Cat Electric Role Shovel 150-RB Excavator Operation & Maintenance Manual - PDF DOWNLOAD

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OPERATION

and MAl NTENANCE of

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equipped as

ISO·RB excavators

SHOVEL DRAGUNE

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RUSTON- BUCYRUS LIMITED EXCAVATOR WORKS, Telephone: Lincoln 25261

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P.O. Box No. 14,

LINCOLN,

Telegrams: Bucyruston. Lincoln Telex

ENGLAND Telex No. 5650

The illustrations used in this booklet may not agree in absolute detail with the actual machine, modification of design being made from time to time.

BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR CARE, MAINTENANCE AND OPERATION INSTRUCTIONS

J TABLE OF CONTENTS

SECTION

1 - General Suggestions.

SECTION

2 - Operating Instructions.

SECTION

3 - Description of machinery, Lower Works, Upper Works, Shovel Front End.

SECTION

4 - Compressed Air Plant, Compressor, Air Valves, Brakes and Clutches, Dipper Trip, Steering Control (Power Locking)

SECTION

5 - Manual Steering.

SECTION

6 - Reeving Instructions -Shovel, Boom Suspension, Hoist Reeving, Crowd Reeving, Dipper Trip Reeving.

SECTION

7 - Lubrication. Lubrication Instructions, General Lubrication, LowerWorks Lubrication- Upper Works Lubrication- Sho'Vel Front End Lubricants.

SECTION

8 - Adjusting Instructions, Lower Works Adjustments, Upper Works Adjustments, Shovel Front End Adjustments, Instructions for Checking Air Leaks in Compressed Air Plant, Instructions for Crowd Machinery Slipping Clutch, Replacement of Boom Suspension Bridge Strands.

SECTION

9 - Dragline Front End Equipment, Description of Machinery, Reeving, Lubrication, Boom Angle Indicator.

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SECTION 10 - Conversion Instructions, Converting from Shovel to Dragline.

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The illustrations or figures refered to in the following pages will be found at the end of the book.

Publication 2. (Static Control)

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BI379509

RUSTON-BUCYRUS 150-RB EXCAVATOR (M/c. No. 31884 and all future machines} INDEX TO DRAWINGS AND DIAGRAMS BASE MACHINE. ARRANGEMENTS Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. ·Fig. Fig. Fig. Fig. Fig.

1/R2 2/R2 3/R1 4 /R1 5 6 7 /R1 8 9 10 ll/R1 12 13 14 15 16 17 18/R2 19/R3.

20/R1 20A/R2 21 22 23 24 25.

26 27 28 29 30 31

Plan Arrangement- Shovel Plan Arrangement - Dragline Operator's Control Console- Key Diagram Magnetic Air Valve Control- Schematic Arrangement Lower Works Standard Cats Lower Works - Long and W.ide Cats Collector Gear Steering Levers Take Up - Caterpillars Swing Machinery Hoist and Propel Motor \)haft Hoist or Propel Clutch Type AR-C Intermediate Shaft - Main Machinery Centre Pintle and Shovel Hoist Shaft Hoist Bearing Cap Shims Motor Brake - Main Machinery Motor Brake - Swing Machinery Air Piping - Schematic Diagram L.H. Side Piping F H. Side Piping Steering- Magnet Valve Piping Triple Swivel Truck Frame Piping Swivel Joint Assembly Tools and Instructions Compressor Compressor Valve Assembly Compressor 'Oilmatic' Unloader Adjustment of Pressure Switch Magnet Valve Type 'A' Magnet Valve Type 'B' Lower Works Lubrication Upper Works Lubrication

SHOVEL FRONT END. STANDARD MACHINE Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

40/R4 41/R4 43 44/R4 46 47 48/R1 49/R4 50/R1 51/R1 53 54/R2 55/R1 56 57 58/R3 61/R2

36' 0" Shovel Sales Drawing =" Shovel Front End Equipment """ Boom Limit Switch Dipper and Handle Padlock - Shovel Dipper Door Snubber Dipper Teeth Assembly Dipper Trip ._ Dipper Trip Cylinder Dipper Trip Piping Hoist Rope Reeving Crowd Rope Reeving Crowd Machinery Crowd Slipping Clutch Type AR-E Motor Brake - Crowd Shovel Front End Lubrication Crowd Equalizer with Spring Cushion

SHOVEL FRONT END. LONG RANGE EQUIPMENT Fig.

67

Boom Limit Switch

DRAGLINE FRONT END Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

75 76 77 78 79 80 81 83

Standard Dragline Sales Drawing Boom Suspension and Mast Boom Point Sheaves Fairlead Boom Hoist Machinery Hoist Shaft Padlock Lubrication Dragline Front End

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{M/c. Nos. 31732 and 31733) INDEX TO DRAWINGS AND DIAGRAMS BASE MACHINE. ARRANGEMENTS Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

1/R2 2/R2 3/R1 4 5 6 7 /R1 8 9 10 11/R1 12 13 14 15 16 17

18/R1 19/R3 20/R1 20A/R2 21 22 23 24 25 26 27 28 29 30 31

Plan Arrangement- Shovel Plan Arrangement - Dragline Operator's Control Console - Key Diagram Magnetic Air Valve Control- Schematic Arrangement Lower Works Standard Cats Lower Works - Long and Wide Cats Collector Gear Steering Levers Take Up - Caterpillars Swing Machinery Hoist and Propel Motor Shaft Hoist or Propel Clutch Type AR-C Intermediate Shaft - Main Machinery Centre Pintle and Shovel Hoist Shaft Hoist Bearing Cap Shims Motor Brake - Main Machinery Motor Brake - Swing Machinery Air Piping- Schematic Diagram L.H. Side Piping .

R H. Side Piping Steering- Magnet Valve Piping Triple Swivel Truck Frame Piping Swivel Joint Assembly Tools and Instructions Compressor Compressor Valve Assembly Compressor 'Oilmatic' Unloader Adjustment of Pressure Switch Magnet Valve Type 'A' Magnet Valve Type 'B' Lower Works Lubrication Upper Works Lubrication

SHOVEL FRONT END. STANDARD MACHINE Fig. Fig. Fig, Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

40/R2 41/R2 43 44/R2 46 47 48/Rl 49/R2 50/Rl 51/R1 53 54/R2 55/Rl 56 57 58/R2 61/R

36' 0" Shovel Sales Drawing Shovel Front End Equipment Boom Limit Switch.

Dipper and Handle Padlock - Shovel Dipper Door Snubber Dipper Teeth Assembly Dipper Trip Dipper Trip Cylinder Dipper Trip Piping Hoist Rope Reeving Crowd Rope Reeving Crowd Machinery Crowd Slipping Clutch Type AR-E Motor Brake - Crowd Shovel Front End Lubrication Crowd Equalizer with Spring Cushion

SHOVEL FRONT END. LONG RANGE EQUIPMENT Fig.

67

Boom Limit Switch

DRAGLINE FRONT END Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

75 76 77 78 79 80 81 83

Standard Dragline Sales Drawing Boom Suspension and Mast Boom Point Sheaves Fairlead Boom Hoist Machinery Hoist Shaft Padlock Lubrication Dragline Front End

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INDEX TO DRAWINGS AND DIAGRAMS BASE MACHINE. ARRANGEMENTS Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

1/R1 Z/R1 3 4 5 6 7/R1 8 9 10 11/R1 12 13 14 15 16 17 18/R1 19/R3 20/R1 20A/R2 21 22 23 24 25 26 27 28 29 30 31

Plan Arrangement- Shovel Plan Arrangement - Dragline Operator's Control Console - Key Diagram Magnetic Air Valve Control- Schematic Arrangement Lower Works Standard Cats Lower Works - Long and Wide Cats Collector Gear Steering Levers Take Up - Caterpillars Swing Machinery Hoist and Propel Motor Shaft Hoist or Propel Clutch Type AR-C Intermediate Shaft- Main Machinery Centre Pintle and Shovel Hoist Shaft Hoist Bearing Cap Shims Motor Brake - Main Machinery Motor Brake - Swing Machinery Air Piping- Schematic Diagram L.H. Side Piping F H. Side Piping Steering - Magnet Valve Piping Triple Swivel Truck Frame Piping Swivel Joint Assembly Tools and Instructions Compressor Compressor Valve Assembly Compressor 'Oilmatic' Unloader Adjustment of Pressure Switch Magnet Valve Type 'A' Magnet Valve Type 'B' Lower Works Lubrication Upper Works Lubrication

SHOVEL FRONT END. STANDARD MACHINE Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

40/R2 41/R2 43 44/R2 46 47 48/R1 49/R2 50/R1 51/R1 53 54/R2 55/R1 56 57 58/R2 61/R

36' 0" Shovel Sales Drawing Shovel Front End Equipment Boom Limit Switch Dipper and Handle Padlock - Shovel Dipper Door Snubber Dipper Teeth Assembly Dipper Trip Dipper Trip Cylinder Dipper Trip Piping Hoist Rope Reeving Crowd Rope Reeving Crowd Machinery Crowd Slipping Clutch Type AR-E Motor Brake - Crowd Shovel Front End Lubrication Crowd Equalizer with Spring Cushion

SHOVEL FRONT END. LONG RANGE EQUIPMENT Fig.

67

Boom Limit Switch

DRAGLINE FRONT END Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

75 76 77 78 79 80 81 83

Standard Dragline Sales Drawing Boom Suspension and Mast Boom Point Sheaves Fairlead Boom Hoist Machinery Hoist Shaft Padlock Lubrication Dragline Front End

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BASE MACHINE. ARRANGEMENTS Fig. Fig. Fig. Fig. Fig. Fig. Fig: Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

1/R1 2/R1 3 4 5 6 7/R1 8 9 10 11/R1 12 13 14 15 16 17 18/R1 19/R2 20 20A/R1 21 22 23 24 25 26 27 28 29 30 31

Plan Arrangement'- Shovel Plan Arrangement - Dragline Operator's Control Console -Key Diagram Magnetic Air Valve Control - Schematic Arrangement Lower Works Standard Cats Lower Works - Long and Wide Cats Collector Gear Steering Levers Take Up - Caterpillars Swing Machinery Hoist and Propel Motor Shaft Hoist or Propel Clutch Type AR-C Intermediate Shaft - Main Machinery Centre Pintle and Shovel Hoist Shaft Hoist Bearing Cap Shims Motor Brake - Main Machinery Motor Brake -.Swing Machinery Air Piping - Schematic Diagram L.H. Side Piping R.H. Side Piping Steering- Magnet Valve Piping Triple Swivel Truck Frame Piping Swivel Joint Assembly Tools and Instructions Compressor Compressor Valve Assembly Compressor 'Oilmatic' Unloader Adjustment Of pressure Switch Magnet Valve Type 'A' Magnet Valve Type 'B' Lower Works Lubrication Upper Works Lubrication

SHOVEL FRONT END. STANDARD MACHINE

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40/R1 41/R1 43 44/R1 46 47 48/R1 49/R1 50/Rl 51/R1 53 54/R1 55/R1 56 57 58/R1 61

36' 0" Shovel Sales Drawing Shovel Front End Equipment Boom Limit Switch Dipper and Handle Padlock - Shovel Dipper Door Snubber Dipper Teeth Assembly Dipper Trip Dipper Trip Cylinder Dipper Trip Piping Hoist Rope Reeving Crowd Rope Reeving Crowd Machinery Crowd Slipping Clutch Type AR-E Motor Brake - Crowd Shovel Front End Lubrication Installation and Adjustment of Rope Take Up

SHOVEL FRONT END. LONG RANGE EQUIPMENT Fig.

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Boom Limit Switch

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DRAGLINE FRONT END

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Standard Dragline Sales Drawing Boom Suspension and Mast Boom Point Sheaves Fairlead Boom' Hoist Ma~hinery Hoist Shaft Padlock Lubrication Dragline· Front End

75 76 77 78 79 80 81 83

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(M/c. No. 27591, 27592 or later than 27593) INDEX TO DRAWINGS AND DIAGRAMS BASE MACHINE. ARRANGEMENTS Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

1/R1 2/R1 3 4 5 6 7 /R1 8 9 10 11/R1 12 13 14 15 16 17 18/R1 19/R1 20 20A/R1 21 22 23 24 25 26 27 28 29 30 31

Plan Arrangement - Shovel Plan Arrangement - Dragline Operator's Control Console -Key Diagram Magnetic Air Valve Control- Schematic Arrangement Lower Works Standard Cats Lower Works - Long and Wide Cats Collector Gear Steering Levers Take Up - Caterpillars Swing Machinery Hoist and Propel Motor Shaft Hoist or Propel Clutch Type AR-C Intermediate Shaft - Main Machinery Centre Pintle and Shovel Hoist Shaft Hoist Bearing Cap Shims Motor Brake - Main Machinery Motor Brake - Swing Machinery Air Piping - Schematic Diagram L.H. Side Piping R.H. Side Piping Steering - Magnet Valve Piping Triple Swivel Truck Frame Piping Swivel Joint Assembly Tools and Instructions ·Compressor Compressor Valve Assembly Compressor 'Oilmatic' Unloader Adjustment Of pressure Switch Magnet Valve Type 'A' Magnet Valve Type 'B' Lower Works Lubrication Upper Works Lubrication

SHOVEL FRONT END. STANDARD MACHINE Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

40/R1 41 /Rl 43 44/R1 46 47 48/R1 49/R1 50/R1 51/R1 53 54/R1 55/R1 56 57 58/R1 61

36' 0" Shovel Sales Drawing Shovel Front End Equipment Boom Limit Switch Dipper and Handle Padlock -Shovel Dipper Door Snubber Dipper Teeth Assembly Dipper Trip Dipper Trip Cylinder Dipper Trip Piping Hoist Rope Reeving Crowd Rope Reeving Crowd Machinery Crowd Slipping Clutch Type AR-E Motor Brake - Crowd Shovel Front End Lubrication Installation and Adjustment of Rope Take Up

SHOVEL FRONT END. LONG RANGE EQUIPMENT Fig.

67

Boom Limit Switch

DRAGLINE FRONT END Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

75 76 77 78 79 80 81 83

Standard Dragline Sales Drawing Boom Suspension and Mast Boom Point Sheaves Fairlead Boom Hoist Machinery Hoist Shaft Padlock Lubrication Dragline Front End

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BI379509 RUSTON-BUCYRUS 150aRB EXCAVATOR (M/ c. No. 27593) INDEX TO DRAWINGS AND DIAGRAMS BASE MACHINE. ARRANGEMENTS Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

1 2 3 4 5 6 7/R1 8 9 10 11/R1 12 13 14 15 16 17 18/R1 19/R1 20 20A/R1 21 22 23 24 25 26 27 28 29 30 31

Plan Arrangement - Shovel Plan Arrangement - Dragline Operator's Control Console -Key Diagram Magnetic Air Valve Control- Schematic Arrangement Lower Works Standard Cats Lower Works - Long and Wide Cats Collector Gear Steering Levers Take Up - Caterpillars Swing Machinery Hoist and Propel Motor Shaft Hoist or Propel Clutch Type AR-C Intermediate Shaft- Main Machinery Centre Pintle and Shovel Hoist Shaft Hoist Bearing Cap Shims Motor Brake -Main Machinery Motor Brake - Swing Machinery Air Piping - Schematic Diagram L.H. Side Piping R.H. Side Piping Steering -Magnet Valve Piping Triple Swivel Truck Frame Piping Swivel Joint Assembly Tools and Instructions Compressor Compressor Valve Assembly Compressor 'Oilmatic' Unloader Adjustment of Pressure Switch Magnet Valve Type 'A' Magnet Valve Type 'B' Lower Works Lubrication Upper Works Lubrication

SHOVEL FRONT END. STANDARD MACHINE Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

40/R1 41/R1 43 44/R1 46 47 48/R1 49/R1 50/R1 51/R1 53 54/R1 55/R1 56 57 58/R1 61

36' 0" Shovel Sales Drawing Shovel Front End Equipment Boom Limit Switch Dipper and Handle Padlock - Shovel Dipper Door Snubber Dipper Teeth Assembly Dipper Trip Dipper Trip Cylinder Dipper Trip Piping Hoist Rope Reeving Crowd Rope Reeving Crowd Machinery Crowd Slipping Clutch Type AR-E Motor Brake - Crowd Shovel Front End Lubrication Installation and Adjustment of Rope Take Up

SHOVEL FRONT END. LONG RANGE EQUIPMENT Fig.

67

Boom Limit Switch

DRAGLINE FRONT END Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

75 76 77 78 79 80 81 83

Standard Dragline Sales Drawing Boom Suspension and Mast Boom Point Sheaves Fairlead Boom Hoist Machinery Hoist Shaft Padlock Lubrication Dragline Front End

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(M/c. No. 26613, 26614, 26615 or 27590) INDEX TO DRAWINGS AND DIAGRAMS BASE MACHINE. ARRANGEMENTS Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

1 2 3 4 5 6 7 /R1 8 9 10 11/R1 12 13 14 15 16 17 18/R1 19/R1 20 20A/R1 21 22 23 24 25 26 27 28 29 30 31

Plan Arrangement - Shovel Plan Arrangement - Dragline Operator's Control Console -Key Diagram Magnetic Air Valve Control - Schematic Arrangement Lower Works Standard Cats Lower Works - Long and Wide Cats Collector Gear Steering Levers Take Up - Caterpillars Swing Machinery Hoist and Propel Motor Shaft Hoist or Propel Clutch Type AR-C Intermediate Shaft - Main Machinery Centre Pintle and Shovel Hoist Shaft Hoist Bearing Cap Shims Motor Brake - Main Machinery Motor Brake -Swing Machinery Air Piping- Schemtaic Diagram L.H. Side Piping R.H. Side Piping Steering -Magnet Valve Piping Triple Swivel Truck Frame Piping Swivel Joint Assembly Tools and Instructions Compressor Compressor Valve Assembly Compressor 'Oilmatic' Unloader Adjustment of Pressure Switch Magnet Valve Type 'A' Magnet Valve Type 'B' Lower Works Lubrication Upper Works Lubrication

SHOVEL FRONT END. STANDARD MACHINE Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

40/R1 41/R1 43 44/R1 46 47 48 49/R1 50/R1 51/R1 53 54/R1 55/R1 56 57 58/R1 61

36' 0" Shovel Sales Drawing Shovel Front End Equipment Boom Limit Switch Dipper and Handle Padlock - Shovel Dipper Door Snubber Dipper Teeth Assembly Dipper Trip Dipper Trip Cylinder Dipper Trip Piping Hoist Rope Reeving Crowd Rope Reeving Crowd Machinery Crowd Slipping Clutch Type AR-E Motor Brake - Crowd Shovel Front End Lubrication Installation and Adjustment of Rope Take Up

SHOVEL FRONT END. LONG RANGE EQUIPMENT Fig.

67

Boom Limit Switch

DRAGLINE FRONT END Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

75 76 77 78 79 80 81 83

Standard Dragline Sales Drawing Boom Suspension and Mast Boom Point Sheaves Fairlead Boom Hoist Machinery Hoist Shaft Padlock Lubrication Dragline Front End

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR (M/c. No. earlier than 26613 but later than Lot 3) INDEX TO DRAWINGS AND DIAGRAMS BASE MACHINE. ARRANGEMENTS Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

1 2 3 4 5 6 7 /Rl 8 9 10 11/Rl 12 13 14 15 16 17 18 19/Rl 20 20A/Rl 21 22 23 24 25 26 27 28 29 30 31

Plan Arrangement - Shovel Plan Arrangement - Dragline Operator's Control Console - Key Diagram Magnettc Air Valve Control- Schematic Arrangement Lower Works Standard Cats Lower Works - Long and Wide Cats Collector Gear Steering Levers Take Up - Caterpillars Swing Machinery Hoist and Propel Motor Shaft Hoist or Propel Clutch Type AR-C Intermediate Shaft - Main Machinery Centre Pintle and Shovel Hoist Shaft Hoist Bearing Cap Shims Motor Brake - Main Machinery Motor Brake- Swing Machinery Air Piping - Schematic Diagram L.H. Side Piping R.H. Side Piping Steering -Magnet Valve Piping Triple Swivel Truck Frame Piping Swivel Joint Assembly Tools and Instruction Compressor Compressor Valve Assembly Compressor 'Oilmatic' Unloader Adjustment of Pressure Switch Magnet Valve Type 'A' Magnet Valve Type 'B' Lower Works Lubrication Upper Works Lubrication

SHOVEL FRONT END. STANDARD MACHINE Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

40 41 42 43 44 46 47 48 49 50 51 52 53 54 55 56 57 58 60

36 1 0" Shovel Sales Drawing Shovel Front End Equipment Section Through Shipper Shaft Boom Limit Switch Dipper and Handle Padlock - Shovel Dipper Door Snubber Dipper Teeth Assembly Dipper Trip Dipper Trip Cylinder Dipper Trip Piping Bridge Strand Snubber Hoist Rope Reeving Crowd Rope Reeving Crowd Machinery Crowd Slipping Clutch Type AR-E Motor Brake - Crowd Shovel Front End Lubrication Back Haul Take Up

SHOVEL FRONT END. LONG RANGE EQUIPMENT Fig. Fig. Fig.

65 66 67

45 1 0" Shovel Sales Drawing Front End Equipment Boom Limit Swtich

DRAGLINE FRONT END Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

75 76 77 78 79 80 81 83

Standard Dragline Sales Drawing Boon Suspension and Mast Boom Point Sheaves Fairlead Boom Hoist Machinery Hoist Shaft Padlock Lubrication Dragline Front End

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1 2 3 4 5 6 7 8

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13 14 15 16 17 18 19 20 20A 21 22 23 24 25 26 27 28 29 30 31

Plan Arrangement - Shovel Plan Arrangement - Dragline Operator's Control Console -Key Diagram Magnetic 4\.ir Valve Control- Schematic Arrangement Lower Works Standard Cats Lower Works - Long and Wide Cats Collector Gear Steering Levers Take Up - Caterpillars Swing Machinery Hoist and Propel Motor Shaft Hoist or Propel Clutch Type AR-C Intermediate Shaft -Main Machinery Centre Pintle and Shovel Hoist Shaft Hoist Bearing Cap Shims Motor Brake - Main Machinery Motor Brake - Swing Machinery Air Piping - Schematic Diagram L.H. Side Piping R.H. Side Piping Steering- Magnet Valve Piping Triple Swivel Truck Frame Piping Swivel Joint Assembly Tools and Instructions Compressor Compressor Valve Assembly Compressor 'Oilmatic' Unloader .Adjustment of Pressure Switch Magnet Valve Type 'A' Magnet Valve Type 'B' Lower Works Lubrication Upper Works Lubrication

SHOVEL FRONT END. STANDARD MACIDNE Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

40 41 42 43 44 46 47 48 49 50 51 52 53 54 55 56 57 58 60

36'0" Shovel Sales Drawing Shovel Front End Equipment Section Through Shipper Shaft Boom Limit Switch Dipper and Handle Padlock - Shovel Dipper Door Snubber Dipper Teeth Assembly Dipper Trip Dipper Trip Cylinder Dipper Trip Piping Bridge Strand Snubber Hoist Rope Reeving Crowd Rope Reeving Crowd Machinery Crowd Slipping Clutch Type AR-E Motor Brake - Crowd Shovel Front End Lubrication Back Haul Take Up

SHOVEL FRONT END. LONG RANGE EQUIPMENT Fig. Fig. Fig.

65 66 67

45 1 0" Shovel Sales Drawing Front End Equipment Boom Limit Switch

DRAGLINE FRONT END Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.

75 76 77 78 79 80 81 83

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OPERATING SUGGESTIONS A. INSPECT MACHINE BEFORE STARTING SHIFT Before beginning to operat~ the machine at the start of a shift, make a general inspection of the machine to make sure it is ready for operation:

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

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

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on~e-a-shift (B..;hour) points as covered in the Lubrication Section of this Instruction Book.

3. Lubricate all twice-a-shift (4-hour) and

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

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

6. Check main line air pressure which must be at least 110 lb./sq.in., and see that crowd clutch pressure falls within range on the instruction plate mounted near crowd clutch air gauge.

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

B. POINTS TO WATCH DURING SHIFT During the shift, watch for any signs of improper operation or adjustment. The following items are of particular importance: I. Check generator, motors and gearfor any unusual noise, loss of power or failure to respond.

2. Check the hoist, propel and crowd air clutches immediately if they should start to slip excessively during normal operation.

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

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

5.

When operating auxiliary functions such as the steering clutches etc., note any tendensy of the controls to "hang up" or jam which would indicate improper operation. Correct the adjustment at the earliest possible opportunity.

6. Watch the air gauge in the operators cab and investigate immediately should there be a sudden drop in air pressure Section 1

Page 1

RUSTON-BUCYRUS 150-RB EXCAVATOR

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C. CHECK MACHINE AT END OF SHIFT At the end of the shift go over the machine again for evidence of excessive wear or damage which may have occurred during the shift.

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1. Examine all ropes carefully for broken strands or other evidence of weakness. Arrange to replace weakened ropes before starting another shift.

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

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

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

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

6.

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

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D. SHOVEL OPERATING HINTS Actual digging operations with a shovel require combining the hoist, crowd and swing motion into a fast, smooth operating cycle which cannot be described in any step by step procedure, as actual movement of the levers and pedals depends on actual digging conditions. There are many little operating tricks which will come from experience.

Some of these are as follows:

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1. Keep the shovel as near the face of the bank as saf~ty will permit and always move up before it is necessary to ~reachout" with the dipper to get material.

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

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

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

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5. Hoist the ~ipper .onlY. just high enough to provide clearance for the door· when the d1pper 1s tnpped. ·

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6. Keep dipper teeth sharp.

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7. Move up while waiting for trucks whenever possible.

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

Section 1

c Page 2

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BI379509 RUSTON-BUCYRUS

150-RB

EXCAVATOR

OPERATING INSTRUCTIONS OPERATOR'S CONTROLS. To enable the operator to be fully familiar with ti1e equipment and controls on the machine, Figs. 1 and 2 show the deck layout for shovel and dragline. The operators control levers, pedals and switches on control console are illustrated by Fig. 3.

STARTING UP PROCEDURE The auxiliary transformer circuit breaker and the control cubicle isolator should be in the 'ON' position. The controller handles should be in neutral and all brake switches should be set to 'ON'.

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

Before starting to operate the machine, check that the mam aH line pressure is at least 110 lbs./sq.in.

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

(See Schematic arrangement - Fig. 4).

The hoist, swing and crowd brakes on the shovel (or drag, swing and hoist brake on the dragline), should be released by setting the appropriate switches on the console to the 'OFF' position. The propel brake switch should be placed in the 'ON' position corresponding to the automatic setting. · HOIST MOTION (SHOVEL AND DRAGLINE) To hoist - push the controller handle forward.

To lower - pull the controller handle back.

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

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

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

Section 2

Page 1 a

RUSTON-BUCYRUS

BI379509

150-RB EXCAVATOR

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SWING MOTION (SHOVEL AND DRAGLINE)

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To swing left • depress the left pedal.

To swing right - depress the right pedal.

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

CROWD MOTION

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depressed. The

SHOVE·L

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To cr.owd - push the controller handle forward.

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To retract -pull the controller handle back.

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

DRAG MOTION

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DRAGLINE

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To drag - pull the controller handle back.

To pay out - push the controller handle forward.

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

The bucket is maintained in the desired carrying pos1t1on during hoisting by the drag rope pull, which is dependent on the distance the drag controller handle is pulled back.

DIPPER TRIP (SHOVEL)

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The dipper trip is operated by the push button switch on the shovel hoist controller.

Depress the switch to dump dipper. The dipper door will .latch as the dipper is lowered.

PROPELLING

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

(

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

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Section 2

Page 2a

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BI379509 RUSTON-BUCYRUS

150-RB EXCAVATOR

Machines are fitted with either standard side frames and crawlers (see Fig. 5) or long side frames and crawlers (see Fig. 6).

The following instructions are based on travelling with the driving tumblers to the rear of the machine: Machines with standard side frames and crawlers (see Fig. 5).

To move forward - pull controller handle back.

To move backward - push controller handle forward.

On machines with long side frames and crawlers (see Fig. 6): To move forward - push controller handle forward.

To move backward - pull controller handle back.

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

To move straight ahead or astern set the track steer switch in the 'straight' position.

To turn to left or right select the appropriate position of track steer switch.

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

Complete shut down is effected by depressing the emergency stop button. If it is desired to close down the machine for short periods without stopping the main generating set, the auxiliaries stop button on the operator's console should be depressed.

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

COLLECTOR GEAR Inspect collector shoes and see that the vertical play 1s sufficient. A very little Vaseline smeared on the collector gear bearing surfaces assists in preventing rusting.

Keep insulators clear of any accumulation of dirt.

Section 2

Page 3a

BI379509

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BI379509 .RUSTON-BUCYRUS 150-RB EXCAVATOR DESCRIPTION OF MACHINERY TRUCK FRAME AND PROPELLING MACHINERY CAT MOUNTING See drawing arrangement of Lower Works Figs. 5 or 6.

The truck frame is of all-welded, steel construction. The truck frame is supported by cast-steel side frames having a heavy box section. These side frames are secured to the truck frame by hook connections at the bottom _and fit bolts ~t t~e top .. In the c;.a~e L & W mounting only (Fig. 6), additional secunty of connection 1s obtamed by held welds to Drg. 273597.

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The cat belts, made up of closely fitting treads connected by specially heat-treated steel pins, run around the driving and idler tumblers of the side frames. The idler tumblers run on short extra large diameter shafts rigidly secured to the side frames. The driving tumblers, of cast alloy steel, are mounted on the keyed section of forged-steel shafts turning in bronze-bushed bearings in the side frames. These shafts also carry, on splined sections, the driving gears which mesh with the pinions on the transverse '3haft. Both the gear and pinion are enclosed in an oil tight case.

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

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

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

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

Section 3

Page 1

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

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This switch is normally left in the "OFF" position, power being furnished for the magnet valve when the "Dig/Propel" switch is placed in the propel position. Thus the brake is automatically placed in the released position when propelling but it may be set at any time by placing the propel brake switch to the "ON" position.

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In case of power failure when propelling, the brake sets immediately.

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UPPER WORKS The revolving frame consists of a main frame casting with welded-steel, rear ballast section on which is mounted the main generator set. The main frame has lugs cast in it for the boom feet also A-frame front and rear leg connections. On the under side of the main frame are machined grooves into which the rails of the roller circle are fitted and held by clamps. The ballast section is held securely to the main frame by shear plugs at both top and bottom and by a wedge being driven between shear plates welded to the front of the ballastcontainer andthe rearweb ofthe casting. This wedge is finally welded in position during erection in the field. The operator's cab is built as an extension of the revolving frame forward and to the right to provide ample room and a clear view for the operator.

SWING MACHINERY

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(SEE FIG. 10)

The two vertical swing motors and gear cases are mounted as independant units at the left and right front of the revolving frame. The three spur-gear reductions from the motors to the vertical swing shafts are totally enclosed and lubricated by a splash system.

The swing motors have brakes on their extended armature shafts, these brakes being spring set and air-released. They are applied automatically incase of power failure or may be applied by the operator by opening a switch controlled solenoid valve. These brakes are to be used only to· hold the machine against swinging, and not service brakes to retard the swing when operating.

CENTRE PINTLE WITH SPHERICAL THRUST WASHER (SEE FIG.14.)

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

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( MAIN MACHINERY

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

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

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BI379509 R U ST 0 N · B U C Y R U S 150· ·R B E XC A V AT 0 R

...

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the hoist gear. The hoist gear meshes with the hoist pinion, on the right end of the intermediate shaft. The intermediate shaft is a steel forging and runs in anti-friction bearings.

The hoist intermediate gear meshes with the hoist motor pinion and shaft which, in turn is coupled to the motor by the Airflex clutch (Figs. 11 & 12 ). In addition to the pinion and clutch, the hoist brake is also mounted on the shaft. The entire assembly runs free on anti-friction bearings.

On the right end of the hoist motor the propel Airflex clutch (Figs 11 & 12) is mounted. The clutch housing and propel sprocket shaft is mounted in anti-friction bearings.

The propel power flow is from the motor through the air clutch to a sprocket on which a roller chain connects it to the first intermediate shaft of propelling machinery. A spur pinion on the opposite end drives the gear on the second intermediate propel shaft. This shaft drives the vertical propel shaft which drives the longitudinal propel shaft and the centre drive shaft at the rear of the truck frame.

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Section 3

Page 3

/~

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RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

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FRONT END EQUIPMENT

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SHOVEL BOOM

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Refer to Drawing of Shovel Front End Equipment Fig. 41/Rl. The shovel boom is comprised of two main parts. The lower section consists of a one-piece box section supporting the shipper shaft and provided with lugs at the upper end, to which the upper section of the boom is pin-connected. Two supporting struts extend from the shipper shaft to the head of the A-frame, to support the lower section, whilst four bridge strand cables, also attached to the head of the A-frame, support the upper section at the boom point.

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CROWD MACHINERY

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Refer to Drawing of Crowd Machinery Fig. 55/Rl, and Reeving Drawings Figs. 53 & 54/Rl.

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The crowd motor and machinery are mounted on the front of the revolving frame.

The dipper handle is forced outward and pulled inward by the crowd and retract ropes respectively.

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

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The crowd motor drives the crowd rope drum through an Airflex slipping clutch (Fig. 55/Rl and 56) and three gear reductions.

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

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

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

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DIPPER HANDLE (FIG. 44/Rl) The dipper handle consists of a single, tubular member supported in the saddle block. The tubular dipper handle minimizes weight, eliminates torsion since it is free to rotate initially within a small range and subsequently retarded by means of a patented friction stabilising device. This feature, together with the rope crowd eases off the shock compression loads in the handle.

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

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Section 3

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Page 4a

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR

( the hoist gear. The hoist gear meshes with the hoist pinion, on the right end of the intermediate shaft. The intermediate shaft is a steel forging and runs in anti-friction bearings.

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The hoist intermediate gear meshes with the hoist motor pinion and shaft which, in turn is coupled to the motor by the Airflex clutch (Figs. 11 & 12 ). In addition to the pinion and clutch, the hoist brake is also mounted on the shaft. The entire assembly runs free on anti-friction bearings.

On the right end of the hoist motor the propel Airflex clutch (Figs 11 & 12) is mounted. The clutch housing and propel sprocket shaft is mounted in anti-friction bearings.

