record this measure ment as dimension “A”.

6.

Through the hole in the center of the retainer, obtain a measurement of the actual thick ness of the retainer plate. Record this measurement as dimension “B”.

7.

Subtract dimension “B” from dimension “A” and record this measurement as dimension “C”.

8.

Dimension “C” is the total distance to be compensated for in the tolerances of the machine.

9.

0.080" must be subtracted from dimension “C” to allow for endplay of the vertical swing shaft.

10.

Dimension “C” minus 0.080" is the required thickness of the shimpack required for beneath the shaft assembly.

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11.

While supporting the pinion gear install a shimpack equal to the dimension arrived at by subtracting 0.080" from dimension “C”.

12.

Torque bolts on lower retainer plate in diametric patterned sequential stages of 50 ftlbs each until the value of 450 ftlbs is reached. This is critical to allow for proper seating of the tapered portion of the shaft within the bearing surface.

13.

Apply a final torque to the bolts on the lower side of the retainer plate to 480 ftlbs, and lockwire.

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SWING MACHINERY BEARING TEMPERATURE MONITOR SYSTEM Thermocouples are provided for the monitoring of bearing temperatures at critical locations within the swing machinery. These thermocouples transmit an electrical signal to the PLC which will activate a visual screen alarm when the temperature of the monitored bearings increases to point where excessive heat has been achieved.

These thermocouples aremounted in brass compression fittings to prevent lubricant leakage.

SWING MACHINERY THERMOCOUPLE LOCATIONS

Use extreme care when performing maintenance around the delicate sensors!

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HOIST MACHINERY GEAR TRAIN INSPECTION At least once a month, check the hardware of the hoist motor, shaft, and coupling for tightness, and tighten if necessary.

HOIST MACHINERY OVERVIEW

Check the coupling for evidence of lubricant leak-age. Under normal circumstances, the coupling will operate from three to five years before disassembly is needed. However, if leakage from the coupling is noticed, the coupling should be disassembled and repaired. Refer to Section 6 for coupling repair.

Every 12 months, remove the gear guard and inspect the pinions and gears for pitting, abrasion, scratching, spalling, galling, and other tooth wear.

Check the gearcase for evidence of lubricant leakage. Replace any defective seals.

Frequently check the machine for loose or missing hardware. Tighten loose hardware. Replace missing hardware.

Seal lips face toward bearings.

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HOIST MACHINERY GEARCASE COMPONENTS

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HOIST MOTOR PINION REPAIR Normal repair of the hoist gear train will only involve replacement parts. To disassemble the geartrain: NOTE: Removal of the appropriate roof panel is necessary to allow entry of a crane block and sling.

1.

Shut off power and tag controls. Disconnect any lubrication lines attached to the gearcase covers.

HOIST MOTOR PINION ARRANGEMENT

2.

Remove coupling guard.

3.

Unbolt the coupling halves and separate the coupling.

4.

Remove the bolts securing the motor shaft retainer cap and retainer. Slide the retainer on the motor side toward the coupling. Remove the retainer cap on the opposite end of the shaft.

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5.

Remove the bolts securing the intermediate shaft cap, and remove the cap. Remove bolts

from retainer on right-hand side of the first reduction gear.

6.

Attach a crane sling to the gearcase cover. Remove bolts securing the cover to the gearcase and lift the cover from gearcase. Remove the gearcase cover seal from the gearcase.

7.

Remove intermediate shaft right-hand bearing cap bolts and remove bearing cap.

HOIST - FIRST REDUCTION GEARING

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8.

Remove the bolts which secure the drum gear guard seal retainers. Remove the bolts securing the rear half of the drum gear guard cover and remove the cover.

9.

The motor shaft, it’s bearings, and the intermediate gear, shaft and bearings can now be removed as units from the gearcase.

10.

Disassemble the shafts as needed for inspection and replacement of parts.

NOTE: The intermediate shaft R.H. spherical bearing has an interface fit of .0045 - .0059 inch to the shaft. Therefore, the shaft is machined with two grooves under the bearing for hydraulic assist in bearing removal CAUTION: When using hydraulic assist for bearing removal, take precautions to prevent grease from being sprayed about as the bearing is removed.

11.

Clean and inspect the bearings for pitting, scoring, scratches, and other damage. Replace defective bearings.

12.

Check the seals for damage to the sealing surfaces. Replace seals and O-rings if neces sary.

13.

Check the gears for broken teeth, pitting, abrasion, scratching, spalling, and galling. If one side of the intermediate gear teeth is worn, the gear can be reversed to make use of the unloaded side. Be sure to position key properly when reinstalling gear.

CAUTION: When reversing the intermediate gear, a pinion with a special reversed helix will be required Contact the Bucyrus Parts Department for the availability of this special shaft.

14.

If disassembled, reassemble the shafts. Some bearings and spacers are interference fit so they must be preheated in an oil bath prior to insertion onto the shafts.

NOTE: All seals and O-ring should be lightly lubricated at installation.

15.

Install the shafts in the gearcase. Be sure all components are properly positioned to pre vent damage to them at installation.

16.

Be sure the flanges of the gearcase cover are clean. Install the seal in the groove in the gearcase. Apply a continuous bead of LOCKTITE #515 to the gearcase flange halfway between the bolt pattern and the inside of the flange.

17.

Install the gearcase cover and drum gear guard rear half cover and secure with the attach ing hardware.

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18.

Install the intermediate shaft bearing cap bolts and hoist gearcase bolts and tighten all bolts securely.

NOTE: Before tightening bearing cap rod bolts install 3/4" x 2-1/4" bolt and lockwashers into frame and bearing cap. Lubricate threads and torque to 385 ft.lbs. This will ensure bearing cap is tight against rear of frame. Tighten the bearing cap rod bolts.

19.

Install the bearing end caps and bolt securely. Securely bolt the inner seal retainer.

20.

Lubricate the bearings after installing the lube lines.

21.

Bolt the coupling halves together after checking coupling alignment.

22.

Re-install coupling guard.

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HOIST GEAR AND DRUM INSPECTION Monthly check the drum spider mounting hardware for loose or missing bolts and nuts These bolts and nuts were tightened at the factory using Turn-of-the-Nut torque method. Loose bolts or nuts should not be re-tightened but replaced with new bolts and nuts. Tighten the new bolts and nuts using Turn-of-the-Nut method as described in the topic Torque Application found later within this section.

HOIST GEAR AND DRUM ARRANGEMENT

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Check the spiders for cracks. Consult the Bucyrus Service Department for corrective maintenance if found.

Every 12 months, remove the guard and inspect the drum gear for tooth wear.

Check the hoist drum for wear and any cracks that could lead to unexpected failure of the drum.

Consult the Bucyrus Service Department if drum defects are noted.

REPAIR Repair of the hoist drum components will normally involve disassembly of the hoist drum: 1.

Place the dipper on the ground and remove the hoist ropes from the hoist drum. Refer to the appropriate topic earlier in this section for rope replacement.

NOTE: Removal of the appropriate roof panel above the hoist drum is necessary to allow entry of a crane block and sling.

2.

Disconnect the lubrication lines from the drum gear and the drum shaft bearing caps.

3.

Attach a hoist to either the front or rear part of the drum gear guard and remove the bolts securing the guard. Lift the guard off. Remove the other guard half in the same manner.

4.

Attach a crane to the drum. Remove the pins that hold the drum shaft bearing housing to the side frames; then with the crane lift the drum assembly from the side frames and out of the machine.

5.

If necessary to disassemble the drum assembly, remove the bearing outside covers and 0rings.

6.

Remove the bearing retainers and slide the housings with bearings and inner retainers off the spider stub shafts. Remove the bearings, inner retainers, and O-rings from the hous ings. Remove the bearing inner spacers from the stub shafts.

7.

Inspect the bearings for pitting, scoring and other damage. Replace defective bearings

8.

If necessary remove the bolts securing the gear to the spider, and the spider to the drum.

If one side of the drum gear teeth is worn, the gear can be reversed to make use of the unloaded side.

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9.

Re-assemble the drum, spiders and drum gear using new bolts and nuts. For the 1-1/2" dia. (grade 8) bolts, lubricate with Locktite #277and torque to specifications shown in Ap pendix 495TQ. For the 1-3/4" dia. body-fit bolts, lubricate with Locktite #277 and torque to specifications shown in Appendix 495TQ. Replace all 0-rings and seals. The bearing and spacers are interference fit so they must be preheated in an oil bath prior to installation on the shafts.

10.

Install the drum unit on the pedestals, and insert the housing pins. Secure the pins with bolts and lockwire.

11.

Install the gear guard halves, bolting them together and to the gearcase.

12.

Lubricate the hoist drum gear and bearings.

13.

Install the hoist ropes as described in the topic covered earlier in this section.

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HOIST MACHINERY BEARING TEMPERATURE MONITOR SYSTEM Thermocouples are provided for the monitoring of bearing temperatures at critical locations within the hoist machinery. These thermocouples transmit an electrical signal to the PLC which will activate a visual screen alarm when the temperature of the monitored bearings increases to point where excessive heat has been achieved.

These thermocouples aremounted in brass compression fittings to prevent lubricant leakage.

HOIST MACHINERY THERMOCOUPLE LOCATIONS

Use extreme care when performing maintenance around the delicate sensors!

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HOIST LIMIT SWITCH The hoist limit switch, when used, prevents the padlocks on the dipper from being pulled into the boom point sheaves. It electrically cuts the reference signal. The limit switch is mechanically connected to the drum shaft which drives a gear reducer which drives an encoder. Setting the hoist limit switch is a function of the Panelview monitor in the operator’s cab and that procedure is detailed earlier in this section.

HOIST LIMIT SWITCH DETAILS

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HOIST MOTOR Inspection, lubrication and maintenance instructions for the hoist motor are described in the motor’s manufacturer’s manual. If removal of the hoist motor is necessary, follow the instruction below: NOTE: Removal of the appropriate roof panel is necessary to facilitate this procedure.

1.

Place the dipper on the ground.

DANGER: Press the MAIN POWER OFF button and tag it to avoid inadvertent energizing before attempting to disconnect the hoist motor leads. A voltage hazard is presentand could cause electrocution resulting in death or serious injury. Do not attempt todisconnect any wires until the auxiliary power has been disconnected and the main power is OFF.

HOIST MOTOR ARRANGEMENT

2.

Disconnect and identify the electrical leads to the hoist blower motor and the hoist motor.

3.

Remove the hoist blower motor and duct as a unit from the hoist motor.

4.

Remove the brake from the motor. Refer Section 6 under the topic Hoist Brake.

5.

Separate the coupling on the gearcase end of the motor.

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6.

For repair of original motor: remove the two chocks and wedges located on the side of the motor towards the hoist drum. For replacement of original motor with a new motor: remove the four chocks and wedges located on both the front and rear sides.

7.

Remove the motor mounting hardware. Attach the crane to the motor and lift it from the machine. Wire shims together, if used, and identify their location for future use.

8.

Install the motor by reversing the steps used to remove it. For installation of a new motor, mount and align the motor coupling per instructions in Section 6.

9.

Re-install four chocks and wedges on both sides of the motor.

10.

For re-installation of the original motor: position the motor and provide the specified end clearance at the coupling. Re-install the two chocks and taper wedge on the hoist drum side of the motor.

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CROWD MACHINERY

CROWD MACHINERY GEARCASE ARRANGEMENT

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GEAR TRAIN INSPECTION Weekly, check the crowd cases for lubrication leaks at all cover and case junctions and at the bearing retainers. Replace seals or rings if lubrication leaks are excessive. Replace sealant as required.

Weekly, check the electrical connection of the crowd motor and blower motor for tightness. Tighten the connection hardware if necessary.

Every six months remove the inspection covers of the gearcases and inspect the gears and pinions for pitting, abrasion, scratching, galling, spalling, and other abnormal tooth wear.

Check the crowd machinery attachment pins for movement under load. Tight attachment pins minimizes wear on the pins and pin holes. Check every 100hours.

Weekly, remove the pipe plugs in the first reduction gearcase and the second reduction gearcase and check the lubricant level. The first reduction gearcase lubricant level plug is located at the rear of the gearcase cover to the rear of the first reduction pinion.

The second reduction lubricant level plug is located on the inboard side of the second reduction portion of the gearcase. Maintain the lubricant level at the bottom of the pipe plug opening. When lubricant sample tests makes it necessary, drain the gearcase immediately after operation, flush out the gearcase, and refill with the recommended lubricant. Refer to Section 3 for the correct lubricant.

REPAIR Repair of the crowd reduction gears is basically a matter of component replacement. Use the following procedure to disassemble the crowd machinery either on or when separated from the revolving frame.

NOTE: Removal of the appropriate roof panel is necessary to facilitate this procedure.

1.

Remove the crowd and retract the ropes from the drum. Refer to the appropriate topic earlier in this section.

2.

Disconnect any lubrication lines attached to the crowd gearcases and covers. Drain the lubricant from the gearcase.

3.

Disconnect the electrical leads to the crowd motor and the blower motor. Identify theleads to ensure correct installation.

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CROWD MOTOR PINION DETAILS

DANGER: Press the MAIN POWER OFF button and tag it to avoid inadvertent energizing before attempting to disconnect the hoist motor leads. A voltage hazard is presentand could cause electrocution resulting in death or serious injury. Do not attempt todisconnect any wires until the auxiliary power has been disconnected and the main power is OFF. 4.

Remove the motor coupling guard and separate the coupling.

5.

Remove the motor shaft outboard end cover and unbolt the inboard bearing retainer. Re move the two first intermediate shaft end covers. Remove the second intermediate shaft end cover and unbolt the inboard bearing retainer. Remove the bolts that secure thesecond intermediate shaft left side bearing cover and inner retainer.

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CROWD 1ST REDUCTION GEAR AND PINION ARRANGEMENT

6.

Attach a crane to the gearcase cover and remove the bolts securing the cover to the gearcase. Remove the bearing cap bolts, nuts and washers. Lift the cover from the gearcase.

Remove the gearcase cover seal from the gearcase.

7.

Attach a crane to the motor shaft and lift the shaft assembly from the gearcase. Remove the first and second intermediate shafts in the same manner.

8.

Dismantle the shafts as required 9. If the shafts were dismantled, inspect the bearings for pitting, scoring, and other defects. Replace damaged bearings.

9.

Check the oil seals for cuts, abrasions, and other damage to the sealing surface. Replace as necessary.

10.

Install new O-rings and gaskets where required.

11.

Some bearings and spacers are interference fit and must be preheated in an oil bath prior to installation on the shafts.

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CROWD 2ND REDUCTION SHAFT AND GEAR ARRANGEMENT

12.

Install the shafts in the gearcase, using the crane to lift the shaft units.

13.

Be sure the flanges of the gearcase and gearcase cover are clean. Install the seal in the groove in the gearcase. Apply a continuous bead of LOCKTITE #515 to the gearcase flange half-way between the bolt pattern and the inside of the flange. Install the gearcase cover securing it with the necessary hardware.

14.

Pre-load the second intermediate bearing cap against rear hook of frame with a 1-1/2" by 4" GR5 bolt. Apply LOCTITE and torque to 1,700 ft.lbs. Install rod bolts and tighten using turn-of-the-nut method. Refer to Appendix 495TQ for details on torque application.

15.

