Cat Electric Rope Shovel 495BI-395BIII 290B Series Electric Mining Shovels Parts Manual - DOWNLOAD

© Bucyrus All Rights Reserved

BI115345

BUCYRUS R

Parts Catalog

BI115345

495B1 - 395B1II - January 30, 1999

RELIABILITY ENHANCEMENTS

5

23

5

23

5

23

5

23

5

23

5

23

5

23

5

23

6

23

Bliminated cross-over walk below shipper shaft. LH side of boom accessed via from

8

24

Moved RH boom stairs outward to clear the hoist

8

24

for

11

24

Added shims to boom point sheave bearing retainer to achieve proper bolt

13

25

Added

14

27

reduces stress concentrations onto boom bottom

New

. New foot transition lowers stress at weld

950723

of foot attachment.

Flange transitions are chamfered on both sides where unequal thickness plates to UT and MT tested for soundness.

welds are 100%

manhole added to bottom ladders in boom

I' .

below above

shaft.

960707

shaft.

950802

950803 960717

and web to bottom

welds now 100%

22 23

30

25

»30

Boom with 3" bottom

26

»30

Extra

Boom jacking limit switch relocation for improved access. Roller added to push rod ..

970116

980420

on boom stair

980315

5

23

One piece liners with dual contact point machining reliefs reduce handle contact

. ,.

9984b:wp:dml

Page 1 of 12

Updated March 10, 1999

BI115345

495BI - 395BllI - January 30, 1999 RELIABILITY ENHANCEMENTS

. . "

. I I

liner retention

5

17

6

23

Eliminated two

11

24

Added shims to sheave

for holes at each end of saddle block in retainer to achieve

stress area.

bolt

960717

24 20

30

27

»30

m.

960720 material & heat treat

shaft:

980318

HANDLE

4

15

Increased handle tnbe wall thickness from 1-5/8" to 2-1/4".

5

14

Enlarged rope retainer at end of crowd cnshion sheave for ease of crowd rope

910823

5

23

Re-designed boom stop on handle end to prevent boom damage if handle end

911109

5

23

5

23

.......

5

for shim retainer

23

7

23

7

24

8

N/A

11

24

15

»27

15

30

26

30

33

»30

IV;

to better

valves and hoses.

Installed manganese bronze bushings between crowd cushion piston and housing and for increased to eliminate Deleted to Machined, flame hardened retract rope guides at the handle end eliminate the cast-decarburization zone that resulted in wear.

Increased

. crowd cushion

960718

for extended life.

Crowd cushion assembly attachment to handle strengthened with longer grade Delete

960622

cushion. seamless one

2.5" wall

Fixed crowd half sheave at rear end of

handle. handle

Page 2 of 12

970108 970101

980306

of handle

PADLOCK

9984b:wp:dml

960715

rod end terminations to

Revised

7

retention.

Updated March 10, 1999

BI115345

495BI - 395BIII - January 30, 1999

RELIABILITY ENHANCEMENTS

5

lower

5

23

12

. . . . 25 ...

13 · ......

24

23

30

23

30

for increased

Indnction hardened the

orientation"

resistance .

E016749.

Padlock sheaves with smaller core holes

960703 960706 980320

clad

HOIST

V. · .. . . . .

0 wire rope increased to 2-3/4" on 495-B.

4

14

4 · ......

N/A

5

16

Increased tooth depth and addendum ratio in first reduction gearing for decreased stress.

16

Brake solenoid moved to top side of hrake to hetter clear aisleway. Brake air line relocated to remove from floor

5

I I II . . . . .

I I I

5

I I I I I

2-5/8"

Drum ferrnle becket

increased in size to suit

"buttons",

I . . . .

5

24

6

23

6

23

6

23

6

23

8

23

10

24

10

24

10

24

bolts and

11

25

Carburized 1st reduction

13

25

14

27

9984b:wp:dml

950804

seal added to hoist case bolt 2nd reduction pinion induction hardening increased to full face pattern. Tooth iucreased 6" to reduce shaft stress and to stress concentrations.