The propel power flow is from the motor through the air clutch to a sprocket on which a roller chain connects it to the first intermediate shaft of propelling machinery. A spur pinion on the opposite end drives the gear on the second intermediate propel shaft. This shaft drives the vertical propel shaft which drives the longitudinal propel shaft and the centre drive shaft at the rear of the truck frame.

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Section 3

Page 3

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

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( FRONT END EQUIPMENT

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SHOVEL BOOM

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See Drawing of Shovel Front End Fig. 41 Standard - Fig. 66 Long Range The shovel boom consits of two parts. The lower section consists of a one-piece box section supporting the shipper shaft and it, in turn, supported by two struts which are pinned to the A-frame. The upper section of the boom is pinned to the shipper shaft bearings at the lower end and supported by four bridge strand cables at the point sheaves.

CROWD MACHINERY See Drawing of Crowd Machinery Fig. 55, Shipper Shaft Fig. 42, and Reeving Drgs Figs. 53 & 54.

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The crowd motor and machinery are mounted on the front end of the revolving frame.

The dipper handle is forced outward and pulled inward by the crowd and retract ropes respectively.

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

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The crowd motor drives the crowd rope drum through an Airflex slipping clutch (Fig. 55 & 56) and three gear reductions.

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

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The shipper shaft is mounted in the shaft bearings at the upper end of the lower boom section. Mounted on the centre of the shaft is a large concave-faced roller on which the tubular handle moves. The roller also .has machined grooves for the twin crowd and retract ropes.

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The saddle block is a long steel casting with bearings straddling the roller. The saddle block is provided with rubber cushioned ·slide plates at both ends which aid in absorbing the swing shock loads taken by the handle.

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DIPPER HANDLE (FIG. 44 .)

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The dipper handle consists of a single, tubular member supported in the saddle block. The tubular type dipper handle minimizes weight, eliminates torsion since it is free to rotate, and with the rope crowd eases off the shock compression loads in the handle.

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The dipper handle is held in the saddle block by rubber cushioned slide shoes on the sides, two wearing shoes on the top and the roller drum on the bottom. The slide shoes have a rubber cushion vulcanized to the back side to absorb side loads resulting from swinging.

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( Section 3

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Page 4

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR DIPPER TRIP FIG. 49/R3 The dipper trip mechanism is electrically operated through a. variable torque motor, suitable reduction gearing and associated rope drum, all mounted as a .unit on the. righthand leg of the boom lower section.

The dipper trlp rope, anchored to the drum, is reeved over a deflection sheave mounted on a support on the lower end of the dght-hand leg of the upper section of the boom and is connected d{rectly to the dipper door latch lever. · The electric motor normally has a low torque characteristic and keeps the rope just taut. When the dipper trip latch button is pressed, -the torque is increased and the rope is pulled back on the drum, and so operates the trip. On releasing the button, the motor resumes its normal low torque condition and the rope pays out as the door closes.

BOOM UMIT SWITCH (STANDARD MACHINE).FIG. 43.

If the uppe~ Jsection of the boom is raised by operating the dipper in some unusual position, the boom limit switch motmted on the lower side of the upper section is operated by the ,spring loaded plunger cutting off power and automatically applying the brakes to all mot!ions .. The boom will lower under gravity when all controllers are returned to the neutral position, the falling dipper being controlled by the hoist brake or by "plugging".

If the upper section is raised by moving the point section into the bank it may be necessary to bridge out the terminals to which the limit switch is connected at the cubicle before· the machine can be propelled away from the bank. This bridging link should be removed when the boom is restored to its normal position.

BOOM LIMIT SWITCH (LONG RANGE MACHINE) FIG. 67.

The boom limit switch restricts the height to which the hoist ropes lift _the dipper and this prev~nts the dipper lifting the boom upper section to a dangerous position, it also prevents the flange of the saddle block from fouling and damaging the crowd ropes.

The .switch mounted on the top side oft he. boom upper section is operated automatically by a lever mounted on the Saddle Block cutting off power and automatically applying the brakes to all motions.

The dipper will lower under gravity when all controllers are returned to the neutral position, _the falling dipper being controlled by the hoist brake or by "plugging•.

If the-dipper becomes wedged in the raised position preventing it from being lowered it may be necessary to pridge out the terminals to which the limit switch is connected at the cubicle before the machine may be propelled away from the bank. This bridging .link must be reiDoved when normal digging is resumed.

Section 3 Page 5b

R U ST 0 N- B U CYRUS 150- R B E X'C AVA T 0 R

BI379509

c

DUAL PURPOSE CROWD DRUM GUARDS AND DRUM CARRYING BRACKETS (SEE FIG. 41 OR FIG. 41/R1)

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For use when dismantling for transport or when converting to Dragline etc., the Crowd Drum Guards (Ref. 24) which are normally bolted to the inside face of the Bumpers (Ref. 13) may instead be used as brackets which enable the boom lower section to be removed with the crowd drum and crowd ropes still reeved, the brackets being bolted to angles on the inside of the boom lower section, and to the ends of the crowd drum. With the brackets in place it is possible to remove the crowd drum shaft and leave the crowd drum suspended from the boom lower section.

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR DIPPER TRIP FIG. 49/R2 The dipper trip mechanism is located on the top of the saddle block, where it is protected against falling bank material. The mechanism consists of a cylinder and airactuated lever on the outer end of which is a sheave.

The dipper trip rope passes from the rear end of the dipper handle, between two guide sheaves, then round the deflecting sheave, over a stationary sheave, under the travelling sheave, over the second stationary sheave and forward on the dipper handle to another stationary sheave located to the rear of the dipper. The rope passes over this sheave and down and is dead-ended on_ a sheave segment on a rotating shaft to which is attached the chain operating the latch bar. The vertical movement of the travelling sheave takes up the rope between the two stationary sheaves and actuates the latch bar and trips the dipper door.

BOOM LIMIT SWITCH (STANDARD MACHINE)FIG. 43 . . If the upper Jsection of the boom is raised by operating the dipper in some unusual

position, the boom limit switch mounted on the lower :Side of the upper section is operated by the spring loaded plunger cutting off power and automatically applying the brakes to all motions. The boom will lower under gravity when all controllers are returned to the neutral position, the falling dipper being controlled by the hoist brake or by "plugging".

If the upper section is raised by moving the point section into the bank it may be necessary to bridge out the terminals to which the limit switch is connected at the cubicle before the machine can be propelled away from the bank. This bridging link should be removed when the boom is restored to its normal position.

BOOM LIMIT SWITCH (LONG RANGE MACHINE) FIG.67.

The boom limit switch restricts the height to which the hoist ropes lift the dipper and this prevents the dipper lifting the boom upper section to a dangerous position, it also prevents the flange of the saddle block from fouling and damaging the crowd ropes.

The switch mounted on the top side of the boom upper section is operated automatically by a lever mounted on the Saddle Block cutting off power and automatically applying the brakes to all motions.

The dipper will lower under gravity when all controllers are returned to the neutral position, the falling dipper being controlled by the hoist brake or by It plugging•.

If the dipper becomes wedged in the raised position preventing it from being lowered it may be necessary to bridge out the terminals to which the limit switch is connected at the cubicle before the machine may be propelled away from the bank. This bridging link must be removed when normal digging is resumed.

Section 3

Page 5a

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

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DUAL PURPOSE CROWD DRUM GUARDS AND DRUM CARRYING BRACKETS (SEE FIG. 41 OR FIG. 41/Rl) For use when dismantling for transport or when converting to Dragline etc., the Crowd Drum Guards (Ref. 24) which are normally bolted to the inside face of the Bumpers (Ref. 13) may instead be used as brackets which enable the boom lower section to be removed with the crowd drum and crowd ropes still reeved, the brackets being bolted to angles on the inside of the boom lower section, and to the ends of the crowd drum. With the brackets in place it is possible to remove the crowd drum shaft and leave the crowd drum suspended from the boom lower section.

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR DIPPER TRIP FIG. 49 .

The dipper trip mechanism is located on the top of the saddle block, where it is protected against falling bank material. The mechanism consists of a cylinder and airactuated lever on the outer end of which is a sheave.

The dipper trip rope passes from the rear end of the dipper handle over a stationary sheave, under the travelling sheave, over the second stationary sheave and forward on the dipper handle to another stationary sheave located to the rear of the dipper. The rope passes over this sheave and down and is dead-ended on a sheave segment on a rotating shaft to which is attached the chain operating the latch bar. The vertical movement of the travelling sheave takes up the rope between the two stationary sheaves and actuates the latch bar and trips the dipper door.

BOOM LIMIT SWITCH (STANDARD MACHINE)FIG. 43.

If the upper section of the boom is raised by operating the dipper in some. unusual position, the boom limit switch mounted on the lower side of the upper section is operated by the spring loaded plunger cutting off power and automatically applying the brakes to all motions. The boom will lower under gravity when all controllers are returned to the neutral position, the falling dipper being controlled by the hoist brake or by "plugging".

If the upper section is raised by moving the point section into the bank it may be necessary to bridge out the terminals to which the limit switch is connected at the cubicle before the machine can be propelled away from the bank. This bridging link should be removed when the boom is restored to its normal position.

BOOM LIMIT SWITCH (LONG RANGE MACHINE) FIG.67.

The boom limit switch restricts the height to which the hoist ropes lift the dipper and this prevents the dipper lifting the boom upper section to a dangerous position, it also prevents the flange of the saddle block from fouling and damaging the crowd ropes.

The switch mounted on the top side of the boom upper section is operated automatically by a lever mounted on the Saddle Block cutting off power and automatically applying the brakes to all motions.

The dipper will lower under gravity when all controllers are returned to the neutral position, the falling dipper being controlled by the hoist brake or by "plugging•.'

If the dipper becomes wedged in the raised position preventing it from being lowered it may be necessary to bridge out the terminals to which the limit switch is connected at the cubicle before the machine may be propelled away from the bank. This bridging link must be removed when normal digging is resumed.

Section 3

Page 5

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

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DUAL PURPOSE CROWD DRUM GUARDS AND DRUM CARRYING BRACKETS (SEE FIG. 41 OR FIG. 41/R1) For use when dismantling for transport or when converting to Dragline etc., the Crowd Drum Guards (Ref. 24) which are normally bolted to the inside face of the Bumpers (Ref. 13) may instead be used as brackets which enable the boom lower section to be removed with the crowd drum and crowd ropes still reeved, the brackets being bolted to angles on the inside of the boom lower section, and to the ends of the crowd drum. With the brackets in place it is possible to remove the .crowd drum shaft and leave the crowd drum suspended from the boom lower section.

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR COMPRESSED AIR PLANT Arrangement drawings of the piping and fittings Figs 19. to 22. inclusive show all the pipe lines, fittings, and equipment required for shovel and dragline. A schematic diagram Fig. 18 shows the function of all the various units.

AIR COMPRESSOR FIGS 24 & 25 .

The compressed air for operating-the clutches and brakes is taken from an air receiver supplied by an electrically driven single stage compressor.

The compressor can be rur;t in either direction. If the desired rotation is such that the big end bearing throws the oil up towards the crankcase breather (4040C) the oil filter body (3466C14) carrying the breather should be changed with the door on the other side.

To fill crankcase, remove the crankcase breather (4040C) and pour in the correct grade of lubricating oil (approximately 8 pints or 4.5. litres) until the maximum level indicated on the dipstick (3464C67) is reached). After the first 5.0 hours running, drain all the oil and refill as indicated above.

An automatic light load starting device is fitted which allows the compressor to start up in an off load condition. (See separate instruction).

LUBRICATING SYSTEM The oil for lubricating the bearings of the compressor is supplied by a plunger type oil pump at normal pressure of between 5 and 15 lbs. per square inch. If the oil pressure · is not between the desired limits adjustment should be made as follows: Unscrew the oil regulator locknut (3 768A2) and turn the oil regulator screw (3464C25) in a clockwise direction to increase pressure and in the opposite direction to decrea8e ·pressure. When the desired pressure has been obtained retighten the locknut. If after final adjustment the pressure is below the minimum specified, investigation should be mad as to the cause. The normal causes are: 1. Dirty oil blocking filter (3464C20) 2. Dirt on the valve seating of the oil regulator in the cylinder 3. Ins.ufficient oil in the crankcase.

Note: The oil level must be kept between the minimum and maximum marks on the dipstick.

4. Worn oil pump plunger (3464C19A) or damaged ball valve seat.

It is advisable to check the oil filter and oil. pipe for cleanliness and freedom from blockage at regular intervals.

THE OIL IN THE CRANKCASE SHOULD BE DRAINED AFTER EVERY 600 HOURS RUNNING, BY REMOVING THE CRANKCASE DRAIN PLUG (3764A2). REPLACE THE PLUG AND REFILL THE CRANKCASE WITH NEW OIL TO THE MAXIMUM LEVELMARK ON THE DIPSTICK AS INDICATED ABOVE. .

VALVES The efficient working of the compressor depends very largely on the condition of the valves, and it is essential that these are examined at regular intervals of not more Section 4

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RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

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than three months duration. To remove the delivery valve unscrew the delivery valve cap screw (3615Cll) lift off the delivery valve cap (3615C8) and joints (3615C9, 3615Cl0) and remove the delivery valve plug (3615Cl), then lift out the delivery valve clamping tube (3615C4) and the valve assembly. The suction valve assembly may be removed similarly after disconnecting the unloader pipe and unscrewing the suction valve plug (3812C32). Dismantle the valves, carefully clean off the carbon and examine all parts, replacing any worn or broken components. When replacing the valve parts make sure that the unloader fork (3615C6) is located correctly in the holes in the section valve seat and that the unloader piston (3727ClO)is a good sliding fit in the suction valve plug.Always renew the delivery valve cap joints. . .

At regular intervals test for air leaks through the delivery valve. With pressure in the air receiver depress the suction valve plate by operating the hand. unloader cam (3615C23) or turning the wing nut on the automatic air governor through 90°. Air leaking past the delivery valves will be heard blowing back through the suction valve.

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AIR SUCTION FILTER The air filter should be cleaned at regular intervals. Wash the filter element in paraffin and dip in clean lubricating oil. This must be done frequently if the atmosphere is dusty.

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BEARINGS When renewing the main bearings it is essential to see that they are carefully bedded down to ensure that maximum contact with the crankshaft. Make quite certain that the· oil hole drilled in the crankshaft is clear of obstruction.

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ANNUAL OVERHAUL Remove the inspection door and check all interior fittings for security. Lift off the cylinder head and cylinder block and clean the cylinder bore and air passages carefully and remove all carbon from piston and rings. Replace the tings in the grooves from which they were taken. Make certain when reassembling the compressor that all the joints are in good condition. .

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"OILMATIC" LIGHT LOAD STARTING GEAR

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GENERAL The purpose of this equipment is to ensure that when the compressor has been stopped it will be unloaded automatically, and will remain unloaded after restarting until the unit has attained its correct running speed. Attention will also be dr:awn to any failure in the lubricating system, as the "Oilmatic" equipment will not allow the compressor to work under full load if the oil pressure is inadequate.

NOTE: Alternative parts are called for when the equipment is fitted to certain types of compressor. These are shown on the drawing and parts list.

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR OPERATION Oil, under pressure from the compressor oil pump, is admitted to the unloader body (154624) through the port at the base. When the oil pressure in the body is adequate the plunger will be raised against the plunger spring (154623A) lifting the operating rod and the operating arm. This releases the compressor unloader fork in the cylinder head and the suction valve plate will resume its normal position on the suction valve seat. To allow the compressor time to attain its correct running speed the flow of oil to the unloader body is restricted by an unloader speed screw (154614). This restrictor is set to give a delay of 5 seconds for loading and unloading the unit when the correct grade of compressor lubricating oil is used.

MAINTENANCE AND ADJUSTMENT (Adjustment to be carried out when the compressor is warm).

Compliance with the following instructions will ensure that the· equipment functions correctly.

1. The 5 seconds time lag must always be maintained. If it is necessary to adjust the unloader speed screw (154614) make certain that the locknut is retightened. As a guide to obtaining the correct time lag tighten the screw fully then turn back through two complete turns.

2. Clean the speed valve, the unloader body and the unloader spindle (154611) at regular intervals.

3. Keep the external parts of the equipment clean and oiled as necessary.

4. Make certain that the compressor unloader fork lifts sufficiently to allow about 3/64" (1.2mm) clearance between the foot of the unloader and the suction valve plate. This can be done by increasing the oil pressure if it is below the minimum specified for the compressor lubricating system. (See compressor instructions card). If the oil pressure is correct loosen the locknut and alter the length of the operating link.

Where this means of adjustment is not provided or is unsatisfactory, disconnect the operating arm at theend remote from the cylinder head loosen the adaptor locknut (3768A3) on the cylinder head; and screw the adaptor clockwise or and-clockwise, with the compressor running and the operating arm held down, until the compressor just unloads (tl;tat is until air is heard being sucked in and exhausted from the suction side of the compressor). Turn the adaptor anticlockwise half a turn and reassemble the operating arm. Retighten the locknut. Failure to maintain this clearance means that the suction valve plate may be held off its seat slightly when the compressor is on load, which would impair the efficiency of the machine seriously.

5. If the compressor has been idle for a long period it may be necessaryto soak the plunger cup leather (154620) in a clean lubricating oil to ensure a good fit in the body.

PRESSURE SWITCH SEE FIG.27.

ADJUSTMENT The pressure at which the switch will open or close its contacts is set by adjusting the large slotted-head screw which is exposed when the switch cover is removed. Turn clockwise to decrease the setting; turn anti-clockwise to increase the setting.

ALWAYS EASE OFF MAIN SPRING BEFORE REMOVING AIR INLET FLANGE. When renewing a diaphragm, first release all pressure from the main spring by turning the adjusting screw clockwise; t"!oke out the screws holding the diaphragm cover; the diaphragm cover and the diaphragm can then be removed. Take note of the relative positions Section 4 Page 3

RUSTON-BUCYRUS 150-RB EXCAVATORS

BI379509

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( of the spacer ring and the diaphragm, and take care to replace them, together with any shims which may be included, in the correct positions. Note also that one of the screws holding the diaphragm cover is shorter than the others, and should· be replaced in the upper hole.

To change a fixed contact, remove the connection screw, and the contact can then be lifted out.

To remove a moving contact, release the spring tips from the hole in the contact, and pull the contact forward. When replacing the contact, check that the spring is properly in place, and is anchored in the hole in the moulding.

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COMPRESSED AIR PLANT - GENERAL The compressor is set to operate between110 and 140 pounds pressure. The pressure switch is set at the factory to cut in and out at the required pressure. If resetting is necessary follow instructions given (See Fig.27 .. ), A safety valve, check valve, and globe valve are fitted in the pipeline from the compressor to the receiver, the safety valve set at 175 pounds is to protect the compressor should the globe valve accidently be left in the closed position, the check valve protecting the compressor fro.in back pressure from the tank and the globe valve to isolate .the compressor from the air.·r-eceiver for servicing.

The tank should be cleared of water at least once a day by opening the globe valve on the bottom of the air receiver until all the water in the tank has been blown out.The air receiver is protected by a fusible plug and pop safety valve set at 155 pounds. The air filter and separators, fitted in the main feed line and dipper trip line should also h~ drained in the same manner as the air receiver through the cock provided. Occasional cleaning of the filter and removal of solid particles are easily affected by removing the bottom cover and with-drawing the filter element.

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The line pressure regulating valve is set at 110 pounds pressure; this valve setting should not be changed as the Airflex clutches are not designed to operate at a greater pressure.

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Lubricators are fitted in the main air line and the dipper trip line and these should be serviced with suitable oil.

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The air system is provided with gauges located at the compressor, two in the operator's cab and when equipped as a shovel one in the crowd clutch line. . The Gauge at the compressor shows pressure in the air receiver, those in the operator's cab showing pressure in the main feed line and the reduced pressure in the steering clutches and the one in .the crowd line shows the reduced pressure required for the crowd clutch.

Instruction plates indicate correct working pressures in all lines and adjustable reducing valves should be set accordingly.

Before the machine is placed in operation a check should be made to see that there is adequate pressure in the tank to operate brakes and clutches.

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A sudden drop of pressure should be promptly investigated as to cause. All lines, tank and compressor should be checked for leaks and repaired as soon as possible.

All brakes and clutches are controlled through use of magnet valves. Air is admitted to a brake or clutch by either energizing or de-energizing the proper magnet valve.

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Section 4

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATORS All brakes are spring-set and air-released. This arrangement ensures the automatic setting of all brakes in case of power failure.

Some minor adjustments of the steering clutch springs may have to be made to ensure proper action of the clutches when air pressure is released when machine is first placed in operation. (See Steering Machinery Drawing Fig. 8 ).

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Section 4

Page 5

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

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MAGNET VALVE TYPE "A" (FIG. 28 )

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CONSTRUCTION

( The magnet valve consists of two parts: a magnet portion and a pneumatic portion, the latter containing two valves which are opened or closed by the movement of an armature. A terminal box for electrical connections is incorporated on the pneumatic portion.

OPERATION --

Air enters the valve at "A" and flows into the cavity above the main valve 3, which remains seated all the while the magnet is de-energised. When the magnet is energised the armature 19 is lifted and its stem 12, seats the sealing valve 7 and unseats the main valve 3. Direct communicatign is thus established between the air inlet connection "A" and the outlet connection "B".

Upon de-energisation of the magnet the armature 19 and its stem 12 drop down and allows the main valve 3 to re-seat, whilst. the sealing valve 7 un-seats. Air from the Outlet "B" is vented to atmosphere via the Sealing Valve 7 and the holes in exhaust valve stop 9a.

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INSTALLATION The magnet valve must be installed vertically as shown in the diagram, the dropaway function of the armature being dependant upon gravity.

When the magnet valve is viewed from the terminal box side the air inlet connection must be brought to the union nipple "A" on the right side, whilst the outlet connection is taken from the main union nipple "B" on the left side.

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MAINTENANCE Magnet valves normally require no attention except at general overhaul periods when they should be completely dismantled and cleaned. Leakage of air is generally due to dirt on the valves or valve seats. If leakage persits after cleaning and adjusting it ',may be necessary to lap in the valves, using metal polish, to give a true bearing between each valve and its seat.

Care should be taken not to make the valve seats unduly wide and normally the seat should not exceed 1/16" on width.

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Examine spring 2 and replace it if it appears to be in any way defective.

Renew gaskets 27 and 40 if necessary.

Fit a new magnet coil if the following test shows it to be faulty.

Throughly clean all other parts, reassemble, adjust and test as follows.

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR ADJUSTMENTS

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Valve Adjustments With the cap 1 and spring 2 removed, valve 3 seated, and valve 7 unseated, measure the height of the valve stem protruding. above its valve seat 4, with a depth gauge.

Then force valve 7 on to its seat and again measure the height of the valve above its seat. The valve lift should be not less than 1/16". If the lift is less than this fit a new valve 3, but should the lift be greater than this it will be necessary to file the bottgm of the valve until correct lift is obtained.

The clearance between valve 3 and valve 7 must be approximately .010" when valve 7 bears against exhaust valve stop. If the clearance is too small metal must be removed from the lower surface of valve 7 where it bears on the .exhaust valve stop.

If the clearance between valve 3 and valve 7 is too large a new valve 7 must be fitted and the above acfjustments repeated to give the correct: clearances

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Armature Adjustments Remove magnet cap 18 and split pin 20. Screw the armature 19 well down on its stem and then push up on the armature stem 12 until valve 7 is seated. Adjust the position of the armature 19 until the residual pins 19a just touch the pole face.

Now unscrew the armature half a turn and insert the split pin 20. If the holes in the armature and stem do not coincide the armature should be turned to the nearest hole so that the split pin can be inserted.

To obtain the correct clearance of 1/64" between armature stem 12 and valve 7, when the latter is seated on stop 9a proceed as follows.

Replace the magnet cap 18 and its lock spring 24. After loosening the locknut 22 unscrew the adjusting stop 21.

Hold the valve 7 on the stop 9a and then screw up the adjusting stop 21 until the armature stem 12 just touches valve 7. Slacken back a quarter of a turn and then tighten the locknut 22. The clearance between the armature stem and valve 7 will now be correct i.e. approximately 1/64 ". Replace the magnet closing cap 23.

TESTING After overhaul and reassembly the magnet valve should be teste9 as follows.

Mount the valve in a vertical position and connect a supply of compressed air at the maximum pressure normally used in service.

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Gravity Test- Armature and Valves Connect the terminals of the magnet valve to an electrical supply at the correct operating voltage. With no air pressure on the valve and with cap 1 removed energise the magnet and see that valve 3 moves upwards off its seat.

Then de-energise the magnet and note that the valve moves downwards on to its seat under its own weight. If valve 3 does not return to its seat when the magnet is de-energised the fault must be rectified before proceeding. Replace cap 1.

Section 4

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RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

( (b)

Leakage Test - Cap 1 and Valve 3.

( Admit maximum air pressure to the inlet connection "A" and test for leakage with soap and water at the outlet "B" and at the joint between cap 1 and body 5.1f leakage occurs at the outlet, the valve 3 must be re-lapped to its seat. If leakage occurs at the cap it must be made air-tight.

Energise the magnet and note that there is a free flow of air from the outlet connection (c)

Leakage Test - Valve 7 De-energise the magnet valve and .connect a small reservior fitted with a pressure gauge to the outlet connection "B ". Energise the magnet and charge the reservior to supply pressure.

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When the reservior is charged, check with soap and water for leakage at the vent at the top of the magnet portion, taking particular care to prevent soap and water from entering the valve, since it may run down the armature stem into the windings.

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Any leakage at this point indicates that sealing valve 7 should be re-lapped to its seat.

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Venting Test - Valve 7 and Exhaust Stop 9a

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In the case of the valve shown there must be a rapid flow of air at the vent when the magnet is de-energised, and the pressure in the reservior must drop to zero.

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NOTE: After any valve is relapped to its seat, the valve lifts and valve clearance must be readjusted, if necessary, as described under the heading "Adjustments".

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MAGNET VALVE TYPE "B"(FIG. 29 ) CONSTRUCTION

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The magnet Valve consists of two parts: a magnet portion and a pneumatic portion, the latter containing two valves which are opened or closed by the movement of an armature. A terminal box for electrical connections is incorporated in the pneumatic pordon.

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OPERATION Air enters the valve at connection "A" and in the de-energised condition of the magnet flows through the ports in the main valve bush 3 past the unseated main valve 4 and thence to the clutch cylinder by way of outlet "B ". In this condition the exhaust valve 5 is seated, preventing any loss of pressure through the ports "C".

When the magnet is energised. the armature 16 is lifted and its stern 13 unseats the exhaust valve 5 and seats the main valve 4, the closing of which cuts off the incoming air from connection "A". The air pressure at connection "B" vents to atmosphere by way of the unseated exhaust valve 5 and the ports "C". The spring 2 ensures the prompt re-opening of the main valve 4 when the magnet is de-energised.

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Section 4

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BI379509

RUSTON-BUCYRUS 150·RB EXCAVATORS INSTALLATION The Magnet Valve must .be installed as shown in the diagram, the dr"op-away function of the armature being dependant upon gravity.

When the magnet valve is v.lewed from the terminal box side, the air inlet connection must be brought to the union nipple "A" on the right side, whilst the outlet connection is taken from the union nipple "B" on the left side.

MAINTENANCE The magnet valve normally requires no attention except at general overhaul periods, when it should be completely dismantled, cleaned and inspected as follows: Leakage of air is generally due to dirt on the valves. or valve seats. If leakage persits after cleaning it inay be necessary to grind in the valves to give a tr.ue bearing on their .seats. Care should be taken to keep the valve seats. as. narr.ow as possible.

H leakage takes place when the magnet valve is de-energised a leaking exhaust valve 5 is indicated, but should leakage occur .when the magnet is energised a leaking .main main valve 4 is .indicated.

Examine the return spring 2 and renew if defective in any way. Renew the cover gasket 36 if necessary.

H a fault occurs in the coil, a new spool and coil should be fitted.

Throughly clean all other parts and re-assemble.

ADJUSTMENTS The. following adjustments should be made after re-assembly and before testing.

MAIN VALVE The lift .of the main valve 4 should be 5/64". If the lift .is excessive a .new valve should be fitted, but if the lift is .insufficient, remove a little of the metal from the lower end of the valve. until the required lift is obtained.

ARMATURE With the magnet .cap 21 removed, lift the armature until the main valve 4is.closed. ·Screw the armature upwards.untilthe residual pins 16a touch.the pole face. Now unscrew half a turn and replace the split pin 17. If the holes for the split pin in the armature and stem do O:ot coincide after half a turn has been made, the armature must be further .unscrewed to line up the nearest hole in the armature with the hole in the stern. Replace the· magnet cap 21 but with. the cap 20 removed, ensuring that .the armature adjusting stop 19 is screwed back from the lower end of the armature. See that the lock spring 22 engages with a slot in the cap 21.

EXHAUST VALVE CLEARANCE Remove cap 1 and spring_ 2. Hold the main valve 4 open so that the exhaust valve 5 is fir.mly. seated. Now screw in the adjusting stop 19 until the armature stem first touches the exhaust valve. Turn back a quarter of a turn which will give the required clearance between the armature stem and the lower end of the exhaust valve. Tighten locknut 18, replace the spring 2, cap 1 and the magnet dosing cap 20.

Section 4

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BI379509

RUSTON-BUCYRUS 150-RB EXCAVATOR

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TESTING After overhaul and adjustment the magnet valve should be tested as follows: Connect an air .supply at operating pressure to connection "A", having an isolating cock in the supply pipe. Connect the terminals of the magnet portion to an electrical supply at the correct operating voltage.

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LEAKAGE TEST FOR MAIN VALVE Energise the magnet .and admit compressed air .at normal operating pressure to the valve. Test with soap and water at the joint between the cap 1 and the body 7; if leakage takes place this joint should be made air tight.

Now test with soap and w·ater at the outlet connection "B". Leakage here will indicate a leaking main valve 4 and the valve should be reground to its seat, cleaned, re-assembled and the leakage test repeated.

Finally close the cock.

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LEAKAGE TEST FOR EXHAUST VALVE Plug the outlet connection "B" and with the magnet de-energised admit compressed air to the valve by means of the cock.

Test with soap and water at the exhaust .port "C ". Leakage will indicate a leaking exhaust valve 5. If the valve leaks re-grind to its seat, clean re-assemble and repeat the test.

When testing, care should be taken to avoid water gaining access to the coil by running down the armature stem.

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BI379509

RUSTON-BUCYRUS

lSO~RB

EXCAVATOR

CONTROL OF BRAKES AND CLUTCHES- DIPPER TRIP

CONTROL OF BRAKES All brakes are controlled by means of switches located at the L.H. side of the operator's console.

Placing the switch to the 'OFF' position energises the magnet valve which in turn allows air to enter the brake cylinder thus releasing the brake. If the magnet valve is de-energised by power failure, by opening the brake switch, or if a broken air line causes loss of pressure,. the brake shoes are set by spring pressure, It should be noted that all brakes are in the nature of 'Parking' brakes or for emergency operation.

The hoist brake is separately controlled by the switch marked 'Hoist - Brake' in the console at the operator's right. If the loaded dipper is held extended or the hoist line is otherwise under load when shifting from hoist to propel it is a good plan to set brake by means of the 'Hoist - Brake' switch before placing the 'Dig/Propel' switch to the propel position. The swing and crowd brake are controlled by the switches marked 'Swing Brake' and 'Crowd Brake'.

CONTROL OF CLUTCHES The hoist and propel clutches are controlled by means of switches located at the console. The hoist and propel clutches are primarily used as a coupling only and are used as slipping clutches only when the load becomes excessive.

The hoist and propel clutches see Figs.ll & 12 are controlled by the switch marked 'Dig/Propel'. To admit air to the hoist clutch the switch is placed in the hoist position.

This de-energises the hoist clutch magnet valve and admits air to the clutch coupling the hoist machinery to the hoist motor. At the same time the propel clutch magnet valve is energised thus shutting off the suiPlY of air to the propel clutch and disengaging it.

To engage the propel clutch place the hoist brake to the 'ON' position and the 'Dig/Propel' switch to the Propel position. This de-engerises the propel magnet valve and admits air to the propel clutch, thus coupling the hoist motor to the propel machinery. At the same time the hoist clutch magnet valve is energised shuttin·g off off the supply of air to the hoist clutch and disengaging it. By moving the propel brake switch to the 'OFF' position, the machine is ready to move.

The crowd clutch see Figs. 55 & 56 is engaged at all times as long as sufficient air pressure is available. The crowd air gauge should be checked daily to see that proper pressure is being obtained.. Adjust pressure at regulator in crowd line in accordance with instructions shown on the instruction plate mounted near gauge. The crowd clutch differs from the hoist and propel clutch in that a certain amount of slippage is permitted under heavy loads thus protecting the machinery from shocks encountered in hard digging.

The Airflex clutches require very little maintenance other than a daily visual inspection to ensure proper working order. Air lines should be checked for leaks, clutch lining inspected for wear, clutch tubes for cracks or weak spots. Lubricants should not be allowed to get on clutch lining as it will cause wear and slipping.

Included in Section 8 is a separate instruction:- 'Checking Air Leaks in the Compressed Air Plant'. Read these instructions carefully and conduct this test periodically so as to determine if any leaks have developed which would tend to overwork the air compressor. Any leaks should be located and repaired immediately.

Section 4

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150-RB EXCAVATOR

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DIPPER TRIP (FIG. 49/R4) The dipper trip is operated by a latch handle mounted on the hoist ~ever, which when depressed, results in an increase of torque in the dipper trip motor. Th'~ increased torque causes the dipper trip drum to rotate and pull the trip rope to release the dipper door latch. '

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1. Depress the latch handle to dump dipper. · 2. The dipper door will latch when the dipper is lowered.

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Page 12b

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BI379509 RUSTON-BUCYRUS

150-RS EXCAVATOR

STEERING CONTROL (POWER LOCKING) FROM OPERATOR'S POSl'(ION. (See Schematic Arrangement of Air Piping Fig. 18 and Steering Machinery Drawing Fig. 5.)

The following instruction applies to machines fitted with additional cylinders for operating steering clutches into lock position.