Install the retainer hardware. Install and secure the shaft end covers. Be careful not to pinch the O-rings. Attach the lubrication lines and lubricate the bearings. Fill the gearcases with oil to level with the bottom of the oil filler opening. Attach the electrical leads to the motor and the blower motor.

Install the crowd and retract ropes on the drum Refer to the appropriate topic earlier in this section for installation instructions.

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CROWD MACHINERY BEARING TEMPERATURE MONITOR SYSTEM Thermocouples are provided for the monitoring of bearing temperatures at critical locations within the crowd machinery. These thermocouples transmit an electrical signal to the PLC which will activate a visual screen alarm when the temperature of the monitored bearings increases to point where excessive heat has been achieved.

These thermocouples aremounted in brass compression fittings to prevent lubricant leakage.

CROWD MACHINERY THERMOCOUPLE LOCATIONS

Use extreme care when performing maintenance around the delicate sensors!

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CROWD MOTOR Inspection, lubrication and maintenance instructions for the crowd motor are described in the motor manufacturer’s manual. If removal of the crowd motor is necessary, follow the instructions below.

NOTE. Removal of the appropriate roof panel is necessary to facilitate this procedure.

Crowd the dipper forward, and place the dipper on the ground.

DANGER: Press the MASTER POWER OFF button and tag it to avoid inadvertent energizing before attempting to disconnect the hoist motor leads.

A voltage hazard is present and could cause electrocution resulting in death or serious injury. Do not attempt to disconnect any wires until the auxiliary power has been disconnected and the main power is OFF.

CROWD MOTOR ARRANGEMENT

1.

Disconnect and identify the electrical leads to the crowd blower motor and the crowd motor.

2.

Remove the blower motor and duct as a unit from the crowd motor.

3.

Remove the brake from the motor. Refer to the topic Crowd Brake in Section 6.

4.

Remove the motor coupling guard and separate the coupling

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5.

For repair of the original motor: remove the two chocks and wedges located on the side of the motor towards the boom.

6.

For replacement of the original motor or motor pinion, remove the four chocks and wedges located on both the front and rear side. Also remove the two chocks at the brake end of the motor.

7.

Remove the bolts securing the crowd motor to the crowd machinery frame. Use a crane to lift the motor from the frame.

8.

For re-installation of the original motor and pinion: position the motor against the two inplace chocks and wedges. Re-install the two chocks and wedges on the boom side of the motor. Re check coupling alignment.

For replacement of the original motor with a new motor refer to Section 6 for instructions for installing the coupling on the motor. Align the motor coupling per instructions in Section 6.

Install the four chocks and wedges on both sides of the motor.

9. Install the motor by reversing the steps used to remove it.

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CROWD GEAR AND DRUM INSPECTION Inspect the drum gear to drum mounting hardware for loose or missing nuts and bolts. These bolts and nuts were tightened at the factory using Turn-of-the-Nut torque method. Loose bolts and nuts should not be re-tightened but replaced with new bolts and nuts. Tighten the new bolts and nuts using the Turn-of-the-Nut method as described in Appendix 495TQ.

CROWD GEAR AND DRUM ARRANGEMENT

Check the drum for cracks. Check the drum grooves for rough edges and other defects which would damage the crowd and retract ropes. Check the retract rope Security and damage.

Inspect the drum gear teeth for pitting, abrasions, spalling, galling and other damage.

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REPAIR If repair of the crowd drum is needed: 1.

Remove the crowd and retract ropes from the drum. Refer to the appropriate topic earlier in this section.

2.

Remove the gear guard from the drum gear.

3.

Disconnect the lubrication lines at the shaft end covers. Remove the end covers.

4.

Remove the bolted-in crowd frame lower front cross tie

5.

Attach a crane to the drum and remove the lock nuts and full nuts securing the drum shaft bearing caps to the machinery frame. Remove the bearing caps. The drum can then be lowered to the ground.

6.

Cut the lock wire and remove the retainer bolts. Remove the bearing retainers from each end of the shaft. Remove the shim pack, bearings, bearing spacer and labyrinth seals and wire together for future use.

7.

If necessary, remove the hardware securing the drum gear to the drum and remove the gear. Consult the Bucyrus Service Department for repair procedures for the drum and gear.

8.

Inspect the bearings for pitting, scoring, scratches, and other defects. Replace defective bearings.

9.

If removed, reinstall the drum gear using new bolts and nuts and torque the nuts to 1120 ft.lbs. (lubed threads, 100% proof load) or torque the nuts to 224 ft.lbs. followed by 1/3 turn of the nut. Let the joint set for 24 hours; loosen and retighten.

When re-tightening use LOCTITE #277 on nuts. The bearings and spacers are interfer ence fit and must be preheated in an oil bath prior to installation.

Attach a crane to the drum unit and position it in the frame. Install the bearing caps and rod bolts with slotted nut and cotter pin. Pre-load the bearing caps against the front hook using 3/4" x 7-1/2" GR8 bolts and lockwashers. Lubricate threads and torque to 385 ft.lbs. Secure rod bolts in place with special torque nuts.

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MACHINERY HOUSE The machinery house has separate structural members consisting of front and rear main truss and interconnecting beams. These form the permanent house structure.

Roof panels are individually fastened to the interconnecting beams. Any panel can be removed separately to provide access to a machinery house unit. All roof panels are secured with hold down bolts on retainer bands. Vinyl tape weather stripping is installed between the retainer band and roof panel.

Shroud covers around the A-frame legs have vinyl tape between the leg and shroud. Shroud support joints are sealed with rubber cement or silicone caulking.

All mating surfaces of the machinery house wall panels are sealed with rubber cement or silicone caulking to ensure weather tight seal.

INSPECTION Frequently inspect all house panels and structural members for cracking. Include a close examination of all roof structures. Examine all struts, beams, and braces used to reinforce the machinery house.

Always restore defective structural members to their original state by repair welding.

Periodically observe the hinges and closure mechanisms on all doors and windows to ensure they will remain closed during machine operation. Verify the sealing of the leg closures of the A-frame.

Tighten all loose bolts and replace all missing hardware. The absence or looseness of these fasteners can result in excessive vibration and wear of house components. Individually, these faults can be considered minor, but taken collectively, they represent a major exposure of the electrical and mechanical elements of the house to dust and water.

Check the condition of the house paint. Paint is not impervious to deterioration. A well-painted machine is less susceptible to rust, corrosion and progressive failure.

Be sure the pressurization system is functioning properly to keep the house well-ventilated at a pressure higher than atmospheric pressure.

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WALKWAYS Each day inspect walkways, platforms, and stairways on the machine. The maintenance authority should do the inspecting. Should a structural member become damaged, repair or replacement may be necessary. Replace nuts and bolts where required or repair weld to restructure individual access members such as steps and railings.

TYPICAL WALKWAYS AND RAILINGS

Eliminate accumulations of wiping rags, oil and grease, dust and dirt, and mislaid maintenance tools. They can create a safety hazard. Keep new and used wiping rags in barrel containers rather than draped or tied to railings. Clean off oil and grease in the primary walking and working areas to prevent workers from slipping. Maintain a tool bench and rack for the storage of all tools used in the shovel upkeep. Do not let tools lie scattered upon walkways and stairways.

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OPERATOR’S CAB individual operators may adjust the operator’s seat as desired with respect to height, tilt, and swivel travel.

Periodically lubricate all pivot points and bearings to maintain smooth movement of the seat.

WINDSHIELD WIPERS There are two electrically operated windshield wipers on the front window of the cab, one for the lower potion of the window, and one for the upper portion of the window.

WINDSHIELD WIPER/WASHER ARRANGEMENT

Check the wiper blades to make sure they swing freely across the window without contacting the window frame. Re-position the pantograph arm on the wiper motor shaft if necessary to prevent contact with the window frame.

Frequently check the condition of the wiper blades and replace if damaged.

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WINDSHIELD WASHER An optional electric operated windshield washer unit supplies a cleaning agent to the windshield through spray nozzles when activated. When operating in warm climates, water may be used as the agent. In areas where freezing temperatures are encountered, a suitable commercial windshield washer solvent with anti-freezing characteristics is recommended.

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SUPERBOLT APPLICATIONS INSTALLATION PROCESS PREPARATION 1.

Ensure that all jackbolt tips are flush, or recessed within the bottom of the nut

2.

Lubricate the threads of the main stud.

3.

Slide the hardened washer into place over the main stud.

4.

Lubricate the side of the washer facing the jackstuds. (An alternate method is to lubricate the tips of the jackstuds)

body.

TIGHTENING PROCEDURE 1.

Spin the tensioner (nut body) down onto the threads of the main stud until it contacts the surface of the hardened washer. Back off the nut until a gap of 1/16 to 1/8 inch (XX mm to XX mm). Refer to Helpful Hint #3.

2.

Tighten the 4 jackbolts at the 3, 6, 9, and 12 o’clock positions of the nutbody to a torque equal to 30-70% of the target torque indicated in the table for the size SuperBolt in use. Refer to table found later in this section.

NOTE: If using either pneumatic or electric impact tools set torque at 100% of the target torque required and secure by “burping” the impact gun to ensure even distribution of the torque load on the surface, 3.

Once all 4 jackbolts have been tightened to a value of 30-70% target torque, re- tighten all four jackbolts at 100% target torque. Refer to Helpful Hint #6.

4.

Tighten all of the jackbolts (1 time only) to 100% of the corresponding target for that specific size SuperBolt application in a circular pattern

torque

5.

Repeat step 4 as many times as needed until all jackbolts have stabilized (no rotation at applied torque value). This will normally require fron 2 to 4 more passes around the circular pattern.

NOTE: If the Superbolt fastener has either 4 or 8 jackbolts in the face use a diametric “star” type pattern during the torque application process. Refer to image.

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SUPERBOLT DETAILS

REMOVAL PROCEDURE

CAUTION: The proper removal of SuperBolt fasteners requires the strictest following of procedures. Jackbolts must be unloaded in a gradual manner. If some jackbolts are completely unloaded prematurely, the remaining jackbolts will carry the entire load of the fastener and may be extremely hard to turn. In extreme circumstances a jackbolt may deform, making removal of the fastener very difficult.

NOTE: It is a good practice to spray the entire fastener and jackbolts with a penetrating type lubricant prior to attempting removal. This step will be critical if evidence of rust exists.

1.

Loosen each jackbolt ¼ turn using a circular pattern (diametric if 4 or 8 jackbolts are present) one time only. Ensure that all studs have been loosened prior to proceeding to the following step.

2.

Repeat step 1 for all the jackstuds a second time.

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3.

Repeat step 1 for all the jackstuds a third time.

4.

Repeat this step until all jackbolts are hand completely loose and can be removed by hand.

5.

Remove all jackstuds. Clean, inspect and lubricate jackstuds for re-installation.

6.

Remove the nut body and hardened washer. Clean, inspect and lubricate these components for re-assembly.

NOTE: On smaller SuperBolt fasteners it may be possible to utilize impact tools to speed removal after the third repeat of step 1. DO NOT use impact tools for the first three rotations of step 1. Those SuperBolt fasteners requiring long studs or tie rods may require addition repeats of step 1 prior to switching to impact tools for assistance.

LUBRICATION For the main studs of SuperBolt fasteners and standard anti-seize compound may be used. A thin, brush-on type application, or aerosol spray lubricant is acceptable.

The jackbolts of the SuperBolt fasteners are pre-lubricated from the factory with either moly or graphite lubricants depending on the intended use. Similar lubricants may be utilized on the jackbolt tips and hardened washer during installation.

HELPFUL HINTS: Prior to Tightening: 1.

Threads: Check all threads of the main stud to verify that the nutbody will spin on freely prior to installation. If a restriction is found, attempt to free-up the movement by use of a lapping compound on the main threads and work the nutbody back and forth over the tight area. Making small advances will usually loosen the threads tight tolerances. If necessary chase the threads in either the nutbody or the main stud using a good tie or tap. The unrestricted movement of he nutbody on the main stud is critical in the installation process.

2.

Spacers: The nutbody (tensioner) should be positioned at the end of the main stud when installation is complete in order to minimize exposed threads which could possible be damaged. This will also serve to minimize and difficulty in reaching the jackbolts and avoid the need for thinwall, or deepwell sockets. A spacer, or stacked washers can be used beneath the hardened washer to accomplish this. The spacer will also allow a step-over of a damaged area on stud where years or repeated installations have deformed the threads.

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3.

Gaps: Back off the tensioner (nutbody) to provide a gap of 1/16 to 1/8 inch between the nutbody and the hardened washer prior to beginning the torque application process. This will allow additional jackbolt extension which provides easy access for jackbolt tip lubrication prior to removal. Note: In some cases where you may have an exceptionally long bolt, tierod, or are closing a gap between flanges, there may be insufficient jackbolt stroke to allow this step.

4.

Sockets: Use only six-point quality sockets which are in good condition. Worn sockets will eventually round out the corners of the jackbolts. Rounded corners will in turn, add stress to the socket which may result in damage or injury.

While Tightening: 5.

To improve efficiency when using impact tools; don’t wait for the socket to completely stall on a specific jackbolt prior to moving on to the next jackbolt. As the tensioner is tightened, the first jackbolt that was tightened in that sequence will have a tendency to loosen. It will be faster to make multiple passes by moving quickly between jackbolts.

6.

Overshoot the Target Torque: You may want to utilize 110-125% of the of the target torque during step #3, 4 and the first 2 rounds of step #5 of the installation process. This may serve to eliminate a round of the tightening sequence. Be careful NOT to “stabilize” the jackbolts at this amplified torque however! For long bolts or tierods, you may want to experiment using even higher torque values while exercising care not to “cock” the nutbody in the process.

While Removing: 7.

Don’t be too aggressive: Removing the jackbolts too quickly (more than ¼ turn at a time) during disassembly may actually slow down the removal process by increasing the removal torque of the remaining jackbolts. A jackbolt may becomejammed by an overly aggressive approach. If the lubricant has burned up, or washed away, and a jackbolt seems to be jammed, try to tighten the jackbolts on either side of the affected jackbolt to relieve some pressure. Then try to remove the jackbolt.

8.

Damaged Jackbolt Removal: Should a jackbolt tip “mushroom” due to an extreme overload condition, the tip may be cut off with a cutoff wheel (abrasive disc).

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WIRE ROPE CARE AND MAINTENANCE STORAGE Reels of wire rope stock may be kept on hand for a considerable length of time. This is particularly true of slow-moving special ropes that may not be disposed of completely for several years.

Consequently, wire rope should be stored in an are that is well-ventilated and stable with regard to temperature and humidity.

Do not store rope in contact with the bare ground or expose it to the elements. Excessive atmospheric vapors will condense moisture on the rope causing corrosion. If exposed to the direct sun, next to a boiler or in similarly warm conditions, the original lubrication will dry out and lose its preservation properties.

Similarly, storage in a dusty or chemical laden environment may coat the surface of the rope with corrosive materials or even deteriorate the fiber core. If it should be necessary to store rope outside, the reel should be set on blocks or raised off the ground, and covered with a waterproof covering.