960701

case

2nd added to Ballast box

casual access to hoist drum area.

950728

section made removable to better access hoist motor.

from 2 disc to 3 disc for increased wear life. at the rear of the hoist frames for increased for increased surface

life.

Page 3 of 12

Updated March 10, 1999

950417 950731 960630

495BI - 395BIII - January 30, 1999 RELIABILITY ENHANCEMENTS

BI115345

........

14

27

24

N/A

1

30

26

30

..

18

30

of RH .... Elemination .....

960708

Hoist lube drain lines from ........

970109 welded hoist Increased ........bnll

& cleanout

bolts

»30

for face

.......

»30

Resized frame

»30 32

»30

33

»30

(

VI.

980422

bolts for

980717

installed to reduce deflections

Motor

added to

end

980821

SWING

... . . . . .

3

14

5

23

5

23

Third rednction pinion shaft radius changed adjacent to pinion teeth to reduce tooth/shaft stress

5

23

Vertical

5

23

Rack pinion gnard has had opening cut into bottom flange to permit escape of debris and

8

24

Stress reducing transition plates added between swing case and lower edge of frame.

8

30

10

24

10

to

shaft lower

rack rim

lnbe

from oil bath to OGL.

two

cast rack.

Softer springs added to brake for smoother swing braking. Electric operated air valves

960713

Swing pinion catcher prevents pinion from being wedged between gear and case in the event of a failure.

12

24 I I

....

Swing motor shafts changed to heat treated high aBoy steel for increased life.

Increased seal carrier clearance added to eliminate shaft

14

960619 970102 9984b:wp:dml

Page 4 of 12

Updated March 10, 1999

495BI - 395BIII - January 30, 1999

BI115345

RELIABILITY ENHANCEMENTS

Carburized vertical

VII.

shaft

980415

EOJ5558-01

CROWD increased to 2-112".

4

N/A

5

16

5

23

7

N/A

7

23

Crowd blower

9

24

Bull

9

24

Thicker

10

24

Superbolt Torquenuts on drum bearing block rod bolts for ease of tightening and increased Rolled threads with fmer thread class increase

910814

12

30

Retract ropes with dual ferrnle becket buttons.

960617 980407

13

25

13

25

13

25

13

25

Sealaut on outside diameter of seal carrier between the 1st aud 2nd reduction cases cross-case oil transfer. . . . .eliminates . . . .. . ......... .

950804

seal added to 1st reduction shaft/pinion incorporates larger shaft diameter, eliminating a stress shoulder. bracket

920729

for increased

to drnm bolts

8.

drnm to

relocated

6

centerline ..

seal life. seals

with drain lines.

Gearcase drains moved to outside of

house.

960624

13

14

27

Protective

15

30

Crowd encoder inside

30

54" diameter crowd

16M

970103

60" diameter

30

crowd frame

27

»30

Carburized crowd 2nd intermediate

29

»30

Drnm/bull

vm.

960621

house.

20

»30

960628

over crowd encoder

970112

closures

980324

increased from 24 to 48

980403

welded

HOUSE - ROOF - STAIRS

9984b:wp:dml

later

Page 5 of 12

Updated March 10, 1999

BI115345

495BI - 395BIII - January 30, 1999

RELIABILITY ENHANCEMENTS

5

23

Cable

transformer

for better

5

23

Roof

5

23

House pressurization changed from single centrifugal blower to dual vertical

7

24

8

23

Gussets and torque tube added to alumiuum boarding stairs for increased

11

24

Boarding stair latch deleted! More reliable spring bumper stop softens raised

13

24

Roof mounted air receiver

13

25

Roof hold-down bars retained from

13

25

Additional roof truss joints over 1st reduction hoist case to better access

at front center lowered to clearcrowd cushion sheave.

to eliminate

950428

a floor mounted unit. for and

960704 920716

25

960711

13

27

960627

15

30 "Power

20

30

960623

raiu hoods.

960626

machine access

Louver at

Control

I

24

:

I· ..

»30

One

I

28

...: IX.