W.ith full steering control, steering and individual locking of the cat belts is cop.trolled from the operator's position with the revolving frame in any position.

Track steer and lock positions are controlled by a five position semi-rotary switch located at the right hand of the operator's console having positions 'Straight', 'Steer Right', 'Lock Right', 'Steer Left', and 'Lock Left'.

Air under pressure for operation of the clutch cylinders is obtained from the compressor mounted on the left side of the revolving frame.

Pressure to the steering cylinders ~s at line pressure or at a reduced pressure of 35 P .S.I. (according to steering selected at the operator's position) and at line pressure only in the case of the propel brake.

Three pipes, with a three-way swivel connection at the lower end (See Fig.21.) carry air through the centre of rotation to the left-hand and right-hand clutch-shiftcs.r cylinders and the digging-brake operating cylinder in the truck frame.

To turn to the left with driving tumblers to the rear, turn the switch to 'Steer Left'.

This energises the left hand cylinder solenoid admitting air at a reduced pressure of 35 P.S.I. to the cylinders in the base which overcomes the spring sufficiently to move It may be necessary to move the the clutch to the neutral or disengaged position. machinery slightly with the controller in order to disengage the steering clutch.

Moving the left hand steering clutch to the neutral position allows the left cat belt to idle when power is applied and a turn may be made.

To lock the left cat belt in order to obtain a 'sl;tarp' turn to the left with the driving tumblers to the rear, turn the switch to 'Lock Left'.

This energises both the cat lock solenoid and the left hand cylinder so,lenoid admitting air at main line pressure to the cylinders in the base which fully overcomes the spring, moving the clutch to the extreme outside position, locking the left hand cat. belt >to the side frame.

It may be necessary to move the machinery slightly in order that jaw clutch may engage fully with mating jaws on the cat frame.

With left hand cat belt locked to the side frame when power is applied to the right hand cat belt, a 'sharp' turn to the left may be made.

Turns to the right are made by turning switch to the 'Steer Right' position, and 'Sharp' turns to the right by turning the switch to 'Lock_ ~ight', otherwise the sequence of operation is the same as for turns to the lef~.

In all cases the clutch is returned to the engaged position by spring pressure when air pressure is released from the system by setting the track steer switch in the 'Straight' position, which exhausts air from lines. It may be necessary to move machinery slightly with controller in order to re-engage the clutch.

IMPORTANT NOTE: When it is desired to move from either track lock position into either steer position, it is necessary to turn the switch back to 'Straight' position • This is necessary in order to exhaust air at 100 P.S.I. locked in the cylinder by check valve.

Movement of the switch to the 'Straight' position results in the un-wanted air being exhausted through the appropriate steering cylinder solenoid.

Subsequently the switch can be moved to either steer position, when air at the reduced pressure of 35 P .S.I. will be admitted.

Section 4

Page 13

RUSTON-BUCYRUS

150-RB EXCAVATOR

BI379509

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( Since the steering clutches are jaw clutches, always stop the machine before shifting or in time the clutch jaws will become worn and round.

When steering the machine with either clutch in the locked posmon, the operator must ensure that the locked side frame does not ride over or turn into a rock or other projection from the site floor.

To do so would place dangerous stresses in the links and side frames ..

If it is so desired the machine may be steered manually, in which case it is necess· ary to have a ground man to move the steering clutches as required by means of the steering clutch handle tube extension supplied with tools and supplies.

It is important that 'Manual Steering' Section 5 is read carefully before proceeding.

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Page 14

BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR MANUAL STEERING (SEE FIG. 8 .)

To steer the machine manually it is necessary to have a ground man to move the steering clutches as required. A steering clutch handle tube extension is supplied with tools and supplies to assist the movement of the clutches.

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With both clutches engaged and desiring to turn right the ground man moves the right dutch shifter lever to the outside. This disengages the clutch and allows the right hand cats to free wheel when power is applied as desribed under "Propelling". The opposite applies to turning to the left using the left clutch shifter lever.

2.

In order to use the locked steering it is nec·essary to move the steering clutch manually so that it engages with locking jaws which are welded to the cat side frames. The clutch lever should be pinned to the clutch guard before starting to propel. To disengage the clutch it may be necessary to relie"le the load on the jaws by momentarily reversing the controller .. When steering the machine with either clutch in the locked position, the ground man must be very careful so as not to allow the side frames to ride over or turn into a rock which may be projecting from the floor of the quarry. To do so would place dangerous stresses in the links and side frames.

NOTE: THE · STEERING CLUTCH LEVER TUBE EXTENSION MUST BE REMOVED AFTER EACH MOVEMENT OF THE CLUTCHES OTHERWISE WHEN MOVEMENTS OF THE CLUTCHES BY AIR OPERATION ARE CARRIED OUT THE TUBE WILL "WHIP" VOILENTLY ACROSS THE MACHINE ENDANGERING THE GROUND MAN. THE OPERATOR MUST BE AWARE AT ALL TIMES OF THE GROUND MAN'S INTENTIONS SO THAT STEER SWITCH IS NOT OPERATED WITH HANDLE EXTENSION IN PLACE.

Section 5

Page 1

BI379509

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR

REEVING INSTRUCTIONS GENERAL (SEE REEVING DIAGRAMS) Before reeving shovel, measure ropes and check lengths with data on Reeving Diagram. Do not install short cables on machine.

BOOM SUSPENSION (SEE GENERAL ARRANGEMENT SHOVEL FRONT END FIG. 41.)

The boom is supported by two struts, one end of each fastened to the 'A' frame and the other to the shipper shaft plus four independent bridge cables, two to each side, running from the 'A' frame to the boom point and pin-connected at each end.

BOOM SUSPENSION Bridge strand cables are specially manufactured for this application and to ensure maximum life their careful handling and correct fitting to the machine is most important.

Points to observe are:When storing or handling cables never coil cables into a small diameter, fbr preference keep in a straight line or alternatively with socket ends together and rope in a single coil; if this is not possible coil cables with a minimum radius of 10 ft.

Do not use small rope slings in the centre of the cable length which will cause local kinking when assembling cables on a machine.

When installing bridge strand cables be sure that the painted line running the length of the cable is not twisted.

For replacement of bridge strand cables re!er to Section 8 Page 6.

HOIST REEVING (SEE REEVING DIAGRAM FIG. 53.)

Place the middle of the right hoist rope through the padlock sheave (remove sheave) and run both ends over the boom point sheave and down to the hoist drum. The lead or outer rope should be wrapped around the drum one complete turn and bolted to the flange with special anchor bolts. The follow or inner rope should have one-half dead wrap and be· socketed. This procedure should then be followed for the left hoist rope with the exception that the lead rope is socketed and the follow or inner rope is anchored to the drum flange.

The hoist ropes should be of equal lengths and should be put on so that the dipper hangs straight. In order to compensate for any slight error in the dipper hang, the rope length can be equalized at the bolt anchors.

CROWD REEVING (SEE CROWD ROPE REEVING DIAGRAM FIG. 54, 54/R or 54/R2.)

Instructions for reeving the crowd and bad:haul rope are given on the crowd rope reeving diagram.

NOTE: On new machines or when a. new crowd· rope is installed, the rope anchor pins should be checked for tightness after one hours running and again after 24 hours, this will ensure that rope does .not pull out at anchor pins.

Section 6

Page 1

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

(

( DIPPER TRIP (FIG. 49/R3) The dipper trip rope is reeved from the dipper door latch lever, over the trip rope deflecting sheave and down to the bottom Of the dipper trip drum.

This wire rope is anchored to the latch lever by means of a rope thimble and three rope clips. At the other end the rope is led through the anchorage opening provided in the outer flange of the drum and is fastened by a rope clip. Both methods of fastening are shown in enlarged detail views on Fig. 49/R3.

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Page 2a

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BI379509

RUSTON-BUCYRUS 150-RB EXCAVATOR REEVING INSTRUCTIONS GENERAL (SEE REEVING DIAGRAMS) Before reeving shovel, measure ropes and check lengths with data on Reeving Diagram. Do not install short cables on machine.

BOOM SUSPENSION (SEE GENERAL ARRANGEMENT SHOVEL FRONT END FIG. 41.)

The boom is supported by two struts, one end of each fastened to the 'A' frame and the other to the shipper shaft plus four independent bridge cables, two to each side, running from the 'A' frame to the boom point and pin-connected at each end.

BOOM SUSPENSION Bridge strand cables are specially manufactured for this application and to ensure maximum life their careful handling and correct fitting to the machine is most important.

Points to observe are:When storing or handling cables. never coil cables intd a small diameter, for preference keep in a straight line or alternatively with socket ends together and rope in a single coil; if this is not possible coil cables with a minimum radius of 10 ft.

Do not use small rope slings in the centre of the cable length which will cause local kinking when assembling cables on a machine.

When installing bridge strand cables be sure that the painted line running the length of the cable is not twisted.

For replacement of bridge strand cables refer to Section 8 Page 6.

HOIST REEVING (SEE REEVING DIAGRAM FIG. 53.)

Place the middle of the right hoist rope through the padlock sheave (remove sheave) and run both ends over the boom point sheave and down to the hoist drum. The lead or outer rope should be wrapped around the drum one. complete turn and bolted to the flange with special anchor bolts. The follow or inner rope should have one-half dead wrap and be ·socketed. This procedure should then be followed for the left hoist rope with the ·exception that the lead rope is socketed and the follow or inner rope is anchored to the drum flange.

The holst ropes should be of equal lengths and should be put on so that the dipper hangs straight. In order to compensate for any slight error in the dipper hang, the rope length can be equalized at the bolt anchors.

CROWD REEVING (SEE CROWD ROPE REEVING DIAGRAM FIG. 54, 54/R or 54/R2.)

Instructions for reeving diagram.

re~ving

the crowd and backhaul rope are given on the crowd rope

NOTE: On new machines or when a. new crowd· rope is installed, the rope anchor pins should be checked for tightness after one hours. running and again after 24 hours, this will ensure that rope does .not pull out at anchor pins.

Section 6

Page 1

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

c

DII'PER TRIP (FIG. 49, 49/R or 49/R2) The dipper trip cable runs from the dumpshaft segment (which should have flat side parallel to the handle when latch bar is engaged), over sheave on handle and through sheaves at the dipper trip cylinder over- the sheave segment on bumper casting and socket in fitting. Cable slack is taken up through eyebolt at this fitting. If slack becomes excessive, remove cable and cut excess cable off at fitting end. Then rig as per above instructions and readjust.

The trip rope is returned to the engaged position by spring pressure. A 3/8" rope runs from the segment lever on the dump shaft to the fitting in the spring. The slack can be taken up at the spring by removing the pipe cap from spring container and tightening up nuts on fitting. The spring follower should be adjusted so that it is 1.7 /8" below top of-spring container.

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Page 2

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RUSTON-BUCYRUS

150-RB EXCAVATOR

BI379509

LUBRICATION INSTRUCTIONS

FREQUENCY OF LUBRICATION With greater use made of anti-friction bearingsthenumber.ofpoints requiring frequent lubrication has been greatly reduced. It is necessary, however, to keep an accurate record or "log" of the machine lubrication in order to keep track of just when lubrication is required at any particular point.

When the machine is operated more than one shift each day, all crews must cooperate so that no lubrication point will be overlooked but at the same time. over lubrication can-be'avoided. It is usually best to take care of most of the lubrication at the beginning of the shift. A few points that need lubrication more than once a shift can usually be taken care of during a short wait for a truck or some other such delay. 1f no such delay occurs the machine must be stopped and the lubrication attended to because senous damage can result if the machine is operated without proper lubrication.

Keep a written record on a calendar or in a notebook showing just which points have been serviced on a given date.

The lubricationcharts Figs 30,3158&83show the principal pointsrequiring regular lubrication. The heavy lines are brought out from the point .to be lubricated tc the side of the chart. The number at the end of each line refers to the line numbers on the list of recommended lubricants at the end of this section. The column in which the number appears aetermines the frequency for normal lubrication requirements. For instance, all points requlfrng lubrication once a shift are brought out to the column headed "Once a shift".

In recommending frequency of lubrication five general divisions have been made namely: 1.

2.

3.

4, 5.

Twice a shift (Every 4 hours) Once a shift (Every 8 hours) Every five shifts (Every 40 hours) Seasonal As required.

The frequency of lubrication, as given· in the above tabulation is intended as a guide and it does not mean that under certain unusual operating conditions some points may not require more frequent lubrication or other special attention. Use good judgement and common sense in lubricating a machine. If a bearing is showing signs of trouble by overheating or making an unusual noise it should get attention immediately. Possibly the grease was dirty or of the wrong grade.

New bushings sometimes overheat from being too tight to allow normal distribution of lubricant. An old bushing may overheat .because it .is worn so that the grease would not stay in for the full stated frequency of lubrication. In some cases it may be necessary to "bGtby" the bearing along by frequent greasing until it is worked in or the cause of trouble is overcome. It is much better to lose a little time on one shift, to give extra attentioa to a point which needs lubrication, than to try to keep running until the end of the shift.

The most common cause of overheating of an anti-friction bearing is churning of the grease which occurs when the bearing is packed too full. If grease leaks out of an anti-friction bearing it is almost a sure sign that too much grease was added to the bearin.!} Don't change the frequency of greasing but decrease the amount of grease added at each servicing.

Section 7 Page 1

RUSTON-BUCYRUS 15D-RB EXCAVATOR

BI379509

( CAUTION:

Only use hand grease gun when greasing anti.:friction bearings to avoid rupturing grease seals or building up excess pressure in bearing enclosures.

Lubrication of all points at specified 4 hout and 8 hout intervals must be taken care of but (or the longer intervals, specified for the anti-friction bearings, etc., it is permiss~ble to vary from the. basic hours within reasonable limits. For instance, if the machine was working two shifts, of eight hours each, the forty hour interval would fall on opposite shifts each successive time. It would be quite satisfactory to lubricate the 40 hour points at the end of 32 hours or allow them to go until 48 hours have elapsed so that the same shift could take care of the lubrication. The important thing is to be sure not to omit points requiring lubrication and aot to over-lubricate the anti-friction bearings which need lubrication less frequently.

A good operator never neglects lubrication of his machine. It may require a little study on his part to find out just how much lubricant should be added at each servicing, but such a study will be repaid by a smooth running machine and long wearing parts.

Most wearing parts need lubricant applied regularly in small quantities rather than large amounts at infrequent intervals. It does no good to pump grease into a plain bearing after the grease starts to come out_ except that bearings, such as the lower works bearings, which may collect dirt SHOULD HAVE EXCESS GREASE ADDED TO THE BEARiNGS TO FORCE OUT THE OLD GREASE, which m~y have collected grit. On the other hand, when lubricating anti-friction bearings the oiler must be earful not to force grease into the bearing under pressure. Too much grease will cause an anti-friction bearing to overheat or may damage tlie grease seal.

No definate rules can be given as to how much grease s·hould be added to any particular bearing. How much to add depends on the size of the bearing, how hard the machine is being worked, how much the bearing is worn. and grade of grease being used. Keep a close check on all of the bearings uqtil you are sure the grease added at one servicing is enough to last until the next servicing.

Even the best lubricant is useless in preventing wear if it has become dirty by careless handling and storage methods. The manufacturer usually packs the lubricant in tight containers to keep it clean and it is the duty of the operator and the oiler ( if one is assigned to the machine ) to see that no dirt gets in the lubricant.

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KEEPING LUBRICANTS CLEAN

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Keep all oil and grease in tightly covered containers.

Wipe off covers before opening containers.

Keep funnels, oil cans, gt:ease guns, etc., in a clean place and wipe off before using.

Wipe off each grease fitting just before attaching grease gun. Wipe off oil filler caps before taking them off.

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When making regular inspection of the machine, watch for signs of incorrect lubrication such as an accumulation of excess grease. Be sure that the grease has not come from a broken or disconnected grease pipe. If a grease line or fitting is found damaged have it repaired at once so that proper lubrication can be restored.

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Section 7

Page 2

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR LOWER WORKS LUBRICATION

All bearings in the lower works are sleeve bearings grease lubricat~d through pressure fittings. The fittings for the propelling machinery in the truck frame and the fittings for the driving tumbler and side transverse shafts are .brought out to a lubrication header at the rear of the truck frame and the rear inside of each set of cats (see lubrication chart for guide).

The idler and

take~up

tumbler shafts have individual fittings.

There is a drain plug in addition to a level plug in the cat drive tumbler gear case and drain plug for the propel gear case. To fill propel gear case remove cover plate in a side diaphragm and place a sufficient amount of lubricant in gear case so that bevel gear dips into the oil.

The cat drive and the propel gears may be lubricated with either an oil or a compound depending on the user's wish.

Since the caterpillar mounting may have to operate in water .be sure the grease gun is filled with a water repellent General p·urpose Grease.

Add grease. to each bearing until some· old grease is forced .out. This will tend to flush out any dirt or grit which may have worked into the bearing.

Frequency of lubrication given on the charts is based on normal operating service.

When travelling on long moves, service the Lower Works grease fittings once every two hours. Watch all bearings closely and if there is any· excessive heating, force in extra grease until beartng runs cooler.

In addition to the fittings on the Lqwer Works service all propelling bea-rings on upper works every two hours when propelling long distances.

The quantities of oil required for the gear cases of the Lower Works are as follows: Bevel gears at bottom of centre post Transverse bevel gears Standard cat frames (each) Long and Wide cat frames (each)

5~ 6~ 3~ 5~

gallons. gallons. gallons. gallons.

.

Remember that .e~en ~hough the machine .is not propelled very much there is constderable back and for1:h movement while the machine is working. This. movement tends to squeeze the grease out of the bearings and cuttiqg will start .if lubrication of the shafts is neglected.

Reference Notes - Lower Works Lubrication Chart Fig. 30 Note l. Before placing machine in service remove plug and fill with grease.

Remove cap occasionally and check to see that cap is filled with grease and that water has not leaked in.

2. The pocket in the top part of the clutch shifter collar should be filled with an oily waste and checked daily.

3. Twice a shift d;te oil .hand pump should be operated two or three times to ensure adequate lubrication of the thrust collar.

Section 7

Page 3

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

( 4. Clean fittings before applying the lubricant gun.

Propel the machine back and forth a short distance after greasing to ensure distribution of the grease all the way round the bushing.

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5. Swing Roller Path and Swing Rack - Keep the roller path thinly coated with oil and swing rack thinly coated with gear compound.

Check daily. If dirt accumulates, wash off the old lubricant and apply a fresh coat.

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6. Propel Gear Case and Cat Drive Gear Case should be checked every five 8-hour shifts, check oil level with machine on level ground and add lubricant if necessary. If compound is used check daily and repaint gears if required. If water has accumulated in gear case remove drain plug and allow to drain off.

Twice a year, or when temperature changes make it necessary, drain the propel gear case and cat drive gear cases immediately after propelling and fill with gear lubricant of correct grade. Refer to Lubrication Charts.

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7. Keep the steering clutches free of dirt, clay, etc. These clutches must be kept clean as their return into the engaged position is by spring action.

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8. The swing rollers are separately lubricated through pressure grease fittings tapped in the ends of the pins. Service these fittings at least once every five shifts.

9. The brake pins should be oiled at least once every five shifts.

( UPPER WORKS LUBRICATION FIG. 31 .

Most of the bearings for the upper works have grease fittings tapped directly into the bearing. Location of the$e fittings as well as other points requiring lubrication are shown on the Upper Works Lubrication Chart.

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Reference Notes - Upper Works.

Note 1. Hoist The hoist first reduction gears and the propel chain are enclosed in oil tight cases. Refer to Upper Works Lubrication Diagram. The hoist gear case is provided with a sight level gauge, a drain plug and an opening for filling the case. Tht:: quantity of oil for this case is approx 7 gallons.

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The hoist open ge:flrs should be checkea twice a shift and compound applied. 'as required.- The drum shaft sleeve bearings should be serviced twice a shift and all anti-friction bearings weekly.

Consult charts fpr proper .lubricant.

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2. Swing The swing machinery three spur-gear reduction from the motor to the vertical swing shaft is totally enclosed and lubricated by a splash system. Keep the gear case filled to the indicated level with the proper oil.

Section 7

( ( Page 4

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BI379509 RUSTON-BUCYRUS

150-RB EXCAVATOR

An air filter on the breather pipe prevents dirt entering the oil, however, the gear case should be drained and refilled after apJ:?roximately one month of operation. Thereafter, drain and refill once each six months or whenever atmospheric conditions require a change in the body of the lubricant.

The first and second intermediate shafts are mounted friction bearings lubricated by the splash of the oil.

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In order to ensure proper lubrication of the upper first intermediate shaft bearing an impellor oil pump is placed in the shaft.

If necessary to disassemble shaft be sure that ball check and spring are assembled correctly. The vertical swing shaft upper bearing is oil lubricated and the lower bearing is 1ubricated through a standard grease fitting brought out to a convenient location on the revolving frame deck.

Approximately 35 gallons of lubricant are required for each swing unit. Consult charts for proper lubricant.

Note. 3 Crowd All of the crowd gears are of the open type and should be inspected twice a shift and the teeth recoated with proper gear compound if necessary. The intermediate shafts are mounted on anti-friction bearings and should be lubricated once every five shifts. · Before placing machine in operation check to be sure that the clutch grease guard. is in place. This guard protects the crqwd clutch from lubricant accidentally getting on the clutch lining.

When checking gears be sure and lubricate the drum shaft bearings.

4. Propel The propel chain case is totally enclosed and oil tight.

It takes about 7~ gallons of the proper oil to fill to the correct level. A sight gauge, drain pJ.ug and covered opening for filling are provided. Drain and refill once each six months or whenever temperature changes require. All of the bearing fittings for the propel gears above deck are brought out to a common "header" on the right side frame and should be serviced twice each shift.

All of the propel gears on the deck are of the open type and should be checked daily and compound applied as required.

The anti-friction propel sprocket shaft bearings should be serviced sparingly once a week or every five shifts.

Note

Before placing machine in service or after 'field' service requiring the withdrawal and replacement of the vertical propel shaft it will be necessary to proceed as follows to ensure that the centre pintle lower bush is adequately lubricated:The cavity between vertical propel shaft and the centre pintle sleeve will hold approx 6% pints of lubricant. Therefore it will be necessary to measure and inject 7% pints of Shell Nerita Grease 2 in order to ensure that the cavity is filled and surplus grease is seen to emerge from the bottom of the centre pintle.

(Inspection cover in truck frame is to be removed for this purpose).

Section 7

Page 5

RUSTON-BUCYRUS

~50-RB

BI379509

EXCAVATOR

( SHOVEL FRONT END LUBRICATION (FIG.58.)

5. Air Compressor Use only a good grade of oil. Refer to line on the lubrication charts for recommended lubricants. The oil level in the compressor should be checked at least once a day by removing the dip stick and observing the oil level. If the oil is not up to the required level, add sufficient oil to raise the oil level and replace cover. The lubricators in the main air line and dipper latch trip cylinder line should be serviced with a suitable oil.

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Be sure that the oil used in the air pressure system will remain fluid at the lowest temperatures, refer to a reputable lubrication supplier for recommendations of special oils suitable for extremely cold weather operation.

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6. Miscellaneous

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1. Clean all fittings before applying lubricant gun.

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2. Oil can points - place a few drops of oil on all ievers, pins, etc. not provided with fittings.

3. Inspect all open gears twice a shift for lack of lubricant.

GENERAL When lubricating machine do not forget to service the Front End Equipment which is working under severe dirt and moisture conditions. Use a water repellent grease for all fittings of front end equipment. Be sure to add sufficient grease so that a portion of the old grease is forced out of the bearings each time these fittings are serviced. This will keep dirt out of the bearings.

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Reference Notes - Front End Lubrication Chart.

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Note 1. The dipper handle should be inspected frequently for bare spots and proper lubricant applied as soon as noticed.

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2. Once a shift, preferably at the start, lubricate all points as indicated on chart.

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3. Lubricate the dipper latch bar each shift. Be sure to keep trip mechanism free of all dirt.

4. Clean all fittings before applying lubricant.

Section 7

Page 6

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BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR LUBRICANTS

RECOMMENDED BY SHELL OIL COMPANY

PARTS TO BE LUBRICATED

LINE

RECOMMENDED LUBRICANT

PLAIN BEARINGS 1 2a 2b

Macoma 275 Alvania Grease E.P.2 Alvania Grease E.P.2

5

Alvania Grease E.P.2

6

Cardium Compound D

9

Talpa Oil 20

12a

Macoma 82

13 14

Cardium Compound F. Cardium Compound F

Oil Lubricated Grease Lubr. Upper Works (Deck Mchy) Grease Lubr. Lower Works & Front End BALL OR ROLLER BEARINGS Grease Lubricated WIRE ROPE Wire Rope CHAIN DRIVE Roller Chain ROLLER PATHS Live Rollers SLIDING SURF ACES Rolling Contact Shoe Contact

OPEN & PARTIALLY ENCLOSED GEARS Gears

15

Cardium Compound F

16

Cardium Compound F

21a 20

Macoma 82 Macoma 82

RACK TEETH Swing Rack Teeth ENCLOSED PROPELLING GEARS -./'

Bevel Gear Cases Cat Side Frame Gear Cases ENCLOSED GEARS

Bearings Using Same Lubr.· Swing Mchy. 23 Bearings Separately Lubr .• Main Mchy. and Dipper Trip Gear Case 24

Macoma 275 Macoma 275 Section 7

Page 7b

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

( PARTS TO BE LUBRICATED ELECTRIC MOTORS & GENERATORS

LINE

RECOMMENDED LUBRICANT

28

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See Separate instructions for Lubrication of Electrical Machines.

AUXILIARY AIR COMPRESSOR Compressor AIRLINE LUBRICATORS

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Talpa Oil 20

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Talpa Oil 20

.LOW TEMPERATURE OPERATION When machine is operating at very low temperatures, (e.g. Temperatures to minus 40°C) the following change to lubricant is recommended:-

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In place of Alvania Grease E.P.2 use 'Alvania RA' or 'Aeroshell Grease 6'.

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The above recommendation is subject to availability in the country concerned.

Consult local agent or representative of Shell Oil Company.

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Page Sb

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BI379509 R U ST 0 N- B U C Y R U S 150- R B E XC A V AT 0 R ADJUSTING INSTRUCTIONS

This section covers all ordinary adjustments required in normal service and no unit should be adjusted without carefully reading the instructions covering that unit and following the procedure described. Keep your spanners and other tools clean and in good repair. Do not try to work with tools that are in poor condition.

Remember that a unit which is in correct adjustment will operate easier and wear less than one which has been allowed to get out of adjustment. For instance a clutch or brake which drags when released overheats and will not hold properly. It is m_uch better to utilise a few minutes to correct the adjustments than to try to "limp along" until the end of a shift.

Before changing the adjustments of any unit, check over machinery and controls very carefully to make sure a bent reach rod, worn pins, grease or oil or water on the lining or housing, or binding of some part is not causing the trouble.

LOWER WORKS - SEE DRAWING CATERPILLAR MOUNTING FIGS. 5 or 6.

CAT BELTS No definate rule can be given as to how tight or loose the cat belts should be as the correct adjustment depends on the type of ground over which the machine is to be moved. In general, the belts should be kept as loose as possible without losing proper tracking of the driving tumblers.

AD JUST ME NT OF CAT BELTS Adjustment of the cat belts is made at the take-up tumbler end of the mounting. The take-up tumblers are .bushed on a single forged axle which slides in guides formed in the cat frames. Chock bars, held in place by a retainer, hold the axle with the desired tension on the belts.

To adjust the cat belts, first remove the chock bar retainer from each side, bolted on the take-up axle. Then place the jack furnished with the machine in position on one side between the truck frame and the take-up axle as shown on the drawing. Work the jack until the cat belt is just tight enough to ensure· proper tracking of the driving tumbier. Insert the necessary thickness of chock bars, back off the jack and replace chock bar retainer. Repeat this procedure on the other side, be sure to insert the same thickness of chockbars.

After the cat belts have been properly adjusted, store the jack where it will be read-

ily available the .next time it is needed., ADJUSTMENT OF PROPEL BRAKE The toggle spring "63" should first be adjusted by means of the "T" .. \head bolt "62" to a length of 5. 13/16" in the released position.

The compression spring "72" should also be adjusted to by means of the reach rods and the spring rod.

1' 3" with bnike set

The brake band is adjusted at the splice with adjusting bolt "49" ·and toggle links in the released position, sci that . when toggle is moved to set position, toggle spring is not more·than 5. 3/4".

Bra~e lining wear is taken up with adjusting bolt "49" only.

Section 8

Page 1

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

UPPER WORKS- SEE GENRAL ARRANGEMENT DRAWINGS The three Airflex air clutches used for connecting the motors to the machinery require no adjustment once the units have been installed properly.

A daily inspection of clutches and piping to check for proper operation should be made.

All machinery, units, gears, bearings, etc,, require daily inspection for heating adjustment, wear and other mal functions which may occur during operation of the shovel.

ADJUSTMENT OF CENTRE PINTLE

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See instruction drawing for assembly and adjusting centre pintle sleeve Fig. 14 .

All adjustment of the centre pintle sleeve is made at the lower end. To take. up on the sleeve follow instruction as given on Fig. 14.

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VERTICAL PROPELLING SHAFT ADJUSTMENT See instruction drawing for assembly and adjusting centre pintle sleeve Fig. 14 .

The vertical propelling shaft through the centre of rotation has thrust washers at the top and bottom. With normal service there is very little wear of the thrust washers, but if excessive slack develops the split washer "66" should be replaced with a thicker one or shims of proper thickness added between split washer ·"66" and centre pintle sleeve "2". To replace the top and bottom thrust washers proceed as follows: The top washer "65" is a split washer and it requires the !DOvement of the upper propel shaft "53" to the right and removal of the bevel pinion "55" and raising bevel gear "64" for replacement.

The bottom washer "66" is split and can easily be replaced by loosening the lock nut "68" and dropping lower bevel pinion "67".

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( HOIST SHAFT BEARINGS Hoist shaft bearing wear is to be taken up as shown on Fig. 15 • under bearing keys are furnished with Tools. and Supplies.

shims for use

LEFT HAND SIDE FRAME & GEAR CASE

( (

Should it be necessary to open the left hand side frame gear case to inspect the motor pinion or hoist intermediate gear, the oil tight joint is to be remade in the following manner. First scrape off the old shellac and cotton from the flanges of the gear case and gear case cover. Coat gear case flange with shellac and place a cotton (No.40 machine) on wet shellac inside of the bolt line and replace cover.

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HOIST BRAKE

(

See drawing Main Machinery Motor Brake Fig. 16 Full instructions are given on the Main Machinery Motor Brake drawing for assembling the cylinder and for making brake adjustments. Follow these instructions carefully when · making any adjustment to the brake.

CROWD AND SWING MACHINERY MOTOR BRAKE SEE FIG. 17.

Full instructions for adjusting the crowd and swing motor post brakes are shown on the Crowd and Swing Machinery Motor Brake drawing. Follow these instructions carefully when adjusting these brakes.

Section 8 Page 2.

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BI379509

RUSTON-BUCYRUS 150-RB EXCAVATOR SHOVEL FRONT END ADJUSTMENTS DIPPER SNUBBER SEE FIG. 47.

After shovel has been in operation the snubber friction disc will wear, to compensate for this the snubber spring should be readjusted to 49,{ 6" by tightening the bolt.

ELECTRICAL ADJUSTMENT OF D.C. REEL TYPE DIPPER TRIP .

AS USED ON QUARRY MACHINES GENERAL

The Electrical Adjustments on the D.C. Dipper Trip should be made such that the following . . two conditions are met:1.

When digging, the quiescent torque on the motor should be high enough to reel in the excess trip cable when retracting the dipper .and should,be low enough to prevent accidental tripping of the dipper when crowding out. •.

2. · When tripping the dipper, sufficient. torque must be available to quickly take up any slack in the trip line and trip the dipper CAUTION: THE TRIP MOTOR IS NOT RATED FOR CONTINUOUS OPERATION AT STALL. CARE SHOULD BE EXERCISED WHEN TESTING TO SEE THAT THE MOTOR IS NOT HELD ON TRIP FOR MORE THAN 2 TO 3 SECONDS MORE THAN ONCE PER MINUTE.

SUPPLY LEAD

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LEAD

ADJUSTMENT QUIESCENT

For minimum pull - connect supply lead to 'Rl'. wards 'R2'.

To increase - move lead to-

TRIPPING

For maximum pull - connect contactor lead to 'R4' - to reduce move lead towards 'R3'.

Section 8

Page 3d

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

INSTRUCTIONS FOR CHECKING AIR LEAKS IN COMPRESSED AIR PLANT

The air compressor can be overworked by having too many leaks in the system which result in high maintenance cost on the compressor. Therefore, it is important that leaks are kept down to a minimum.

The Broom and Wade Type N.3. compressor operating range is between 110 lbs. and 140 lbs. Compressor should be set so that it starts to pump when the pressure drops to 110 lbs. and shuts down when the pressure reaches 140 lbs.

Test must be made to check the compressor operati.ng factor to take care of leaks.

This test must be made in the shop and again in the field before the machine is put into operation.

The following procedure should be used to determine compressor operating factor for leaks.

1. Hoist crowd and swing brakes to be released i.e. air to be in the cylinders. The "Dig/Propel" clutch button to be in the dig position, i.e. the hoist Airflex clutch to be engaged.

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2. Start the compressor and when the gauge at the compressor or at air tank indicates about 140 lbs. at which point the compressor shuts down, time the compressor from this moment.

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3. Check the time from the moment compressor shuts down at 140 lbs. until it again starts to pump around 110 lbs. Also the time from the moment it starts to pump at 110 lbs. until it shuts down at 140 lbs.

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Operating functions that use air are not to be operated during the time the compressor is being timed.

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4. To get the compressor operating factor for leaks, divide the time that it took the compressor to build up from 110 lbs. to 140 lbs. by the total time from the moment the compressor shut down at 140 lbs. until it built up the pressure again to 140 lbs.

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Example:Elapsed time when pressure dropped Say - 70 minutes. from 140 lbs. to 110 lbs.

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Time that it took compressor to build pressure from 110 lbs to 140 lbs.

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Factor =

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55 sees.

a

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Say - 55 seconds. (a) Total 70 min. 55 sec. (b)

=

4255

sees =.