CHECKING DIAMETER It is critical to check the diameter of the delivered rope BEFORE installation on the machine. This is to ensure that the rope diameter meets the specified requirements for the given machine or equipment. An UNDERSIZE diameter rope will bring about a condition where stresses are exceeding design limitations. This will increase the possibility of injury or machine damage as the chances of breaking the rope will be increased. Use of an OVERSIZE diameter rope will bring about premature wear of that rope. The rope constantly being pinched and compressed in the grooves of the sheaves and drum causes this.

CORRECT METHOD FOR CHECKING WIRE ROPE DIAMETER

When checking it is imperative that the actual rope diameter is measured. This is defined as the diameter of the circumscribing circle, or its largest cross-sectional dimension. To ensure accuracy this measurement should be made with a wire rope caliper to obtain the outside dimension of 2 diametrically opposing strands of the rope. When measuring a rope with an odd number of outer strands, special techniques must be employed. Refer to the manufacturer of the product for accurate information.

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HANDLING WIRE ROPE When re-reeling wire rope from a horizontally supported reel to a drum you must keep in mind that a wire rope has a “memory” to be considered. If at all possible, it is preferable for the rope to travel from the top of the reel to the top of the drum during this process. The same would hold true for the bottom of the reel to the bottom of the drum. Re-reeling in this manner will avoid putting a reverse bend into the rope as it is being installed. If a rope is installed so that a reverse bend is induced, it may cause the rope to become “cranky” and, consequently, more difficult to work with.

There are several methods, which can be used to uncoil rope from a spool or coil. The particular situation, or application, will determine the method you use.

One method begins by placing the coil or spool on a vertical unreeling stand. The stand consists of a base with a fixed vertical shaft. On this shaft there is a “swift” or rotating sleeve” consisting of a plate with inclined pins.

This is positioned so that the coil or spool may be placed over them allowing the coil or spool to rotate in the horizontal axis. The whole swift and coil then rotate as the rope is pulled off without adding twist or the possibility of kinks. This method is particularly effective when the rope is to be wound on a vertical drum.

The most common, and the easiest uncoiling method is merely to hold one end of the rope while rolling the coil along the ground like a hoop.

NOTE: Avoid unreeling and uncoiling methods that are likely to provide kinks. Such IMPROPER procedures should be strenuously avoided in order to prevent the occurrence of loops. These loops, when pulled taut, will inevitably result in kinks. No matter how a kink develops, it will damage strands and wires, resulting in a kinked section that must be cut out.

Proper and careful handling will keep the wire rope free from kinks.

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Methods to be avoided:

IMPROPER METHODS FOR UNCOILING WIRE ROPE

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SEIZING WIRE ROPE While there are numerous ways to cut wire rope, in every case, certain precautions must be observed. It is critical that before any cut is made proper seizings must be applied on both sides of the location where the cut is to be made. Carelessly or inadequately seized, ends may become distorted and flattened. This will also prevent the strands at the ends from loosening or fraying.

Subsequently, when the rope is installed there may be an uneven load distribution to the strands.

This will create a condition that will significantly shorten the life of the rope.

There are two widely accepted methods of applying a seizing, which are illustrated. The seizing material itself should be soft, or an annealed wire or strand. Seizing wire diameter, and the length of the seize, will be dependant on the diameter of the wire rope. But the length of the seize should never be less than the diameter of the rope in use. Normally, for a preformed rope, one seize on each side of the cut is sufficient. For ropes that are not preformed, a minimum of two seizings on each side is recommended; and these should be spaced six rope diameters apart.

For larger wire ropes: lay one end of the seizing wire in the groove between two strands; wrap the other end tightly in a close helix over a position of the groove using a seizing iron (a round bar 1/ 2" to 5/8" diam. x 18" long) as shown. Both ends of the seizing wire should be twisted together tightly, and the completed seize should appear as shown. Seizing widths should not be less than the rope diameter.

SIEZING LARGER WIRE ROPES

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The procedure illustrated below is the second of the two accepted methods for placing seizing on wire rope. This method is normally used on smaller ropes.

METHOD OF SIEZING SMALLER WIRE ROPES

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END PREPARATIONS/TERMINATIONS There may arise a need for special end preparations in order to compensate for certain applications such as tight drum openings, or other complicated reeving systems. When these situations are encountered a number of basic designs (and combinations) are available to choose from. Whenever possible end preparations should be removed after final installation.

“Beckets” are what is referred to when we discuss a termination utilized to pull the operating rope into place. The rope end must be fastened to a mechanism so that force and motion are transferred efficiently without distortion of the wire rope. End terminations become items of great importance for transferring these forces. Each basic type of termination has its own individual characteristic.

Hence, one type will usually fit the needs of a given installation better than the others. It should be noted that not all end terminations will develop the full strength of the wire rope being utilized. To lessen the possibility of error, the wire rope industry has determined terminal efficiencies for various types of end terminations. Four commonly used beckets are illustrated.

COMMONY USED WIRE ROPE END TERMINATIONS (BECKETS)

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WIRE ROPE CLIPS Wire rope clips are widely used for making end terminations. Clips are available in two basic designs; the U-BOLT and FIST GRIP. The efficiency of both types is approximately the same.

COMMONLY USED WIRE ROPE CLIPS

NOTE: When using U-BOLT clips, extreme care must be exercised to make certain that they are positioned correctly. The important factor is that the U-BOLT clip be applied in order that the “U” section is in contact with the dead end of the rope. Also, the tightening and re-tightening of the nuts must be accomplished as required.

WIRE ROPE CLIP APPLICATION The following is the recommended method of applying U-Bolt clips in order to get the maximum holding power from the installation: 1.

Turn back the specified amount of rope from the thimble. Apply the first clip a distance of one base width from the dead end of the wire rope (U-bolt over the dead end - live end rests in the clip saddle). Tighten nuts diametrically and evenly to recommended torque.

2.

Apply the next clip as near the loop as possible. Snug down the nuts, but do not tighten.

3.

Space additional clips (if required) equally between the first two. Turn on nuts evenly to take up rope slack. Continue to tighten all nuts evenly (on all clips) until recommended torque is reached.

NOTE: Apply the initial load to the strand of rope, and then re-tighten nuts to the recommended torque. This is accomplished because the rope will stretch and be reduced in diameter when loads are applied. Inspect periodically and tighten to recommended torque each time.

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PROPER WIRE ROPE CLIP APPLICATION

A termination complying with the above instructions, using the number of clips shown, has approximately an 80% efficiency rating. This rating is based upon the nominal strength of the wire rope. If a pulley is used in place of a thimble where the rope turns back, add one additional clip.

The number of clips shown is based upon using right regular or lang lay wire rope, 6 x 19 class or 6 x 37 class, fiber core or IWRC, IPS or EIP. If Seale construction is to be used for sizes 1 inch and larger, or similar large outer wire type construction in the 6 x 19 class, add one additional clip.

The number of clips shown also applies to right regular lay wire rope, 8 x 19 class, fiber core, IPS, sizes 1-1/2 inch and smaller; and right regular lay wire rope, 18 x 7 class, fiber core, IPS or EIP, size 1-3/4 inch and smaller.

For other classes of wire rope not mentioned, it may be necessary to add additional clips to the number shown. If a greater number of clips are used than shown in the table, the amount of rope turn-back should be increased proportionately. THE ABOVE IS BASED ON THE USE OF CLIPS ON A NEW ROPE. IMPORTANT: Failure to make a termination in accordance with the aforementioned instructions, or failure to periodically check and re-tighten to recommended torque, will cause a reduction in the efficiency rating.

The correct spacing and number of clips is shown above.

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WEDGE SOCKETS One of the more popular field end attachments for wire rope is the wedge socket. Attachment, and the dismantling of this device is both easy and simple.

1.

Inspect the wedge and socket; remove all rough edges/ burrs that might damage the rope.

WEDGE SOCKET INSTALLATION DETAILS

2.

Welded ends of the rope should be cut off prior to assembly. This will allow the rope strands to distort slightly as they bend sharply around the wedge. If the welded end were not removed the minimal sliding of the strands would be restricted and evidenced further up the rope. This may result in the development of high strands, wavy rope and uneven loading.

3.

Place the socket in an upright position and bring the rope around it in a large, easy to handle loop. Care must be taken to make certain that the live-loaded-side of the rope is in line with the ears.

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4.

The dead end of the rope should extend from the socket for a distance of six to nine times the rope diameter. The wedge is now placed in the socket.

5.

Secure the socket and carefully apply a gradually increasing load to the live side of the rope in order to pull the wedge into position. Only tension sufficiently to hold the pieces in place.

6.

After checking alignment increase the load GRADUALLY until the wedge is properly seated.

Avoid sudden shock loads.

NOTE: This is the recommended procedure. If variations are made to suit special conditions, they should be carefully evaluated beforehand.

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INSPECTION OF SHEAVES AND DRUMS Machines should receive periodic inspections, and the results concerning their over-all condition recorded. Such inspections usually include the drum, sheaves, and any other parts that may come into contact with the wire rope. These are considered high wear items. As an additional precaution, any rope-related working parts, particularly those in the areas described below, should be re-inspected prior to the installation of a new wire rope.

EXAMPLES OF SHEAVE GROOVE CONDITIONS

These cross-sections are illustrating three sheave-groove contact areas. “A” is correct, “B” is too tight, and “C” is too loose.

The very first item to be checked when examining sheaves and drums is the condition of the grooves. To accurately check the size, contour and amount of wear, a groove gauge is used. As shown in the figure, the gauge should contact the groove for about 150 degrees of arc when in optimal condition.

There are two types of groove gauges in general use. You must be aware which of these is being used. The two differ by their respective percentage over nominal.

GROOVE GUAGE FOR NEW OR RE-WORKED SHEAVES

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For new or re-machined grooves, the groove gauge is nominal plus the full oversize percentage.

The gauge carried by most wire rope representatives today is used for worn grooves and is made nominal plus 1/2 the oversize percentage.

This latter gauge is intended to act as a sort of “no-go” gauge. Any sheave with a groove smaller than this must be re-grooved or, in all likelihood, the existing rope will be damaged.

INSPECTING FOR WORN SHEAVE

These sheave-groove cross-sections represent three wire rope seating conditions: “A” - a new rope in a new groove; “B” - a new rope in a worn groove; and “C” - a worn rope in a worn groove.

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BREAKING IN A NEW WIRE ROPE A new wire rope requires careful installation. Adherence to the previously covered procedures is highly recommended. After the rope has been installed, and the ends secured in the applicable manner, the mechanisms should be started carefully and then permitted to run through a complete cycle of operation at greatly reduced speed. During this trial operation, a very close watch should be kept on all working parts such as sheaves, drums and rollers to ensure the rope runs freely. Be vigilant to ensure there are no obstructions as it makes its way through the system. If no problems are apparent, the next step should include several run-through’s of the normal operational cycle under light load conditions at a reduced speed. This procedure allows the component parts of the new rope to gradually adjust to the actual operating conditions.

INSPECTION DATA It is essential to maintain a well-planned program of periodic inspection. Frequently, there are statutory and/or regulatory agencies who incur additional requirements that must be adhered to.

Whether or not these exist in your location, the wire rope user can be guided by the suggested procedures that follow.

Abrasion - Bending and crushing represent the ABC’s of wire rope abuse. It is the primary goal of a good inspection practice to uncover such conditions early enough that corrections may be made, or ropes replaced, safely, with minimum effort. When any sudden degradation indicates a loss of original rope strength, a timely decision is required as to allowing the rope to remain in service.

Such a decision can only be made by an experienced inspector. And his/her determination should be based on: 1.

Details of the equipment’s operation.

2.

Frequency of inspection.

3.

Maintenance history.

4.

Consequences of failure.

5.

Historical records of similar equipment.

To ensure sufficient information can be obtained, the following pages contain guidelines that should be adhered to.

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GUIDELINE TO INSPECTIONS AND REPORTS (Equipment, Wire Rope and Wire Rope Slings) 1.

Maintain all inspection records and reports for the length of time deemed appropriate.

2.

Prior to daily use, the following procedure should be followed.

3.

a.

Check all equipment functions.

b.

Lower load blocks and check hooks for deformation or cracks.

c.

During lowering procedure and the following raising cycle, observe the rope and the reeving. Particular notice should be paid to kinking, twisting or other deformities.

Drum winding conditions should also be noted.

d.

Check wire rope and slings for visual signs of any unsafe condition; to include, broken wires, excessive wear, kinking or twisting, and severe corrosion. Particular attention should be given to any new damage during operation.

Periodic inspections consistent with applicable standards are recommended with a signed report by an authorized and competent inspector. These Periodic Reports should include inspection of the following: a.

All functional operating mechanisms for excessive wear of components, brake system parts and lubrication.

b.

Limit switches.

c.

Crane hooks for excessive throat opening or twisting, along with a visual for cracks.

d.

Wire rope and reeving for conditions causing possible removal.

e.

Wire rope slings for excessive wear, broken wires, kinking, twisting and mechanical abuse.

d.

All end connections such as hooks, shackles, turnbuckles, plate clamps, sockets, etc. for excessive wear, and distortion.

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4.

At least one annual inspection with signed report must be made for the following: a.

Crane hook for cracks.

b.

Hoist drum for wear or cracks.

c.

Structural members for cracks, corrosion and distortion.

d.

For loose structural connections such as bolts, rivets, and weldments.

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WIRE ROPE INSPECTION CRITERIA The following is a fairly comprehensive listing of critical inspection factors. It is not, however, presented as a substitute for an experienced inspector. It is rather a user’s guide to the accepted standards by which ropes must be judged.

ABRASION: Rope abrades when it moves through an abrasive medium or over drums and sheaves. Most standards require that rope is to be removed if the outer wire wear exceeds 1/3 of the original outer wire diameter. This is not easy to determine and discovery relies upon the experience gained by the inspector in measuring wire diameters of discarded ropes.

REDUCTION IN ROPE DIAMETER: Any marked reduction in rope diameter indicates degradation. Such reduction may be attributed to: Excessive external abrasion.

Internal or external corrosion.

Loosening or tightening of rope lay.

Inner wire breakage.

Ironing or milking of strands.

In the past, the determination on the continued service of a rope was largely dependant on the rope’s diameter at the time of inspection. Recently this practice has undergone significant modification.

Previously, a decrease in the rope’s diameter was compared with published standards of minimum diameters.

The amount of change in diameter is, of course, useful in assessing a rope’s condition. But, comparing this figure with a fixed set of values can be misleading. These long-accepted minimums are not, in themselves, of any serious significance since they do not take into account such factors as: 1)

Variations in compressibility between IWRC and Fiber Core.

2)

Differences in the amount of reduction in diameter from abrasive wear, or from core compression, or a combination of both.

3)

The actual original diameter of the rope rather than its nominal value.

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As a matter of fact, all ropes will show a significant reduction in diameter when a load is applied. Therefore, a rope manufactured close to its nominal size may, when it is subjected to loading, be reduced to a smaller diameter that stipulated in the minimum diameter table. Yet, under these circumstances, the rope would be declared unsafe although it may, in actuality, be safe.

As an example of the possible error at the other extreme, we can take the case of a rope manufactured near the upper limits of allowable size. If the diameter has reached a reduction to nominal or slightly below that, the tables would show this rope to be safe. But it should, perhaps, be removed.