3

»30

45

@

OPERATOR CAB

I I I I

stairs

15

slanted outward at

14

Electric windshield

3

14

Freezer

5

15

5

16

5

15

5

23

13

27

3

I . . . .

9984b:wp:dml

for reduced dust adhesion. and air exhaust noise.

door latch and

attached to a custom runbber sealed door.

910807

removable frame. sunshades and con vex mirror.

Air conditioner/heater ducting diverts air to corners of cab for greater operator Two Page 6 of 12

Updated March 10. 1999

960620

BI115345

495BI - 395BIII - January 30, 1999 RELIABILITY ENHANCEMENTS

14

cab Farr

30

26 X.

blower with reinforced

seat with

960625 970114

footrest and flat cnshion

ROLLER CIRCLE' RAILS- REVOLVING FRAME

3

14

Center Pintle Sleeve and nuts converted to buttress threads for increased anti-

5

23

5/8" thick

5

23

Dual 9/16" diameter roller

5

23

7

23

10

24

14

27

9

»27

Crowd frame

1" thick.

bands bolts

1" diameter.

from 1.25" to 2"

on

end rails eliminate outside end Horizontal

910809

at front crowd

holes. on

frame.

950724 960714

1

31

»30 I I

32

I I

XI;

980402

nut increased Enhanced _·"·''''--frame rear a-frame

•••

later

LOWERWORKS

3

24

3

24

5

24

5

24

Lower rollers revised to improve dirt exclusion via "dirt slinger" roller hub, rubber vee dirt and dirt deflector.

5

24

Lower roller shaft changed to incorporate enlarged and recessed corner radii at the collar

5 .......

24

Crawler frame lower roller hub

roller tee bolt retainers Doubled

8 shear bolts.

of lower roller lube - to suit

contoured to reduce stress flow.

23

5

24

Vee

5

24

Crawler link

tumbler to exclude dirt from

960705

from 375/415 BHN to 440/495 BHN.

910813.

face seal added to

24

9984b:wp:dml

Page 7 of 12

Updated March la, 1999

BI115345

495BI - 395BIII - January 30, 1999 RELIABILITY ENHANCEMENTS

12

24

Weld joint between crawler and truck frame modified per FEA analysis for increased

12

25

13

25 .......

13

25

13

27

Opt.

Opt.

Optional manganese bushed, alloy steel crawler link for extremely abrasive conditions.

25

Lower roller shaft retaining bull pins stepped, carburized and plated for ease.

14 .

I I I I

.

18 21

30

I I I

30

'1

19

Rim thickness increased Front upper rollers redesigned to incorporate extended length bushings, dirt seals and induction hardened shafts.

960618

at lower roller shaft hub.

30 I I I

1•

24

. . ... . ..

960710

resistance.

950726

970118

motor lube

950730

lower rollers

I

26 28

»30 I

I· ..

I I

'"Ir"_,,~

tumblers with

»30

980414

SL-lllube

aluminum ram for

NA

980330

k

29

»30

29

»30

Truck frame structural rathole elemination

»30

Crawler I truck frame weld

XII.

980416

axle

fromO.

980401 980406

& connection revision

later

DIPPER

3

14

Snubber

7

23

Cast latch lever with

10

24

Added anti-friction bearings to dipper trip sheaves on dipper door. Sheave with

970113

to increase life.

brace

sheave bracket.

27

14

27

9984b:wp:dml

970106

for reduced heel band wear in abrasive conditions.

960721

latch lever 13

950808

4824.

Plastic

Page 8 of 12

Updated March 10. 1999

960702

BI115345

495BI - 395BIII - January 30, 1999

RELIABILITY ENHANCEMENTS

18

30

970104

One part dipper trip rope system ..... . .

20

30

25

30

20

30

Elastomer snubber for .......

Carburized ........

970113

door

980404

motor

970107

XIII. LUBE & AIR SYSTEMS

6

23

10

24

12

24

14

27 .......

15

27

17 .......

30

20

30

30

»30 .......

20

30

20

30

31 .......

»30

30

»30 XIV.

on

Platform over the lube manifold between hoist and crowd cases for access ease.