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It normally should take about 55 (a) seconds to build the pressure up from 110 lbs. to 140 lbs. If it takes considerably longer then compressor is not operating properly and requires attention.

If the factor is more than .015 it indicates that excessive leakage is in the system and steps must be taken to eliminate the leaks. By applying light oil or soap water with

Section 8

Page 4

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BI379509 RUSTON.aUCYRUS 150-RB EXCAVATOR an oil can on the joints, leaks can be detected. The rotor -seal joints at the shaft connections should be inspected for leakage.

The magnet valves should be given a careful inspection because any foreign matter in the system may stick on the valve seats and prevent the magnet valves from functioning properly.

After the leaks have been eliminated the test should be repeated to check the cornpressor operating factor allowed for leaks.

The propel piping should be checked for leaks. The "Dig/Propel" switch should be in the propel position and all joints between the magnet valves, Airflex clutch and the brake must be inspected. Inspect the steering air lines by admitting rair to each side separately by operating control switches in operator's cab.

After machine is in operation, it is pm>sible that some JOlnts may loosen ap and cause leaks. Therefore it is advisable to conduct a leak test soon after the machine is put into operation and later periodically so as not to overwork the compressor.

INSTRUCTIONS FOR CROWD MACHINERY SLIPPING CLUTCHES

The Airflex Clutch is used as a slipping clutch to protect the machinery and crowd ropes from shock loads. In order for the clutch to be effective, the air pressure must be adjusted so that the clutch will slip slightly (1/4 to 1/2 turn) under shock loads, but .lt should not be allowed to slip to such an extent that it gets hot. For normal digging the air pressure is to be between 45-50 lbs., and for tougher digging the pressure must be raised to limit the slipping so that clutch does not overheat. Air gauge pressure should be checked a few times a shift to see that proper pressure is being obtained.

Through field experience it was found that in some cases the clutch lining has a tendency to seize or adhere to the housing. This could happen when machine is working in tough digging and the clutch warms up due to slippage, and later when easier digging is encountered where no slipping occurs. The seizing could also occur when the machine is not working steady and is shut down for a period of time.

Therefore to make· sure that the clutch is in good. operating condition, let air out from the clutch through the vented cock which should release the clutch. If clutch fails to release, operate crowd machinery slowly to make sure the clutch lining frees itself from the housing. After clutch is disengaged the pressure should be raised to proper level so that clutch will slip a little (1/4 to1/2 turn) under shock loads, but it should. not be allowed to slip excessively to such extent that it gets hot.

To ensure proper functioning of the slipping clutch for protection of machinery and· ropes, it is recommended that the clutch be checked for slippage at least once a week.

Section 8

Page 5

RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

REPLACEMENT OF BOOM SUSPENSION BRIDGE STRANDS

It is necessary that the two boom suspension strands on each side of the boom be of equal length. This necessity requires that the pair of strands on either side must be replaced in pairs.

The reason for this requirement is that strands in service have altered in length because of the natural pull through of the zinced sockets and the natural stretch resulting in wear and seating of the individual wires in the strand. A new strand must acquire this change and until it does, the difference in length of one old and one new strand may exceed the take- up provided in the clamp at the centre of the span,

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If strands of different lengths are assembled as a pair, the variation may be greater than the effective limit of the Snubbing clamp and this will result in the shorter one taking all the load without any sbubbing effect to dampen the individual strand vibration, consequently defeating the object of the snubbing clamp. Our field investigations reveal that a pair of unequal strands re.sult in wire failure in the strand taking all the load. The reason is not entirely due to the higher tension in the tight strand, but that this strand has a radically different vibration to cause fatigue failure of the wires.

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Should one of the strands removed be in good condition, it can be used with another used strand if the lengths can be matched. A strand can be considered good for further use if only two or three wires are broken because a strand strength is directly proportional to the number of wires in its construction. The matching of old strands may be accomplished by anchoring one end and pulling the strand taut with a tractor. A careful check should then be made with a steel tape, pulled taut to get the measurement accurately within 1/32". If the two used strands considered for re-use vary more than l/8" for compensation with damp, further compensation can be provided with 1/8" smaller pin dia. at one end of shorter strand, which gives an increase of 1/8" in effective length. A 1/8" smaller pin provided at both ends compensates 1/4" in effective length.

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The essential necessity is that each pair of strands must be matched, but the pairs on either side may vary from each other ± 3/32".

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Page 6

BI379509 RUSTON-BUCYRUS 150-RB EXCAVATOR an oil can op. the joints, leaks can be detected. The rotor-seal joints at the shaft connections should be inspected for leakage.

The magnet valves should be given a careful inspection because any foreign matter in the system may stick on the valve seats and prevent the magnet valves from functioning properly.

After the leaks have been eliminated the test should be repeated to check the compressor operating factor allowed for leaks.

The propel piping should be checked for leaks. The "Dig/Propel" switch should be in the propel position and all joints between the magnet valves, Airflex clutch and the brake must be inspected. Inspect the steering air lines by admitting air to each side separately by operating control switches in operator's cab.

After machine is in operation, it is possible that some JOints may loosen up and cause leaks. Therefore it is advisable to conduct a leak test soon after the machine is put into operation and later periodically so as not to overwork the compressor.

INSTRUCTIONS FOR CROWD MACHINERY SLIPPING CLUTCHES The Airflex Clutch is used as a slipping clutch to protect the machinery and crowd ropes from shock loads. In order for the clutch to be effective, the air pressure must be adjusted so that the clutch will slip slightly (1/ 4 to 1/2 turn) under shock loads, but it should not be allowed to slip to such an extent that it gets hot. For normal digging the air pressure is to be approximately 65lbs., and for tougher digging the pressure must be raised to limit the slippi~g sci that clutch does not overheat. Air gauge pressure should be checked a few times a shift to see that proper pressure is being obtained.

Through field experience it was found that in some cases the clutch lining has a tendency to seize or adhere to the housing. This could happen when machine is working in tough digging and the clutch warms up due to slippage, and later when easier digging is encountered where no slippii?:g-_ occurs. The seizing could also occur when the machine is not working steady and is ·shut down for a period of time.

Therefore to make sure that the clutch is in good operating condition, let air out from the clutch through the vented cock which should release the clutch. If clutch fails to release, operate crowd machinery slowly to make sure the clutch lining frees itself from the housing. After clutch is disengaged the pressure should be raised to proper level so that clutch will slip a.little (1/ 4 to 1/2 turn) under shock loads, but it should not be allowed to slip excessively to such an extent that is gets hot.

To ensure proper functioning of the slipping clutch for protection of machinery and ropes, it is recommended that the clutch be checked for slippage at least once a week.

Section 8.

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RUSTON-BUCYRUS 150-RB EXCAVATOR

BI379509

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REPLACEMENT OF BOOM SUSPENSION BRIDGE STRANDS It is necessary that the two boom suspension strands on each side of the boom be as near to equal in length as possible. This necessity requires that the pair of strands on either side must be, replaced with great care,preferably as a complete set or at least in pairs.

The reason for this requirement is that the strands in service have altered in length because of the natural pull through of the zinced sockets and the natural stretch result· ing in wear and seating of the individual wires in the strand. A new strand must acquire this change and until it does, it may be found considerably shorter than any of the old strands . ..(\!though the suspension rope extension links (to which the lower ends of the strands are attached) will take care of slight variation between the two strands in a pair, the essential necessity is that the pairs on either side do not vary from each other by more than plus .or minus 3/32 ".

To be sure of avoiding serious trouble it is strongly recommended that any replacement suspension bridge strands be obtained through Ruston-Bucyrus Ltd., or where this is not possible that great care should be taken to ensure that only replacements conforming to the correct specifications are fitted.

Great care should be exercised in all the various phases of handling and storing replacement bridge strand ropes. The ideal for storing is to lay right out in a straight line; next to this, ends laid together with the ropes in a single coil; if neither is feasible then multiple coiling not less than 20 feet diameter.

For transport from Stores to assembly point, avoid tight coiling, and prohibitentirely the use of small rope slings which are a frequent cause of local kinking. For assembling ropes on the machine again avoid the use of small rope slings in the middle of the suspension rope.

On each Boom Suspension Bridge Strand will be found a brass tubular identification piece bearing the wire rope manufacturer's Works Number and all sockets h·ave the effective rope length marked thereon, together with the rope manufacturer's test reference.

These permanent identification arrangements are intended to assist the user with his surveys and records after the machine has been in operation.

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RUSTON-BUCYRUS lSD- RB

EXCAVATOR

BI379509

DRAGLINE FRONT END EQUIPMENT The following instructions cover both the drag line-shovel combination and the dragline only machine. In the event that the machine is dragline only then that portion of these instructions pertaining to conversion may be ignored, those portions of these inst_. ructions which apply to operation will apply in either case.

MAIN MACHINERY GENERAL ARRANGEMENT OF MAIN MACHINERY PLAN VIEW FIG. 2 .

Before commencing opera~ing the machine as a dragline, particularly if the machine has been converted from a shovel machine it is important to check that the instruction plates for controllers and brake switches are in accordance with Fig. 6 . for dragline machine. lf incorrect all thatis necessary is to remove the instruction plate and on the underside will be found the correct engraving.

DRAG MACHINERY FIG. 2 .

The shovel hoist machinery is used for the dragline drag motion and is operated by the L.H. Controller (See Fig. 3 .) The double twin grooved hoist drum lagging used on the shovel must be replaced by a single grooved lagging for the drag rope.

The crowd drum must be removed from a shovel in order to allow room to mount the fairlead. The fairlead is mounted at the front of the revolving frame. In order for the rope to clear the crowd machinery, a slightly different mounting bracket is furnished with a combination machine than is furnished with. a dragline only. The drag rope mud trough is bolted in place and extends from the fairlead to the back of the drag drum. This mud trough is also made differently on a combination machine in order to clear the crowd machinery.

The drag brake which is mounted on the motor p1mon shaft next to the drag air-. flex clutch is spring-set and air-released. It is used as a holding brake only and is not used during the regular operating cycle.

HOIST M:ACHINER Y FIG. 80 .

The hoist machinery is mounted behind the back A-frame legs on the welded rear end section of the revolving frame. The hoist machinery is driven· by an .independant motor and like the drag machinery is controlled "from the operator's position at all time~ during digging cycle.

The dragline hoist drum shaft is forged steel and runs in anti-friction bearings supported by cast steel side frames. The hoist gear is keyed to the hoist shaft and the right flange of the grooved drum is bolted to d1e hoist gear, the other end of the drum being supported on the hoist shaft. The hoist gear meshes with the hoist motor pinion which is keyed to the hoist motor shaft, at the other end of 1the hoist motor shaft is keyed the hoist brake. The hoist brake which is controlled by the hoist brake switch is spring set and air released. (For brake operation see Control of Brake Section 4 Page 11.) Lubricate where indicated in accordance with 'Lubrication Instructions'.

Both the drag and hoist brakes are electrically controlled and are so arranged that they will set in case of power failure.

Section. 9

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R U ST 0 N · B U C Y R U S 150 -.R B EX C AV A T 0 R

BI379509

BOOM HOIST MACHINERY FIG. 79 .

The boom hoist is mounted between the A-frame legs just above the cab roof. It is operated locally and is powered by an A.C. Electric Motor which has an electrically operated brake mounted at one end of the motor shaft extensjon. The boom hoist drum is driven through a worm gear reduction, a spur gear reduction and a chain reduction from the reversible motor. The worm shaft is extended and carries a hand set band type brake to prevent any possible chance of the boom creeping during operation.

'The worm dips in oil, and the oil level must be maintained with the recommended lubricant.

Before raising or lowering the boom lubricate where indicated on Fig. 83. in accordance with 'Lubrication Instructions'.

NOTE: As normally this unit is used infrequently it should be operated occasionally to ensure that the equipment is serviceable.

FAIRLEAD FIG. 78 .

Lubricate where indicated on Fig. 83. in accordance with Lubrication Instructions

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REEVING INSTRUCTIONS: See Boom Suspension and Mast Fig. 76 .

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On 90ft. booms the suspension rope is reeved directly between the A-frame and the boom point.

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Booms of 100• - 0" length and over use mast type suspension the boom being attached to the mast by two single Bridge Strands.

The mast is raised by the boom hoist rope, reeved 8 parts as follows:Reeve the boom suspension from the boom hoist drum over the left-hand sheave on the A-frame, thence over the top of the left-hand inner sheave on mast, back and through bottom yoke sheaves from left .to right, then through right-hand inner sheave on mast from bottom to top, back through the top yoke sheaves from right to left, then from top to bottom of left-hand outer mast sheave then back and through middle yoke sheaves from left to right, thence around right-hand outer mast sheave from bottom to top and anchor in socket provided on yoke.

These reeving instructions will also apply to machines without a mast. The sheaves referred to above as being on the mast will in that case be located at the boom point.

On machines with a mast, bridge strands are placed between the mast and boom point.

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Before hoisting or lowering the front end equipment it is important to ensure that all lubricating points shown on Fig. 83 . together with ropes and rope grooves have been adequately coated with the recommended lubricant in accordance with 'Lubrication Instructions'.

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DRAGLINE BOOM AND BOOM POINT FIGS 76 & 77.

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Dragline booms usually consist of the following units, boom lower section, boom upper section and boom point, together with intermediate sections of varying length which determines the total length of boom. Booms 90' -0" in length do not require mast type suspension, the reeving being taken to the boom point as shown on Fig. 76. The boom point sheave or sheaves, depending on whether 2 or 3 part hoist is used, are mounted on roller bearings and should be lubricated accordingly See Fig. 83 .

Before hoisting or lowering boom it is important that all lubricating points shown on Fig. 83 . together with ropes and rope grooves have been adequately coated with the recommended lubricant in accordance with 'Lubrication Instructions'.

Section 9

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RUSTON- BUCY R·U S 150- RB EXCAVATOR

BI379509

BOOM ANGLE INDICATOR The boom angle indicator mounted on the right side of the boom foot is a simple devke for indicating ~he angle the boom makes with true horizontal. A plate, showing the angle in degrees, is bolted to the right side of the boom. A pendulum pointer suspended from one end hangs free. When the boom is parellel with 1evel ground the pendulum would indicate zero degrees. As the boom is raised the angle indicated by the pendulum increases.

CONSULT MACHINE SAFE LOAD FIGURES. (FIG. 82 .) FOR CORRECT OPERATING RADIUS For successful operation of machines with drag line type booms it is necessary to operate well within the stability of the machine. Dragline Safe Load Figures Fig. 82 . tabulate permissible bucket size or maximum suspended load (bucket contents) for length of boom supplied. The operating radius means the distance of the suspended load from the centre of rotation when the machine is on firm level ground.

SET BOOM ANGLE WITH MACHINE ON FIRM LEVEL GROUND When the machine· first goes into operation the correct operating radius should be determined, taking into consideration the weight and size of the bucket used and the weight and condition of the mat~rial being handled. Wet material weighs more than the same material dry; With the machine on firm, level ground, measure off the radius determined and raise the boom until the load is suspended at the correct radius. The boom angle indicator .will then show the true angle of the boom with the horizontal,

WATCH BOOM ANGLE INDICATOR AT ALL TIMES While the. machine is working, watch the boom angle indicator and if, at any time, due to working on a grade or soft footing, the indicator shows. an angle less than that determined when the machine was on level ground, raise the boom ·until the indicator shows an angle equal w, or greater than, that shown when on level ground. Failure to do this means that the machine is being .,operated in excess of its ratings and damage may result.

CHANGE BOOM ANGLE IF BOOM LENGTH OR LOAD IS CHANGED If the .length of boom is changed or a ?ifferent bucket is used, or if the nat~re of the mat~rial handled is such as to change the weight of the loaded bucket, a new operating radius must be determined and a. new setting for tl;le boom angle indicator, determined.

Section 9

Page 3

BI379509

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BI379509 R U ST 0 N- B U C Y R U S 150- RB EX C A V AT 0 R CONVERTING FROM SHOVEL TO DRAGLINE See Plan Fig. 2 . Hoist Machinery Fig. 80. Boom Hoist Fig. 79. Reeving_ Fig. 76.

The following procedure should be followed when converting from a shovel to dragline. No mention will be made of guards or cab parts which have to be removed, however, when removing guards it is a good plan to replace the bolts and nuts after taking off the guards so that the correct bolt will immediately be available when reassembling. Another point to remember is that it is impossible to cover all of the details involved in converting since the exact procedure will differ according to the lifting equipment, blocking etc., that is available. _..---..,,_

1. Remove the shovel boom, handle and struts, using a mobile crane or other suitable lifting tackle.

2. Remove the lock bars holding the crowd drum shaft in place.

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3. Slide out the crowd drum shaft and remove the drum and gear as a unit. Brackets are provided for bolting the crowd drum to the lower boom so that the drum can be removed with the lower section of boom if desired.

4. Remove crowd motor blower. A temporary cover plate should be placed over the opening in the crowd molor frame to keep out mud.

S. Remove the shovel hoist drum lagging by taking out the bolts from the gear and spider.

NOTE: Both shovel hoist drum lagging and drag drum lagging are split so that the halves can be removed or installed through the roof hatch between the A-Frame legs.

6. Install the drag drum lagging by bolting it to the gear and spider .

7. Install the mud trough over the remaining crowd machinery and under the drag drum by bolting it to brackets which are supplied. Remove cover plate on Roof Hatch for dragline hoist rope.

8. Additional ballast is required amounting to 13 tons for Dragline op-· eration and should be distributed evenly each side of the centre line of the rear end ballast compartment. (Note: This additional ballast must be removed for Shovel Operation).

9. Install Dragline boom by lifting or jacking boon. foot so that holes in boom foot line up with holes in lugs on revolving frame. Insert boom foot pins and lock bolts.

10.

Install boom hoist unit between A-frame legs as shown on Boom Hoist General Arrangement drawing. When installing boom hoist unit on machine for first time it will be necessary to ream the holes In the A-frame.

11. Install mast if boom is of such a length that mast is required.

12. Install the dragline hoist machinery as shown on the general arrangement 'Plan View' drawing. Align the motor so that there is .020 11 -028 11 gear backlash as shown on Fig.80, also install air piping to hoist brake magnet valve as shown on Fig. 19. If the machine is again converted to shovel the dragli.ne hoist machinery may be left in place.

Section 10

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R.U ST 0 N - BUCYRUS 15 0- R B EX CAVA T 0 R

BI379509

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13. Reeve the boom hoist, drag and hoist ropes in accordance with instructions give1;1 under reeving instructions in section 'Dragline Front End Equipment'.

Reverse the above procedure to convert the machine from a drag line to shovel. The dragline hoist machinery is left in place but is not used when using the machine as a shovel.

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BI379509 R U ST 0 N • B U C YR U S 150· R B E X CAVA T 0 R

COMMISSIONING AND ADJUSTMENT INSTRUCTIONS FOR 150-RB SHOVELS AND DRAG LINES.

The correct performance of the electrical equipment on the machine 1s expressed in numerical values which are recorded on the electrical adjustment sheets. The correct settings for the machine are obtained by adjusting the resistances which control the excitation currents and normally every machine is correctly set and all readings taken before the machine leaves Ruston-Bucyrus Ltd. All adjustments are checked by the . erecting engineer and blueprint copies are supplied for each machine, the figures as finally verified by Ruston-Bucyrus Engineering Department being entered in the line marked 'Standard', spaces in the line marked 'Actual' are left blank to record check readings made in the field.

The settings are not identical for all front end equipments. If front end equipment is changed at any time, apply to Ruston-Bucyrus Ltd. for the correct adjustment figures applicable to the new equipment.

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(1) Observe all measures necessary to ensure safety.

Do not attempt to open or close any motor or generator armature or field circuits when the equipment is running.

This is IMPORTANT. (2) When recording readings for all controller steps move the controller smartly to the last notch forward and take readings on each step as the handle is returned to neutral.

Then, repeat starting at the last notch reverse.

Take readings as smartly as possible consistent with reasonable accuracy and return controller to 'Neutral' without delay t_o avoid over-heating of windings and resistances.

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(3) It is essential that the rotation of machines is correct and that wiring is carried out to give correct field polarities, as otherwise serious damage to the equipment could result.

If at any time subsequent to commissioning of the machine any reconnection is made to the cables between the driving motors and the ultimate supply, rotation should be checked before allowing the equipment to run up to any appreciable speed.

(4) Initial Commissioning of Equipment.

Before starting the equipment for the first time after erection, equipment changes or wiring changes, polarity checks should be made as described later on circuits which have not been previously checked.

The following circuit should be opened and should not be reconnected until the appropriate polarity check has been made. (a) Self field on each control exciter. each control exciter terminal box.

Open by disconnecting X2 at

(b) Voltage field on each control exciter. Open by disconnecting each control exciter terminal box.

XX3 at

(c) Main Armature circuit of each, motion.

Open by disconnecting the external main cable to HD3, CH3; and S4, at the control exciter set bedplate terminal box. (d) Motor Field of each motibri.

Open by disconnecting the cable to field at terminal 129, 229, 327 and 328 at resistance frames.

Section 11

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RUSTON-BUCYRUS 150-RB EXCAVATOR

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BI379509

(S) Constant Voltage Exciter- Volta~ Adjustment.

The C.V.E. voltage should be 125 volts when the machine is hot, but will be approximately 130 volts when cold.

With all equipment shut down and controllers in neutral connect a suitable voltmeter across the C. V.E. terminals A and YY (A is positive).

Set the cubicle test switch in the 'TEST' position, start exciters not M.G. set.

Note that control exciters, blowers, and compressor will start at the same time.

Check rotation and read C. V.E. volts.

To increase the voltage decrease resistance R Tl in main field circuit.

To decrease the voltage increase resistance R Tl. As the C. V .E. voltage falls as the machine warms up, resistance RT21 in the temperature compensating field circuit should be increased, if necessary, to bring the voltage up to 125 volts.

(6) Polarity Checks and Adjustment Sheet Readings.

Polarity checks must be made in the following sequence:· Control Field Main Generator Field Check.

With all equipment shut down.

Check controller in off position.

Main armature circuit • open.

Control exciter self field • open.

Control exciter voltage field • open.

Motor field - open.

The above circuits must be open on all motions which have not been checked previously.

Connect voltmeter (250 v) across control exciter terminals A and AA. Connect voltmeter (650 v) across generator terminals.

Set cubicle test switch in the 'RUN' position.

Start M.G. set and check rotation.

Start exciters and check rotation.

Move controller to step 6 and record voltages at control exciter and generator ensuring that the polarities correspond to the controller position as indicated on the D~C. Wiring Diagram.

Self Field Check.

With control exciter shut down and controllers in neutral connect self field on control exciter being checked, the self fields on other motions being left open if they have not been checked previously.

Start exciters.

Move controller to step 6 and record voltages ensuring that the polarities are correct and that both voltages show an increase from readings with control field only.

Voltage Field Check.

With control exciters and M.G. set shut down and controllers in neutral connect the voltage field, on the exciter being checked, the voltage field on the other motion (not swing) being left open if it has not be checked previously.

Start M.G. set and exciters.

Move controller to step 6 and record voltages ensuring that the pol• arities are correct and that both voltages show a decrease from read· ings with control and self field combined.

(Will not apply on swing motion).

Section 11 Page 2

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RUST 0 N.· BUCYRUS

15 0 • R B EX CAVA T 0 RS

BI379509

MAIN GENERATOR OPEN CIRCUIT VOLTAGE READINGS. Following the previous checks the main generator open circuit voltage for each controller step should be recorded.

If, subsequent to commissioning, field check readings are required, proceed as follows:· Check (I) All equipment shut down.

(2) Controllers in neutral.

(3) Control exciter control field • closed.

(4) Control exciter self field • closed.

(5) Control exciter voltage field - closed.

(6) Main Armature circuit-open (see para. 4).

Connect voltmeter (650v) across generator terminals.

Start M.G. set and exciter set.

Record voltage for each controller step.

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Main Generator Differential Series Field.

Polarity Check and Control Exciter Current Field Witb control exciters and M.G. set shut down and controllers in neutral connect the main armature circuit for the motion being checked, the main armature circuits for the other motions being left open if they have not been checked previously.

Motor field • open. Air supply available to clutches.

Brakes applied.

Connect millivoltmeter to generator armature shunt.

Start M.G .Set ONLY • NOT exciters.

Watch the Current Reading!

With correct differential series field polarity the current value should be less than 100 amps. but if it tends to rise to a high value STOP the M.G. set IMMEDIATELY as the indication is that the generator series field is reversed, which should be reported to Ruston-Bucyrus Limited.

After the forgoing check has proved correct polarity for the Generator Differential Series Field ensure that controllers are in neutral.

Start the exciters and watch the current reading.

If the current tends to rise to a high value SHUT DOWN THE EXCITER SET IMMEDIATELY. If wiring is correct, the indication is that the control exciter current field is reversed which should be reported to Ruston-Bucyrus Limited.

With correct control exciter current field polarity the current value should be very low.

MAIN GENERATOR STALL CURRENT READINGS. Following the previous checks the main generator stall current for each controller step should be recorded If, subsequent to commissioning, field check readings are required, proceed as follows:· Check (1) All equipment shut down.

(2) Controllers in neutral.

(3) Control exciter control field • closed.

(4) Control exciter self field • closed.

(5) Control exciter voltage field • closed.

(6) Main Armature circuit • closed.

Section 11

Page 3

L;·

RUSTON· BUCYRUS 1SO-RB EXCAVATORS

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Check (7) Motor Field Open (8) Air Supply available to clutches.

(9) Brakes applied.

Connect millivoltmeter to generator armature shunt.

Start M.G set and exciter set.

Record current for each controller step.

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(2) Motor Field Closed.

(3) Main Armature circuit open.

Connect voltmeter (150 v) across motor field terminals.

Start C. V. exciter set.

Record values of motor field voltage for all controller steps.

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Mo_tor Rotation.

With equipment shut down and controllers in neutral make all connections. Start up equipment as for normal operation.

Operate the controllers and check that motion movement is correct for the controller position.

In the case of the swing motion, the motion should be checked for each swing motor unit in turn.

The field on one swing motor only should be connected. Having deter· mined the correct motion for this motor this field should be opened and, the field on the other swing motor should be connected and correct motion determined.

Both fields may then be connected. Do not open or close fields with equipment running.

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DESCRIPTION EXHAUST FAN MOTOR SWING GENERA TOR DRAG GENERATOR M.G. SET MOTOR STARTER AND STARTER ISOLATOR HOIST GENERATOR INDUCTION MOTOR CAB FAN MOTOR STARTER AUXILIARY TRANSFORMER OPERA TORS CONSOLE DRAG DRUM DRAG SHAFT GEAR RESISTANCE FRAME PROPEL CHAIN CASE CONTROL CUBICLE COMPRESSOR UNIT AIR RECEIVER EXCITER MOTOR EXCITER GENERATOR 'A" FRAME HOIST MOTOR HOIST MOTOR BLOWER HOIST DRUM HOIST SHAFT GEAR DRAG MOTOR DRAG MOTOR BLOWER LEFT HAND SWING MOTOR RIGHT HAND SWING MOTOR FAIRLEAD PROPEL BRAKE MAGNET VALVE HOIST CLUTCH AND BRAKE MAGNET VALVES SWING BRAKE MAGNET VALVE PRESSURE SWITCH RIGHT HAND STEERING MAGNET VALVE LEFT HAND STEERING MAGNET VALVE LOCK MAGNET VALVE PROPEL CLUTCH MAGNET VALVE

FIG. 2/R2. PLAN ARRANGEMENT-150-RB FULL/ELECTRIC DRAGLINE WITH STATIC CONTROL. IMD 293/R

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DESCRIPTION EXHAUST ·FAN MOTOR SWING GENERATOR CROWD GENERATOR M.G. SET MOTOR STARTER AND STARTER ISOLATOR HOIST GENERATOR INDUCTION MOTOR CAB FAN MOTOR STARTER AUXILIARY TRANSFORMER OPERATOR CONSOLE HOIST DRUM HOIST SHAFT GEAR RESISTANCE FRAME PROPEL CHAIN CASE CONTROL CUBICLE COMPRESSOR UNIT AIR RECEIVER EXCITER MOTOR EXCITER GENERATOR 'A' FRAME HOIST MOTOR HOIST MOTOR BLOWER CROWD DRUM INTERMEDIATE SHAFT GEAR CROWD MOTOR CROWD MOTOR BLOWER LEFT HAND SWING MOTOR RIGHT HAND SWING MOTOR SLIPPING CLUTCH GEAR PROPEL BRAKE MAGNET VALVE HOIST CLUTCH AND BRAKE MAGNET VALVE SWING BRAKE MAGNET VALVE CROWD BRAKE MAGNET VALVE PRESSURE SWITCH RIGHT HAND STEERING MAGNET VALVE LEFT HAND STEERING MAGNET VALVE LOCK MAGNET VALVE PROPEL CLUTCH MAGNET VALVE

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DIG/PROPEL SWITCH HOIST CONTROLLER DRAG AND PROPEL CONTROLLER SWING PEDALS HORN PUSH BUTTON SWING BRAKE SWITCH PROPEL BRAKE SWITCH DRAG BRAKE SWITCH HOIST BRAKE SWITCH TRACK STEER SWITCH EMERGENCY STOP-RESET BUTTON EXCITER START BUTTON EXCITER STOP BUTTON C.V. EXCITER VOLTMETER

OPERATOR'S CONTROL CONSOLE - KEY DIAGRAM FIG. 3/Rl

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DIRT SEAL 115 116 ROlLER BUSHING 117 RETAINING PIN liS SPECIAL NUT TAKE UP AXLE 119 120 TAKE UP Ti.JMBLER 121 HUB CAP 122 BUSHING 123 . DIRT SEAL THRUST PLATE 124 125 CLAMP COLLAR 126 SCREW JACK 127 JACK SPACER BAR 128 JACK SPACER BAR 129 CHOCK BAR RETAINER 130 CHOCK BAR 131 CAT LINK 132 CAT LINK PIN 133 LINK PIN IDCK UPPER ROlLER 134 135 UPPER ROLLER SHAFT 136 BUSHING 137 RETAINING COLLAR 138 BLANK BOLT 139 BLANK BOLT 140 CHOCK BAR 141

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FRAME TRUCK RACK AND TRACK ASSEMBLY OF RAILS BUSHING BUSHING BUSHING BUSHING BUSHING BUSHING BOLT LUBRICATION DOWEL COVER CENTRE PLATE TOP COVER PLATE COVER PLATE COVER RAIL TRUCK FRAME

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90 91 92 93 94 95 96

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SHAFT BRAKE HOUSING BRAKE PINION BRAKE SHAA"!'

WASHER THRUST PLATE IDCK RETAINER GUARD PROPEL BRAKE BAND BRAKE END ADJUSTING BOLT END ADJUSTING BOLT PIN ADJUSTING BOLT END BOLT ADJUSTING GUIDE BRAKE SUSPENSION BRAKE SUSPENSION BRAKE BAR GUIDE ANCHOR PROP BRAKE PIN BRAKE ANCHOR BOLT BLANK ARRANGEMENT PROP BRAKE BAND LINK TOGGLE PIN TOGGlE LINK END ROD END ROD BOLT SPRING TOGGlE PIN ROD END SPAGER LINK BRAKE

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114 115 116 117 11El 119 120 121 122 123 .124 125 126 127 128 129 130 131 132

PIN LINK LEVER 1511 BRAKE SHAFT BRAKE LEVER CYLINDER END ROD SPRING COMP. ROD SPRING WASHER SPRING 1 11 BSP IDCKNUT PIN !EVER PIN LEVER

133 134 135 136 137 138 139 140

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144 GEN ARRANGMENT 5 11 x 4•7/8 11 CYLINDER PIN COVER CLUTCH GUARD LEVER UPPER CLUTCH SHIFTER COVER LUBRICATION HOLE GUARD CLUTCH UPPER HALF GUARD CLUTCH IDWER HALF SHIM GENERAL ARRANGEMENT , SCREW CAP 5/El 11 x 2 11 UNC FRAME SIDE CRAWlER R.H. FRAME SIDE CRAWLER L.H. JAW lOCKING MALE BUSHING BUSHING TRANSVERSE SHAFT BUSHING DRIVE TUMBlER BUSHING DRIVE TUMBLER COVE;R END SCREW DOWEL COVER GEAR R.H. COVER GEAR L.H, TUMBlER DRIVlNG SHAFT DRIVING TUMBlER KEY GIB-DRIVING TUMBlER SEAL DIRT WASHER THRUST COLLAR CLAMP GEAR DRIVING TUMBLER SHAFT SIDE TRANSVERSE JAW DRIVEN MALE PINION SHAFT ROUER ROUER IDWER CAP HUB COLLAR CLAMP SEAL DIRT · BUSHING ROUER PIN RETAINER AXIE TAKE-UP TUMBlER TAKE-UP CAP HUB TAKE-UP BUSHING TAKE-UP. TUMBlER SEAL DIRT PLATE THRUST COLLAR CLAMP JACK SCREW JACK SPACER RETAINER CHOCK BAR LINK CRAWLER PIN CRAWlER LINK PIN LINK IDCK

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148 .149 150 151 152 153 154 WIRE IDCK NO • 12 155 WIRE !DCK NO. 10 156 DOWEL 157 STUD 158 BOLT BODY FIT 1!11 x 7" uNC 159 BOLT BODY FIT 1 2 11 x ~ 11 UNC 160 BOLT 7/8" x 9 11 UNC 161 PIN COTTER 3/16 11 X 1i'! UNC 162 SCREW CAP 3/4" x 11" UNC 163 ·SCREW CAP 3/411 x 1 11 UNF 164 SCREW CAP 7/8 11 x 1~ 11 UNC 165 166 SCREW CAP l..rr x 1-k" UNF 167 SCREW CAP ; 11 x 1!11 UNF 16El SCREW CAP 5/8 11 x 1f 11 UNC 169 SCREW CAP 5/8 11 X 1 II UNF 11 UNF 170 SCREW CAP 5/8 11 x 171 SCREW CAP 3/4 11 x 2 11 UNF 172 SCREW CAP 3/411 x 2!11 UNF 173 SCREW CAP 7/8 11 x 511 UNF 174 SCREW CAP 1 11 x 1!11 UNC 175 SCREW CAP x 1 11 UNC 11 UNF 176 SCREW CAP 5/8 11 x 177 SCREW CAP 5/8 11 x 3:it11 UNE 178 WASHER SPRING IDCK ~ 11 • 179 WASHER SPRING IDCK 7/El 11 180 WASHER SPRING lOCK 1 11 181 WASHER SPRING IDCK ?{11 1El2 WASHER SPRING LOCK 5/El" 183 BOLT HEX '1i" x 6!" UNC 1El4 B~LT HEX 1 11 x 4" UNC 185 S REW CAP 5/8 11 x 1 11 uNC 1El6 NUT FULL .l.n UNF 187 "NUT FULL ~" UNF 188 NUT FULL 7/8" UNF 189 NUT FULL 1" UNC 190 NUT FULL 11.." UNC 191 NUT FULL 1;" UNF 192 NUT FULL 5/8 11 UNF 193 NUT JAM 1i" UNC 194 SCREW CAP ! 11 x 1:it11 UNC 195 NUT FULL i 11 UNC 196 NUT JAM ! 11 UNC

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TERMINAL LUG FIXING TO COLLECTOR RINGS

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DESCRIPTION

DESCRIPTION

No.