Today, evaluations of the rope diameter are first predicated on a comparison of the original diameter when ‘new ‘ and subjected to a ‘known ‘ load with the current reading under comparable circumstances. Periodically, throughout the life of the rope, the actual diameter should be recorded while the rope is under equivalent loading and in the same operation section. This procedure, if followed carefully, reveals a common rope characteristic: after an initial reduction, the diameter soon stabilizes. Later, there will be a continuous, albeit small, decrease in diameter throughout its life.

Core deterioration, when it occurs, is revealed by a more rapid reduction in diameter and is time for removal.

Deciding whether or not a rope is safe is not always a simple matter. A number of different but interrelated conditions must be evaluated. It would be dangerously unwise for an inspector to declare a rope safe for continued service simply because its diameter had not reached the minimum arbitrarily established in a table, while at the same time, other observations lead to an opposite conclusion.

Because criteria for removal are varied, and because diameter in itself, is a vague criterion, the table of minimum diameters has been deliberately omitted from this publication.

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ROPE STRETCH: All ropes will stretch when loads are initially applied.

As a rope degrades from wear, fatigue, etc. (excluding accidental damage), continued application of a load of constant magnitude will produce varying amounts of rope stretch. A “stretch” curve plotted for stretch vs. time displays three distinct phases:

Phase 1. - Initial stretch, during the early (beginning) period of rope service, caused by the rope adjustments to operating conditions (constructional stretch).

Phase 2. - Following break-in, there is a long period-the greatest part of the rope’s service lifeduring which a slight increase in stretch will take place over an extended time. This results from normal wear, fatigue, etc. On the plotted curve stretch vs. time-this portion would almost be a horizontal straight line inclined slightly upward from its initial level.

Phase 3. - Thereafter, the stretch occurs at a quicker rate. This means that the rope has reached the point of rapid degradation; a result of prolonged subjection to abrasive wear, fatigue, etc. This second upturn of the curve is a warning indicating that the rope should soon be removed.

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CORROSION: Corrosion, while difficult to evaluate, is a more serious cause of degradation than abrasion. Usually, it signifies a lack of lubrication. Corrosion will often occur internally before there is any visible external evidence on the rope surface. Pitting of wires is a cause for immediate rope removal. Not only does it attack the metal wires, but also prevents the rope’s component parts from moving smoothly as it is flexed. Usually, a slight discoloration because of rust merely indicates a need for lubrication.

Severe rusting on the other hand, leads to premature fatigue failures in the wires necessitating the rope’s immediate removal from service. When a rope shows more than one wire failure adjacent to a terminal fitting, it should be removed immediately. To retard corrosive deterioration, the rope should be kept well lubricated. In situations where extreme corrosive action can occur, it may be necessary to use galvanized wire rope.

KINKS: Kinks are permanent distortions caused by loops drawn too tightly. Ropes with kinks must be removed from service.

BIRD CAGING: Bird caging results from torsional imbalance that comes about due to mistreatments such as sudden stops, rope being pulled through excessively tight sheaves, or wound on too small a drum for a given rope diameter. This is cause for rope replacement unless the affected section can be removed.

LOCALIZED CONDITIONS: Careful attention must be paid to wear at the equalizing sheaves. During normal operation this wear is not visible. Excessive vibration, or whip can cause abrasion and/or fatigue. Drum crossover and flange point areas must be carefully evaluated. All end fittings, to include splices, should be examined for worn or broken wires, loose or damaged strands, cracked fittings and worn or distorted thimbles and tucks of strands.

HEAT DAMAGE: After a fire, or exposure to elevated temperatures, there may be discoloration, or an apparent loss of internal lubrication. Fiber core ropes are particularly vulnerable. Under these circumstances the rope should be replaced.

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PROTRUDING CORE: If, for any cause, the rope core protrudes from an opening between the strands, the rope is unfit for service and should be removed.

DAMAGED END ATTACHMENTS: Cracked, bent, or broken end fittings must be eliminated. The cause should be sought out and corrected. In the case of bent hooks, the throat openings must be measured at the narrowest point and should not exceed 15% over normal. Twisting be no greater than 10 degrees.

PEENING: Continuous pounding is one of the causing of peening. The rope can strike against an object, such as some structural part of the machine, or it beats against a roller, or itself. Often this can be avoided by placing protectors between the rope and the object it is striking. Another common cause of peening is continuous working under high loads over a sheave or drum. Where peening action cannot be controlled it is necessary to have more frequent inspections and be prepared for premature rope replacement.

SCRUBBING: Scrubbing refers to the displacement of wires and strands as a result of rubbing against itself or another object. This, in turn, causes wear and displacement of wires and strands along one side of the rope. Corrective measures should be taken as soon as this condition is observed.

FATIGUE FRACTURE: Wires that break with square ends and show little surface wear, have usually failed as a result of fatigue. Such fractures can occur on the crown of the strands, or in the valleys between the strands where adjacent strand contact exists. In almost all cases, these failures are related to bending stresses or vibration.

If diameter of the sheaves, rollers or drum cannot be increased, a more flexible rope should be used. But, if the rope in use is already of maximum flexibility, the only remaining course that will help prolong its service life is to move the rope through the system by cutting off the dead end. By moving the rope through the system, the fatigued sections are moved to less fatiguing areas of the reeving.

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BROKEN WIRES: The number of broken wires on the outside of a wire rope are an index of 1) its general condition, and 2) whether or not it must be considered for replacement. Frequent inspection will help determine the elapsed time between breaks.

On occasion, a single wire will break shortly after installation. However, if no other wires break at that time, there is no need for concern. On the other hand, should more wires break, the cause should be immediately investigated.

On any application, valley breaks (where the wire fractures between strands) should be given serious attention. When two or more such fractures are found, the rope should be replaced immediately.

NOTE: No valley breaks are permitted in elevator ropes.

It is well to remember that once broken wires appear within a rope operating under normal conditions many more will show up within a relatively short period. Attempting to squeeze the last measure of service from a rope that is beyond the allowable number of broken wires, will create an intolerably hazardous situation.

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EXAMPLES OF BROKEN WIRES

A wire broken under a tensile load that has exceeded its strength is recognized by the “cup and cone” configuration at the fracture point (Rope A). The necking down of the wire at this point shows that failure occurred while the wire retained its ductility. Shear-tensile fracture (Rope B) occurs in wire subjected to a combination of transverse and axial loads. Fatigue breaks are usually characterized by squared-off ends perpendicular to the wire either straight across or Z-shaped (Ropes C and D).

ELECTRIC ARC: Rope that has either been in contact with a live power line or been used as “ground” in an electric welding circuit, will have wires that are fused, discolored and/or annealed, and must be removed.

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TORQUE APPLICATION TORQUE WRENCH METHOD The bolts should be torqued to the specified total value in increments, alternating from bolt to bolt to assure gradual, even pull up of mating parts. Tightening should progress systematically from the most rigid part of a joint to its free edges.

Circular bolt patterns should be torqued in a diametric crosshatch type pattern while applying torque in increasing values to ensure proper pull-up of parts.

NOTE: The following tables show torque values for bolt grades 2, 5 and 8 with UNC threads only. Table 1 lists torque values for dry thread and table 2 for lubricated or plated threads

TABLE 1 - DRY THREADS

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TABLE 2 - LUBRICATED OR PLATED THREADS

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TURN OF THE NUT METHOD CAUTION: This tightening procedure is only applicable for bolt grades 5 and 8 with UNC threads. For bolts with other than UNC threads, contact Bucyrus International Service Department.

Note: When using this procedure the bolt threads and the surfaces under the bolt head and nut must be lubricated.

This procedure is applicable only if the joint and under head surfaces for bolt and nut are machined for parallelism.

1.

The bolts should be brought to a “snug tight” condition to insure that the parts of the joint have good contact with each other. “Snug Tight” is defined as the tightness attained by torquing a bolt to the value specified in the table on thefollowing page. Snug tightening should progress systematically from the most rigid part of the joint to its free edges while alternating from bolt to bolt to assure gradual even pull up of the mating parts. After all bolts have been snugged, the first bolts tightened at the most rigid part of the joint should be rechecked for proper torque retention. If these bolts are loose due to pull up of the joint, the snug tightening sequence should be repeated for all bolts in the connection. This rechecking and re-torquing procedure should be repeated as many times as is required until the joint is completely pulled up and all bolts are at the specified “snug tight” torque. Tightness of the mating surfaces of the joint should then be verified by using feeler gauges.

TABLE OF “SNUG TIGHT” TORQUE VALUES

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Note (1)

2.

Tighten to values listed ± 10%. The torque values listed are calculated for 20% x proof load with lubricated threads and under the head surfaces of the bolt and nut.

The nuts and bolts should then be matched marked by center punching the bolt end and nut. On rod bolts match mark both rod ends and nuts. The bolts and nuts should then be tightened additionally by the applicable amount of nut rotation as specified in Table 4.

It is not necessary to follow any particular bolt to bolt sequence during this portion of the “turn of the nut” tightening.

NOTE: Nut rotation is read between punch mark on the bolt and punch mark on the nut. For rod bolts, nut rotation is the cumulative total rotational movement between punch marks on both ends of the rod bolt.

Part No.

Nut Rotation

Bolt Length (2)

747773-01

1/3 Turn ± 10%

Up to and including 4 diameters.

747773-02

1/2 Turn ± 10%

Over 4 diameters but not exceeding 8 diameters

747773-03

Note (2)

2/3 Turn ± 10%

Over 8 diameters but not exceeding 12 diameters

In case part number or nut rotation designation is not given, the nut rotation can be determined by the bolt length (Grip length + 1/2 bolt diameter.)

For bolt lengths exceeding 12 diameters contact the Bucyrus International, Inc. Service Department.

Manual No. 10028, April 99

Section 5, Major Maintenance - 167

BI616793

Bucyrus International, Inc. 495B Mining Shovel

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

SECTION 6 - BRAKES AND COUPLINGS BRAKE HUB INSTALLATION ....................................................................................................... 2 SWING BRAKE ............................................................................................................................. 4 INSTALLATION ................................................................................................................. 4 FRICTION DISC REPLACEMENT .................................................................................... 7 REPLACEMENT OF “O” RING SEALS ............................................................................. 9 SWING BRAKE BURNISHING ................................................................................................... 10 WHY BURNISH-IN BRAKES .......................................................................................... 10 BURNISH-IN PROCEDURE ........................................................................................... 10 CROWD BRAKE ......................................................................................................................... 11 INSTALLATION ............................................................................................................... 11 FRICTION DISC REPLACEMENT .................................................................................. 13 REPLACEMENT OF “O” RING SEALS ........................................................................... 15 HOIST BRAKE ............................................................................................................................ 17 INSTALLATION ............................................................................................................... 17 BRAKE ADJUSTMENT ................................................................................................... 18 ADJUSTMENT STAGE 1 ................................................................................................ 19 ADJUSTMENT STAGE 2 ................................................................................................ 20 FRICTION DISC REPLACEMENT .................................................................................. 21 REPLACEMENT OF “O” RING SEALS ........................................................................... 22 PROPEL BRAKE......................................................................................................................... 23 ADJUSTMENT ................................................................................................................ 24 FRICTION DISC REPLACEMENT .................................................................................. 26 O-RING REPLACEMENT ............................................................................................... 28 SPRING REPLACEMENT ............................................................................................... 29 MOTOR COUPLING INSTALLATION ......................................................................................... 31 MOTOR COUPLING ALIGNMENT ............................................................................................. 33 PARALLEL MISALIGNMENT .......................................................................................... 33 ANGULAR MISALIGNMENT ........................................................................................... 34 COMBINATION MISALIGNMENT ................................................................................... 35 BRAKE MONITORING SYSTEM............................................................................................. .36

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 1

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Brake Hub Installation

Brake hubs must be shrunk onto tapered motor shafts in order to achieve the tension and lockup required for the torque values involved. The procedure described below is intended to develop sufficient frictional force to transmit the imposed torque without dependence on the keyway.

Clean and dress the bore and shaft to remove any deformity and foreign matter.

Mount the cold hub onto the shaft and measure the position of the hub on the shaft carefully. Measure from the end of the shaft to the end of the hub. The dimension derived during this step will be used later.

Remove the hub and pre-heat the item until the “estimated temperature difference” has been reached. Refer to table below.

Example: If the shaft temperature = 25° C (77°F) and the estimated temperature difference derived from the table is 100°C (180°F), the hub must be heated to 125°C (257°F) for mounting.

CAUTION: Brake Hub temperature should never exceed 190°C (374°F) for installation.

CAUTION: Pre-heated components temperatures will often be brought to temperatures that can be extremely hazardous to the human body. Use extreme care and always wear appropriate safety equipment when working with pre-heated components and around the processes.

Wipe all oil from both the shaft and the bore of the hub prior to installation.

Replace the heated hub on the shaft once again and take care to note the amount of advance (further movement) onto the shaft that has been obtained. If the advance amount does not fall within the limits called out in the table it will be necessary to remove the hub and re-heat it to the specified temperature. IN ALL APPLICATIONS THE PROPER AMOUNT OF ADVANCE MUST BE ACHIEVED!

Section 6, Brakes and Couplings - 2

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

The taper fit between mating parts shall be checked at assembly with Dykem or Blueing to assure a minimum of 80% bearing contact.

HUB ADAPTER PRE-HEAT ADVANCE REQUIREMENTS TABLE

NOTE: This table makes reference to brake hubs only, motor coupling advance data appears in a seperate table later within htis section.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 3

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

SWING BRAKE

SWING BRAKE OVERVIEW

INSTALLATION

The brakes utilized on your shovel are all of the type that are spring set, air released.

Regular inspections for lining wear should become a part of your maintenance and servicing regimen.

SWING BRAKE TACHOMETER LOCATION/ORIENTATION Section 6, Brakes and Couplings - 4

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Installation of the tachometer, furnished with the electric motor, is required before beginning to install the swing brake assembly. Install the tachometer and the torque arm in relation to the image provided.

NOTE: Tachometer will only be installed on one of the two swing motors. Due to mechanical coupling the 2 swing motors and gearboxes will operate at identical speeds.

1.

Install the drive hub and keyway on the motor as per the Brake Hub Installation procedure covered earlier within this section.

2.

Install motor shaft nut and secure to shaft with lockwasher by bending tabs over flats.

SWING BRAKE CUTAWAY - DETAILS

3.

Install brake adapter onto the motor and secure with hardware. Use care to align the access slots in the adapter for future tachometer inspections.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 5

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

4.

Lightly coat the splines of the drive hub with a teflon grease allowing only a thin film of lubricant to remain on the splines. Excess grease will be thrown outward by centrifugal force and have a degrading effect on the brake.

5.

Using a lifting device and the holes provided in the outer portion of the drive ring, place the brake assembly onto the drive hub and lower as you ensure the fit of the splines in the drive hub align with those in the brake disc.

6.

Apply compressed air of between 30-50 psi to the air inlet allowing the brake to achieve a disengaged posture.

NOTE: The brake will be fully disengaged once air pressure exceeds 28 psi on a properly functioning brake. Air pressure in excess of 125 psi could possible damage internal seals of the piston.

7.

Install shims, as required, at location A of image, to achieve a gap of 0.015 0.030 inches between the pressure plate and the friction surface of the brake disc.

CAUTION: A minimum of 30 psi must remain applied to the brake while this dimension is determined. The brake must remain disengaged fully!

8.

Release the air pressure from the brake piston to relax the internal springs.

9.

Secure and torque the brake housing into place for final installation.