COLLECTOR RINGS INSULATORS INSULATOR SHIELD INSULATOR ADAPTOR PLATE DISTANCE PIECE COLLECTOR RING SETSCREWS LOCK WASHER FOR REF. No.6 COLLECTOR RING SHOE COLLECTOR RING SHOE SUPPORT COLLECTOR RING SHOE GUIDE PIN BRUSH ASSEMBLY SPRING FLEXIBLE BRAID BRUSH ASSEMBLY GUIDE PLATE INSULATOR SUPPORT EYE BOLT LUG ANCHOR ROPE EYE BOLT CABLE GRIP ANCHOR ROPE ANCHOR ROPE CLIP

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CABLE GRIP CABLE COUPLER CABLE COUPLER ADAPTOR COVER CABLE COU~LER SUPPORT COMPOUND BARRIER CONDUIT FLANGE OIL COVER ADAPTOR PLATE SETSCREWS INSULATOR UPPER SETSCREWS TERMINAL SCREW BOLT FOR FLEXIBLE BRAID SETSCREW FOR FLEXIBLE BRAID SHOE SUPPORT SETSCREW INSULATOR SUPPORT SETSCREW OIL COVER SETSCREW DANGER PLATE SETSCREW INSULATOR LOWER SETSCREWS DANGER PLATE DANGER PLATE

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GENERAL ARRANGEMENT OF

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COLlECTOR RINGS INSULATORS · INSULATOR SHIElD INSULATOR ADAPTOR PLATE inSTANCE PIECE SPECIAL SETSCREWS S~AKE PROOF LOCKWASHER COLlECTOR RING SHOE COLlECTOR RING SHOE SUPPORT PIN SPRING FLEXIBlE BRAID GUIDE PLATE INSULATOR SUPPORT EYE BOLT LUG SPLIT EYE BOLT 3/811 DIA WIRE ROPE

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24 25 26 27 28 29

30 31 32

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Clutch Guard - Upper Half R.H. Clutch Guard - Upper Half L.H. Truck Frame Clutch Guard - Lower Half Cylinder Head- Back Cylinder Head - Front Cylinder Piston Rod Back Piston Follower Front Piston Follower Packing Cup Gasket Rod Bolt

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FOR ARRANGEMENT OF L,H.SIDE PIPING SEE FIG.I9/RI

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BRAKE SUPPORT MALE & FEMALE ELBOW CLUTCH SPIDER BOLTS INSPECTION COVER SHAFT END COVER

F IG .. l If~Ru.I~Gi!.!:E:..!.N:!!E::.!RuA:l!:L::..-.:Ao.!l.R~RA!:l;N~G=E.!!:M!.!:E:..!..:N~T!..-..!:O::!..!F~I=...S~O.!!R...!:::'!B:.......:....:H~Or:::.:.:IS=....T!........!:A:!!.N.:.::D~P;,.:,;·R~O~P....;,!:-E::.:L=---:.M:..:..O~if-=-O.:.:.:.R--=-S~H~A~FT

DESCRIPTION HOIST OR DRAG CLUTCH HOIST OR DRAG CLUTCH HOUSING CLUTCH HOUSING HUB CLUTCH HOUSING HUB BOLTS -':J: 34 PROPEL CLUTCH ~~ 35 PROPEL CLUTCH HOUSING ~3 36 CLUTCH HOUSING HUB a..u 37 CLUTCH HOUSING HUB BOLTS 38 PROPEL MOTOR SPROCKET SHAFT 39 SHAFT RETAINER 40 OUTER SPACER 1-=4~1"1--';0~U:-;T~E;;::R~B='EA?-R~IN~G~R:-::E:-::T::-:A-:-1N:-c-=ER=c------l 42 BEARING RETAINER OIL SEAL RING 43 OUTER BEARING ,_ 44 INNER Be.ARtNG RETAINER l:! 4S PROPELLING CHAIN g 46 SPROCKET SHAFT BEARING COVER !f 47 INNER BEARING "' 48 SPROCKET SHAFT BEARING BASE (5 49 INNER BEARING INNER RETAINER 6 50 INNER BEARING OUTER RETAINER ~ 51 BEARING RETAINER OIL SEAL RING

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SPIDER

~ 54 AIR HOSE ASSEMBLY

::5

55 CLUTCH SPACER

I[ 56 EXTENSION PIPE 57 58 59 60

MALE& FEMALE UNION ELBOW CLUTCH GUARDS ROTOR SEAL SHAFT END COVER

FOR ARRANGEMENT OF R.H.SIDE PIPIN.G. S!OE FIG.20

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SHAFT

HOIST SHAFT L.H. SIDE FRAME GEAR CASE COVER R & M BEARING RETAINING PLATE SPACER BEARING RETAINER "0" RING GASKET SPACER GITSEAL OIL RING OIL SEAL RING SPACER "O" RING GASKET OIL SEAL RING BRAKE AND CLUTCH SPIDER BRAKE HOUSING SPECIAL BOLT

18 19 20 21 22 23 24 25 26 27 28 29

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BRAKE SUPPORT ARRANGEMENT HOIST BRAKE TEE ADAPTOR CLUTCH PIPING HOSE ANCHOR L H S PIPING ROTOR SEAL END COVER INSPECTION COVER CLUrCH I:IO!JSING HUB CLUTCH HOUSING AIRFLEX CLUTCH HOIST CLUTCH GUARD PROPEL CLUTCH GUARD HOIST/bRAG MOTOR PROPEL SPR<ICKET SHAFI' BEARING BASE

35 36 37

3B

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44 45 46 47 48 49 50 51

' BEARING COVER BEARING RETAINER "O" RING GASKET SPACER OIL SEAL RING TIMKEN BEARING SPACER BEARING RETAINER "0" R.IN'G GASKET OIL SEAL RING DoUBLE TRIPLEX ROLLER PROPEL CLUTCH SPIDER SPACER CLUTCH PIPING HOSE ANCHOR R.H.S. PIPING END COVER

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1NSTRUCTIONS FOR ASSEMBLING AR-C TYPE 'AIRFLEX' CLUTCH ELEMENT

COMPRESSED AIR RElEASED FROM CllllTC\1 AIR TUBE. CLUTCH btSENGP..GED

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SPRING

housing on a flat surface resting on' the small flange as •FJ!fown in Fig .1. qlutch sizes up to and including 14 AR-C have one air tube & 16 AR-C to 45 AR-C inclusive have 2 air tubes.

P,lace the valve of rubber air tube.through the valve hole tn the housing, fit J~ed fibre washer and assemble G.M. elbow, making sure that the joint is airtight ~hen the elbow is tightened and turned ~ound in line with the air Qole in the large flange to enable the screwed connec-t;.or to be assembled.

Do not forget to put red fibre washe1• and locknut to connnector before screwing home.

Tighten locknut.

If clu+...ch has 2 air tubes, repeat above procedure for the second tube.

Stroke ~he rubber air tube or tubes into position round the internal surface of the housing, making sure that they have been fitted squarely.

With clutch ~esting as Fig.l insert torque bars into their respective holes in the housing taking care that the narrowest part of the tapered section is tc!Wards the J1entre..

Now slide a friction block between each pair of torque ·bars and . ~lide a spring between the outside surface of each torque bar and the overhanging rejections on 2 adjacent friction blocks.

Make sure that the 2 spring ends ere bearing on the torque bar.

Using a piece of steel or brass, lightly tap ;, Now place the end 1hese springs into position central with friction blocks.

1plate inrposition and fit 2 or 3 bolts temporarily finger tight so that the end Jplate bears lightly on the ends of the torque bars.

Check that the qir hole c~r holes in the end plate which fit over the head of the M.S. connector are in t he correct position.

Check also that the countersunk holes (if any) in the 1 plate are in the correct position relative to the tapped holes in the elnd r{ousing flange.

Manoeuvre one torqu"e bar at a time into its respective hole in fJhe end plate.

This will be simplified if a screw driver or piece of metal is ~~sed to press the torque bar outwards from the centre against the spring tressure action until it is lined up with the hole.

A slight tap on the end P,late will cause it to enter and this entry can be increased by tapping the ~fther end of the torque bar.

Continue round the element in one direction until ~Lll t.he torque bars are correctly assembled.

Whilst this is being done, keep ~l11 the bolts finger tight only.

When all torque bars are entered, press or lightly tap the end plate until it is against the housing flange and fit 2 ljountersunk head screws (if fitted) or 2 fitted bolts to hold the element to1rether.

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TORQUE. BARS

CLUTCH DISENGAGED THE. PRINC.IPLE ON Wr\IC.H Tr\E 'AIRFLE.X' C.l!.;UTC.I-\ OPERATES IS AS FOLLOWS:- COMPRESSED AIR IS ADMITTED TO A SPECIALLY CONSTRLlC.TE.D AIRT161-\T TUBE WHICI-\ E.')I..PANDS AND FORCES THE. SPECIALLY DE.SIGNE.D FRICTION BLOCKS OR SLIPPERS DN TO THE FRIC.TION RIM. TO DISEN-GP...GE. THE C.LLlTC.\"\, AIR IN TI-\E. RUBBER TLIBE. 1.5 E')I...HAUSTED TO AiMOSPHERE

M.S. CONNE.~TOR RED FIBRE. 'N~SHER &. LOC.K.NUT

RE.O FIBRE WASHE S THICKNESS TO SUIT BUILD UP TO 4_ OF C.ONNE.C.TOR

HOIST OR PROPEL CLUTCH TYPE AR-C FIG. 12.

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OPERP...TING PRINCIPLE &. ASSE.MBLY OF CROFTS 'A.R-C' CONSTRICTING TYPE 'AIRFLE.'>\' Cll\TCI-\

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BI379509 j INSTALLI>.TION OF CENTRE PINTLE &LEEWE AND PROPELLING SHI>.FT I. PLACE REVCJL:'VING FRI>.ME. ON TRUCK. FRAME. WITH CENTRE. PINT'l..E. BORE& IN PERFECT ALIGNMENT <.REMOVE. RETA(INE.R PLII.TE.S PC. MK.e.. 51 AND 5B FROM UPPER PROP SHI>IFT PC.Mi<..S~. SLIDE UPPER PROPEL SHAFT PC.M. 53 ·'TO THE RIGHT AGI>IINll.T .'ri'HE PROPEL CHI>IIN CASE PC.MK..BI HI>.VING REMOVED COVER PLii-TE PC.MKtBE. FRDM THE PROPEL C:.HI>.IN' CASE PC.MK.BI TO PROVIDE. ENOUGH. CLE.ARI>.NC:.E. FOR UPPER PRO*L SHAFT PC.Mi<..53.

3.APPLY A LIB!:.Ri>.L COATING OF GREA&E TO THE. CENTRE. PINTLIE. SLEEVE., THE BORE IN THE REVOLVING . ,.

FRAME. AND hHE BUSH IN~ IN THE. TRUCK. FRAME. 4.1N&ERT THE. ~CENTRE PINTLE SLEEVE FROM THE. TOP AND &ECURE IN PLACE WITH THE. Ld'CK PLI>.TE. PC.MK.9 BOLTED TO T/HE. DECK. S.ASSEMBLE. THE THRUST COLLP.R PC.MK.Gri~>.ND SLEEVE LOCKNUT PC.Mi<..S TO THE BOTTOM OF THE. SLEEVE. SECURE THE \LOCKNUT IN PDSITIOK BY IKSERTING LOC:.i<.BII.RS PC.Mi<..!!, HELD IN PLI>ICE. il.Y CAPSCREWS WITH THE. HBADS WIRED TOGETHER. .

6.1NSERT THE VE.RTICI\L PROPELLING SHII.F1' IN n's BUSHINGS IN THE. CENTRE PINTLE SLEEVE., THEN PLACE THRUST WASHER PC.Mi<-.65 IN POSITION AND PLACE THE BEVEL GEAR PC.Mi<..64 IN POSITION, SECLJRE. THE. SHI'IFT IN PLkE BY INSERTING THE TWO PART5 OF RE.TI'>INING COLLAR PC. MK. 6~. lRAISE THE. VERTICAL SHAFT ENOUGH TO PERMIT PLII.CING BE.YE.L PINION PC.MK..Gl IN POSITION, THEN LOWER SHI>IFi: INTO PINION WITH SPLIT THRU&T WASHER PC:.Mi<..SG IN POSITION. SECURE. PINION IN PLACE.

BY INSTALLINii\ LOCKNUT PC. MK. 6B B.PLII.CE BEVEtl PINION PC.MK. 55 IN POSITION, SLIDE. UPPER PROPEL SHAFT PC. MK..S:'i TO THE LEFT. SECURE THE SHAFT 1'N PLACE. BY INSTALLING RETAINER PLATES PC.MK.S. 51 ANOSB HELD IN PLACE. WITH CAPSCRE.WS WITH THE HclAD& WIRED TOGETHER

I

II.DJU5TMENT OF CENTRE. PINTLE. SLEEVE. ALL II.DL!USTh~ENT OF THE. CENTRE PINTLE &LEEYE. TO COMPE.N&ATE FOR WEAR OF THRUST COLLAR, ROLLERS TRACK. Bi>.RS !Ere. IS MADE. I>.T Tf-\E. LOWER END OF THE SLEEVE !.DRAIN OIL FR'OM THE GE.II.R CASE. AT THE. CENTRE OF ROTATION AND REMOVE THE GEAR CASE COYER. a. REMOVE LOC~~ BII.R::i PC. MI<..B AND ENGAGE. LOCKNUT ADL!USTING PIN PC. MK.IS WITH THE SLEEVE LOCKNUT 1 ~.ROTATE REVOLVING FRAME TO THE. RIGKT TO TIGHTEI'\ THE. LOCKNUT, OR TO THE LEFT TO LOOSE.N. 4.AFTE.R ADL!CJSTMENT, RE.PLI'ICE. THE. LOCK BARS PC.MK.B AND DISENGAGE. THE. ADLIUSTING PIN PC:.MK.19.

MAKE SURE. •:rHAT HANDLE ON PIN IS TURNED PARALLEL WITH PIN AND LOCKED IN SLOT TO PREVENT PIN FROM ENGAoiiNG SLEEVE LOCK NUT PC.MK.S THEN REPLACE THE COVER AND REFILL WITH SUITABLE LUBRICANT.

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ADL!UBTMENT OF VERTICAL PROPELLING SHI\FT THE VE.RTIC:Alll SHAFT THRUST WASHERS AT TOP AND BOTTOM WILL WEAR VERY LITTLE IN SERVICE 1 BUT IF EXCESSIVE SLACI<. DEYE.U> PS REPLP..CE SPLIT THRUST WASHER PC.MK.66 WITH A THICKER ONE.

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' REF. NAME. OF PIECE NO. I REVOLVING FRAME. 2 CENTRE. PINTLE &LEEVE. ~ UPPER E.USHING 4 LOWER BUSI-'.ING 5 LOCKNUT uJ THRUST W.c>.SHER :L <1 l OPERATORS PLATFORM !>': B LOCK BAR lL 9 UPPE.R LOCK PLI>ITE. {9 10 GITSEAL z. II SEI!>.L RETAI NE.R ~ 12. REV. FRAME. RAIL 0 (;'j I~ RAIL CLAMP 14 rt: IS

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VERTICAL PROPEL SHAFT SPLIT RETAINING COLLAR 64 BEVEL GEAR 65 SPLIT THRUST WASHER Go SPLIT THRUST WASHER 61 BEVEL PINION 6B LOCK NUT 69 10 11 12. LONGITUDINAL PROPEL SHAFT l~ BEVEL GEAR 14 GE.AR R.IM lS THRUST WASHER 16 RETAINING WASHER 11 SETSCREW >&' UNC.x I>," 1& LOCKWIRE 10(;A.XI2.'

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8.1 CHAIN CASE. 8.2. CHAIN CASE. COVER B3 GASK.E.T 84 COVER PLI!>.TE BS GASK.E.T &6 COVER PLATE 81_ BB B9 MOIST SHAFT 190 HOIST DRUM LAGGING 91 LAGGING SPIDER 92. THRUST WASHER 9~ HOIST DRUM GEAR 94 K.E.Y 95 96 81 SB ROLLER ASSEM!!.LY

99

100 GE.N. PIRR'G'T DF COLLECTOR GEAR 101

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INSTRlJC.TIONS FOR T~KING UP BE.P..RI~G WEAR I. DE.CRE.P..SE. Tl-\ICKNE.SS OF Sl-\IMS ·~TO OBTP..IN '1e.4'' RUNNING C.LEP..RANC.E..

2. ADD 51-\\MS ( I-~-3-4-40Z:JB02) UNDE.R KE.Y.S AT 'X' E.QUP-.L TO THlC.KNE.S5 RE.MOVE.D FROM Sf-\lMS 'P.:,

NOTE.: Sl-\\MS l-e.-3-4- 40~&02 P--RE. FURNISI-\E.D WITH TDOL5 AND SUPPLlE.S UNIT.

HOIST BEARING CAP SHIMS FIG. 15.

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BI379509 PG. MK.I SHOVEL. HOIST AND CRAGL.INE' CRAG MOTOR !lRAKE: ASSEMBLY COMPRISING ALL DETAILS IN 6ROUP(D PC. MK.~. CRfiGL.INIO: CONPRI51NG

HOIST

1 2 3 4 5 6 7 8 9 10

MOTOR BRAKE A55E:M6L.Y

fiLL. OETI'IIL.S IN GROUP

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GEAR CASE LH SIDE FRI\ME

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BRAKE SUPPORT 1\RRANGEMENT ON SHOVEL & DR/'IGLINE DRAG

BRAKE HOUSING BRAKE HOUSING HUB BRAKE SUPPORr BRAKE SHOE BRAKE SUPPORT WOVEN ASBESTOS LINING BRAKE LEVER TRUNNION PIN PIN SPRING SPECIAL STUD TRUNNION SPACER PIN SPECIAL BOLT CUP POINT SET SCREW PIN CYLINDER I PISTON PISTON FOLLOWER HELICAL COMP. SPRING SPRING RETAINER ROD BOLT MOULDED PACKING CUP ANGLE SPRING ASSEMBLY PIN ADJUSTING NUl'S BRAKE SHOE SPECIAL STUD BRACKET

1\SS~BJ.Y H~IGHT'fi OPERATING HEIGHT"fi PIN IN PLACE BRAKE StT

LOCATION

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SH.HOIST& ,ORI\G·I50·B&I90·B 'Y, HOIST -150· B

!.l INSTRUCTIONS

FOR

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ASSEMBLING CYLINDER

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II',! GYLJNi:lER@WITH WEMBLY PIJ'@IN PLACE INSERT PISTON & INSTALL I'ISSEMBLE SPRING@& SPRING RETAINER ROO BOLTS@ A=UST SPRING @ToPROPER I'ISSEMBLY HEIGHT AS SHOWN. WORKING HEIGHT WILL RESULT WHEN I'ISSEMBLY PIN@IS REMOVED. 00 NOT REMOVE ASSEMEILY PIN@~ COMPLI.:TE BRI'IKE ASSEMBI.Y IS MOUNTEQ ON MOTOR & AIR PRE:SSURE: CAN BE I'IPPLIED. LE:AVE: PIN IN POSITION. WHEN SHIPPING.

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INSTRUCTIONS

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FOR

1\0:TUSTING

BRI'IKE

I'IFJE:R MO~TING BRI'IKE: ON MOTOR APPLY AIR PRESSURE TO CYLI~ @ REMOVE ASSEMBLY PIN 1"\DJ"UST LE R STOP BOLT@ TO GIVE:~' Cl.EARI'INCE BE:T\JEEN BRAKE SHOE: 4 &HousiNG(}JIN REI.EASE: POSITION. AD:fUST NUTS f3 WITH BRAKE IN RELEASE: POSITION SO THAT BOTH ENIJS~F SHOE: HAVE: EG.UAI. RELEASE:. RE:I'ID:TUST Lf:V R STOP BOI.T 15 TO COMPENSI'ITE: FOR WE:f'IR ON LINING I'IFTE:R CON E:RI'IB~E: WEf'IR ON LINING 6 IT WIL~ BE NECE:SSI'IRY TO f'IO:TUST SPRINB@~N Ts@ BE SURE LE:VE:R STOP agg_1@£L INSTAI.LE:O 6EFORE: 1\PPLYING 1\IR PRESSURE:. ROOS @ MUST HI'IVE: EQUAl. I'IO:TUSTMENT SO PISTON DOE:S NOT BIND IN GYLINOE:R.

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BRAKE SUPPORT ARRANGEMENT ON ORPIGWNE: HOIST

NOTE:: I'ISSE:MBLE BRI'IKE CYLINDER ON MOTOR PER. MI'ICHINERY DRPI\JING.

·:I STuo@ MUST NOT BE SCREWED INTO LINING

,&_tOTOR BRAKE I'ISSEMBLIE:S BIVEN PIECE MARKS :ANI:l DETAILS GROUPED FOR 150 RB MI'ICHINES

MOTOR BRAKE- MAIN MACHINERY

FIG. 16.

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INSTRUCTIONS FOR P>.OiJLJSTING BRI>.KEI>.DJUST SCRE-WS @ \"i\Ti'l BRI>.KE. IN RE.LE.I>.SED POSITION SO Tf-11'-T BOTi'l E.NDS OF SHOE H!WE. EQUI>.L RELEI>.SE-1'-BDUT ;IG THE. ONLY P>.OiJUSTME.NT REQUIRED \S TO COMPE.NSfi.TE. FOR WEAR OF Tf\E. LINING OF Tf\E. BRfi.KE SHOE.S- WHEN THE. BRI>.KE. WILL NO LONGER f-\OLD TIGHTE.N Tf-\E Sf\OE. P>.DJUSTME.NT M FOLLOWS: WITH THE BRP>.KE. SET INSERT A SCREW DRIVER BETWEEN WASHER@I>.ND Tf\E. END OF Tf-\E. CYLINDER, RELIEVE PIN(j) OF Tf\E SPRING LOI>.D

BY PRYING WITI-\ Ti'IE. SCREW DRIVER 1\ND REMOVE PIN (j) LOOSEN LOCK NUT@I\ND TURN E.YE.BOLT@TO TI-\E RIGHT (CLOCKWISE) TO TIGHTEN Tf\E. BRI\KE. HOLD WMHER@ FROM TURNING BY INSERTING SCRE.W DRIVER IN ONE. OF THE. SLOTS IN Tl-\E. WMI-\ER TIGHTEN LOCK NUT@ !\NO RE.PLI>.C.E. PIN (]) IT WILL !\LSD BE NEC.ESSP>.RY TO RE-SET THE RELEME. SCREWS@ FOR UNIFORM RELE.!)..SE. OF Tl-\E Sl-\DES

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SEC.TIDNAA

M0 T 0 R B R A K E - SWI N G MAC H I N E RY FIG. 17.

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3.THE SOLENOID VALVE IS DE- ENERGIZED TO ADMIT AIR >-ui TO CLUTCHES. t;ja: 4.STEERING CYLINDERS OPERATE CLUTCHES TO BOTH LOCK ILUl <,... . ,O.ND STEER POSITIONS, STEERING CYLINDERS ARE tilCONTROLLED BY A FIVE POSITION SEMI- ROTARY SWITCH HAVING POSITIONS "STRAIGHT'; "STEER RIGHT'; "LOCK RIGHT'; "STEER LEFT" & "LOCK LEFT:' WITH SWITCH .IN THE "STEER RIGHT" POSITION, THE R.H. SOLENOID IS ENERGIZED, ADMITTING ·AIR AT A REDUCED PRESSURE OF 35 P.S.I. (INDICATED BY THE GAUGE IN THE OPERATOR'S CAB) TO THE CYLINDERS, SO DISENGAGING THE R. H. CLUTCH. THE MACHINE JOINT. _ WILL TURN TO THE RIGHT WHEN THE DRIVING TUMBLERS ARE AT THE REAR. WITH THE SWITCH IN THE" LOCK RIGHT" CROWD SUPPING POSITION, BOTH THE LOCK SOLENOID AND THE R. H. SOLENOID CLUTCH. ARE ENERGIZED, ADMITTING AIR AT MAIN LINE PRESSURE TO THE lcilowol STEERING CYLINDERS WHICH MOVE THE R.H. CLUTCH TO THE EXTREME OUTSIDE POSITION, LOCKING THE R.H. CAT. BELT TO THE SIDE FRAME. THE MACHINE TURNS SHARPLY TO THE RIGHT WHEN THE DRIVING TUMBLERS ARE AT THE REAR. STEERING TO THE LEFT IS OBTAINED BY MOVING THE SWITCH TO EITHER THE "STEER LEFT" OR ''LOCK LEFT" POSITIONS. THE MACHINE TURNS TO THE LEFT WHEN THE DRIVING TUMBLERS ARE AT THE REAR. WHEN THE SWITCH IS IN THE "STRAIGHT" 3: Ill . til>< POSITION ALL SOLENOIDS ARE DE- E!'lERGIZED, ENGAGING' R.H. & ·< J;o: L.H. CLUTCHES. THE MACHINE TRAVELS STRAIGHT AHEAD WHEN o:m .

GAUGES IN THE .DRIVING TUMBLERS ARE AT THE REAR. ,.

OPERATORS CAB 35P.S.I. 110 P.S.I. Ill

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VALVE. NOTE:I.ALL BRAKES ARE SPRING SET AND PRESSURE RELEASED. UJ 2. THE SOLENOID VALVE A IS ENERGIZED TO ADMIT AIR TO :'j BRAKES OR STEERING CYLINDERS. ~---------~-----------Y . z 3.THE SOLENOID VALVE IS DE-ENERGIZED TO ADMIT AIR g~ >-ui TO CLUTCHES. a: ' :;Jt[j~·---..., 4.STEERING CYLINDERS OPERATE CLUTCHES TO BOTH LOCK u.lll ~I ~< W-1 ..:,...

AND STEER POSITIONS, STEERING CYLINDERS ARE 0 t--' J:< Ul1-, UJUJ ui U?'" GAUGE CONTROLLED BY A FIVE POSITION SEMI- ROTARY SWITCH a:"' a: HAVING POSITIONS "STRAIGHT',' "STEER RIGHT',' "LOCK RIGHT~ 0: iilwo ~-50P.S.I. m tn>tO "STEER LEFT" & "LOCK LEFT~ WITH SWITCH IN THE "STEER RIGHT" POSITION, THE R.H. SOLENOID IS ENERGIZED, I' a.>lADMITTING AIR AT A REDUCED PRESSURE OF 35 P.S.I. ''L.. .rl------~-~-:-::::-1 ,d/~· ~,..: swiVEL n (INDICATED BY THE GAUGE IN THE OPERATOR'S CAB) TO THE ..J"' JOINT. Y CYLINDERS, SO DISENGAGING THE R.H. CLUTCH. THE MACHINE ;; ~ . .-L..

WILL TURN TO THE RIGHT WHEN THE DRIVING TUMBLERS ..J ~ [ __] ARE AT THE REAR. WITH THE SWITCH IN THE" LOCK RIGHT" UJ CROWD SUPPING POSITION, BOTH THE LOCK SOLENOID AND THE R. H. SOLENOID cLUTCH. ARE ENERGIZED, ADMITTING AIR AT M.A,IN LINE PRESSURE TO THE ~ROW"'[] STEERING CYLINDERS WHICH MOVE THE R.H. CLUTCH TO THE EXTREME OUTSIDE POSITION, LOCKING THE R.H. CAT. BELT TO THE SIDE FRAME, THE MACHINE TURNS SHARPLY TO THE RIGHT WHEN THE DRIVING TUMBLERS ARE AT THE REAR, STEERING TO THE LEFT IS OBTAINED BY MOVING THE SWITCH TO EITHER THE "STEER LEFT" OR "LOCK LEFT" POSITIONS. THE MACHINE TURNS TO THE LEFT WHEN THE DRIVING TUMBLERS ARE AT THE REAR. WHEN THE SWITCH IS IN THE "STRAIGHT" POSITION ALL SOLENOIDS ARE DE- ENERGIZED, ENGAGING R.H. & :i~ L.H. CLUTCHES. THE MACHINE TRAVELS STRAIGHT AHEAD WHEN ci"' GAUGES IN THE DRIVING TUMBLERS ARE AT THE REAR. WHEEL OPERATORS ~VALVE. ~~CAB 3SP.S.I. flO P.S.I.

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FIG.ISj_RI SCHEMATIC DIAGRAM OF ISO RB AIR PIPING I.M.Il323.

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4. Steering cylinders operate clutches to both lock and steer positions. Steering cylinders are controlled by a five ,position semi:rotary switch having positions 'straight.',_ 'steer right', 'lock right', 'steer left' ~nd 'lock left'.

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With switch in the 'steer right' position, the R.H. solenoid is energised admitting air at a reduced pressure of 35 P .S.I. (indicated by the gauge in the operator's cab) to the cylinders, so disengaging the R.H. clutch.

The machine will turn to the right when the driving tumblers are at the rear.

With the switch in the 'lock right' position, both the lock solenoid and the R.H. solenoid are energised, admitting air at main line pressure to the steering cylinders, which move the R.H. clutch to the extreme outside position, locking the R.H. cat. belt to the side frame.

The machine turns sharply to the right when the driving tumblers are at the rear.

Steering to the left is .obtained by moving the switch to either the 'steer left' or 'lock left' positions.

The machine turns to the left when the driving tumblers are at the rear.

WHE.iL VALVE

BI379509

When the switch· is in the 'straight' pos1t1on all solenoids are de-energised, engaging R.H. and L.H. clutches the machine travels straight ahead when the driving tumblers are at the rear.

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PIPE t2 11 ESP MEDIUM x 6.~s11 LONG PIPE t211 ESP MEDIUM x 7.1 Sll LONG PIPE ~2 11 ESP MEDIUM x 6 '-4. 5/S11 LONG PIPE ~2 11 ESP MEDIUM x 4.~S 11 IDNG PIPE t2 11 ESP MEDIUM x 101 211 IDNG PIPE ~2 11 ESP MEDIUM x lt-Olj211 LONG PIPE ESP MEDIUM: X 9Y2 11 LONG PIPE ~211 ESP MEDIUM: x 2'-3t211 LONG PIPE ~2 11 ESP MEDIUM x 2'-7Y2 11 IDNG PIPE ~2 11 ESP MEDIUM x 4'-211 LONG PIPE ~2 11 ESP MEDIUM X J'-41/411 LONG PIPE ~2 11 ESP MEDIUM x l'-lllj411 IDNG PIPE t2 11 ESP MEDIUM x 2' -Q. 5/Sll IDNG PIPE ~2 11 ESP MEDIUM x 3Y411 LONG .

PIPE t211 ESP MEDIUM x 2'-6~/411 IDNG PIPE ~2 11 ESP MEDIUM x 3' -S1 211 LONG PIPE ~211 ESP MEDIUM: x 1.3/411 IDNG 6E5 PIPE ~211 ESP MEDIUM x l'-5-7/S11 LONG PIPE ~2 11 ESP MEDIUM x. l t-61j4* IDNG 69.

70 PIPE ~211 ESP MEDIUM x S.%411 LONG .

71 PIPE ~2 11 ESP MEDIUM x 4. S11 IDNG 72. PIPE ~2 11 ESP MEDIUM x 3'-31j211 IDNG PIPE ~211 ESP MEDIUM x l'-2./{16 11 LONG 73 PIPE ~211 ESP MEDIUM x 3'-S.7 16 11 LONG 74 PIPE ~2 11 ESP MEDIUM x lO.J/S11 LONG 75 PIPE t211 ESP MEDIUM x 3 '-5.3/S11 LONG 76 PIPE ~211 ESP MEDIUM x l'-l.7/S11 IDNG 77 PIPE ~211 ESP MEDIUM x l'-611 LONG 7S PIPE ~2 11 ESP MEDIUM x 41j211 IDNG 79 11 so PIPE ESP MEDIUM X· 9-~4 11 IDNG Sl PIPE 3/S11 ESP MEDIUM x l 4 11 IDNG PIPE 3/S11 ESP MEDIUM x '5'-0.5(S11 IDNG S2 PIPE 3/SII ESP MEDIUM x lt-llj211 IDNG S3 PIPE 3/SII ESP MEDIUM x lt-lllj211 LONG S4 PIPE 3/S11 ESP MEDIUM x 6. 5(S 11 LONG .