10.

Apply air pressure once again as in step 6, verify that the proper gap remains between the pressure plate and friction surface of the disc.

11.

Install safety guard around the brake assembly.

12.

If installed, install the micro-switches and brackets for the wear and release indicators.

Section 6, Brakes and Couplings - 6

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

REPLACING THE FRICTION DISC

The friction disc will require replacement when excessively worn or when contaminated by grease, oil or other foreign materials.

Check for a worn disc by using a depth micrometer as depicted in the image below.

The reading must be taken from the same location with the brake engaged and released. Due to the tapered surface of the pressure plate, care must be taken to duplicate the position and process as closely as possible.

SWING BRAKE FRICTION DISC INSPECTION - DETAILS

The disc will be considered excessively worn when the difference between the 2 readings approaches 0.200 inch.

CAUTION: Major damage will occur to the components of the brake assembly if the friction disc is not replaced when wear approaches 0.200 inch. The result of “pushing” will result in metal-to-metal contact that will cause extremely expensive repairs and a seriously degraded braking system.

CAUTION: Do Not remove the socket head cap screws near the bore of the piston as this will release the spring pressure within the brake assembly and make re-assembly much more difficult.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 7

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

1.

Release air pressure and remove the air line from the inlet to the piston.

2.

Install a ball, or gate, type valve into the fitting where the air line was removed. This valve will be used to capture pressure within the piston during removal.

3.

Reconnect the air source and pressurize the piston to a minimum of 30 psi as needed to disengage the brake. Close the valve, and then remove the air lines. At this point the brake is disengaged and not connected to an air source.

NOTE: The cylinder, piston and pressure plate may be removed as a single unit.

4.

Remove the outer cylinder stud nuts at this time and the lift the entire brake assembly off the top of the studs as a unit. Once removed from the swing motor the pressure may be removed from the cylinder.

5.

Slide the friction disc up and off of the hub adapter splines and free it from the assembly.

6.

Clean the area where the friction disc resides and coat the splines with fresh teflon lubricant lightly.

7.

Install the replacement friction disc ensuring that the machined step, near the center, is facing downward - toward the motor.

8.

Carefully align the splines between the hub and the disc and allow the new disc to rest.

9.

Reinstall the piston and pressure plate onto the top of the friction disc and align the pneumatic fitting, access holes and studs accordingly. Pressurize the piston once more to minimum pressure allowing complete disengagement of the components.

10.

Replace the stud nuts and tighten to value that does not exceed 90 - 100 ftlbs.

CAUTION: Tighten the stud nuts as per the instructions on the brake drive ring. Excessive, or improper, torque application can cause the drive ring to become deformed and seriously reduce the effectiveness and life of the brake assembly.

11.

Ensure air line and micro-switches are properly reconnected.

Section 6, Brakes and Couplings - 8

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

REPLACEMENT OF “O” RING SEALS

These seals, located around the piston of the brake assembly are what will allow the pneumatic pressure applied to transfer into mechanical movement. Leakage around these seals could result in increased pressure requirements for the brake to release or even the possibility of partial brake release. A partial brake release could result in excessive heat buildup and damage to the friction components of the brake assembly.

1.

Release air pressure to the brake assembly.

2.

Remove the socket head capscrews on the top of the piston area of the brake.

Theses will allow access to the seal components beneath.

CAUTION: Do Not remove the cylinder stud nuts as this will release the spring pressure and make re-assembly much more difficult.

3.

Slide the piston up and remove from the brake assembly.

4.

Dress out any nicks or grooves in the cylinder walls with a very fine stone and finish polish with emery cloth to ensure a good sealing surface is maintained.

5.

Clean area thoroughly while using care not to allow solvents to drip down on the fiction disc below.

6.

Oil all “O” rings and seals judiciously prior to assembly and then hand wipe to remove any possible contaminants.

7.

Lay seals and “O” rings in place while ensuring there are no twists, bends, or unnatural deformities.

8.

Grease all metal surfaces with a light coat of teflon grease prior to assembly.

9.

Install piston back into brake and secure capscrews to 200-220 ftlbs of torque in a diametric pattern. Refer to section on Torque Application, near the back of Section 5, if questions arise concerning torque.

10.

Burnish all replacement linings in accordance with the instructions under the topic of Swing Brake Burnishing provided later within this section.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 9

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

SWING BRAKE BURNISHING

After the brake has been properly installed in accordance with the installation procedures provided, check to ensure that the disengaged running clearances listed on the assembly diagrams exist at the friction surfaces.

WHY BURNISH-IN BRAKES

The swing disc brake of the 495B1 is designed as a “single disc assembly” A disc assembly consists of a ductile iron disc to which multiple metallic lining segments, called pucks, are riveted along the outer edge of the top and bottom surfaces. The burnishing-in procedure for a new or relined disc brake allows an initial controlled wear process that is required to develop the maximum contact area between braking surfaces. The burnish-in process will also start the formation of an oxide layer on the surface of the pucks to stabilize and to establish the design coefficient of friction.

BURNISH-IN PROCEDURE

Prior to beginning the burnishing procedure check and record the brake pressure plate temperature with a hand held temperature measuring device. Between each stop, continue monitoring the pressure plate temperature. Do Not allow the pressure plate temperature to exceed 300 degrees Fahrenheit (149 degrees C) NOTE: There are two swing brakes on each shovel, check the temperature of each brake. If the temperature exceeds 300 degrees F (149 degrees C) stop the burnishing procedure and allow the brakes to cool to 200 degrees F (93 degrees C) prior to continuing. Always be attentive for overheated or malfunctioning brakes. If found, check to see if the brake is releasing properly. It is normal for a small amount of disc particles to be ejected from the brake and for sparking to occur during this operation. Large amounts of either may indicate a problem such as overheating or improper release. If this occurs, stop and correct the situation prior to continuing.

BURNISH-IN PROCEDURE (DIPPER EMPTY) # of stops at speed

Time between stops

4 stops/1/4 speed 8 stops/1/2 speed

1 minute minimum 2 minutes minimum

Perform one additional full load-3/4 speed stop with the dipper handle in the horizontal position and the hoist rope vertical on the swing motion to ensure that the brakes are functional. Record the swing stopping times and angles. Forward these recorded readings to the Bucyrus International service department.

Section 6, Brakes and Couplings - 10

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

CROWD BRAKE INSTALLATION

The brakes utilized on your shovel are all of the type that are spring set, air released.

Regular inspections for lining wear should become a part of your maintenance and servicing regimen.

CROWDBRAKE TACHOMETER LOCATION/ORIENTATION

Installation of the tachometer, furnished with the electric motor, is required before beginning to install the crowd brake assembly.. Install the tachometer and the torque arm in relation to the image provided.

1.

Install the drive hub and keyway on the motor as per the Brake Hub Installation procedure covered earlier within this section.

2.

Install motor shaft nut and secure to shaft with lockwasher by bending tabs over flats.

3.

Install brake adapter onto the motor and secure with hardware. Use care to align the access slots in the adapter for future tachometer inspections.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 11

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

4.

Lightly coat the splines of the drive hub with a teflon grease allowing only a thin film of lubricant to remain on the splines. Excess grease will be thrown outward by centrifugal force and have a degrading effect on the brake.

5.

Using a lifting device and the holes provided in the outer portion of the drive ring, place the brake assembly onto the drive hub and lower as you ensure the fit of the splines in the drive hub align with those in the brake disc.

Brake Guard Outer Cylinder Stud (Do not remove unless replacing friction disc)

Brake Adapter

Brake Mount Bolt

Adapter Mount Bolt Pressure Plate

Wear Plate

Piston

Tachometer

Drive Hub Motor Output Shaft Socket Head Capscrews (Do not remove unless replacing "O" Rings) Lockwasher

See Details Next Page LockNut S6_07

CROWD BRAKE CUTAWAY - DETAILS

6.

Apply compressed air of between 30-50 psi to the air inlet allowing the brake to achieve a disengaged posture.

NOTE: The brake will be fully disengaged once air pressure exceeds 28 psi on a properly functioning brake. Air pressure in excess of 125 psi could possible damage internal seals of the piston.

Section 6, Brakes and Couplings - 12

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

CAUTION: A minimum of 30 psi must remain applied to the brake while this dimension is determined. The brake must remain disengaged fully!

7.

Release the air pressure from the brake piston to relax the internal springs.

8.

Secure and torque the brake housing into place for final installation.

9.

Apply air pressure once again as in step 6, verify that the proper gap remains between the pressure plate and friction surface of the disc.

10.

Install safety guard around the brake assembly.

REPLACING THE FRICTION DISC

The friction disc will require replacement when excessively worn or when contaminated by grease, oil or other foreign materials.

CROWD BRAKE FRICTION DISC INSPECTION - DETAILS

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 13

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Check for a worn disc by using a depth micrometer as depicted in the image below.

The reading must be taken from the same location with the brake engaged and released. Due to the tapered surface of the pressure plate, care must be taken to duplicate the position and process as closely as possible.

The disc will be considered excessively worn when the difference between the 2 readings approaches 0.200 inch.

CAUTION: Major damage will occur to the components of the brake assembly if the friction disc is not replaced when wear approaches 0.200 inch. The result of “pushing” will result in metal-to-metal contact that will cause extremely expensive repairs and a seriously degraded braking system.

CAUTION: Do Not remove the socket head cap screws near the bore of the piston as this will release the spring pressure within the brake assembly and make re-assembly much more difficult.

1.

Release air pressure and remove the air line from the inlet to the piston.

2.

Install a ball, or gate, type valve into the fitting where the air line was removed.

This valve will be used to capture pressure within the piston during removal.

3.

Reconnect the air source and pressurize the piston to a minimum of 50 psi as needed to disengage the brake. Secure the valve, and then remove the air lines.

At this point the brake is disengaged and not connected to an air source.

NOTE: The cylinder, piston and pressure plate may be removed as a single unit.

4.

Remove the outer cylinder stud nuts at this time and the lift the entire brake assembly off the top of the studs as a unit. Once removed from the swing motor the pressure may be removed from the cylinder.

5.

Slide the friction disc up and off of the hub adapter splines and free it from the assembly.

6.

Clean the area where the friction disc resides and coat the splines with fresh teflon lubricant lightly.

7.

Install the replacement friction disc ensuring that the machined step, near the center, is facing downward - toward the motor.

8.

Carefully align the splines between the hub and the disc and allow the new disc to rest.

Section 6, Brakes and Couplings - 14

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

9.

Reinstall the piston and pressure plate onto the top of the friction disc and align the pneumatic fitting, access holes and studs accordingly. Pressurize the piston once more to minimum pressure allowing complete disengagement of the components.

10.

Replace the stud nuts and tighten to value that does not exceed 90 - 100 ftlbs.

CAUTION: Tighten the stud nuts as per the instructions on the brake drive ring. Excessive, or improper, torque application can cause the drive ring to become deformed and seriously reduce the effectiveness and life of the brake assembly.

REPLACEMENT OF “O” RING SEALS

These seals, located around the piston of the brake assembly are what will allow the pneumatic pressure applied to transfer into mechanical movement. Leakage around these seals could result in increased pressure requirements for the brake to release or even the possibility of partial brake release. A partial brake release could result in excessive heat buildup and damage to the friction components of the brake assembly.

1.

Release air pressure to the brake assembly.

2.

Remove the socket head capscrews on the top of the piston area of the brake.

Theses will allow access to the seal components beneath.

CAUTION: Do Not remove the cylinder stud nuts as this will release the spring pressure and make re-assembly much more difficult.

3.

Slide the piston up and remove from the brake assembly.

4.

Dress out any nicks or grooves in the cylinder walls with a very fine stone and finish polish with emery cloth to ensure a good sealing surface is maintained.

5.

Clean area thoroughly while using care not to allow solvents to drip down on the fiction disc below.

6.

Oil all “O” rings and seals judiciously prior to assembly and then hand wipe to remove any possible contaminants.

7.

Lay seals and “O” rings in place while ensuring there are no twists, bends, or unnatural deformities.

8.

Grease all metal surfaces with a light coat of teflon grease prior to assembly.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 15

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

9.

Install piston back into brake and secure capscrews to 200-220 ftlbs of torque in a diametric pattern. Refer to section on Torque Application, near the back of Section 5, if questions arise concerning torque.

Section 6, Brakes and Couplings - 16

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

HOIST BRAKE INSTALLATION

The brakes utilized on your shovel are all of the type that are spring set, air released and require virtually no adjustment. Regular inspections for lining wear should become a part of your maintenance and servicing regimen.

Unlike the swing and crowd brake however; the hoist brake is multiple disc type brake.

This brake is used in this application due to it’s increased heat capacity.

HOIST BRAKE TACHOMETER LOCATION/ORIENTATION

Installation of the tachometer, furnished with the electric motor, is required before beginning to install the crowd brake assembly. Install the tachometer and the torque arm in relation to the image provided.

1.

Install the drive hub and keyway on the motor as per the Brake Hub Installation procedure covered earlier within this section.

2.

Install motor shaft nut and secure to shaft with loctite.

3.

Install brake adapter onto the motor and secure with hardware. Use care to align the access slots in the adapter for future tachometer inspections.

4.

Lubricate the hub and friction disc splines with a light coat of teflon grease or anti-seize compound.

5.

Install the friction discs and center plates onto the shaft adapter in the required order before sliding on the brake assembly. Tighten the drive ring hardware and install the brake guard.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 17

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Brake Adapter

Center Plates Wear Plate

Brake Guard See Details Next Page

Motor Output Shaft

Socket Head Capscrews

Keyway Hoist Motor

Nut Drive Hub Piston

Pressure Plate

Cylinder Stud Nuts Tachometer

S6_10

HOIST BRAKE CUTAWAY - DETAILS

BRAKE ADJUSTMENT

This brake is equipped with 2 adjustment shims to compensate for lining wear.

Section 6, Brakes and Couplings - 18

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

To inspect for excessive disc wear use a micrometer as shown in the image below. The reading must be taken from the same location with the brake engaged and released.

Due to the tapered surface of the pressure plate, care must be taken to duplicate the position and process as closely as possible.

Consideration should be given to the adjustment of the friction discs when the total wear has reached an amount nearing 0.400 inches.

HOIST BRAKE FRICTION PLATE INSPECTION - DETAILS

NOTE: Adjustment shims are split for ease of removal and installation. DO NOT DISCARD shims after removal during brake adjustment. These shims will be required when reassembling brake following a friction disc replacement.

ADJUSTMENT STAGE 1

When wear has reached a figure close to 0.400 inches you can remove the outer cylinder nuts and remove a single shim from the stack at location A of the image. After having removed a shim the nuts should be re-installed and torqued to a value that does not exceed 120 ftlbs.

CAUTION: Tighten the stud nuts as per the instructions on the brake drive ring. Excessive, or improper, torque application can cause the drive ring to become deformed and seriously reduce the effectiveness and life of the brake assembly.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 19

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Re-check to total cylinder movement at this time. A reading of 0.270 inches should be the minimum movement allowable.

If the total movement is found to be acceptable place the unit back into service.

ADJUSTMENT STAGE 2

If the brake has already had a single shim removed to bring the piston movement within acceptable limits a second adjustment is possible.

When the brake movement once again reaches 0.400 inches the second shim may be removed in an identical procedure to that accomplished in Adjustment Stage 1.

NOTE: When removing the second shim it is required that the friction discs and center plates be removed and inspected at this time. Use care during disassembly to keep track of the order the components were removed in.

If the wear seems to be unequal between the inner and outer friction discs they should be reversed during reinstallation (Place the inner disc to the outside, place the outer disc to the side nearest the motor).

NOTE: Always be certain the machined step on the disc, near the center, is facing the motor during installation.

Replace the brake piston and nuts. Torque as in Adjustment Stage 1 and check total piston movement. Once again the movement shouls approximate 0.270 inches and the brake can be returned to service.

Section 6, Brakes and Couplings - 20

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

FRICTION DISC REPLACEMENT

Continue to monitor the brake lining wear until that wear is once again reaching a level where 0.400 is noted as total piston movement.

Once both shims have been removed from the brake assembly, and the wear approaches 0.400 inches, it is now required to replace the friction discs.

CAUTION: Major damage will occur to the components of the brake assembly if the friction disc is not replaced when wear approaches 0.400 inch. The result of “pushing” will result in metal-to-metal contact that will cause extremely expensive repairs and a seriously degraded braking system.

1.

Release the air pressure to the brake and remove the air line.

2.

Install a gate or ball valve on the fitting. Replace the air line and pressurize the brake piston until a minimum of 50 psi is on the piston to hold it in the disengaged position. Secure the air valve and remove the air line. At this point air pressure should be captive within the piston.

NOTE: The cylinder, piston and pressure plate may be removed as a single unit.

3.

Remove the outer stud nuts and remove the piston and pressure plate as a single unit.

CAUTION: Do Not remove the socket head cap screws near the bore of the piston as this will release the spring pressure within the brake assembly and make re-assembly much more difficult.

4.

Slide the friction discs and center plates out of the brake housing withou disturbing the springs and collars of the center plates.

5.

Clean the internal area of the brake and apply a fresh light coat of teflon lubricant to the splines of the hub adapter and the replacement friction discs.

6.

Insert the replacement friction discs into the brake housing while ensuring tht the machined step, near the center of the discs, is facing the mortor.

7.

The center plates should be installed between the friction discs with the springs facing the motor.

8.

Place both complete shims onto the brake housing prior to installing the pressure plate and piston back into it’s location on the stud bolts.

9.

Replace the stud nuts and tighten according to the instructions on the brake ring.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 21

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

CAUTION: Tighten the stud nuts as per the instructions on the brake drive ring. Excessive, or improper, torque application can cause the drive ring to become deformed and seriously reduce the effectiveness and life of the brake assembly.

REPLACEMENT OF “O” RING SEALS

These seals, located around the piston of the brake assembly are what will allow the pneumatic pressure applied to transfer into mechanical movement. Leakage around these seals could result in increased pressure requirements for the brake to release or even the possibility of partial brake release. A partial brake release could result in excessive heat buildup and damage to the friction components of the brake assembly.

1.

Release air pressure to the brake assembly.

2.

Remove the socket head capscrews on the top of the piston area of the brake.

Theses will allow access to the seal components beneath.

CAUTION: Do Not remove the cylinder stud nuts as this will release the spring pressure and make re-assembly much more difficult.

3. Slide the piston up and remove from the brake assembly.

4.

Dress out any nicks or grooves in the cylinder walls with a very fine stone and finish polish with emery cloth to ensure a good sealing surface is maintained.

5.

Clean area thoroughly while using care not to allow solvents to drip down on the fiction disc below.

6.

Oil all “O” rings and seals judiciously prior to assembly and then hand wipe to remove any possible contaminants.

7.

Lay seals and “O” rings in place while ensuring there are no twists, bends, or unnatural deformities.

8.

Grease all metal surfaces with a light coat of teflon grease prior to assembly.

9.

Install piston back into brake and secure capscrews to 200-220 ftlbs of torque in a diametric pattern. Refer to section on Torque Application, near the back of Section 5, if questions arise concerning torque.

Section 6, Brakes and Couplings - 22

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

PROPEL BRAKE

The brake friction discs should be inspected monthly by removing the air hole guard and measuring the distance between the pressure plate and the cylinder. The measurement should be taken with the brake engaged and again with the brake disengaged. When the difference between the two measurements reaches 0.31", the brake must be adjusted or the friction discs replaced.

PROPEL BRAKES OVERVIEW

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 23

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

ADJUSTMENT

The brake is equipped with three 0.094" thick shims located between the drive ring and the cylinder. When piston travel reaches 0.31", remove one shim as follows: CAUTION: Never allow brake to operate with piston travel of less than 0.220".

Removal of shims, prior to normal wear adjustment requirements, will not increase brake holding capacity. Premature shim removal will reduce running clearances, causing premature wear and heat damage to linings and brake.

NOTE: Before removing each shim, check the friction disc assembly for unequal wear. If the discs are wearing unequally (inside vs. outside), additional brake life can be achieved by reversing the disc assemblies. With two shims out, allowable piston travel before friction disc replacement is 0.31".

CAUTION:Due to damage which can occur to pressure and wear plates, it is recommended that the third shim never be removed for adjustment purposes.

1.

With machine parked on flat level surface, with dipper heel resting on the ground, remove the tach cover, the tach, the tach supports, and the brake guard.

2.

Pressurize brake (release brake), and back-off on the cylinder stud nuts 0.06".

3.

Spread one shim at split line and remove from brake. Take care not to bend or spring shim when removing. Save shims for reuse when new replacement friction discs are installed.

NOTE: For ease of removal, shims are split radially.

4.

Retorque cylinder stud nuts in a pattern 180° apart to 90-100 ft.lbs. and check piston travel. De-pressurize brake.

CAUTION: Do not overtorque the stud nuts as this will cause drive ring distortion leading to excessive wear on brake disc and mating surfaces.

5.

Reinstall the brake guard, the tach supports, the tach, and the tach cover.

Section 6, Brakes and Couplings - 24

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

PROPEL BRAKE CUTAWAY - DETAILS

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 25

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Friction Disc Replacement

With machine parked on flat level surface, with dipper heel resting on the ground, the friction discs may be changed by disassembling the brake as follows: 1.

Remove the tach cover, the tach, the tach supports, and the brake guard.

2.

Release air pressure to the brake. Disconnect the air line to the brake inlet.

Install a temporary pressure regulator with gauge and a closed shutoff valve to the brake inlet.

NOTE: The pressure regulator with gauge should be located between the brake and the shutoff valve.

3.

Connect an auxiliary air line with a quick disconnect to the closed shutoff valve.

4.

Slowly open the temporary shutoff valve and pressurize the brake cylinder to the full released position.

CAUTION: The maximum allowable air pressure to the brake is 125 PSIG.

Observe the temporary regulator pressure gauge. The brake full release pressure should be 43 PSIG plus or minus 5 percent.

WARNING: Full release pressure greater than the above amount indicates that either too many, or too stiff brake springs are used in the brake assembly.

This condition can result in drive train component damage and destruction because the brake stopping force now exceeds the motion design limits.

Install correct springs immediately!

Note: If the full release pressure is less than the above amount, the brake assembly has weak or broken brake springs which need replacement.

5.

Close the temporary shutoff valve to keep the brake pressurized in the full released position and disconnect the auxiliary line from the temporary shutoff valve.

6.

Remove the cylinder stud nuts and slide piston with cylinder and pressure plate as a complete assembly from the studs. Leave the temporary regulator and closed shutoff valve attached to the brake inlet to keep the cylinder assembly pressurized.

NOTE: Do not remove the piston bolts) securing piston to pressure plate as this will release the brake springs and make reassembly difficult.

Section 6, Brakes and Couplings - 26

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

7.

Slide friction disc assemblies and center plate from the drive hub splines.

Replace the friction disc assemblies.

NOTE: When removing friction discs, note which side faces outward and be sure to reinstall discs in the same direction.

8.

Clean dust and loose particles out of the brake.

9.

Wash the drive member and hub splines with a solvent.

CAUTION: Solvents may be toxic or flammable. Adequate ventilation must be provided to minimize fire and health hazards caused by using solvents for cleaning. Use away from sparks, heat or flame to prevent fire or explosion.

Follow manufacturer’s instructions.

Apply teflon type lubricant to all splined areas.

NOTE: Do not use heavy grease or anti-seize grease to lubricate hub and disc splines, as these greases attract brake dust particles to the splines and will cause disc “lock-up.”

10.

Slide the new friction disc assemblies and center plate onto the drive hub. Be sure the assembly moves easily on the splines. Assemble three 0.094" shims between the drive ring and the cylinder.

11.

Slide the piston, cylinder and pressure plate assembly (still pressurized) onto the cylinder studs.

NOTE: Observe the temporary regulator pressure gauge. If the piston, cylinder, pressure plate assembly pressure has dropped, the piston O-rings may need replacement.

Secure the assembly in place with the stud nuts. Torque the nuts in a pattern 180° apart to 90-100 ft.lbs.

CAUTION: Do not overtorque the stud nuts as this will cause drive ring distortion leading to excessive wear on brake disc and mating surfaces.

12.

Open the temporary shutoff valve and release the brake pressure. Remove the temporary regulator with gauge and the shutoff valve from the brake inlet and reconnect the brake air line to the brake inlet

13.

Reinstall the brake guard, the tach supports, the tach, and the tach cover.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 27

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

O-RING REPLACEMENT

With machine parked on flat level surface, with dipper heel resting on the ground, the O-rings may be replaced by disassembling the brake as follows: 1.

Remove the tach cover, the tach, the tach supports, and the brake guard.

2.

Release air pressure to the brake. Disconnect the air line to the brake inlet.

Install a temporary pressure regulator with gauge and a closed shutoff valve to the brake inlet.

NOTE: The pressure regulator with gauge should be located between the brake and the shutoff valve.

3.

Remove the piston bolts attaching the piston to the pressure plate and remove the piston.

NOTE: Do not remove cylinder stud nuts securing cylinder to pressure plate as this will release the brake springs and make reassembly difficult.

NOTE: It is recommended that piston and cylinder be marked so that the piston bolts pass through the same piston and pressure plate bolt holes at reassembly.

4.

Inspect O-rings for cleanliness, wear, deterioration, or cracks. Clean each as required and replace old or damaged O-rings.

5.

Lubricate O-rings and groove generously before assembly. Install O-rings in grooves as they would lay naturally. Do not nick, pinch, or twist O-rings.

NOTE: It is a good practice to coat the inner surfaces of the piston and cylinder with a teflon type lubricant. This coating of lubricant acts as a final filter to remove air system dust particles which could damage O-rings.

6.

Reassemble piston to pressure plate with piston bolts. Torque the bolts in a pattern 180° apart to 200-220 ft.lbs.

7.

Connect an auxiliary air line with a quick disconnect to the closed shutoff valve (installed in step one of this procedure) and follow step four of the Replacement of Friction Discs procedure.

8.

Close the temporary shutoff valve and disconnect the auxiliary airline. Observe the temporary regulator pressure gauge. If no pressure drop is observed, which would indicate an air leak in the brake assembly, release the brake pressure by opening the temporary shutoff valve.

Section 6, Brakes and Couplings - 28

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

9.

Remove the temporary regulator with gauge and the shutoff valve from the brake inlet. Reconnect the brake air line to the brake inlet.

10.

Reinstall the brake guard, the tach supports, the tach, and the tach cover.

SPRING REPLACEMENT To replace the brake springs, disassemble the brake as follows: 1.

Follow steps one through five of the Replacement of Friction Discs procedure.

2.

Remove the cylinder stud nuts.

NOTE: It is recommended that the piston cylinder, pressure plate, and drive ring be marked so that the same studs pass through the same bolt holes at reassembly.

Slide the piston with cylinder and pressure plate as a complete assembly from the studs and place on a clean level working area.

3.

Slowly open the temporary shutoff valve and release pressure from the piston with cylinder and pressure plate assembly.

CAUTION: The brake springs are under compression. Care must be taken when removing piston bolts in order to avoid injury.

4.

Remove all piston bolts except for four located at 90° from one another.

NOTE: Reinstall one piston bolt to the right of each of the four remaining piston bolts turning each of the reinstalled piston bolts two turns. Only enough bolt thread is engaged to permit these reinstalled piston bolts to act as a safety stop during the removal of the four remaining piston bolts 90° from each other.

Carefully loosen each of the four remaining piston bolts two turns each in a pattern 180° opposite each other until all four piston bolts have been loosened two turns. Repeat loosening each of the four piston bolts in the above manner until the brake spring compression has been fully released at all four remaining piston bolts.

CAUTION: Tap the piston to make sure it has not bound against the cylinder.

Though piston bolts are of sufficient threaded length so that spring compression can be fully released before the piston bolt threads are no longer engaged in the pressure plate, care must be taken when loosening piston bolts so that the piston does not bind against the cylinder.

Remove the four remaining piston bolts and the safety stop bolts, and lift the cylinder with piston off the pressure plate and brake springs.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 29

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

5.

Remove all brake springs and insulating washers.

NOTE: The springs are equipped with insulated fiber washers. Be sure the washers are in place at reassembly.

6.

Place new insulating washers, then new springs into the counterbores of the pressure plate. Reposition the cylinder with piston onto the springs taking care that each spring end properly seats into each counterbore of the brake cylinder.

Using piston bolts, reassemble the cylinder with piston to the pressure plate and springs by reversing step 4 above. Torque all piston bolts to 200-220 ft.lbs. in a pattern 180° apart.

7.

Close the temporary shutoff valve. Reconnect the auxiliary air line to the temporary shutoff valve and follow steps four and five of the Replacement of Friction Discs procedure.

8.

Slide the pressurized piston with cylinder and pressure plate assembly onto the cylinder studs. (When applicable, make sure cylinder shimming is in place between the cylinder and drive ring.) Secure the assembly in place with the stud nuts. Torque the nuts in a pattern 180° apart to 90-100 ft.lbs.

CAUTION: Do not overtorque the stud nuts as this will cause drive ring distortion leading to excessive wear on brake disc and mating surfaces.

NOTE: Observe the temporary regulator pressure gauge. If the piston, cylinder, pressure plate assembly pressure has dropped, the piston O-rings may need replacement.

9.

Open the temporary shutoff valve and release the brake pressure. Remove the temporary regulator with gauge and the shutoff valve from the brake inlet and reconnect the brake air line to the brake inlet.

10.

Reinstall the brake guard, the tach supports, the tach, and the tach cover.

Section 6, Brakes and Couplings - 30

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

MOTOR COUPLING INSTALLATION

Motor couplings must be shrunk onto tapered motor shafts in order to transmit the torque values involved without slippage. The procedure described below is intended to develop sufficient frictional force to transmit the imposed torque without dependence on the keyway.

Clean and dress the bore and shaft to remove any deformity and foreign matter.

Mount the cold coupling onto the shaft and measure the position of the coupling on the shaft carefully. Measure the distance from the end of the coupling to the end of the shaft.The dimension derived during this step will be used later.

Remove the coupling and pre-heat the item until the “estimated temperature difference” has been reached. Refer to table below.

Example: If the shaft temperature = 25° C (77°F) and the estimated temperature difference derived from the table is 100°C (180°F), the coupling must be heated to 125°C (257°F) for mounting.

CAUTION: Pinion or Brake Coupling temperature should never exceed 190°C (374°F) for installation.