S5 S6 PIPE 3/S11 ESP MEDIUM x l'-2 11 LONG PIPE 3(S11 ESP MEDIUM x 2'-3.3/411 LONG S7 ss PIPE 3/S11 ESP MEDIUM x 2.7/S11 LONG PIPE 3/S11 ESP MEDIUM: x 7. 9(16 11 IDNG S9 PIPE 3(S11 ESP MEDIUM: x 5.3(S11 IDNG 90 PIPE 3/S11 ESP MEDIUM x' l'-llj4 11 IDNG 91 PIPE 3/S11 ESP MEDIUM x l'-ll.J(S11 LONG .92 PIPE 3/S11 ESP MEDIUM x 3 t-SY211 LONG 93 PIPE 3/S11 ESP MEDIUM x ll.3(S 11 LONG 94 PIPE 3/S11 ESP .MEDIUM x ::;'-511 IDNG 95 PIPE 3/S11 ESP MEDIUM x l011 LONG 96 1 11 ESP FEMALE UNION CRANE FIG. 2S9 97 PIPE ~4 11 ESP MEDIUM x 3'-2.5/S11 LONG 9S PIPE ~4 11 ESP MEDIUM x 7.3/411 LONG 99 100 PIPE Y411 ESP MEDIUM X ll.J/S11 IDNG 51 52 53 54 55 56 57 5S 59 60 61 62 63 64 65 66 67

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101 102 103 104 105 106 107 lOS 109 110 lll ll2 113 114 115 116 117 liS ll9 120 121 122 123 124 125 126 127 l2S 129 130 131 132 133 134 135 136 137 l3S 139

PIPE t411 ESP MEDIUM x 2'-lllj411 LONG PIPE Y4 11 ESP MEDIUM X l'-5-3/411 LONG PIPE SUPPORT PIPE t411 ESP' MEDIUM: X l'-3Y211 IDNG PIPE t411 ESP MEDIUM x 3'-3.11/1611 LONG PIPE ~4 11 ESP MEDIUM x l'-91j211 LONG PIPE ~411 ESP MEDIUM: x 4 11 LONG .

PIPE ~4 11 ESP. MEDIUM x l'-S.5/S 11 LONG PIPE Y411 ESP MEDIUM X lt-1. 7/S11 IDNG PIPE 1 11 ESP HEAVY x 3.3(S11 LONG PIPE CLIP PIPE SUPPORT Y411 ESP PIPE CLIP RIDS367/l ~S 11 ESP PIPE CLIP RBGS367/3 1 2 11 ESP PIPE CLIP RBGS367/5 PIPE SUPPORT PIPE CLIP PIPE SUPPORT ~S 11 ESP FEMALE UNION ELBOW CRANE FIG. 276 1211 ESP BLANKING PLUG CRANE FIG. 147 ~SII TAPER THREAD SOCKET CRANE FIG. 177 1 2 11 x 3(S11 ESP HEXAGON NIPPLE CRANE FIG.l45 PIPE lj211 ESP MEDIUM ;x: l'-5-3/411 LONG PIPE SUPPORT PIPE CLIP 3/S11 ESP ELBOW M & F FIG. 152 PIPE SUPPORT PIPE CLIP PIPE 3/S11 ESP MEDIUM: x 2'-511 LONG PIPE %SII ESP MEDIUM x l'-0.7/SII' IDNG PIPE 2 11 ESP MEDIUM x 3 11 LONG 11 ESP MEDIUM X 1111 LONG PIPE 3/S11 ESP FEMALE UNION TEE CRANE FIG. 279 111 ESP PIPE CLIPS RBGS367/9 PIPE lj211 ESP MEDIUM X 3-3/S11 LONG lj2 11 ESP UNION M & F .c~ FIG. 272 PIPE. ~2 11 ESP MEDIUM x 7 .J/411 IDNG 11 BSP.MEDIUM: X 2 1 -6Y411 IDNG PIPE PIPE SUPPORT

Y2

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BI379509

43 44 45 46 47 4S 49 50

1 11 ESP WHEEL VALVE 300 lbs ~ HATTY FIG. l2 1 11 ESP TEE .M & F CRANE FIG. 163 PIPE Y411 ESP MEDIUM: X 2'-11.13/1611 IDNG 1 11 ESP BEND M & F CRANE FIG. 192 PIPE 1 11 ESP HEAVY x l'-5-7/16 11 IDNG Y2" X Y411 ESP REDUCING ELBOW CRANE FIG. 151 3/SII ESP F~ TEE CRANE FIG. 161 lj211 ESP UNION M & F CRANE FIG. 272 1 11 ESP FEMALE BEND CRANE FIG. 193 PIPE 1 11 ESP HEAVY x l'-91j211 LONG PIPE 1 11 ESP HEAVY x 91j211 LONG PIPE Y211 ESP MEDIUM X 2'-11.5/1611 LONG 2 11 x 1 11 ESP HEXAGON BUSH CRANE FIG. 140 2 11 X lj2 11 ESP HEXAGON BUSH CRANE FIG. 140 ~2'' ESP BlANKING PLUG CRANE FIG. 147 11 ESP F:EMALE UNION ELBOW CRANE FIG. 276 11/411 X BSP HEX: REDUCING NIPPLE CRANE FIG. i45 ~S 11 X Y411 ESP REDUCING SOCKET CRANE FIG. 132 11 ESP CIDSE NIPPLE CRANE C 52 ~2 11 ESP TAPER THREAD SOCKET CRANE FIG. 133 t2 11 ESP EQUAL HEXAGON NIPPLE CRANE FIG. l44 ~2 11 ESP FEMALE ELBOW CRANE FIG. 151 ~2 11 BSP ELBOW M & F CRANE FIG. 152 ~2 11 ESP FEMALE TEE CRANE FIG. 161 ~2 11 ESP F:EMALE UNION CRANE FIG. 2S9 ~2 11 ESP UNION ELBOW M & .F CRANE FIG. 277 · ~211 ESP F'EMALE UNION TEE CRANE FIG. 279 ~2 11 ESP UNION TEE M & F CRANE FIG. 200 V2 11 ESP WHEEL VALVE 300 lbs. HATTY FIG. l2 lj2 11 X 3/S11 ESP HEXAGON BUSH CRANE FIG. 140 3(S11 ESP WHEEL VALVE 200 lbs. HATTY FIG. 7 3(S11 ESP F:EMALE ELBOW CRANE FIG. 151 3/SII ESP UNION ELBOW M & F CRANE FIG. 277 3(S11 ESP UNION TEEM & F CRANE FIG. 200 PIPE 1 11 ESP HEAVY x 51j211 IDNG 3/SII ESP CLOSE NIPPLE CRANE FIG. C 52 %SII ESP UNION M & F CRANE FIG. 272 4 11 ESP FEMALE ELBOW CRANE FIG. 151 t411 ESP ELBOW M & F CRANE FIG. 152 · ~411 ESP FEMALE UNION ELBOW CRANE FIG. 76 ~411 ESP UNION ELBOW M & F CRANE FIG. 277 ~2 11 X V411 BSP HEXAGON BUSH CRANE FIG. 140 ~4 11 ESP ;F:EMALE TEE CRANE FIG. 161 Y4•i ESP UNION M & F FIG. 272. .

PIPE ~211 ESP HEAVY x l'-~~2 11 LONG PIPE ~211 ESP HEAVY x 1'~~411 IDNG PIPE ~2 11 ESP HEAVY x l'-2Y211 LONG P:i:PE ~211 ESP HEAVY x 6 11 IDNG PIPE ~211 ESP HEAVY x 5.3/S11 IDNG 11 ESP MEDIUM X l'-4-3/411 IDNG PIPE

REFERENCE LIST FOR L.H. & R.H. AIR PIPING. FIG. 19/R3 & FIG. 20/Rl -

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BSP MEDIUM x 6.~Sn LONG BSP MEDIUM x 7.1 S" LONG BSP MEDIUM x 6t-4.5/S 11 LONG BSP MEDIUM x 4.3/S" LONG BSP MEDIUM x lOY2" LONG BSP MEDiill:[ x l'-OY2" LONG BSP MEDIUM X SY4" LONG BSP MEDIUM x 2'-lY2" LONG BSP MEDIUM x 2'-5.3/4" LONG BSP MEDIUM x 4' -2" LONG BSP MEDIUM x 3'-4Y4" LONG BSP MEDIUM x l'-llY4" LONG BSP,MEDIUM x 2'-0.5/S" LONG BSP MEDIUM x 3Y4" LONG BSP MEDIUM x 2'-6yS/4" LONG BSP MEDIUM x 3 '-S1 2" LONG BSP MEDIUM x 1.3/4" LONG BSP MEDIUM x l'-5· 7/S" LONG BSP MEDIUM x l'-6Y4" LONG BSP MEDIUM x S.~4" LONG BSP MEDIUM x 4.1 S" LONG BSP MEDIUM x 3'-6Y2" LONG BSP MEDIUM X l'-6" LONG t2" BSP MEDIUM x 3'-3.7/S" LONG t2" BSP .MEDIUM x lOY2" LONG ~2" BSP MEDIUM x 3'-2.YS" LONG t2" BSP MEDIUM x 9.3/S" LONG t2" BSP MEDIUM x 2'-1.3/411 LONG t2" BSP MEDIUM x 4.9/16 11 LONG BSP MEDIUM X 7Y2" LONG 3/S11 BSP MEDIUM x 3'-1.7/S" LONG 11 3/S BSP MEDIUM x 5'-0" LONG 3/S" BSP MEDIUM x l'-lY2" LONG 3/S" BSP MEDIUM x lt-UY2" LONG 3/<>n BSP MEDIUM x 6. 5/S11 LONG 3/S" BSP MEDIUM x l'-2" LONG 3/S" BSP MEDIUM x 2'-3-3/4" LONG 3/S 11 BSP MEDIUM x 4" LONG 3/S" BSP MEDIUM x 9Y2n LONG 3/S" BSP MEDIUM x 9" LONG 3/S" BSP MEDIUM x l'-lY4" LONG 3/S11 BSP MEDIUM x 1'-11.3/811 LONG 3/S" ESP MEDIUM x 3 t-SY2" LONG 3/S11 ESP MEDIUM x 11.3/S" LONG 3/S11 ESP MEDIUM x 3'-5" .LONG 3/S11 BSP MEDIUM x 10" LONG 1 11 ESP HEAVY x 3YS" LONG t4" ESP MEDIUM x 7. 5/811 LONG t4" ESP MEDIUM x l'-7.3/4" LONG Y4" ESP MEDIUM X l'-'-6 11 LONG

t2" t2" t2" ~2 11 t2" ~2" t2" %2" ~2 11 t2" t2" t2" t2" ~2" t2" t2" t2" ~2" ~2" t2" t2" t2"

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REFERENCE LIST FOR L.H. & R.H. AIR PIPING. FIG .. 19/R2 & FIG. 20 -

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101 102 103 lD4 105 106 107 lOS 109 110 lll 112 113

ll4 115 119 117 17 12 l 7 22 23 26 31 133

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36 119 120 121 122 123 124 125 126 127 l2S 129 130 131 132 115 134 135 120 22 136 25 23 137 l3S 139 140

PIPE t4" BSP MEDIUM x l'-6tS" LONG PIPE t4" BSP MEDIUM x l'-9YS" LONG PIPE t4" BSP MEDIUM x 3.3/411 LONG PIPE ~4" BSP MEDIUM x 2. 9/16 11 LONG PIPE t4" BSP MEDIUM x 3'-2" LONG PIPE ~4" BSP MEDIUM x l'-9Y2" LONG PIPE t4" BSP MEDIUM x 4" LONG PIPE t4" BSP MEDIUM x l'-4Y4" LONG PIPE Y4" BSP MEDIUM X l'-0.7/S" LONG PIPE 1 11 BSP HEAVY x 3.3/S" LONG PIPE 1 11 BSP HEAVY· x 4-~4" LONG PIPE Y2" BSP HEAVY X 41 2" LONG Y4" BSP PIPE CLIP RBGS367/l ~S" BSP PIPE CLIP RBGS367/3 1 2" BSP PIPE CLIP RBGS367I 5 3/S11 BSP FEMALE UNION ELBOW CRANE FIG. 276 ADDITIONAL PARTS TO COMPLETE SHOVEL PIPE l" BSP HEAVY x 4Y4" LONG lY4" X BSP HEXAGON NIPPLE CRANE FIG. 145 l" BSP UNION M & F CRANE FIG. 272 1 11 BSP WHEEL VALVE 300 lbs. HATTY FIG. 12 1 11 BSP CLOSE NIPPLE CRANE FIG. C 52 BSP FEMALE ELBOW CRANE FIG. 151 BSP ELBOW M & F CRANE FIG. 152 BSP UNION ELBOW M & F CRANE FIG. 277 3/S11 BSP WHEEL VALVE 200 lbs. HATTY Fig. 7 3/S11 BSP FEMALE UNION TEE CRANE FIG. 279 3/S11 BSP FEMALE TEE CRANE FIG. 161 3/S11 BSP CLOSE NIPPLE CRANE FIG. C 52 ~/S 11 BSP FEMALE UNION ELBOW CRANE FIG. 276 }'2" BSP BLANKING PLUG CRANE FIG. 147 ~S" TAPER THREAD SOCKET CRANE FIG. 177 1 2" x~/S" BSP HEXAGON NIPPLE CRANE FIG. 145 PIPE 1 2 11 BSP MEDIUM x l'-5-.3/4" LONG PIPE BSP MEDIUM x 3Y2". LONG PIPE BSP HEAVY X l 1 -9Y4" LONG 3/S" BSP ELBOW M & F FIG. 152 PIPE ~2 11 BSP HEAVY x 3'-0%/4" LONG PIPE BSP HEAVY x lt-S1 S" LONG PIPE 3/S" BSP MEDIUM x 2'-5" LONG PIPE %S" BSP MEDIUM x lt-0.7/S 11 LONG PIPE 1 2" ESP MEDIUM x 3" LONG PIPE ESP MEDIUM X 11" LONG BSP PIPE CLIPS RBGS367/5 l" ESP PIPE CLIPS RBGS367/9 ADDITIONAL PARTS TO COMPLETE DRAGLINE 1" ESP BLANKING PLUG CRANE FIG. 147 ~2" BSP BLANKING PLUG CRANE FIG. 147 t2" BSP FEMALE ELBOW CRANE FIG. 151 t2" BSP UNION M & F CRANE FIG. 272 t2" BSP FEMALE UNION CRANE FIG. 2S9 ESP ELBOW M & F CRANE FIG. 152 PIPE t2" BSP MEDIUM x 7-3/4" LONG PIPE BSP MEDIUM x 2'-6Y4" LONG PIPE BSP MEDIUM X 6YS" LONG lY4" x 1 11 ESP REDUCING BUSH CRANE FIG. 140

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45 46 47 48 49 50

1 11 BSP VJHEEL VALVE 300 lbs. HATTY FIG. 12 1 11 BSP TEE M & F CRANE FIG. 163 l" BSP MALE BEND CRANE FIG. 191 1 11 BSP BEND M & F CRANE FIG. 192 PIPE l" BSP HEAVY x l'-3" LONG l" BSP FEMALE UNION TEE CRANE FIG. 279 1 11 BSP CLOSE NIPPLE CRANE C 52 Y2" BSP UNION M & F CRANE FIG. 272 1 11 BSP FEMALE BEND CRANE FIG. 193 PIPE 1 11 BSP HEAVY x l'-9Y2" LONG PIPE 1 11 BSP HEAVY x S.3/4" LONG 1 11 BSP UNION M & F CRANE FIG. 272 2" x 1 11 BSP HEXAGON BUSH CRANE FIG. 140 2" X Y2" BSP HEXAGON BUSH CRANE FIG. 140 t2" BSP BLANKING PLUG CRANE FIG. 147 BSP FEMALE UNION ELBOW CRANE FIG. 276 lY4" x t2" BSP HEX REDUCING NIPPLE CRANE FIG. 145 ~S 11 x Y4" BSP REDUCING SOCKET CRANE FIG. 132 211 BSP CLOSE NIPPLE CRANE C 52 t2" BSP TAPER THREAD SOCKET CRANE FIG. 133 BSP EQUAL HEXAGON NIPPLE CRANE FIG. 144 t2" BSP FEMALE ELBOW CRANE FIG. 151 t2" BSP ELBOW M & F CRANE FIG. 152 t2" BSP FEMALE TEE CRANE FIG. 161 t2" BSP FEMALE UNION CRANE FIG. 2S9 t2" BSP UNION ELBOW M & F CRANE FIG. 277 BSP FEMALE UNION TEE CRANE FIG. 279 t2" BSP UNION TEE M & F CRANE FIG. 2SO BSP WHEEL VALVE 300 lbs. HATTY FIG. 12 X 3/S11 BSP HEXAGON BUSH CRANE FIG. 140 11 3/S BSP WHEEL VALVE 200 lbs. HATTY FIG. 7 3/S" BSP FEMALE ELBOW CRANE FIG. 151 3/S" BSP UNION ELBOW M & F CRANE FIG. 277 3/S 11 BSP UNION TEEM & F CRANE FIG. 2SO 3/S 11 BSP FEMALE UNION CRANE FIG. 2S9 3/S" BSP CLOSE NIPPLE CRANE FIG. C 52 %S" BSP UNION M & F CRANE FIG. 272 4" BSP FEMALE ELBOW CRANE FIG. 151 t4" BSP ELBOW M & F CRANE FIG~ 152 t4" BSP FEMALE UNION ELBOW CRANE FIG. 76 t4" BSP UNION ELBOW M & F CRANE FIG. 277 t2" X Y4" BSP HEXAGON BUSH CRANE FIG. 140 t4" BSP FEMALE TEE CRANE FIG. 161 Y4" BSP UNION M & F CRANE FIG. 272 PIPE t2" BSP HEAVY x l'-6" LONG PIPE t2" BSP HEAVY x 1'-211 LONG PIPE t2" ESP HEAVY x l'-2Y2" LONG PIPE ~2" ESP HEAVY x 611 LONG PIPE t2" BSP HEAVY x 5-3/S" LONG PIPE BSP MEDIUM X l'-4-3/4" LONG

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WHEEL VALVE PC.MK.29 WITH BLANKING PLUG PC.MK.I20 FOR DRAGLINE

DRAGLINE ARRANGEMENT SHOWN. REPLACE PIPE PC.MK.I37 WITH BLANKING PLUG PC.MK.I20 FOR SHOVEL

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LINE LUBRICATORS

GENERAL ARRANGEMENT SHOVEL ARRANGEMENT SHOWN REPLACE I"BS.P. PIPE PC. MK. Ill WITH BLANKING PLUG PC.MK. 135 FOR DRAGLINE

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1 11 ESP WHEEL VALVE 300lbs. HATTY FIG.l2 1 11 ESP TEE M & F CRANE FIG.l63 1 11 ESP MAIE BEND CRANE FIG.191 1 11 ESP BEND M & F CRANE FIG.l92 PIPE 1" ESP HEAVY x 4.1/8" LONG 1n ESP FEMAlE UNION TEE CRANE FIG.279 1n ESP CLOSE NIPPlE CRANE C 52 PIPE 1n ESP HEAVY x 1'-2.1/Sn LONG 1 11 ESP FEMAlE BEND CRANE FIG.193 .

PIPE 1n ESP HEAVY x 1'-9!n LONG PIPE 1n ESP HEAVY x S~n LONG 1n ESP UNION M & F CRANE FIG. 272 2n x 1n ESP HEXAGON BUSH CRANE FIG.140 2n x !n ESP HEXAGON BUSH CRANE FIG.l40 .!n ESP BLANKING PLUG CRANE FIG.147 In BSP FEMAlE UNION ELBOW CRANE FIG.276 1in x !n BSP HEX REDUCING NIPPlE CRANE FIG.l45 3/Sn x in BSP REDUCING SOCKET CRANE FIG.132 .!n BSP CLOSE NIPPLE CRANE C 52 In ESP TAPER THREAD SOCKET CRANE FIG.133 tn BSP EQUAL HEXAGON NIPPLE CRANE FIG.l44 -n BSP FEMALE ELBOW CRANE FIG.151 ~n ESP ELBOW M & F CRANE FIG.152 BSP FEMALE TEE CRANE FIG.161 11 ESP FEMALE UNION CRANE FIG.289 ~n BSP UNION ELBOW M & F CRANE FIG.277 -n ESP FEMALE UNION TEE CRANE FIG 279 In BSP UNION TEE M & F CRANE FIG.280 In ESP WHEEL VALVE 3001bs HATTY FIG.12 In x 3/8n BSP HEXAGON BUSH CRANE FIG.l40 3/Sn ESP WHEEL VALVE 2001bs HATTY FIG.?

3/Sn ESP FEMAlE ELBOW CRANE FIG.151 3/8n BSP UNION ELBOW M & F CRANE FIG.277 3/8n ESP UNION TEE M & F CRANE FIG.280 3/Sn BSP FEMALE UNION CRANE FIG.289 3/8n ESP CLOSE NIPPLE CRANE FIG.C 52 3/8n ESP UNION M & F CRANE FIG.272 .

1/4n ESP FEMALE ELBOW CRANE FIG.151 1/4n BSP ELBOW M & F CRANE FIG.152 1/4n ESP FEMAlE UNION ELBOW CRANE FIG.276 1/4n BSP UNION ELBOW M & F CRANE FIG.277 in x in BSP HEXAGON BUSH CRANE FIG.l40 1/4n BSP FEMALE TEE CRANE FIG.161 1/4n BSP UNION M & F CRANE FIG.272 PIPE tn ESP HEAVY x 1'-6" LONG PIPE -n ESP HEAVY x 1'-2n LONG PIPE ~n BSP HEAVY x 1'-2!n LONG PIPE -n BSP HEAVY x 6n LONG PIPE ESP HEAVY x 5 .3/8" LONG PIPE 2" BSP MEDIUM x 1'-4~ 11 LONG

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51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97

98 99 100

PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE

t" ESP MEDIUM x - 11 ESP MEDIUM x i" ESP MEDIUM x t" ESP MEDIUM x -n ESP MEDIUM x in ESP MEDIUM x -n ESP MEDIUM x in ESP MEDIUM x ESP MEDIUM x ESP MEDIUM x -n ESP MEDIUM x in ESP MEDIUM x ESP MEDIUM x -n ESP MEDIUM x In ESP MEDIUM x in ESP MEDIUM x -n ESP MEDIUM x ~n BSP MEDIUM x ESP MEDIUM x -n ESP MEDIUM x in ESP MEDIUM x fn ESP MEDIUM x -n BSP MEDIUM x ~n BSP MEDIUM x -n ESP MEDIUM x ~n ESP MEDIUM x ESP MEDIUM x ESP MEDIUM x 'f" BSP MEDIUM x iln BSP MEDIUM x 3/8n ESP MEDIUM 3/8n BSP MEDIUM 3/Sn ESP l-!EDIUM 3/8n ESP MEDIUM 3/Sn BSP .MEDIUM 3/8n BSP MEDIUM 3/8n ESP MEDIUH 3/Sn ESP MEDIUM 3/8n BSP MEDIUM 3/8n BSP MEDIUM 3/Sn BSP MEDIUM 3/Sn BSP MEDIUM 3/8 11 BSP MEDIUM 3/8n BSP MEDIUM 3/Sn ESP MEDIUM 3/8n BSP MEDIUM

6.5/8 11 LONG 7 .1/8" LONG 6'-4·5/8 11 LONG 4-3/8 11 LONG 10!n LONG 2'-1in LONG 9!n LONG 2'-10n LONG 2'-8tn LONG 3 '-2~n LONG 4'-o.,.n LONG 1'-11in LONG 2'-0.5/Sn LONG 3in LONG 2'-6~'' LONG 3'-S!n LONG 1~" LONG 1'-5•7/Sn LONG 1'-6in LONG 8~n LONG 4.1j8n LONG 3 '-6!n LONG 1'-6'' LONG 3 '-3 .7 jan LONG 10!n IONG 3'-2.1/Sn LONG 9·3/8 11 LONG 2'-1~n LONG 4·9/16n LONG 4n LONG x 3'-1·7/Sn LONG x 5'-0n LONG x 1'-1!n LONG x 1'-11!n LONG x 6.5/8n LONG x 1'-2n LONG x2'-3~n LONG x 4n LONG x 9!n LONG x 9n LONG x 1'-1in LONG x 1'-11.3/Sn LONG x 3'-8!n LONG x 11.3/Sn LONG x 3 '-5n LONG x 10n LONG

101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 119

PIPE PIPE PIPE

k" BSP MEDIUM x i" ESP MEDIUM x i" BSP MEDIUM x

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120

REF·ERENCE Ll ST FOR l. H. & R.·H. AIR PIPING.

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MEDIUM MEDIUM MEDIUM MEDIUM MEDIUM MEDIUM MEDIUM MEDIUM

x x x x x x x X

11 LONG 1'-9·1/8 11 LONG 3~ 11 LONG 2.9/16 11 LONG 3'-2n LONG l'-9!n LONG 4n LONG l'-4in LONG 1'-07/8n LONG

in ESP. PIPE CLIP REGS 367/1 3/Sn ESP PIPE CLIP REGS 367/3 !n ESP PIPE CLIP RBGS 367/5 3/Sn BSP FEMAlE UNION ELBOW CRANE FIG.276 ADDITIONAL PARTS TO COMPLETE SHOVEL 1In x 1n ESP HEXAGON NIPPlE CRANE FIG.l45 1.,.n x !n BSP HEXAGON NIPPLE CRANE FIG.l45 1n BSP UNION .M & F CRANE FIG.272 1n ESP WHEEL VALVE 3001bs HATTY FIG.12 1n ESP CLOSE NIPPLE CRANE FIG.C 52 .!n ESP FEMALE ELBOW CRANE FIG.151 . In ESP ELBOW M & F CRANE FIG.152 In ESP .UNION ELBOW M & F CRANE FIG.277 3/Sn ESP WHEEL VALVE 2001bs HATTY FIG.?

3/8n ESP FEMALE UNION TEE CRANE FIG.279 3/Sn ESP FEMALE TEE CRANE FIG.161 3/Sn ESP CLOSE NIPPLE CRANE FIG.C 52 3/Sn ESP FEMALE UNION ELBOW CRANE FIG.276 !n BSP BLANKING PLUG CRANE FIG.l47 3/Sn TAPER THREAD SOCKET CRANE FIG.177 !n x 3/8n BSP HEXAGON NIPPLE CRANE FIG.l45 PIPE tn ESP MEDIUM x 1'-5~ 11 LONG PIPE -n ESP MEDIUM x 3!n LONG PIPE ~n BSP HEAVY x 1'-llin LONG PIPE -n ESP HEAVY x 5. 7 j8n LONG PIPE Jn ESP HEAVY x 3 '-1.3/8n LONG PIPE 2n ESP HEAVY x 1'-8.1/8n LONG PIPE 3/8n ESP MEDIUM x 2'-5n LONG PIPE 3/8 11 ESP MEDIUM x 10~n LONG PIPE tn BSP.MEDIUM x 3n LONG PIPE 2n BSP MEDIUM x 11n LONG !n BSP PIPE CLIPS RBGS 367/5 1n ESP PIPE CLIPS REGS 367/9 ADDITIONAL PARTS TO COMPLETE DRAGLINE 1n BSP BLANKING PLUG CRANE FIG.l47 BSP BLANKING PLUG CRANE FIG.l47 -" ESP FEMALE ELBOW CRANE FIG.151 BSP UNION M & F CRANE FIG.272 -n BSP FEMALE UNION CRANE FIG.289 In BSP ELBOW M & F CRANE FIG.152 PIPE .!n ESP MEDIUM x 7~ 11 LONG PIPE BSP MEDIUM x 2'=6kn LONG PIPE 2" BSP MEDIUM x 6.1/8" LON~

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THIS DRAWING TO BE USED IN CONJUNCTION WITH SCHEMATIC AIR PIPING WHEN CONVERTING SHOVEL TO DRAGLINE AND VICE VERSA.

" SHOVEL/DRAGLINE FOR COMBINED FIT BLANKING PLUG PC.MK. 120 IN. SIDE OF DECK SUPPORT WHEN MACHINE HAS DRAGLINE FRONT END

USE VOLER R 3 THREAD LUBRICANT. ON PIPE JOINTS. ALL DRAIN COCKS TO BE LOCATED ON UNDERSIDE OF RAM CYLINDERS.

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SHOVEL ARRANGEMENT SHOWN"REPLACE fPIPE PC.MK.124 WITH BLANKING PLUG MAGNET VALVE SUPPORT

DRAGLINE ARRANGEMENT SHOWN. REPLACE PIPE PC.MK.I37 WITH BLANKING PLUG PC.MK.I20 FOR SHOVEL

f

PREVIOUS PAGEi1

PRESSURE REDUCING VALVE

MAGNET VALVE ENERGISED TO ADMIT _,__ _ _;-AIR TO SWING BRAKE CYLINDERS AIR FILTER AND

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AIR FILTER CLIPS

AIR LINE LUBRICATORS

CLIP SHOVEL ARRANGEMENT SHOWN REPLACE I"BSP M.AND F. UNION PC.MK.I2 WITH BLANKING PLUG PC.MK.I35 FOR DRAGLINE

GENERAL ARRANGEMENT OF

ISORB

LEFT HAND

SIDE AIR PIPING FIG.I9/.

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NOTE.:-THIS DRAWING TO BE USED IN CONJUNCTION WITH THE GENERAL ARRANGEMENT OF R H. SIDE. AIR PIPING {FUlL LOCK MANUAL STEERING) ORG. NO. 56T32.BB OR R.H.SlDE. AIR PIPING {FULL LOCK POWER STEERING) DRG. NO. 5BT3B.4~ ALL REFERENCE NUMBERS REFER TO THE MATERIAL TABLE. ON EITHER OF TI-\E ABOVE TWO DRAWINGS. USE VOLER (Ro) THREAD LUBRICANT ON PIPE JOINTS ALL DRAIN COCKS TO BE. LOCATED ON UNDERSIDE. OF RAM CYLINDERS.

r..-....

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·pap'si\FE.TY VALVE 155Li>B)SQ.IN. '•i&.S.P.

FUSIBLE. PLUG

SHOVEL ARRANGEMENT SHOWN- REPLACE. >iPIPE PCJ'\i<.Jc4WITH BLP.NKING PWG PC.Mi<.\~0 FOR DRAGLINE.

'•i BSP.

R&t\. REF. V54S6

ROFTS ROTOR SEAL WITH FLE.l\IBLE. PIPE FIG. 2.5551 SIZ.E NO.?..

SE.CTIONAA

AIR PIPING FOR SHOVEL HOIST DRI>.G CWTC.t\ SBR?.?.BI

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t:.ROFTS QUICK REL ME. VI\LVE FIG c4551 NO;:,

MI\GNET VI\L'IE ENERGISED11li\DMIT 1\\R TO HOIST OR DR!I.G BRAKE CYLINDER WE&TINGHOUSE. VALVE PC.Mi<..I-5~E.1\II

M!I.GNE:r VALVE DE-ENERGISED 11li\DMIT !I.IR TO HOIST OR DR!I.G CWTC.H WESTINGHOUSE V!I.LVE PC.Mi<.. 2.-SOE1\B

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SHOVEL 1\RR!I.NGEMENT SHOWN-REPLACE \"&SP M&F UNION 'PC..MK.Ia WITH &LI\NKING PLUG PC.MK.\:55 FOR DRI\GLINE

LEFT H AN D SID E P I P I N G FIG. 19.

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MAGNET VALVE ENERGISED TO A'DMIT AIR TO CROWD BRAKE WE5TINGHOU5E VALVE PC. MK. I-55E71B

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MAGNET VALVE 5UPPORT I-54X70A6 MAGNET VALVE ENE~GI5ED TO ADMIT AIR TO PROPELLING BRAKE WE5TING HOUSE VALVE PC. MK:I-53E718

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BRACKET 5GX9287 ; ''U' BoLT 50X92B2 --+--1--o-'-~l\r-----i

MAGNET VALVE DE-ENERG15ED TO ADMIT AIR TO PROPELLING CLUTCH. WE5TINGHOUSE VALVE PC. Ml<". 2-&oE718

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MAGNET VALVE SUPPORT 1-5

SECTION

AA

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5UPI?ORT 56X9251 CLIP\ RBG5 3G 7/5

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CROFTS ROTOR 5EAL WITH FLEXIBLE PIPE FIG 25551 N2· 2

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WARNIN<; PLATE

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5HOVEL ARRANGEMENT SHOWN- REPLACE 1

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LI SECTiON

THIS DRAWING TO BE USED IN CONJUNCTION WITH THE GENERAL ARRANGEMENT OF U-1.5 AIR ~PING -DRG. N9· 510T3287 USE VOLER (R 3) THREAD LUBRICANT ON ALL PIPE JOINT5.

RIGHT HAND SIDE PIPING

FIG. 20.

ALL DRAIN COCKS TO BE LOCATED Of< UNDERSIDE OF RAM CVLINDER5.

ALL PIPE5 SCREWED EACH END TAPER THREAD.

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I SECTION

AA

MAGNET VALVE ENERGISED TO ADMIT AIR TO DRAGLJNE

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ROTOR SEAL WITH FLEXIBLE PIPE NON-RETURN DRAGLINE ARRANGEMENT SHOWN. REPLACE PIPE PC.MK.I37 WITH BLANKING PLUG PC.MK.I20 FOR SHOVEL

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GENERAL ARRANGEMENT OF

ISORB

LEFT HAND

SIDE AIR PIPING FIG. 19 /.R3

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FIG. 20/RI GENERAL ARRANGEMENT OFf 150-RB RIGHT HAND SIDE AIR PIPING.

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NOTE:- - FOR KEY TO REFERENCE NUMBERS SEE REFERENCE LIST FOR FIG. 19/R3 & FIG. 20/RI. (IMMEDIATELY BEFORE FIG. 19/ R 3.)

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NON- RETURN VALVE WITH SPRING LOADED CLACK VALVE

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NON- RETURN VALVE2B.S.P.

II 12 I3 14 IS 16 17 IB 19

2 SECTION

20 2 I 22 23

DESCRIPTION FEMALE ELBOW MALE AND FEMALE ELBOW FEMALE TEE CLOSE NIPPLE REDUCING BUSH REDUCING NIPPLE FEMALE UNION ELBOW MALE AND FEMALE UNION ELBOW MALE AND FEMALE UNION TEE FEMALE ELBOW FEMALE ELBOW FEMALE UNION ELBOW B.S.PIPE. B.S.PIPE B.S.PIPE B.S.PIPE B.S.PIPE B.S.PIPE B.S.PIPE B.S.PIPE B.S.PIPE B.S.PIPE B.S.PIPE

MAGNET VALVE ENERGISED TO ADMIT AIR TO RIGHT HAND STEERING CYLINDERS

7

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MAGNET VALVE ENERGISED TO ADMIT AIR TO CYLINDERS IN TRUCK FRAME FOR LOCK POSITION

MA((NET VALVE ENERGISED TO ADMIT AIR

IIOLBS/SO.IN.

HAND

NOTE USE VOLER (R3) THREAD LUBRICANT ON PIPE JOINTS ALL PIPES SCREWED BOTH ENDS TAPER THREAD

19

PRESSURE REDUCING VALVE 110 TO 35 LBS/SO,IN.

MAGNET VALVE SUPPORT

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FIG. 20A Rl GENERAL

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ARRANGEMENT OF ISORB MAGNET VALVE PIPING

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5, 6

7 8 9 10 11

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Female Elbow

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2

SE.CTIONAA

DESCRIPTION

12

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B:S.P. Female Elbow

13 14 15

~" ~"

B.S.P. Female Elbow B.S.P. Female Union Elbow

16 17 18

Pipe~" B.S:P. Medium x 1'701 ",{6 " LG.

19 20 21 22

Pipe~" B.S-.P. Medium x 1'-1 1,{6 " LG. Pipe~" B.S.P. Medium x 2'fa" i.G. Pipe~" B.S.P. Medium x 8~" LG.

Pipe~"

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MAGNET VALVE ENERGISED TO ADMIT AIR TO RIGKT K!>.ND STEERING CYLINDERS I

MAGNET V!>.LVE :.NERJISE.D TO ADMIT AIR TO LEFT 1-\I>.ND SiiEERINC. CYLINDE.RS

Pipe~" B.S.P. Medium

24

25 26 28

29

Pipe %" B.S.P. Medium x 10%" LG. Pipe~" B..S.P. Medium x 1 "-1 ,{6 " LG. 1

31

PRESSURdRE.DUC.II'\G VALVE. 110 LBS/SQ.INS. TO ~SLSS/SQ.IN&.

CRANE GUNME.TAL TYPE C:!> 'z" 8.5P F1EMALE. ENDS

x

27

30

£

B.S.P. Mediumx 1'-0it-LG.

!>.lL MAGNET V!>.LVE..S ARE VALVE. F>C.Mi<..I-S~Ell!!.

WE.STINGHOU.S.E

USE. YOLE.R (R~) TfiREAD LUBRICANT ON PIPE JOINTS ALL PIPES .SCREWED BOTH ENDS TAPE.R THREAD.

MAGNET VALVE SUPPORT I-S&R2.S:!>J

.

0

MAGNET VALVE ENERGISED TO ADMIT !>.IR AT liD LE>S/SQ.INS. I TO CYLINDERS IN TRUCK FOR LOCK. POSITION

STEERING- MAGNET VALVE PIPING Fl G. 20A.

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FUNCTION MAGNET VALVE TO PROPELLING BRAKE MAGNET VALVE TO PROPELLING CLUTCH MAGNET VALVE TO LEFT HAND STEERING CYLINDERS

0

OUTLET PRESSURE REDUCING VALVE TO PRESSURE GAUGE (0-100 LBS.) MAGNET VALVE TO RIGHT HAND STEERING CYLINDERS RING MAIN (110 LBS./ SQ. IN.)

NOTE:usE VOLER ( R3) THREAD LUBRICANT ON PIPE JOINTS. ALL PIPES SCREWED BOTH ENDS TAPER THREAD.

MAGNET VALVE ENERGISED TO ADMIT AIR TO LEFT HAND STEERING CYLINDERS.

MAGNET VALVE ENERGISED TO ADMIT AIR TO RIGHT HAND STEERING CYLINDERS.

SECTION

I FEMALE UNION ELBOW 2 FEMALE UNION TEE 3 MALE AND FEMALE UNION TEE 4 HEXAGON BUSH 5 MALE AND FEMALE UNION 6 FEMALE UNION ELBOW 7 CLOSE NIPPLE 0 0 8 MALE AND FEMALE UNION 9 HEXAGON BUSH I 0 MALE AND FEMALE UNION ELBOW I I FEMALE ELBOW I 2 FEMALE UNION ELBOW I 3 MALE AND FEMALE UNION ELBOW I 4 FEMALE ELBOW I 5 FEMALE ELBOW I 6 CHECK VALVE I 7 CHECK VALVE I 8 REDUCING VALVE I 9 STEEL PIPE 20 STEEL PIPE 2 I STEEL PIPE 2 2 STEEL PIPE 2 3 STEEL PIPE 2 4 STEEL PIPE MAGNET VALVE ENERGISED TO ADMIT AIR TO PROPELLING BRAKE. l--'2~5t=SO::TO::E;-::E;:=Lc...:P::-;I~P~E----------I 26 27 28 29 30 3 I 32 3 3

B. B.

STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL

PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE

MAGNET VALVE DE- ENERGISED TO ADMIT AIR TO PROPELLING CLUTCH.

VIEW ON BACK OF MAGNET VALVE SUPPORT.

MAGNET VALVE ENERGISED TO ADMIT AIR AT 110 LBS/SQ. IN. TO CYLINDERS IN TRUCK FOR FULL -LOCK POSITION.

MAGNET VALVE SUPPORT.

SECTION

A. A.

I

FIG. 20A I R2. GENERAL ARRANGEMENT COF 150-RB MAGNET VALVE PIPING. IMD.605

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NAME SWIVEL JOINT. SPINDLE UPPER COLLAR SWIVEL JOINT BODY SPACE/0!

LOWER COL.LAR END COVER PERFECT OIL. SEAL. RING VELUMOID GASKET SPLIT RETAINING COLLAR ANCHOR PIN EYE BOL.T REACH ROD REACH ROD END PIN

PIPE SUPPORT

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SECTIONAA

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B.£. DRG. 233887

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TRIPLE SWIVEL FIG. 21.

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PIPE. 'i. B.5J' MEDIUM 1< 1'-4'•iLG PIPE. '•i BSP MEDIUM>. 1'-3-·<·Lb PIPE.'•< BSP ME.DIUM>.I'-&'•4L{;

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FIG. 22.

CRANE 279 - CRI\11£ 151

PIPE

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Upper Roller Idler Roller

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Vent & Drain- See Note 1 See Note 5: Roller Track See Note 5. Rack Idler Roller Vent & Drain- See Note 1 Roller Pins Upper Roller Idler Roller Vent & Drain Cat Clutch Levers

See Note 6. Cat Gears

Clutch Shifter Guide Bars Brake Shaft Bearing

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Longitudinal Shaft Front Bearing

2b 2b

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WORKS LU)BRI CATION Fl G. 30.

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~ PROPEL CHAIN CASE

HOIST GEAR HOIST JNTERMEDIATE SHAFT BEARING HOIST MOTOR PINION BEARINGS

PROPI!L GEARS VERTICAL SHAFT BEVEL G!AR.S

HOI.ST BLOWER MOTOR HOIST MOTOR HOIST GI:AR CASE

DRACOLINE HOIST SHAP'T IIEARING

DRAGLINE HOIST GEAR

IIIIAGLINI!: HOIST SIIAP'T BEARING

OIIAGLINE HOIST BLOWER UOTOR DRAGUNE HOISTWOTOR

VENTILATING P'AH UOTOII

UP P E R

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ARRANGEMENT OF 150-RB SHOVEL IMD 287/R

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DESCRIPTION A -FRAME FRONT LEG.

A -FRAME BACK LEG

10

16

PIN. 4

A- FRAME PIN,

5 6

SHEAVE.

7 8 9 10 11 12

20

USE WASHERS

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24 A.S SHIMS

BOOM FOOT & LUG ON REV. FRAME

-12

IN POSITION USE WHEN

REMOVING DRUM WITH BOOM. MAX.

CLEARANCE IS PEAMISSABLE.

SUSPENSION PLATE. PIN.

STRUT. STRUT. BOOM -UPPER SECTION. BOOM - LOWER SECTION. BUMPER SUPPORT.

13

BUMPER.

14

PIN.

15

BOOM FOOT PIN.

16

UPPER BOOM HINGE.

17 18 19

CLAt.tP COLLAR.

20 21 22 23 24 25

BOOM POINT SHEAVE.

WASHER.

BUSHING.

SHIPPER SHAFT. SHEAVE.

LOWER SECTION LADDER I HANDRAILS LOWER DRUM GUARD.

PIN.

26

SADDLE BLOCK.

27

WASHER.

28 29 30 31 32 33 34

WASHER.

TRIP ROPE DEFLECTING SHEAVE

35

CLAMP COLLAR.

WASHER. DIPPER HANDLE

DIPPER PADLOCk

DIPPER 'tRIP MOTOR AND DRUM

36

DIPPER SNUBBER

37

PLATFORM.

38 39 40 41 .t.2 43

GUARD RAIL.

44

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BOOM FOOT PIN.

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MAX.

CLEARANCE IS PERMISSABLE.

----------------

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33

NO I 2 3 4 5 6 7 8 9 10 II 12 13 14 IS 16 17 18 19 20 21 22 23 · 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

DESCRIPTION 'A' FRAME FRONT LEGS "!>:FRAME BACK LEGS 'II FRAME LEG PIN "!>:FRAME PIN BOOM HOIST SHEAVE OUTER BOOM SUSPENSION PLATE BOOM STRUT PIN R.H. BOOM STRUT L.H. BOOM STRUT UPPER SECTION "BOOM LOWER SECTION BOOM BUMPER SUPPORT BUMPER BUMPER PIN BOOM FOOT PIN BOOM HINGE PIN BOOM POINT SHEAVE BOOM POINT PIN CLAMP COLLAR BOOM POINT PIN THRUST WASHER BOOM POINT SHEAVE BUSHING SHIPPER SHAFT CROWD SHEAVE LOWER SECTION LADDER & HANDRAILS CROWD DRUM GUARD BUMPER SUPPORT PIN SADDLE BLOCK SHIM WASHER SHIM WASHER SHIM WASHER DIPPER HANDLE DIPPER TRIP CYLINDER DIPPER PADLOCK SUSPENSION ROPE EQUALIZER LINK SHIPPER SHAFT CLAMP COLLAR DIPPER SNUBBER BOOM POINT PLATFORM BOOM POINT GUARD RAIL BOOM FOOT PIN UPPER SECTION HANDRAILS LOWER BOOM PLATFORM SHIPPER SHAFT PLATFORM SUSPENSION ROPE EXTENSION LINK

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32

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GENERAL ARRANGEMENT OF ISORB SHOVEL FRONT END EQUIPMENT FIG. 41/.RI IMD.288

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FIG.41.

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BI379509 INSTRUCTIONS

FOR SHIMMING

TOP WEARING

SHOE@

NOMINAL CLEARANCE IS~~ WITH ONE SHOE AGAINST TUBE, ADD SHIMS AT EACH END SHOE EQUAL TO ONE HALF OF EXCE55 CLEARANCE IN THIS POSITION, MEASURE AT CENTRE OF SHOE .

.-----

SECTION

ct.

NOTE1

AA

SECTION THROUGH UNER ASSEMBLY DO NOT USE SHIMS FOR UNER A55EMBLY@ NOMINAL CLEARANCE AT CENTRE OF LINER IS lfi:. ,TOLERANCE ON PARTS AND COMPRESSION OF RUBBER ON ONE SIDE WILL INCREASE CLEARANCE TO !"ON OPPOSITE SIDE. THIS 'CLEARANCE

SECTION· THROUGH SHIPPER

FIG. 42.

SHAFT

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LUBRICATION

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m:sCRIPTION Bf\SE:' Pl..f\TE I.IMIT 5\JITCH BASE: PUSH ROO SPRING RE:TAINE:R

5

COMPRESSION SPRING

I ;;

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G SE:TSCR~ a~IUNC-ZAX~LN

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NOTE::-TO SET 5\..IITCH REI..! EVE UPPE:R 5ECTION OF' l.OAO (OIPJ'=IER ON GROUND) AQj'USi PUSH ROO

@ WITH CAPSCRE\J

®SO THAT 8\JITCH PI.U~ER AT.A 15 DEPRESSED AN INITIAI.lt4.

WHEN UPPE:R SE:CTION OF' BOOM IS RI\ISE:O ABOVE: 45~ PUSH ROO @ OE:PRE:SSES P~UNGER ON S\JITCH A FURTHER Y.;.AND CUTS OFF PO\JER

B0 0 M Ll MI T SWI T CH FIG. 43.

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FOR GENERAL ARRANGEMENT OF DIPPER TRIP SEE FIG. 49ZB..1

@=LUBRICATION

FOR GENERAL ARRANGEMENT OF SPRING CUSHION SEE FIG b1LR2

150-RB DIPP

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DESCRIPTION

No

4

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

25 26 27

28 29 30 31 32

33 3 35

36 37 38 39 40

41 42

43 44 45 46 47

48

49

so

51 52 53 54 55 56 57

sa

59 60 61 62 63 64 65 66

DIPPER SIDE CASTING DIPPER FRONT TOOTH WEDGE

~

!

DOOR CASTING HINGE PIN LATCH BAR GUICE PLATE GUIDE PLATE LATCH LEVER BAR

59

I

ADJUSTING BOLT RETAINER BAR ROLLER SNUBBER SUPPORT SNUBBER LINK FRICTION DISC COMPRESSION SPRING SNUBBER BOLT FRICTION DISC PLATE SHEAVE SHEAVE FRAME SHEAVE PIN FRAME AND UPPER LINK PIN UPPER LINK LOWER LINK LOWER LINK PIN SHEAVE BUSHING UPPER AND LOWER LINK SUSHI NG DIPPER SIDE BUSHING BLANK BOLT BLANK BOLT SHIPPER SHAFT BUSHING SNUBBER PRESSURE PLATE SADDLE BLOCK THRUST WASHER SHEAVE BUSHING CROWD SHEAVES SETSCREW DOWEL GREASE NIPPLE

SECTION

BB

DOWEL REAR LINER FRONT LINER DOWEL ROPE DEFLECTOR SNUBBER SUPPORT SNUBBER SUPPORT SNUBBER SUPPORT SNUBBER GUIDE SNUBBER PINION FRICTION LINING COMPRESSION SPRING COMPRESSION SPRING ROD BOLT C'SK SETSCREW NUT

LOCKNUT WASHER LOCKNUT DIPPER HANDLE POLYURETHANE BUMPER T'HD. BOLT

WELDED ROPE RETAINER WELDED REAR STOP WELDED ROPE ANCHOR 69 BELLEVILLE SPRING WASHER 70 EQUALISER CASTING 71 TAKE-UP NUT 72 TAKE-UP SCREW 73 WELDED COVER 74 RUBBER AND CANVAS PACKING 75 BACI<HAUL ROPE 76 CROWD ROPE

SECTION

67

AA

68

FOR GENERAL ARRANGEMENT OF DIPPER TRIP SEE FIG. 49lBJ.

68

@:LUBRICATION

is

I FOR GENERAL ARRANGEMENT OF SPRING CUSHION SEE FIG 61LR2

I I

FIG. 44[R3 GENERAL ARRANGE!MENT OF 150-RB DIPPER HANDLE

IMD 511/R

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SECTION

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AA

FOR GENERAL ARRANGEMENT OF PI PPER TRIP SEE FIG. 49/R 2

FOR GENERAL ARRANGEMENT OF SPRING CUSHION SEE FIG. bi/R

ENERAL ARRANGEMENT OF 150-RB DIPPER HANDLE

IMD.Sil

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BI379509 DESCRIPTION

LATCH BAR LATCH BAR FRONT GUIDE PLATE

LATCH BAR REAR GUIDE

PLATE

LATCH LEVER ADJUSTING LINK LATCH ADJUSTING BOLT LATCH BAR ROLLER RETAINER LATCH BAR ROLLER SNUBBER SUPPORT

FRAME & UPPER LINK PIN UPPER LINK

LOWER LINK ACK PIN SHEAVE BUSHING NK BUSHING DIPPER SIDE BUSHING

LOCKPIN DIPPER BACK PIN LOCKING BOLT SHIPPER SHAFT

CROWD SHEAVE BUSHING CROWD SHEAVES THRUST WASHER SETSCREW BUSHING LOCATING DOWEL

GREASE NIPPLE THRUST WASHER LOCATING DOWEL

SADDLE BLOCK REAR LINER SADDLE BLOCK FRONT LINER

SECTION

BB

PLATE

COMPRESSION SPRING

{INNERl

COMPRESSION SPRING

OUTER

CONNECTING PIN SETSCREW TAKE UP SCREW BUSHING ROPE GUARD PIN ROPE GUARD SPLIT PIN ROPE GUARD SPLIT PIN TAKE UP SCREW LOCKNUT HANDLE END ROPE WEDGE

86 87

SECTIONAA

RETRACT ROPE ROPE GRIP PADLOCK LINK PIN LOWERLINKBUSHING

FOR

ARRANGEMENT OF SHOVEL FRONT END EQUIPMENT SEE FIG.41/RI

FOR ARRANGEMENT SEE FIG.49/RI

OF DIPPER TRIP

FOR ARRANGEMENT OF PADLOCK SEE FIG. 46 FOR DIPPER TEETH ASSEMBLY SEE FIG. 4B/Rt FOR ARRANGEMENT OF DIPPER DOOR SNUBBER SEE FIG. 47

FIG. 4l4/.R I GENERAL ARRANGEMENT OF ISORB DIPPER HANDLE I·

I M 0.281/R

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3

4 5

6 7

a

9 10 11 12

l3 14 15 16 17 lS

19 20 21 22 23

24 25

26

27 2S 29

30 31 32 33 34 35 36 37

38 39

40 41

42 43

44

45

46

47 48 49 50 51 52

53 54 55 56 57

DIPPER SIDE CASTING DIPPER FRONT TOOTH WEDGE C CLANP DOOR CASTING HINGE PIN LATCH BAR GUIDE PLATE GUIDE PLATE LATCH lEVER BAR ADJUSTINGLINK ADJUSTING BOLT RETAINER BAR ROLlER SNUBBER SUPPORT SNUBBER LINK FRICTION DISC CONPRESSION SPRING SNUBBER BOLT FRICTION DISC PLATE SHEAVE SHEAVE FRAME SHEAVE PIN FRAl!E AND UPPER LINK PIN UPPER' LINK IDWER LINK IDWER LINK PIN SHEAVE BUSHING UPPER AND IDWER LINK BUSHING DIPPER SIDE BUSHING BLANK BOLT BLANK BOLT BACK HAUL ROPE ANCHOR ANCHOR STOP CASTING SNUBBER PRESSURE PLATE RETAINER PIN SHINS SPECIAL BOLT SHIN HET AINER HANDlE STOP SADDlE BIDCK SPACER PIN HET AINER PLATE LINER ASSENBLY EQUALIBER & HANDIE STOP CASTING SHEAVE SEGNENT ROPE SOCKET WEDGE ROPE SOCKET PIN EYE BOLT SHEAVE PIN EQUALISER SHEAVE BOLT HANDlE STOP PIN RETAINING BAR

FOR INSTALLATION OF LIMIT SWITCH SEE ORG. NO. 56T:II~~

:-• Q SEC.TION

SECTION

BB

AA

FOR GENERAL ARAANGEMENT OF tllPPE.R TRIP SEE. ORG. NO. 56T~I30

FOR ROPE TAAE-UP ADJUSTMENT SEE DRG. N.O. 5SRZ.Z.5&

DIPPER AND HANDLE FIG. 44.

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Kf:EP IT rROM rA~L.ING· OUT DURING SHIPMENT BE:Gf'IUSE: SHE:fWE: IS RE:MOVE:IJ IN F'IE:I.D TO F'f'ICII.ITf\TE: RE:E:VING OF' ROPE:S.

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@ •I.UBRICf'ITION.

P AD L 0 CK - SH0 V E L

FIG.46.

SHEAVE FRAME R.H. SHEAVE FRAME L.H. SHEAVE BUSHING SHEAVE PIN PADI.DCK PIN LINK UPPER LINK I.DWER BUSHING DIPPER BACK PIN BLANK BOLT BLANK BOLT

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SECiiON SHQ\./ING SNUBBER ARRANGME:NT

DIPPER DOOR SNUBBER

FIG. 47.

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ASSEMBLY INSTRUCTIONS

CD

I. TOOTH FITS DIPPER FRONT SOCKET LUGS AT FACES '/\.

AND MUST BE HARD DOWN WHEN CORRECTLY FITTED.

. ~-------------:;:=-?5 .~·\ \ ////

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2. HEAT FORK END OF WEDGE ENTER WEDGE AND DRIVE 'HOME; KNOCK OVER TONGUE TO SECURE WEDGE. 3. A CORRECTLY FITTED TOOTH BEARS ON FACES 'fl. AND THE WEDGE BEARS ON TOP END OF SLOT IN TOOTH SOCKET AND BOTTOM EDGE OF SLOT IN TOOTH.

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3 J DIPPER WEDGE.

FIG. 48/.R.I DIPPER TEETH ASSEMBLY IMD. 286/R

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INSTRUCTIONS -

DIPPER FRONT

'A

SOCKET LUGS AT

POINTS

'A

& 'B' g. MUST

2-

BE HARD DOWN AT PLACE CLAMP

3-

HEAT

FORKED

DRIVE

'HOME'

4-

A CORRECTLY FITTED TOOTH BEARS ON POINT 'A AND FITS AT POINTS • 6''. CLAMP 3 MUST FIT AT POINTS •C AND

W

THAT

2

TOOTH

END KNOCK

BEARS

AT

OF WEDGE OVER

ON THE

POINTS

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FITIED

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ENTER

WEDGE

AND

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TOP

END OF SLOT

IN DIPPER

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BI379509

WEDGE

AND A FIT ON POINTS 'B' WHEN CORRECTLY IN ·POSITION AS SHOWN MAKING SURE

CLAMP FITs

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4 5 6 7 8 9 10 I I

SECTION

B. B.

12 13 14 IS 16 17 18 19

ENLARGED VIEW OF ROPE ANCHORAGE ON TRIP LEVER

20 21

22 23 24

25 26

27 2B

29 30 31

32 33 34 35 36 37 3B 39

40 41 42 43

SEE ENLARGED DETAIL FOR ROPE ANCHOR ON DRUM

44 45

46

47 48

49 50 DIPPER TRIP

f":~

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51

56

52

SECTION

=--/

53 54 __55 56 57 58 59

C-C

DESCRIPTION DEFLECTION SHEAVE SUPPORT TRIP ROPE DEFLECTING SHEAVE DEFLECTING SHEAVE BUSHING DEFLECTING SHEAVE THRUST WASHER DEFLECTING SHEAVE PIN SPLIT PIN GEAR CASE DRAIN PLUG SUPPORT SETSCREWS LOCKWASHERS SUPPORT BRACKET BOLTS· SLOTTED NUT SPLIT PIN DIPPER TRIP SUPPORT BRACKET SUPPORT BRACKET SETSCREWS LOCKWASHERS SUPPORT BRACKET SETSCRE,_,W,_,S'-----4 LOCK WASHERS SETSCREWS ROPE GRIPS ROPE THIMBLE DIPPER TRIP ROPE LOCK WASHERS GREASE NIPPLE DIPPER TRIP BASE DIPPER TRIP MOTOR GEAR AND PINION GUARD DRUM SHAFT DIPPER TRIP GEAR DIPPER TRIP PINION DIPPER TRIP DRUM OUTER BEARING RETAINER OUTER BEARING SEAL DRUM SHAFT RETAINER INNER BEARING SEAL INNER BEARING RETAINER SUPPORT BASE SHIMS DRUM GUARD SHAFT RETAINER SETSCREWS GREASE NIPPLE DRIVE PINION KEY OUTER DRUM SHAFT BEARING INNER DRUM SHAFT BEARING OUTER BEARING SPACER-LEFT HAND OUTER BEARING SPACER-RIGHT HAND INNER BEARING SPACER LOCKWIRE GUARD SUPPORT SCREWS BEARING RETAINER SETSCREWS MOTOR SUPPORT BOLTS SUPPORT BASE SETSCREWS GUARD SUPPORT SETSCREWS GUARD SUPPORT NUTS TRIP LEVER SPACER AND TRIP CHAIN ANCHOR TRIP LEVER KEY TRIP LEVER SHAFT TRIP ROPE ANCHOR PIN SPLIT PIN SPACER KEY

ENLARGED DETAIL SHOWING ROPE ANCHORAGE ON DRUM SECTION

0

A. A.

FIG. 49/ R4 GENERAL ARRANGEMENT OF ISO- RB REEL TYPE DIPPER TRIP

=LUBRICATION

SECTION

E. E.

SECTION D. D.

IMD 590/R

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SECTION B. B. VIEW AT

C. C.

SEE ENLARGED DETAIL FOR ROPE ANCHOR ON DRUM

DIPPER TRIP

/'":.~

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DEFLECTION SHEAVE SUPPORT TRIP ROPE DEFLECTING SHEAVE DEFLECTING SHEAVE BUSHING DEFLECTING SHEAVE THRUST WASHER DEFLECTING SHEAVE PIN SPLIT PIN GEAR CASE DRAIN PLUG SUPPORT SETSCREWS LOCKWASHERS , SUPPORT BRACKET BOLTS SLOTTED NUT SPLIT PIN DIPPER TRIP SUPPORT BRACKET SUPPORT BRACKET SETSCREWS LOCKWASHERS SUPPORT BRACKET SETSCREWS LOCKWASHERS SETSCREWS ROPE GRIPS ROPE THIMBLE DIPPER TRIP ROPE LOCKWASHERS GREASE NIPPLE DIPPER TRIP BASE DIPPER TRIP MOTOR GEAR AND PINION GUARD DRUM SHAFT DIPPER TRIP GEAR DIPPER TRIP PINION DIPPER TRIP DRUM OUTER BEARING RETAINER OUTER BEARING SEAL DRUM SHAFT RETAINER INNER BEARING SEAL INNER BEARING RETAINER SUPPORT BASE SHIMS DR\JM GUARD SHAFT RETAINER SETSCREWS GREASE NIPPLE DRIVE PINION KEY OUTER DRUM SHAFT BEARING INNER DRUM SHAFT BEARING OUTER BEARING SPACER-LEFT HAND OUTER BEARING SPACER-RIGHT HAND INNER BEARING SPACER LOCKWIRE GUARD SUPPORT SCREWS BEARING RETAINER SETSCREWS MOTOR SUPPORT BOLTS SUPPORT BASE SETSCREWS GUARD SUPPORT SETSCREWS GUARD SUPPORT NUTS

ENLARGED DETAIL SHOWING ROPE ANCHORAGE ON DRUM SECTION

0

A. A.

FIG. 49/ R3 GENERAL ARRANGEMENT OF ISO- RB REEL TYPE DIPPER TRIP.

=LUBRICATION

SECTION

E. E.

SECTION D. D. IMD.590

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b 7 8 9 I0 II 12 13 14 15 Ib 17 I8 19 20 21 22 23 24 25 2b 27 28 29 30 31 32 33 34 35

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SECTION

3b

SECTION

CC

SECTION SECTION

EE

37.

38 3 40 41 42 43 44 45

4b

DD

47 48 49 50 51 52 53 54 55 Sb 57 58

DESCRIPTION CROSS HEAD CYLINDER LEVER PIN CYLINDER LEVER TRIP SHEAVE LEVER LEVER SHAFT SPACER TRIP LEVER SHAFT TRIP SHEAVE LEVER KEY TRIP LEVER SHAFT KEY LEVER SHAFT BUSHING CYLINDER LEVER PIN CYLINDER RETAINING PIN CYLINDER PIN BUSHING CYLINDER PIN BUSHING DIPPER TRIP CYLINDER SUPPORT R.H. DIPPER TRIP SUPPORT L.H. DIPPER TRIP SUPPORT DIPPER TRIP SUPPORT SETSCREWS DIPPER TRIP SUPPORT SETSCREWS TRIP ROPE SHEAVES TRIP ROPE SHEAVE NEEDLE BEARINGS TRIP ROPE SHEAVE PIN TRIP·ROPE SHEAVE PIN TRIP ROPE SHEAVE PIN TRIP ROPE SHEAVE PIN SHEAVE PIN LOCKNUT SHEAVE PIN WASHER SPLIT PIN LEVER ROPE GUIDE PIN LEVER ROPE GUIDE TRIP ROPE SHEAVE THRUST WASHER TRIP ROPE GUIDE TRIP ROPE GUIDE TRIP ROPE GUIDE BOLT TRIP ROPE GUIDE BOLT ROPE GUIDE NUT DUMP SHAFT SEGMENT LEVER R.H. DUMP SHAFT SEPERATOR SEPERATOR KEY R.H. SEGMENT LEVER KEY L.H. SEGMENT LEVER KEY SEGMENT LEVER L.H. DUMP SHAFT R.H. BUSHING DUMP SHAFT L.H. BUSHING LATCH SPRING CYLINDER SPRING CYLINDER CAP LATCH SPRING FOLLOWER ROPE ANCHOR STUD TRIP ROPE ANCHOR LATCH SPRING ROPE ANCHOR WEDGE ROPE ANCHOR WEDGE ROPE ANCHOR SOCKET ADJUSTING BOLT ADJUSTING BOLT NUTS ROPE GUIDE BOLT ROPE ANCHOR PIN SPLIT PIN

WELDED REAR STOP

WELDED Dl PPER HANDLE

IMO. 523

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SPRING TO BE COMPRESSED TO 14" WITH LATCH BAR ENGAGED

SHEAVE PIN BRACKET

HANDLE END CASTING

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FOR ARRGT. OF DIPPER TRIP CYLINDER SEE FIG. SO(RI

0

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= LUBRICATION

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KEYWAY AS SHOWN WITH LATCH BAR ENGAGED

_ _ _ _ _.:o,.__-1------L.._. _ _ _ _ _ _ / '

FIG.49f-~R~I__G~E~N:E~RA~L~A~R~R~A~N~G~E~M~E~N~T-=O~F~ii~S~O~R~B~D~IP~P~E~R~T~R~IP I

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DUMP CHI'.IN

(!) LUBRICI'.TION - GREASE.

DIPPER TRIP

Fl G. 49.

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DESCRIPTION CROSS HEAD OPERATING CYLINDER BODY CYLINDER HEAD (FRONT) CY Ll N DER HEAD (BACK) FRONT CYLINDER HEAD BUSHING CYLINDER ROD BOLT PISTON PISTON RING CUP PISTON FOLLOWER PISTON ROD PISTON ROD NUT CYLINDER ROD BOLTS (LONG) SPLIT Pl N INNER PISTON RETURN SPRING OUTER PISTON RETURN SPRING CYLINDER BACK HEAD GASKET CYLINDER DRAIN PLUG CYLINDER RETAINING PIN BUSHING

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SECTION THROUGH DI·PPER TRIP CYLINDER FIG. 50/RI

IMD.284

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D I P P E R T RI P C YL .I N D E R

F.l G~

50.

NAME: CYI.INDE:R H~f'\0- MCK CYI.INDe:R BACK PISTON rDI..L.O\.JtR 1'\CKING CUP I"RONT PISTON F'OL.L.IJ\.JE'R PISTON ROD COMPRE:SSION SPRING GOMF'RE:SSION SPRING CYL.INDtR HtAD- FRONT RE:ACH ROO END ~NBITE: HE:AD GASKtT BOL.T BUSHING ~6.SP. M&F.' E:L.BO\J. C.B. !i48.SP. DRAIN COCK. C..

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DIPPER IN HIGH POSITION

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@MAGNET VALVE BRACKET

REF. NQ I 2 3 4 5 6 7 8 9 10 II 12 13 14 IS 16 17 18 19

DESCRIPTION FLEXIBLE HOSE FEMALE RAILROAD UNION STEEL PIPE EQUAL ELBOW STEEL PIPE MAGNET VALVE STEEL PIPE TAPER THREAD SOCKET FLEXIBLE HOSE RAILROAD UNION ELBOW STEEL PIPE MALE & FEMALE RAILROAD UNION ROTORSEAL FLEXIBLE HOSE FLEXIBLE HOSE STEEL PIPE QUICK RELEASE VALVE PIPE CLIP MAGNET VALVE BRACKET

I

MAGNET VALVE ENERGISED TO ADMIT AIR TO DIPPER TRIP CYLINDER

-~_/

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ROTOSEAL

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NOTE•lliPiPES SCREWED BOTH ENDS- TAPER THR'D USE VOLER (R3) THR'D LUBRICANT ON ALL PIPE JOINTS.

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......_ - - - - - - ! - - - · LOWER BOOM

DIPPER IN LOW POSITION

NOTE. iTTSiMPORTANT THAT THERE IS NO CONTACT BETWEEN FLEXIBLE HOSE & EDGES OF CORED HOLES TO PREVENT DAMAGE TO HOSE WHEN CLIPS ARE IN POSITION.

IMD.296

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Eh\,9~ TRIP CYLINDER 56R2214

FLE.XIBLE. HOSE. 3-41R55~

M!>.GKET VALVE. ENERGISED TO P..DMIT P..IR TO DIPPER TRIP CYLINDER WE5TINGHOUSE. VALVE I-53E.11&

FLEXIBLE HOSE. I-41R552

---+---FLEXIBLE. \-lOSE. I-41R552

NOTE.:ALL PIPE.S SC.RE.WE.D BOTH ENDS TI'\PE.R THRE.P..D USE VOLE.R(R~)TI-IREAD LUBRIC.P..NT ON t>.LL PIPE JOINTS FLEXIBLE HOSE :!,-41R552

FLEXIBLE HOSE

3-41R552

DIPPER TRIP PIPING

FIG. 5 1.

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BRIDGE STRAND SNUBBER FIG. 52.

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\.-:FOLLOW ROPE!l LEAD ROPES

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DIPPER HANGS

STRAIGHT

HOIST ROPES 1

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32mm.Dia.(RBSD·870)x193' ~O"(STD 37 1 ~6" BOOM, 22 1 ~8" HANDLE)

32mm.Dia.(RBSD-870)x220'-~0"(NCB 45 1 ~0" BOOM, 26 ~3" HANDLE)

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CROWD ROPE 3Smm. x 95'-0"(RBSD-872) PIN AND SOLID CONNECTOR

POSITION OF ROPE FOR STEP 4 •

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REEVING RETRACT ROPE

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INSTRUCTIONS FOR REEVING RETRACT ROPE. L CHECK ROPE LENGTH. 2. EXTEND HANDLE WITH REAR STOP AGAINST SADDLE BLOCK WITH DIPPER ON GROUND. 3.LEAD BOTH ENDS OF RETRACT ROPE OVER OUTER GROOVE OF SHEAVE AT SHIPPER SHAFT AND DOWN THROUGH DEFLECTING SHEAVES WITH ROPES TOWARD CENTRE LINE OF BOOM. 4.ANCHOR BOTH ENDS OF REmACT ROPE TO OUTER SOCKETS OF CROWD DRUM WITH SOCKETS IN HORIZONTAL POSITION. S.PLACE MIDDLE OF RETRACT ROPE AROUND GROOVE OF TAKE-UP NUT AT FRONT OF DIPPER HANDLE AND THROUGH GROOVE OF SPREADER CASTING AT SIDES OF HANDLE.