CAUTION: Pre-heated components temperatures will often be brought to temperatures that can be extremely hazardous to the human body. Use extreme care and always wear appropriate safety equipment when working with pre-heated components and around the processes.

Wipe all oil from both the shaft and the bore of the coupling prior to installation.

Replace the heated coupling hubs on the shaft once again and take care to note the amount of advance (further movement) onto the shaft that has been obtained. If the advance amount does not fall within the limits called out in the table it will be necessary to remove the coupling and re-heat it to the specified temperature. IN ALL APPLICATIONS THE PROPER AMOUNT OF ADVANCE MUST BE ACHIEVED! The taper fit between mating parts shall be checked at assembly with Dykem or Blueing to assure a minimum of 80% bearing contact by marking during initial fit-up and comparing to actual fit after assembly.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 31

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

MOTOR COUPLING PRE-HEAT ADVANCE REQUIREMENTS TABLE

Section 6, Brakes and Couplings - 32

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

MOTOR COUPLING ALIGNMENT

Final alignment of direct-driven units is made by moving or shimming the unit so that misalignment of the unit and drive shafts is within required tolerance from the general arrangementt drawing recieved with your machine. Misalignment can be either offset, angular, or a combination of both. Misalignment can occur in both the vertical and the horizontal plane. Refer to the following illustrations to bring couplings within the maximum acceptable misalignment.

The following method of coupling alignment uses a dial indicator. Readings taken 180 degrees apart will measure the runout in one plane. It is important to rotate both shafts to avoid errors due to surface imperfections of the shafts or couplings.

PARALLEL MISALIGNMENT CHECKING FOR PARALELL MISALIGNMENT

1.

Mount the indicator on this coupling hub.

2.

Take readings in the horizontal plane at 90 and 270 degree positions on the hub while turning the shafts.

3.

Correct offset misalignment in the horizontal plane by shifting inboard and outboard feet an equal distance.

4.

Take indicator readings in the vertical plane at 0 and 180 degree positions.

5.

Correct offset misalignment in the vertical plane by adding or removing an equal thickness of shims at each foot.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 33

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

ANGULAR MISALIGNMENT CHECKING FOR ANGULAR MISALIGNMENT

1.

Mount the indicator between the coupling hubs.

2.

Measure the gap between the hubs at 90 and 270 degree positions.

3.

Shift the outboard feet until coupling faces are parallel in the horizontal plane.

4.

Take coupling readings at 0 and 180 degree positions.

5.

Raise or lower the outboard feet with shims to parallel coupling faces in the vertical plane.

EXAMPLE OF PARALELL MISALIGNMENT

Section 6, Brakes and Couplings - 34

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

EXAMPLE OF ANGULAR MISALIGNMENT

COMBINATION MISALIGNMENT

EXAMPLE OF COMBINATION MISALIGNMENT

This condition is encountered often after major repairs have been made to a machine.

To remedy this condition approach the problem from one aspect (either angular, or parallel) at a time. Once close perform the procedure for the other. Duplication of either, or both processes may be required.

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 35

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

BRAKE SENSOR SYSTEM The brake monitoring system provided on your machine is designed to provide the operator an indication of both the condition and status of the brakes aboard your machine.

If a condition of excessive wear exists on one or more of the brakes a signal will be visible on the PLC monitor’s screen. This signal is transmitted by the position of the Wear Switch mounted on the brake piston.

The Release switch serves as an interlock to prevent actuating a motor with the brake assembly engaged. This switch is mounted on the piston of each brake assembly.

Section 6, Brakes and Couplings - 36

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Brake Monitor Switch Overview

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 37

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Swing Brake Details

Section 6, Brakes and Couplings - 38

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Crowd and Swing Brake Wear Switch Details

Manual No. 10028, April 99

Section 6, Brakes and Couplings - 39

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Bucyrus International, Inc. 495B Mining Shovel

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

SECTION 7 - COMPRESSED AIR SYSTEM GARDNER-DENVER “ELECTRA-SCREW” AIR COMPRESSOR ............................................... 2 GENERAL INFORMATION ........................................................................................................... 2 THE COMPRESSION CYCLE ...................................................................................................... 2 AIR FLOW ..................................................................................................................................... 3 OIL FLOW ..................................................................................................................................... 3 COMPRESSOR MAINTENANCE ................................................................................................. 4 PRESSURE SWITCH ....................................................................................................... 4 AIR FILTER ....................................................................................................................... 5 FILTER ELEMENT ........................................................................................................................ 5 SERVICING ....................................................................................................................... 5 FILTER ELEMENT LIFE ............................................................................................................... 6 MOTOR LUBRICATION .................................................................................................... 7 COMPRESSOR LUBRICATION ....................................................................................... 8 SYSTEM CAPACITY ..................................................................................................................... 8 OIL SPECIFICATIONS ................................................................................................................. 8 SYNTHETIC LUBRICANTS .......................................................................................................... 8 HIGH TEMPERATURE OPERATION ........................................................................................... 9 ADDITION OF OIL BETWEEN SCHEDULED CHANGES ........................................................... 9 OIL LEVEL GAUGE .................................................................................................................... 10 OIL CHANGE INTERVAL ............................................................................................................ 10 DRAINING AND CLEANING THE OIL SYSTEM ........................................................................ 10 COMPRESSOR OIL FILTER ...................................................................................................... 11 OIL COOLER .............................................................................................................................. 11 OIL SEPARATOR ........................................................................................................................ 12 REPLACEMENT OF OIL SEPARATOR ELEMENT ........................................................ 12 PERFORMING A PRESSURE DROP CHECK ........................................................................... 13 DRIVE BELT TENSION .............................................................................................................. 14 BELT TENSION ADJUSTMENT ...................................................................................... 14

Manual No. 10028, April 99

Section 7, Main Air System - 1

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

GARDNER-DENVER “ELECTRA-SCREW” AIR COMPRESSOR GENERAL INFORMATION The compressor used on the Gardner-Denver tank mounted air compressor is a single stage, positive displacement rotary machine which utilizes inter-meshing helical rotors to effect the compression action. Both the rotors are supported by large capacity anti-friction bearings which are located outside the compression chamber.

The air inlet port is located on top of the compressor near the driveshaft end. The discharge port is near the bottom on the opposite end of the compressor. The figure below is an inverted view to depict the inlet and discharge ports.

THE COMPRESSION CYCLE Compression is accomplished by the main and secondary rotors synchronously meshing in a one piece cylinder. The main (driven) rotor has four helical lobes cut 90° apart from one another lengthwise. The secondary (idler) rotor has six matching helical cut flutes placed 60° apart in order to allow meshing with the main rotor.

SCREW COMPRESOR - COMPRESSION CYCLE

The compression cycle begins as the rotors begin to unmesh at the inlet port and the air is drawn in into the cavity between the main rotor lugs and the secondary rotor’s flutes (figure A). When the rotors pass the inlet port’s cutoff the air is trapped in the cavity between the two rotors (figure B).

As the rotational meshing continues a greater amount of the main rotor lobe will enter the secondary rotor flute and the volume is reduced as the pressure of the air increases. Oil is introduced at this point to reduce the heat brought on by compression and provide sealing for the internal clearances between the rotors. Volume reduction and pressurization will increase as the rotation continues until the air/oil mixture passes the discharge port (figure C) and is released to the oil reservoir.

Section 7, Main Air System - 2

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

AIR FLOW Air enters the unit through a dry pleated air filter and passes through the inlet manifold and an antiblowback unloader valve to the compressor. While passing through the compressor oil is introduced to the compressed air. At the compressor discharge port the air/oil mixture passes into the oil reservoir where most of the suspended oil is removed due to a change in velocity as it forms droplets which fall back to the reservoir. A multiple element final separator removes the remaining oil and returns it to the compressor oil tank. The air is then allowed to pass to the service valve for intended usage.

SCREW COMPRESSOR _ CUTAWAY DETAILS

NOTE: This system is not intended for use where oil-free air is required.

OIL FLOW Air pressure constrained within the oil reservoir forces oil to pass through the oil cooler and filter assembly to provide the compressor with lubricating oil. A portion of the oil is directed through internal passages to all the bearings ensuring complete lubrication of moving parts. The balance of the oil is injected directly into the cylinder for cooling and lubrication of the rotors and to provide sealing for the internal rotor clearances.

Manual No. 10028, April 99

Section 7, Main Air System - 3

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

COMPRESSOR MAINTENANCE PRESSURE SWITCH An adjustable pressure switch controls motor and unloader shutdown along with the load/unload signals. The factory setting is at 25 psi for the differential pressure between the settings that load and unload signals are introduced. This is the maximum differential pressure allowed with this switch. The cutout, or unload, is set at the factory according to needs of your machine. The cutout pressure is set by the adjustment screw “A” in the above displayed image. The differential pressure can be increased by movement of adjustment screw “B” in a clockwise direction. Do not force this adjustment beyond it’s limits as this will result in an unreliable differential pressure. There will normally be no need to adjust the factory setting.

PRESSURE SWITCH ADJUSTMENT

CAUTION: DO NOT, under any circumstances, adjust the cutout pressure higher than the maximum unit rating. Minimum operating pressure is 25 psi for short periods (under 3 minutes) and 40 psi for sustained operation.

Section 7, Main Air System - 4

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

AIR FILTER The air filter must receive adequate maintenance if maximum service life is to be received from the compressor unit. Establishment of a program by which the air filter receives proper, and timely, service is one of the most critical elements in the longevity of the compressor.

NOTE: A wide range of operating hours is possible between servicing intervals of the air filter.

The environmental conditions encountered will directly affect this interval. Conditions may vary with regard to the location and dust conditions that will affect machine operation. Experience, and a series of systematic checks will aid in determining the interval required. Inspect the filter element every few days until a “feel” is developed my the maintenance personnel as to the interval required.

FILTER ELEMENT The filter element should be serviced when inspection reveals an accumulation of dirt and debris on the outside of the element. An interval with a maximum inspection timeframe of 48 operating hours is suggested initially. Following this, a service interval with no more than 500 operating hours between occurrences is satisfactory. This can only be utilized as a guideline! Actual conditions and circumstances will derive the service schedule .

SERVICING 1.

Remove the filter element from the filter housing.

2.

Remove excess dirt and debris with a compressed air nozzle operating with no greater than 40 psi. When blowing the accumulations off of the filter pleats angle the air stream parallel to the pleats, or use a slightly inward angle. Do not point the blow gun to blast air perpendicular to the filter element pleats. It is possible to damage the filter element.

Elements Contaminated with Dry Dirt Deposits Only a)

Submerge the element and allow to soak in a solution of warm water and mild detergent for a period of approximately 5 minutes. Gently agitate by hand for an additional minute or two.

Manual No. 10028, April 99

Section 7, Main Air System - 5

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Elements Contaminated with Oil or Greasy Dirt Deposits a)

Submerge the element in a solution of 1 gallon warm water, 4 tablespoons mild detergent, and 1/2 teaspoon of tri-sodium phosphate that has been well mixed.

Allow to soak for a period of approximately 5 minutes. Gently agitate by hand for an additional minute or two.

b)

Remove element from solution and discard solution.

c)

Prepare a second batch of the cleaning solution and immerse filter element for an additional period of 5 minutes. Gently agitate by hand for an additional minute or two.

3.

Remove the filter element from the solution and gently rinse with fresh water from all possible angles while not applying pressure from a perpendicular axis to the filter.. Ensure a gentle stream is used for this operation to avoid tearing the filter element.

4.

Inspect the filter element carefully for rupture or severe deformity. Replace defective filters at once. Use a bright light from inside the filter to check for blockages in the filter element.

Replace filter element, or re-clean if necessary to remove blockages.

5.

Allow filter element to air-dry before re-installation.

CAUTION: Do not oil this filter element. Do not use other than suggested cleaning solvents. Never operate the unit without a serviceable filter element in place. Never use filter elements that provide doubt of a proper seal.

NOTE: It is advisable to keep a spare filter element(s) on hand to minimize down time. Store all replacement filter elements in an area where they will be protected from damage, dirt, oil and moisture. Handle filter parts with care.

FILTER ELEMENT LIFE The element should be replaced after a series of 8 cleaning cycles or if inspection revels a rupture, hole, or tear in the filter media. Inspection should be accomplished by placing a bright light source within the filter element and visually inspecting from the outside.

Section 7, Main Air System - 6

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

MOTOR LUBRICATION The ball bearing motors shipped with this unit will contain sufficient grease for an extended operating period, however; re-lubrication at intervals consistent with the usage listed in the table below, will provide the protection required for maximum bearing life. Re-lubricate with a grease meeting the following specifications: Compressor Motor Lubricant Specifications Table Worked Penetration

265-296

Oil Viscosity (CSU @ 100°F)

400-550

Soap Type

Lithium

N-H Bomb, min. hours for 20 psi drop at 210°F.

750

Bleeding, max. weight % in 500 hours @ 212°F

10

Rust Inhibiting

Yes

Compressor Motor Re-Greasing Schedule Table Type of Service

Typical Example

Re-Lubrication Interval

Standard

1 or 2 shifts daily

4 years

Severe

24 hours/day - 365 days/year

1 ½ years

Manual No. 10028, April 99

Section 7, Main Air System - 7

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

COMPRESSOR LUBRICATION The compressor oil system consists of the oil reservoir, cooler and filter assemblies. The oil is circulated through the system by means of a pressure differential and provides 3 functions with the compressor: 1) cooling, 2) lubrication and 3) the sealing of internal passages.

System Capacity The capacity of the compressor lubrication system is 5-6 gallons.

Oil Specifications The recommended compressor lubricant is Gardner-Denver “GD800” Lubricating Coolant” which is suitable for year round operation with the exception of the High Temperature Operation section listed below. GD800 is a superior petroleum based lubricant formulated with additives specifically designed for use in “Electra-Saver” compressors.

CAUTION: The mixing of different types, or the use of incorrect, inferior, lubricants will result in the formation of heavy varnish deposits, and sludge formation throughout the system.

Synthetic Lubricants Certain synthetic lubricants such as synthetic hydrocarbons, diester or polyesters offer an extended drain interval when used in screw type compressor applications. A superior diester type lubricant is available in Gardner-Denver “GD8000” Lubricating Coolant which will extend lubrication change intervals from 2 to four times that found when using GD800. A properly utilized lubricant analysis program can dramatically maximize the change interval.

CAUTION: DO NOT MIX GD800 and GD8000 Lubricating Coolants or any other synthetic and petroleum based lubricants.

CAUTION: Regardless of the synthetic lubricant change interval used, oil filter, and oil separator change intervals remain the same as for GD800.

Compressor Lubricant Recommendations Table Recommended Oil

Temperature Range

Gardner-Denver GD800 Lubricant/Coolant

Year round operation @ discharge temperatures up to 200°F

Gardner-Denver GD8000 Lubricant/Coolant

If conditions may require over 4 hours sustained operation @ a discharge temperature above 200°F

Section 7, Main Air System - 8

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

High Temperature Operation If the discharge temperature is to be above 200°F for a period of 4 hours due to continuing high ambient air or water temperatures use GD8000 which is a synthetic diester lubricant. Short periods of up to four hours sustained discharge temperatures of up to 200°F do not require a change from the year round GD800 fluid.