REEVING CROWD ROPE

INSTRUCTIONS FOR REEVING CROWD ROPE. I. CHECK ROPE LENGTH 2.LOOP THE MIDDLE OF THE CROWD ROPE AROUND THE EQUALIZER AT THE END OF THE HANDLE. LEAD ENDS OVER INNER GROOVE OF SHEAVES AT SHIPPER SHAFT AND LET ENDS HANG TO GROUND. 3.

REm ACT ROPE ON DRUM SHAFT UNTIL FRONT HANDLE STOP IS AGAINST THE SADDLE BLOCK AND THE HANDLE ALMOST HORIZONTAL. 4.FASTEN CROWD ROPE ENDS TO DRUM WITH ANCHOR BOLTS USING THE PROPER NUMBER OF DEAD WRAPS AS NOTED IN THE DIAGRAM TO THE RIGHT OF THIS NOTE. S.ROPES TO BE REEVED AS TIGHT AS POSSIBLE

WiNiiUP

ADJUSTMENt I. TO REMOVE SLACK FROM CROWD AND RETRACT ROPES, DIPPER HANDLE SHOULD BE IN A POSITION WITH DIPPER FLAT ON GROUND OR FARTHER FORWARD AS SHOWN IN POSITION 'x: 2.USE THE CROWD POWER TO TIGHTEN CROWD ROPES 1THEREBY PUTTING ALL THE SLACK INTO THE RETRACT ROPES 3.TAKE-UP SLACK IN REm ACT ROPE WITH SCREW TAKE -UP AT DIPPER END OF DIPPER HANDLE.

NOTE :-

f

12 DEAD WRAPS CROWD DRUM RIGHT SIDE I DEAD WRAF!

FIG. 54/R2 REEVING DIAGRAM AND INSTRUCTIONS FOR 150-RB CROWD AND RETRACT ROPES IMD-518/R

BI379509

THE CONSTRUCTURAL STRETCH MAY BE OUT OF THE CROWD ROPES WHEN IT BECOMES NECESSARY THEREFORE :- AFTER THE 3 •~ ROPE ADJUSTMENT, TO ADJUST ROPES FOR ABOUT THE 3 RD. TIME. TURN AFTER TIGHTENING TO PREVENT WORKING WITH OVER BACK OFF THE TAKE -UP SCREW TIGHT ROPES.

LEFT SIDE -,---

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REAR STOP

RETRACT ROPE IN OUTER GROOVE DIPPER TRIP AIR CYLINDER

CROWD ROPES IN INNER GROOVES

RETRACT ROPE t 3l~x9s'-o' (ISO RS) 1 ~')(9o-o· (II oRB) I !4•:X.I0:2-c5 (IIORB\,LONG RANGE)

X»

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SNUBBER ON

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SHEAVE SEGMENT ANCHOR

ROPE IN THIS POSITION STEP 4.

~

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D~FLECTING

ON

SHEAVES BOOM

CROWD ROPE CROWD ROPE CROWD ROPE

I·87SDEAD WRAP(IIORB) 1·60 DEAD WRAP (IIORB LONG RANGE)

Instructions For Reeving Crowd And Retract Ropes.

1. Check rope lengths.

2. Extend handle with rear stop against saddle block dipper on ground.

3. Lead both ends of retract rope over shipper shaft sheaves so that ropes a~e in outer grooves ot sheaves and down throuqh deflecting sheaves with ropes to <t, o\i boom 4. Anchor both ends ot rope to outer sockets of crowd drum with sockets in hor.lzontal position.

5. Place middle of rope around anchor on front of dipper handle. .1 6. Wind up all the retract rope on the drum until front handle stop is against\ saddle block and the handle is about horizontal. :j 7. Lead crowd rope around curved snubber on crowd drum until there is an eg~lal amount on each side.

8. Reeve crowd ropes around shipper shaft sheaves so that ropes are in inner grobves of sheaves.

9. Lead rop~t over sheave segment on rear handle stop around adjustable rope apcho~ check rope anchors so that they are in position for maximum rope take up.

I 10. Anchor crowd rope in rear stop with rope socket wedge and join ends witH bulldog clip.

11. Take up slack in ropes by screwing down rope anchors-making sure stop is square with tube so there is 3 clearance between tube and stop on each side.

12. Ropes to be reeved as tight as possible.

11/; ')(

99-o'

(11 0 RB)

1 31~)(88·-6 (ISORB) 11/..i'X IOs:.0"(110RB.LONG RANGE)

BULLDOG ROPE GRIP I y4'• (110 RB) BULLDOG ROPE GRIP IW(ISORB)

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VIEW IN DIRECTION OF ARROW

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CROW-D ·F, OPE REEVING

E!)G. 54/BJ . t I

IMD.285

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NOTE.:- ROPE IN OUTER GROOVES

LEFT SIDE l~s- DEIIID WRIIIPS

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CROWD ROPE. l3's" ROPE.x 94'-Q''LONG (3"7~s· 500M) l''f<·~ ROPE x IOe.'-O'LONG ( 4.5'-0' BOOM)

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RIGHT SIDE. l''s DEP>.D WRAPS

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BIIICK HI!>.UL ROPE 13's" ROPE x S~,'-Q" LONG (31'-G" e.ooM) l 3t~' ROPE. )( 9e.'-0' LONG (45'-0' BOOM)

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INSl'RUC.TIONS FOR REEVING 12-ROWD t>.ND RE.TR~C.T ROPE. C.HECK ROPE LENGTHS 1. EXTEND THE. DIPPER H~NDLE UNTIL THE. UPPER STOP RESTS ~GIIIINST SIIIDDLE BLOCK 2. LAY THE MIDDLE OF THE. B~CKHAUL ROPE NEAR THE. ¢ OF THE DIPPER 3. FEED BOTH ENDS OF ROPE OVER SIIIDDLE. BLOCK ROLLER SO THAT ONE ROPE. IS IN THE. RIGHT H~ND INNER GROOVE AND THE OTHER IS IN THE. LEFT H~ND INNER GROOVE. 4. CONNECT ROPE ENDS TO OUTER SOCKETS OF THE. CROWD DRUM WITH . SOCKETS IN HORIZONTAL POSITION S.PLACE MIDDLE. OF BP>.C.KHP>.UL ROPE P>.ROI..lND ANC.I-\0 (DWITH ROPE ANCHOR DR~WN l'IGHT ~GI!>.INST I!>.NC.HOR STOP WITHOUT SHIMS IN PLACE. NO OF 1-\~NDLE...THRE.AD ENDS OF 6.LOOP CROWD ROPE. AROUND SHEAVE().; ROPE OVER LEFT Ht>.ND AND RIGHT H~ND OUTER GROOVES ON S~DDLE. BLOCK ROLLER AND LET ENDS HANG TO THE GROUND. . l. WIND UP ALL THE BIIIC.KHAUL ROPE ON THE DRUM UNTIL LOWER H~NDLE. STOP IS P>.GAINST THE SADDLE BLOCK IIIND H~NDLE IS IIIBOUT HORIZONTAL. 8.FMTE.N CROWD ROPE ENDS TO DRUM WITH P>.NCHOR BOLTS. USING THE PROPER NUMBER OF DE.M WRIIIPS AS NOTE.D IN P>.BOVE. SKETCH 9.ROPES TO BE REE.VE.D I!>.S TIGHT M POSSIBLE · IO.FOR I!>.Di:IUSTMENT OF ROPES SE.E. INSTRUCTIONS ON DRG. N0.56R2.C.BB.

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BI379509 DESCRIPTION CROWD SIDE FRAME FIRST INTERMEDIATE SHAFT FIRST INTERMEDIATE SHAFT PINION SLIPPING CLUTCH GEAR SLIPPING CLUTCH HUB SLIPPING CLUTCH HOUSING

SLIPPING CLUTCH HUB RETAINER SLIPPING CLUTCH GREASE GUARD R.H.OUTER OIL SEAL RING R.H.INNER OIL SEAL RING R.H. BEARING SEPERATOR R.H.ROLLER BEARING INNER OIL SEAL RING GASKET L.H. OIL SEAL R lNG CLUTCH GEAR ROLLER BEARING L.H. ROLLER BEARING L.H. BEARING OUTER SPACER L.H. BEARING INNER SPACER

BACKHAUL ROPE ANCHOR SOCKET

OIL SEAL RING GASKET INNER SHAFT PINION

RETAINER

PINION RETAINER NUT SLIPPING CLUTCH ROTOR SEAL

RETAINER SHIMS SLIPPING CLUTCH AIR PIPING L.H.BEARING CAP R.H. BEARING CAP L.H. BEARING CAP BOLTS R.H.BEARING CAP BOLTS L.H. BEARING END COVER L.H. BEARING OIL SEAL END COVER GASKET, L.H. SHAFT RETAINER

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R.H. OUTER OIL ·SEAL RING R.H. BEARING SEPERATOR SECOND INTERMEDIATE GEAR GEAR RETAINER SECOND INTERMEDIATE SHAFT

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LH.ROLLER BEARING R.H.BEARING CAP L.H.BEARING CAP

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51 52 53

CROWD DRUM' SHAFT CROWD DRUM CROWD MOTOR PIN ION

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CROWD MOTOR CROWD MOTOR CfiOCK BAR BRAt<E .. HOUSING CROWD BRAKE

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64 65 66 67 68 69 70 71 72

CROWD MACHINERY FIG. 55.

SIDE FRAME 1st, INTER SHAFT PINION GEAR SLIPPING CLUTCH HUB SLIPPIN'CLUTCH HOUSING RETAINING WASHER CLUTCH GREASE GUARD OIL SEAL RING OIL SEAL RING SEPARATOR TIMKEN BEARING 110 11 RING GASKET · OIL SEAL RING TIMKEN BEARING · R & M BEARING SPACER SPACER 110 11 RING GASKET RETAINING WASHER qPECIAL SIIOONDS NUT AIRFLEX CLUTCH CROFT ROTOR SEAL SHIMS SLIPPING CLUTCH AIR PIPING 2nd INTER SHAFT & PINION R & M BEARING BEARING END CAP OIL SEAL RING ''0 11 RING GASKET RETAINING PLATE TIMKEN BEARING OIL SEAL RING "0" RING GASKET OIL SEAL RING SEPARATOR GEAR RETAINING PLATE DRUM SHAFT . DRUM DRUM FLANGE BUSH 1vASHERr

GEAR RIM IDCK BAR ANCHOR PIN BEARING CAP ROD BOLT BEARING CAP ROD BOLT BEARING CAP ROD BOLT BEARING CAP ROD BOLT

R.H .s Lst INT L.H.S. 1st IN!' R.H.S. 2nd INT L:.H.S. 2nd INT

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CLUTCH. HOUSIN.G

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' TI-\E. PRINCIPLE. ON 'NH.ICI-\ TH.E. 'AIRFLE.~· CLL.lTCI-\ OPE.R.O..TES IS AS FOLLOWS:- COMPRESSED AIR IS ADMITTED TO A. SPECIALLY CONSTRUC.TE.D AlRTIGI-\T GLP..ND WI-\IC.I-\ E.~PANDS AND FORCES TI-\E.. SPE..C.l.O..LLY DE..SIGNE.D FRIC.TION BLOCKS OR SUPPERS ONTO TH.E. FRICTION RIM. TO DISENGAGE.. TI-\E..

CLUTCH, AIR IN THE. RLIBBE.R GLAND IS E.'i-.1-\f:J...LISTE.D TO ATMOSPHERE.

OPERATING PRINCIPLE. & ASSEMBLY OF CROFTS 'AR-E.' E.XPA.NDING TYPE. 'AIRFLE"'-' CLUTCI-\

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·rN&TRUCTIONS FOR ASSEMBLING AR-E TYPE 'AIRFLEXt CLUTCH ELEMENT Pldce valve of rubber air gland through hole in housing, fit red fibre washer anc~ assemble lock nut..

Make sure that the joint is airtight when locknut is .'l•in correct position.

Lay housing on horizontal surface.

The hole directly above the valve ho:e is a spring hole, so commencing with the two adjacent holes, place the to~Lque bars in each alternate hole round the housing. :1 Slide the friction blocks into position between the torque bars, and then pl~lce the springs in the slots of the friction blocks with the curved end of thEl spring in the hole of the housing. . [ Now place the end plate in position and fit 2 or 3 bolts temporarily finger titfht so that end plate bears lightly on ends of springs.

Manoeuvre 1 spring and torque bar at a time into their respective holes, st~Lrting at one of the pilot bolts.

Continue round the element in one dii~ection until all the springs and torque bars have been correctly assembled.

Wh:llst this is being done, keep the bolts finger tight only.

As each spring end isE~ntered into it's hole in the end plate, a light tap at the other end of 1 thef spring, will increase~he amount by which it is entered, and so prevent it slipping out.

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FIG. 56.

T Y P E ·A R - E

VIE..W SMOWING ASSEMBLY OF 'AR-E.'iYPE. 'AIRFLE.~· CLUTC~ ELE.MENT

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INSTRUCTIONS FOR MiJUSTING BRAKE. I>.DJUST SCREWS @ 1"/ITI·\ BRI>.KE. IN RELEME.D POSITION SO Tf\IIIT BOTH E.NDS Of SHOE. HIIIVE. E.QUP..L RE.LEME-IIIBOUi ~,e; THE. ONLY !>.DOJUSTME.NT REQUIRED IS TO COMPE.NSI>.TE. FOR WE.!>.R OF Tf\E. LINING OF THE. BR!>.KE SHOE.S. WHEN THE. BRIIIKE. WILL NO LONGER HOLD. TIGHTEN Tf\E. SHOE. P..DJUSTME.NT M FOLLOWS: WITH THE BR!>.KE. SE.T INSERT A. SCREW DRIYE.R BE.TI"'E.E.N WP..SHE.R@P..ND THE. E.ND OF THE. CYLINDER, RE.LIE.YE. PIN(]) OF THE. SPRING LOP.D

BY PRYING WITH THE. SCREW DRIVER 1\ND REMOVE. PIN Ql LOOSEN LOCK NUT@AND TURN E.YE.BOLT@TOTHE. RIGHT (CLOCKWISE.) TO TIGHTEN THE BRI>.KE.. HOLD WillS HER@ FROM TURNING BY INSE.RTINI:I SCRE.W DRIVE.R IN ONE. OF THE. SLOTS IN THE WASHER. TIGHTEN LOCK NUT@ 11-.ND RE.PL!Io.C.E. PIN G) IT WILL 11-.LSO BE. NECE.SSIIIRY TO RE.·SE.T THE. RE.LE!Io.SE. SCREWS@ FOR UNIFORM RE.LE.ME. OF THE. SHOE.S

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PADLOCK PIN

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DIPPER DOOR HINGE PIN

DIPPER LATCH BAR

SUSPENSION ROPE SOCKET PINS EQUALISER LINK PIN SUSPENSION PLATE PINS SUSPENSION PLATE

LUBRICATION DIAGRAM OF SHOVEL FRONT END EQUIPMENT FIG. 58/R3 IMD 295/R2

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LUBRICATION DIAGRAM OF SHOVEL FRONT END EQUIPMENT FIG. 58 R2

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LUBRICATION DIAGRAM OF SHOVEL FRONT END EQUIPMENT FIG. 58 .BJ

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CYLINDER LEVER DIPPER TRIP SHEAVES

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SHIPPER SHAF'T ,DRUM BEARINIOS

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SHOVEL FRONT END LUBRICATION FIG. 58.

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&lfiiORRISI'taTClN LE.VE.R PULL f\Oil>T ·srAI<o 9 IPIN INSTRUCTIONS FOR ,:>.DJUSTING BAC\<..1-\P..UL P..ND CROWD ROPES

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WITH 1-IANDLE IN VERTICAL POSITION AND WITH TEETH TOUCHING TI-lE GROUND. USE CROWD POWER TO TIGHTEN CROWD ROPES TO PUT ALL SLACK. INTO TI-lE BACKI-IAUL ROPES. 2. REMOVE HOOK FROM RA1Ci'\ET HOIST CHAIN AND CONNECT RI>.TCHE.T TO ROPE ANC.J-IOR

BY INSERTING PIN @TI-l ROUGH END LINK IN CI'\AIN, TI-\E.N REMOVE. SPECIAL BOLT@AND TAKE UP SLACK IN BACKI'\AUL ROPE. WITJ-1 RATCHET HOIST 3. WI-IE.N SLACK. IS RE.MOVE.D INSTALL AS MANY SI-\IMS 4 @@AS POSSIBLE. TO HOLD ROPE TP>.UT W EN il'C.I-\E.T HOIST B IS RELEASED. 4. REMOVE. RATCHET LEVER HOIST & AND USE BACKHA POWE.R TO CLAMP SHIMS. REPLACE RETAINER BAR~}.!>.ND SECURE WITH SPECIAL BOLT @ S. AFTER MAXIMUM TAKE-UP IS USED fi-ND ROPES NEED FURTHER ADilUSTMENT, IT WILL BE NECESSARY TO PROVIDE FOR MORE ADJUSTMENT BY SHORTENING THE. CROWD ROPES AT THE. ANCHOR BOLTS ON TJ-IE DRUM. (A) WITJ-1 HANDLE. IN VERTICAL POSITION REMOVE ALL SHIMS. (B) RAISE Hfi.NDLE WITH BACKHfi.UL POWER SO TI-l T ROPE. ANCHOR(i) CONTACTS ANCHOR STOP l SET CROWD BRAKE. (c.) REMOVE. ALL SLACK FROM CROWD ROPE.:::. BY PULLING ROPE ENDS THROLIGH ANCHOR BOLl'S AT DRUM AND CLIT OFF EXC.ESS LE.NGl'H OF ROPE..

(D.)LOWE.R DIPPER AND REMOVE. SLP..C.t<.. BY FOLLOWING TI-\E. ABOVE INSTRUCTION N? 5 I 2. ~ 4.

NDl'E: ONE. RE.TP..INER BAR 2. SLIDES IN A SLOT A D PREVENTS SI-\IMS I FROM FALLING OLIT WHEN ADJUSTMENT IS BEING MADE.

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I DIPPER HANDLE I SPRING GUIDE ROD !SPRING WASHERS I ROPE ANCHOR !SPRING GUIDE ROD LOCKNUT b I HANDLE REAR STOP 7 I REAR STOP PIN 8 REAR STOP PIN RETAINING WASHER 9 REAR STOP PIN LOCKNUT 10 I SPLIT PIN II !STOP PIN BOLT l'riSPLIT PIN 13 I CROWD ROPE EQUALIZER 14 CROWD ROPE EOUALISER SETSCREWS 15 LOCKWASHER lb ILOCKWIRE' 17 !ROPE GUARD BOLT IB !SPLIT PIN 19 !ROLLER BEARING PIN 20IBEARING ASSEMBLY 21ISLOTTED NUT 221 SPLIT PIN 231 GREASE NIPPLE 24IGREASE NIPPLE 25ITAPER SOCKET 2bl PIPE NIPPLE

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FIG 61/R2 GENERAL ARRANGEMENT OF CROWD EQUALIZER WITH SPRING .CUSHION FOR 150-RB IMD 520/R

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I I DIPPER HANDLE 2 I SPRING GUIDE ROD 3 I SPRING WASHERS 4 I ROPE ANCHOR 5 SPRING GUIDE ROD LOCKNUT 6 HANDLE REAR STOP 7 )REAR STOP PIN B REAR STOP PIN RETAINING WASHER 9 REAR STOP PIN LOCKNUT I 0 I-SPLIT PIN II )STOP PIN BOLT 12 )SPLIT PIN 13 )CROWD ROPE EQUALIZER 14 CROWD ROPE EOUALISER SETSCREWS 15 LOCKWASHER 16 )LOCKWIRE 17 )ROPE GUARD BOLT IB )SPLIT PIN

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FIG 61/R GENERAL ARRANGEMENT OF CROWD EQUALIZER WITH SPRING CUSHION FOR 150-RB IMD 520

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INSTALLATION OF ROPE TAKE UP UN IT &ADJUSTMENT OF RUBBER BUMPERS I. BACK OFF SCREW 'A' TO PERMIT THE RUBBER TO MOVE BACK. 2.1NSTALL THE UNIT ON HANDLE END. 3.TIGHTEN SCREWS 'A' UNTIL RUBBER CONTACTS HANDLE.MAKING SURE UNIT IS SQUARE WITH ~OF HANDLE. THERE SHOULD BE 3/4'CLEARANCE BETWEEN UNIT AND HANDLE TUBE 4. TIGHTEN SCREWS EQUALLY lf2" TO COMPRESS RUBBER.MAKING SURE UNIT REMAINS SQUARE WITH ~OF TUBE. THIS WILL PRELOAD EACH RUBBER BUMPER APPROX.750LBS.

SECTION THROUGH HANDLE REAR STOP

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PE'R:MI5&1BLE

FRONT END EQUIPMENT FIG. 66.

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UPPER

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SE.C.TION

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"A" FRAME PIN SUSPENSION PLATES OurER "A" FRAME BOOM HOIST 'SHEAVE CLAMP COLLAR BUSHING BUSHING SHEAVE SHEAVE SUPPORT SUSPENSION SHEAVE PIN SUSPENSION SHEAVE MAST FOOT MAST FOOT PIN MAST GUY ROPE LINK GUY ROPE BRIDGE STRAND HAND RAILING LADDER BLANK BOLT RETAINER PLATE BUSHING SHEAVE MAST POINT PIN GUY ROPE LINK MAST SHEAVE GUARD PIN P:ij'E SPACER ROD BOLT WASHER BOOM FOOT PIN GUY ROPE PIN SUSPENSION PLATES INNER

FOR GENERAL ARRP-.NGEM~T OF BOOM POINT SEE

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LENGTH

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R H YOKE SHEAVES BOOM

NOTE:~5 90'- 0' ANO SHORTER DO NOT REQUIRE. MAST TYPE. 5Ll5PENS10N POR DAAG.LINE.

BOOM SUSPENSION FIG. 76.

AND M:.AST

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-D UP A R-- - - - - - - - - - - - - , Telephone: HounsloN 0085/8

Telerroms: Dewhurst, HourtJIOW

DIWBURST a

PARTNIR LTD. (Established 1919)

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INVERNESS WORKS • HOUNSLOW • MIDDX • ENGLAND

Instructions for Mounting and Adjustment of Single Phase {Wound) Electromagnetic Type N Brakes Brake Diam.

GapE/ M Max. Spanner 1 size

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Release the spring pressure by m'eans of pressure screw D; also release the set screw C. Take out pin A and remove the brake arm B. Set the brake base in position on the bed plate and replace brake arm B. Tighten up the pressure screw D so that the brake drum is tightly gripped by the brake arms. The brake base should then rest on the bed plate and the whole face of the brake linings should be in contact with the drum.

The fixing holes in the base should also be exactly in position for the corresponding holes in the bed plate. To compensate for difference in centre height between brake and drum a set of four shims is provided with each brake for use when necessary.

Tighten down the brake on the bed.

Feed up the pressure screw D so that only t* of thread is available for increasing the pressure to compensate for wear of the friction surfaces.

Set the gap E by means of the adjusting screw F. Gap E should be set as small as possible consistent with the brake shoes freeing the drum. Readjust the brake when the gap E reaches the valut; listed in schedule above.

For a period of approximately seven days after installation the gap E should be carefully checked at frequent intervals and ·readjusted to compensate for the initial bedding of the friction surfaces. \Vhilst setting the air, gap E it is essential that the armature H should bear against the pressure rod K. Feed up the set screws C so that both arms lift equally when the armature H closes. In this connection we would point out that it is usually sufficient to adjust screw C on the magnet arm only, as, due to the weight of the magnet there is a natural tendency toward increased clearance between shoe linings and drum on this side by comparison with plain arm B. \\"hen necessary the brake can be manually released by applying a suitable spanner (see schedule) to release device at point.l\I. 12/55

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SHELL LUBRICANTS RECOMMENDED FOR RUSTON-BUCYRUS EQUIPMENT -------------------------------------------------------------------------________________ A_P_P_L_I_C_A_T_I_o_N________________

~--~~~~~=:~z_i~~~~=B~--~----3=0~R=B~----~-----3=3=R~B~~--~--~~3=8=R=B~----t---~5=4~R~B~----T---~l-l=O-R_B -4j~----15._o ___

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SIZE AND TYPE OF ENGINE

3YCN, 6YCN 4YEiN

Diesel Engines-Straight Oil ...

.. • Talpa Oil 20

Heavy Duty Oil

• . . Talona Oil 20

Main Clutch Housing Bearings only Gear Case· and Machine Sump

. . . Alvania Grease 3

...

Bevel Gears at Bottom of Ce1i.tre Post Wire Ropes

... oP£n.o~t P.~Tt"I.\-Y.

Exposed Gears Grease Nipples

Electric Motors and Generators

5YFN

5VPHN

V4RPHN

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V6RPHN

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Talpa Oil 20 Talona Oil 30

Talpa Oil 20 Talona Oil 20

Alvania Grease 3

Above 32°F Oil 20 32°F Talona Oil lOVV

Above 32°F Talona Oil 20 Betow 32°F Talona Oil lOVV

Alvania Grease 3

Alvania Grease 3

I Talona Betow

V12RPHN (Diesel-Electric)

Above Talona Betow [ Talona

32°F Oil 20 32°F Oil lOVV

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Cardium Compound D Cardium Compound F

Hook Roller Paths Swing Rack and Pinion Teeth ...

Dipper Handle Rack Teeth Bushes in Swing Cone Rollers Bushes in Drum Sleeves (on machines, prior to using Ball and Roller Bearings) ...

Ball and Roller Bearings (grease lubricated) { Enclosed Gears (Bearings in gear case separ .. . .. . .. . ately lu.bricated))

Nerita Grease 2 or Alvania Grease 2

Macoma Oil 76 Cardium Compound F or Nerita Grease 2 2 Alvania Grease or Nerita Grease 3 Alvania Grease 3

Macoma Oil 76 Cardium Compound F or Nerita Grease 2 2 Alvania Grease or Nerita Grease 3 3 Alvania Grease

Macoma Oil 82

Macoma Oil 82

Macoma Oil 82

Macoma Oil 82

*Macoma Oil 76

·

I Talpa

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falona Oil 20

i Talona Oil 20

11alona Oil 20

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Alvania Grease 3

-

Oil 20

4YCN

Talpa Oil 20

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Maco.ma Oil 76 Cardium Compound F or Nerita Grease 2 or 2 Alvania Grease · 2 or Nerita Grease 3 or 3 Alvania Grease 3

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Talpa Oil 20

Macoma Oil 76 Cardium Compound F Nerita Grease 2 Alvania Grease Nerita Grease 3 Alvan:a Gre;orse

Macoma Oil 76 Cardium Compound F or Nerita Grease 2 2 Alvania Grease or 'Nerita Grease 3 3 Alvania Grease

or 2 or 3

Macoma Oil 76 Cardium Compound F Nerita Grease 2 · Alvania Grease Nerita Grease 3 Alvania Grease

Macoma Oil 76

Macoma Oil 76 Cardiu:ln ' Compound F ·Compound F I Nerita Grease 2 or N~rita Grease 2 Alvania Grease 2 Alvania Grease Nerita Grease 3 or Nerita Grease 3 Alvania GreaSe 3 Alvania Grease

I Cardium or 2 or 3

*Macoma Oil 76

Maeema

en

5'6

Macoma Oil 82

Shipper Shaft Gear Case

Maeama

On~

*Macoma Oil 76

Macoma Oil 82 Maeahia Oil 5'6

Enclosed Swing Gears "' *Macoma Om 76

*Maooma Oil 76

· · · Engine Oil

Engine Oil

*Macoma Oil 76

Miacoma Oil 76

Macoma Oil 76 Maconta Oil '" +alt-a 9il429-m' Ta.laaa rnr 20

*Macoma Oil 76

*Macoma Oil 76

Maeonm Oil 'r6'

Engi11e Oil

Engine Oil

Esfinc Oil

Walking Ca'ms .and Guides Hydraulic Units

1\.t~MA

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Tellus Oil 29

Clutches and Brakes-Air Set, Operating Cylinders .. . .. . .. .

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TI)LLUS OIL 29

Engine Oil

Ta!ona Oil 20 or Talpa Oil 20

Tlo\t.PA '20

TAL.PA "2t.:::

*Macoma Oil 76 *Macoma Oil 76

*Macoma Oil 76

Red Jeadjflaked or powdered graphite mixed with Engine Oil or Vitrea Oi133 to form paste (S parts red lead to I part graphite, by weight),

*Macoma Oil 76

Tellus Oil 29

Engine Oil

---~

Flexible Couplings-Spring Type

Nerita Grease 2 or Alvania- Grease }.

Gear Type Air Compressor-Straight Oil

Handle and Saddle Block Final Drive (Caterpillar Gears) ...

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Talpa Oil 30

*Macoma Oil 76

Gears at Bottom of Centre Journal

Heavy Duty Oil Boom Hoist Worm

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Primary Transmission Gear Case

Lu~ILc.A.nL

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...

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or 2 o•· 3

Macoma Oil 82 Macoma Oil 82 Macoma Oil 82 Cardium Compound D ~mpound D Cardium ·Cardium Cardium Alvani~ Grease Cardium Cardium Compound F Compound F Compound F E.P. 2 Compound F Compound F Cardium Cardium Compound F Compound F Rhodina Grease 2 or Alvania E.P. Grease 2 Rhodina Grease 2 or Alvania E.P. Grease 2 2 Nerita Grease 2or, Nerita Grease 2 or Nerita Grease 2 or Nerita Grease 2 or Nerita Grease 2 or Nerita Grease 2 or Nerita Grease 2 or Nerita Grease 2 or Nerita Grease 2 or Nerita Grease 2 ot Alvania Grease Alvania Grease 2 Alvania Grease ·2 ~ Alvania Grease 2 Alvania Grease 2 Alvania Grease 2 Alvania Grease 2 Alvania Grease 2 Alvania Grease 2 Alvania Grea~e 2

Enclosed Gears (Bearings using same lubricant as gears) .. . .. . .. .

A'R. '-'"'e.

__

Cardium Compound D Cardium Compound F

Cardium

Vertical Transmission Gear Case

Fluid Couplings_:Tractlon· Type Scoop Type

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• •. *Macoma Oil 76

Live Roller Paths

Chain Drive-Roller Chain-Enclosed

~~=~ne l___::rR-~_r_.il_~_7_R_T_, ~I----4-2T I

... Talpa Oil 60

Macoma Oil 76 . . • Macoma Oil 76 i Macoma Oil 76 Cardium Cardium' 'Cardium E""~t.i,Olii.l:l ...

Compound F Compound F Compou.t1d F Nerita Grease 2 or Nerita Grease 2 or Nerita Grease 2 Alvania Grease 2 Alvania Grease 2 Alvania Grease I Ner;ta Grease 3 or Nerita Grease 3 or Nerita Grease 3 ( Alvania Grease . 3 Alvania Grease 3 Alvania Grease

Chain Drive-Heavy Roller Chain-Open

__R_B_.____+---5_VV ___

Electric Drive

BI379509

AS USED IN AS USED IN AS USED 1N AS USED LN Talpa Oil 20 or DIESEL ENGINE Dl'ESEL ENGINE Di!IESEL ENGINE DIIESEL ENGINE 'E 1 Q'' 118 oQ... T~LPA "Z.o *Macoma Oil 76 Cardium Cardium Compound F Compound F Shell Macoma Oil 82

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Oriwnal Recommendation-Shall Vitrea Oil 79--iB suitable alternative

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ENGINE OILS

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RECOMMENDED,.. PROCEDURE FOR

CHANGING ·FROM

STRAIGHT MINERAL' OILS

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Heavy Duty Oils are not :intended to give a greater number of hours between. drain periods but rather to maintain a clean e~gine. and so to extend the 'running time betwe.en top overhauls The quantity of combustion soot formed is independent of the ·lubricating oil .Ulled, and the advantages of a Heavy Duty oil can be lost by failing to observe the manufacturer's recommended draining period. A Heavy Duty oil must not be considered.as a remedy for all engjn~ troubles For instance, mechanical maladjustment of fuel injection difficulties requfres indepenctent attim. tion, and only after such attention has b~~n. .paid to an engine can the use of a Hfavy Duty oil ,show up to its maximum advantage.

The property of detergency also enables an oil to loosen engirie deposits which ;

already

tl+e oil ways and in hollow crank pins ~ight well remain unsuspeeted. Thus, on changing. from a straight mineral oil to a Heavy Duty oil, the folio wing procedure should be adopted, unless immedia~ely prior to the change t.he engine has been completely overhauled and all parts .th,proughly : .• -.•".:1/ .'\'7;.:f-.:='L '· ··.c. --···:···: .. cleaned.

1. Thoroughly drain the old oil from the sump while the engine is .hot.

RECOMMENDED LUBRICANTS FOR RUSTON-BUCYRUS EQUIPMENT

ha.·ve

f~rmed and which may not be observe,d. easily during top overhaul. The_pre~;ence bf sllidge in

'.

2. Fill with the appropriate grade of Shell Talomi. o'i!; and run the engine under no ioaci conditions for approximately half-an-hour to flush out the system.

3. Drain off the flushing charge and refill with fresh Shell Talorta: Oil. At the ll~me time . thoroughly clean the oil filters, or where they are of the replaceable cartridge type fit a new cartridge.

4. Operate the engine for about 20 hours.

5. Drain the engine sump and again refill with fresh Shell Talona Oil and clean or renew filter element according to type, · After completing the above procedure the normal:drain periods as recommended'l)y the engine manufacturer may then be followed.

When changing the compressor oil it is advisable to adopt the procedure 1-3 above. After this flushing charge, it is not usually necessary to make a further oil change, as is the case for the engine.

Revised June 1957

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