When converting to GD8000 fluid the original lubricant should be completely drained, and the system flushed prior to refilling with the new type lubricant. Complete draining will require the removal of all plugs within the compressor, oil reservoir and lines. In some applications the piping may require removal to ensure complete draining. In order to ensure complete removal of the old fluid it is suggested that after 100 hours operation with the new fluid the case be drained and refilled with GD8000 fluid.

CAUTION: DO NOT MIX GD800 and GD8000 Lubricating Coolants or any other synthetic and petroleum based lubricants.

CAUTION: Do not set the High Discharge Air Temperature switch above 225°F to compensate for high temperature operation.

CAUTION: Use caution when selecting GD8000 lubricating fluid as some components within the system, such as the lubricator bowl gaskets, and valve trim may not be compatible with the synthetic fluid. Be sure to check with component supplier for any issues regarding compatibility.

Addition of Oil Between Scheduled Changes Addition of oil to the system is identified by a condition where the oil level is in the range below the RUN mark while the unit is in operation.

DANGER: be sure to stop the unit and drain the oil reservoir pressure before attempting to add fluid.

1. Wipe away all dirt and material around the oil filler plug.

2. Remove filler plug and add lubricant of the same type in the compressor in order to return the level to the center of the RUN range when the unit is operating. The amount required to raise the level from the top of the ADD range to the centerline of the RUN range is approximately ½ gallon.

NOTE: Repeated addition of oil between scheduled replacements may indicate excessive oilcarryover and should be investigated.

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Section 7, Main Air System - 9

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

OIL LEVEL GAUGE The gauge indicates the amount of oil within the reservoir. The gauge will indicate properly when the unit is in operation. When the unit is stopped the gauge will indicate at a higher level within the RUN range than is actually the case. When the unit is operating the ideal oil level will be near the center of the RUN range ion the gauge. Under normal circumstances the oil level will fluctuate slightly as the compressor loads and unloads. Drain only when the gauge indicates an excess level while the compressor is under load.

OIL CHANGE INTERVAL The frequency of oil change interval is determined by the air filter maintenance performed along with the operating conditions and the quality of the oil utilized. A recommended practice is to change the oil often enough that the drained oil is relatively clean. Under normal operating conditions (not a severe environment), GD*)) lubricant can be used for up to 2,000 hours between changes.

When the operating conditions are extremely severe more frequent changes will be necessitated.

Operating conditions, and the appearance of drained oil, must be surveyed and the cycle planned accordingly.

NOTE: The compressor oil filter must be changed at 1,000 hour intervals!

DANGER: be sure to stop the unit and drain the oil reservoir pressure before attempting to add fluid.

DRAINING AND CLEANING THE OIL SYSTEM Always drain the complete system. Draining the oil while it is hot will aid in the prevention of varnish deposits and assist in the flushing away of impurities within the system. For proper draining of the system employ one of the following methods: 1.

If the unit is not elevated high enough to utilize the oil reservoir drain valve to drain the oil, a small hand, electric, or pneumatically pump may be used to drain the reservoir through the filler opening into an appropriate container for storage or disposal.

2.

If the unit is adequately elevated to utilize the oil reservoir drain valve simply open the valve and drain the fluid into an appropriate container for storage or disposal.

3.

If the drained oil and/or filter element are contaminated with dirt, flush the entire system; This will include the reservoir, oil cooler, mixing valve and associated lines. Inspect the oil separator elements for dirt accumulation and replace if necessary. If varnish deposits are discovered contact the factory for recommendations on the removal and prevention of a recurrence.

Section 7, Main Air System - 10

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

COMPRESSOR OIL FILTER A spin-on oil filter is mounted on the side of the compressor unit. Filter maintenance is vital to trouble free operation of your compressor since the removal of dirt and abrasive material will extend the life of wear items. The filter is disposable. It comes equipped with an internal relief valve that will open in the event of a clogged filter element in order to not restrict oil flow.

Removal of the filter is accomplished by spinning the filter in a counterclockwise direction. The filter can be drained and discarded in an appropriate manner consistent with environmental controls at your location.

NOTE: When the filter is replaced between oil changes you must add 1 quart of the appropriate fluid to the system to replace the volume entrapped in the filter.

Replacement of the filter is by spinning the filter onto the fitting in a clockwise direction. The filter must only be tightened hand tight. If the filter is installed with excessive force the packing on the sealing surface may be torn or deformed to the point where leakage will occur. Add one quart of fluid after replacement of filter.

IMPORTANT: After initial start-up of the compressor the filter should be changed after the first 100 hours of operation.

Under routine maintenance conditions the oil filter should be replaced after each 1,000 hours of operation.

OIL COOLER The compressor oil cooler fan is directly connected to the motor shaft and exhausts air pulled through the cooler away from the unit. It is important to keep both sides of the cooler core clean for efficient operation and optimum cooling of the fluid. Do not allow items to block airflow on either side of the cooler as fluid heat will rise and damage can occur to compressor over time.

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Section 7, Main Air System - 11

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

OIL SEPARATOR The compressor oil separator is located in the oil reservoir and contains a one piece agglomerator element to remove oil from the air stream of the system. Oil from inside the compressor is returned through tubing to the compressor cylinder.

Oil carry-over through the service lines may be due to the oil level being too high, causing excessive foaming, a clogged return oil line, or a return pickup tube being loose or broken. This may also be caused by operation at a pressure below the minimum specified. If it has been determined that none of the previously listed possibilities are at fault, inspect the element within the separator for rupture. A rupture may be caused by heavy dirt or varnish deposits resulting from inadequate air filter servicing, use of an improper oil, or using the same oil for too long a period of operation.

Collapsing of the element is usually due to heavy dirt or varnish buildup in the filtering material.

REPLACEMENT OF OIL SEPARATOR ELEMENT To remove the agglomerator element for inspection or replacement: 1.

Disconnect all tubing and ensure to open a union within the discharge line to release any possibility of trapped pressure.

2.

Remove the bolts securing the top plate on the oil reservoir. In order to avoid puncture of the separator lift the top plate straight up until the oil return tube has completely cleared the separator.

3.

Lift the element from the reservoir using care not to dent or damage the element.

4.

Inspect the element by placing a bright light source within the element and looking for deposits of heavy dirt or varnish, or ruptures. Pay close attention to the gaskets which are bonded to each side of the separator flange.

Installation of the element is the reverse of disassembly.

NOTE: During installation of the element the top plate bolts must be torqued in place to a value of 150 foot pounds.

NOTE: Element life will vary greatly depending on the severity of the service environment and the quality of the oil in use. The condition of the oil can be determined by performing a pressure drop check as covered in the following section

Section 7, Main Air System - 12

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

PERFORMING A PRESSURE DROP CHECK A pressure drop check is performed to evaluate the condition of the separator element and lubricant oil within the compressor reservoir and system.

1.

Connect a pressure gage within the system (as shown in the image below) so that a reading may be taken on either side of the separator.

2.

By opening and closing the valves alternately the pressure differential can be measured.

3.

If the pressure differential exceeds 8 psi the separator should be changed.

The savings from electrical usage alone will outweigh the cost of the new element and the system will operate at optimum efficiency.

NOTE: Do not attempt to clean the separator element - replace it!

PRESSURE DROP CHECK DIAGRAM

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Section 7, Main Air System - 13

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

DRIVE BELT TENSION Proper drive belt tension and alignment are provided initially at the factory. A good practice is to check belt tension and alignment prior to initial start-up of the unit.

The sheaves should be aligned straight across the front by use of a straight edge and the tension should be just adequate to prevent a “squeal” on start.

To remove belts: 1.

Remove the fan shroud from the cooler assembly.

2.

Remove the belt guard from the motor.

3.

Loosen the motor mount bolts which extend through the base of the motor housing.

4.

Using the 2 adjustment bolts provided, release the pressure from the belts adequately to remove them from the sheaves of the pulleys.

Installation of the belts is the reverse operation of the removal.

NOTE: Be sure not to over-tension the belts before securing the motor mount bolts. Refer to the following topic for proper belt tension adjustment.

BELT TENSION ADJUSTMENT Belt tension should be adjusted to avoid to the absolute minimum amount which will allow the belts to rotate without an initial “squeal” from slippage during start-up of the unit.

The following information is a general guideline to achieve the approximate dimension required.

Fine tuning may be required.

CAUTION: Do not over-tension the belts as permanent damage to the compressor and motor bearings and shafts may result.

Section 7, Main Air System - 14

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Preventive Maintenance Checklist Timeframe

Required Maintenance

8 hours of operation

1. Check oil reservoir level - add if required.

2. Observe if the unit loads/unloads properly.

3. Drain moisture traps on air receiver and separator*

125 hours of operation aftercooler* core faces.

1. Check for accumulation of foreign matter on oil cooler and

2. Check for accumulation of foreign matter on the fan and fan motor.

1,000 hours of operation

1. Replace oil filter.

2,000 hours of operation

1. Replace compressor oil and filter (Note 1)

* if used Note 1: Adverse conditions may dictate a more aggressive replacement schedule

BELT ADJUSTMENT DETAILS

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Section 7, Main Air System - 15

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

TYPICAL UPPER WORKS AIR PIPING DIAGRAM

Section 7, Main Air System - 16

Manual No. 10028, April 99

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Manual No. 10028, April 99

Section 7, Main Air System - 17

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Bucyrus International, Inc. 495B Mining Shovel

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

Section 8 - Heating, Ventilation and Air Conditioning AIR CONDITIONING UNIT ........................................................................................................... 2 DESCRIPTION .................................................................................................................. 2 OVERVIEW ....................................................................................................................... 2 EVAPORATOR .................................................................................................................. 2 CONDENSER ................................................................................................................... 2 SPECIFICATIONS ............................................................................................................. 3 HOUSE FANS ............................................................................................................................... 4 INSPECTION .................................................................................................................... 4 LUBRICATION .................................................................................................................. 5 TENKAY FILTERS ............................................................................................................. 5 DYNAVANE AIR CLEANER .............................................................................................. 6

Manual No. 10028, April 99

Section 8, Heating, Ventilation and Air Conditioning - 1

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

AIR CONDITIONING UNIT DESCRIPTION SIGMA MPV9 climate control units are heavy duty systems designed to be roof mounted on the cabs of industrial and mining equipment.

This unit will provide superior performance in a variety of climate conditions and under the most harsh environment.

OVERVIEW EVAPORATOR Air is drawn from beneath the unit, passes over the heat exchanger coil and the heating elements into a double-wheel fan where it is discharged through the base of the unit into the conditioned space below.

The refrigerant id metered by an externally mounted TX valve, and is cut off by a liquid line solenoid valve.

The heat exchanger is large, constructed of heavy gauge tubing with a coarse fin pitch to reduce clogging.

The fan motor is a large shaft, totally enclosed unit that is air cooled.

All pressure controls within the evaporator unit are fully sealed, preset and “O” ring connected.

CONDENSER The compressor is a heavy duty, fully sealed scroll type device. The unit is mounted in flexible mounts in an effort to reduce noise and vibration.

All connections are either soldered, “O” ring type or rotalok.

A large liquid drier is place within the liquid line to filter moisture from the refrigerant.

The condenser operates at a single speed only.

Section 8, Heating, Ventilation and Air Conditioning - 2

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

SPECIFICATIONS Nominal Cooling Capacity

31,000 Btu/hr@460V/60Hz 27,000 Btu/hr@380V/50Hz

Power requirements

380V/3ph/50Hz

415V/3ph/50Hz

460V/3ph/60Hz

17.5 Amps

19.0 Amps

21.0 Amps

Refrigerant

HFC 134a – 24 lbs.

Oil

POE Variety Mobil Arctic EAL22CC or ICI Emcarate RL32CF

Compressor

Fully sealed, scroll type

Condensor Coil

5 row, 3/8 inch copper tube with 8 aluminum fins/inch

Evaporator Coil

4 row, 3/8 inch copper tube with 10 aluminum fins/inch

Detailed information on theMPV9 can be found in the vendor’s documentation that accompanied your machine and the General Arrangement drawings provided by Bucyrus International.

Manual No. 10028, April 99

Section 8, Heating, Ventilation and Air Conditioning - 3

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

HOUSE FANS INSPECTION Check the blades for grease and/or dirt accumulation. Clean if necessary. Blades should rotate freely without binding.

If vibration is detected, check the following 1. Bearing and drive alignment 2. Shaft straightness 3. Wheel or sheaves loose on shaft 4. Loose or worn bearings 5. Loose mounting bolts 6. Motor out-of-balance 7. Sheaves out-of-balance 8. Nose cap loose on wheel 9. Worn or corroded wheel 10. Accumulation of material on the wheel 11. Cracks on blades and/or at the hub 12. Worn fan blades and hubs

Section 8, Heating, Ventilation and Air Conditioning - 4

Manual No. 10028, April 99

BI616793

BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

LUBRICATION All bearings are pre-lubricated and sealed at the factory. Under normal temperature condition (-20ø to +150øF), when the fans are circulating clean air, the bearings are considered lubricated for life and additional lubrication is unnecessary.

If the fans are circulating contaminated air, or operating at elevated temperatures, periodic lubrication is required.

For normal temperatures, a high quality, light neutral mineral grease is used. It is free of abrasive fillers and highly resistant to oxidation.

When fans are operating at elevated temperatures (166øF or higher), silicone or lithium soap base grease should be used. This high temperature grease should have a breakdown point above 350øF. Use a low pressure grease gun for fan bearings. It is preferable that either the gun or the fitting be vented. To prevent overfilling apply only a small amount of grease.

This is especially important when extended lubrication piping is used and the bearing cannot be observed.

TENKAY FILTERS The Farr Tenkay filter is an aspirated cartridge, self cleaning dust filter. Incoming air passes from the outside to the inside of the cartridges. The cartridges are self cleaned sequentially by the revesal of airflow through these cartridges.

Detailed information on the Tenkay filter system may be found in the Vendor’s data provided with your machine.

HOUSE FILER/BLOWER ARRANGEMENT

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Section 8, Heating, Ventilation and Air Conditioning - 5

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BUCYRUS INTERNATIONAL Inc. 495B1 Electric Mining Shovel

DYNAVANE AIR CLEANER Dynavane air cleaners are self-cleaning and do not require the routine service typical of air filters which collect and hold the dirt removed from the air. There are a few maintenance procedures which should be observed, however.

First, the air entering the side of the cells should be kept free of rags, leaves and papers to assure free airflow. Applications exposed to this type of material should have intakes covered with a course mesh (5 mesh) screen to prevent entry of material larger than the bleed slot. This screen can be specified as part of the basic unit.

FILER COMPONENTS OVERVIEW

Periodic inspection should include a check of the bleed system to make sure nothing has impaired bleed air flow.

During periodic inspections, the cells should be examined for build-up of deposits on the blades.

A light coating of dust is normal and will not impair the operation or efficiency of the cell. Occasionally, due to the presence of oil mist or similar vapors in the air, heavier surface accumulations will occur and the cell will require cleaning. Cleaning the cells can be accomplished by brushing the surface of the blades or blowing down with compressed air. Another method of cleaning the Dynavane filters is to reverse the direction of fan rotation. This creates reverse air pressure which helps free up the dirt. The units can be removed for a more thorough cleaning.

Section 8, Heating, Ventilation and Air Conditioning - 6

Manual No. 10028, April 99