DUAL 140

950729

lube tanks made standard. to

manifold.

boom One

200 & 100

lnbe reservoirs made standard

980412

Lube hose kits for boom & lower works PLC controlled air valves

Lincoln lube

added to each lube circuit in the lube room Auto lube added to A-frame

980421

link

MISCELLANEOUS

I . . . . . .

I

7 •• ·1i ••

24

A second electric

23

Hoist and crowd encoder

winch

as standard

I

8

i

7 14 15

with

N/A I I

1 I I I

I·

in

shafts.

950722

construction.

27 »30

diameter

accessible DualS HP

970117

winch as standard.

I

20 26

30 .......

970119

& crowd brake

»30

9984b:wp:dnll

Page 9 of 12

Updaled March 10. 1999

BI115345

495BI - 395BIII - January 30, 1999 RELIABILITY ENHANCEMENTS

XV.

ELECTRIC, UNINTERRUPTABLE POWER SUPPLY - (UPS)

1

14

5

23

5

23

area.

Increased

control

contactor.

SONEXsound

added around the UPS on 60 htz machines. door closed.

XVI. ELECTRIC, MOTORS

5

23

1

Hoist motor end

5

23

2)

a)

reinforced to

flair

Corrected problem with incorrectly hardened swing motor shafts.

B. Siemens Norwood 12

25

1

- 4340 heat treated steel shafts. dust

25

24

11

to minimize dust increase.

xvn.

ELECTRIC, TACOGENERATOR SYSTEM

XVIll.

ELECTRIC, SIEMENS POWER SKID

I

I

5

II

16

A. General 1)

Weld skid cabinets to elimiuate relative movement, minimize

I

. . . . . .I ..

9984b:wp:dml

Page 10 of 12

Updated March 10, 1999

950727

495BI - 395BIII - January 30, 1999 RELIABILITY ENHANCEMENTS

5

BI115345

Consistent shield connections for

16

B. Inverter Cabinets 23

7

Gate driver nnit

for better

inverter cnrrent balance.

GDU connector 1

13

4

14

4)

Separate power supply added to power LEM's reduces demand on isolation and transducer card.

1

13

5)

Relocation of snubber circuit resistor connections to load side of fuses to under fault conditions.

5

16

6)

Feedback wiring routing changed to separate current feedbacks from others.

Latest machine run current feedback conduit under cabinets.

LEM feedback for commutation fault detection.

C. Control Cabinets 13

25 .......

Additional

for rectifier controls.

1

13

6

23

3)

Isolation & signal transducer card connectors to 4-prong for master current feedback. low

4

14

4)

Electronic crowd impact detection to reduce crowd drive faults and improve life.

4

14

3

14

transfer time

with 24 V fan less.

220 fan cooled

to minimize cold

Control room fan GTO door latches

XIX.

970613

ELECTRIC, GENERAL

5

23

A.

5

17

B. Regen current limiting resistor minimizes fuse loss during machine power loss.

shoes doubled.

Resistor

for

heat and altitude

C. Terminal blocks added to auxiliary collector rings to eliminate wire breakage at the Wire sizes to' increased for mechanical

6

13

24

13

24

9984b:wp:dm1

Inverter bus 2)

in

of fifteen for

Larger GTO cellsfor better margin. are field

Page 11 of 12

The interchangeable positive and

Updated March 10, 1999

495BI - 395BIII - January 30, 1999 RELIABILITY ENHANCEMENTS

BI115345

24

3)

The snubber circuits can be accessed by removal of one (\) GTO block.

Snubber diodes can be without removal of

13

24

4)

Single piece current feedback shunts. Feedback wires routed through conduit under the cabinets, for shorter and more noise immunity. Current wires are now isolated with the conduit.

13

24

5)

Skid rearranged for more compact design. Simadyn D processing distributed to the inverter controls. Simadyn D card in each motion rack.

This improves motion control by decreasing internal communication demands. Redundancy of isolators has been eliminated. Pertinent wiring is routed directly to the control cabinets. Control circuits such as crowd work

13

24

6)

The 5.x Simovert software improves current control, the firing transitions have been improved. The software also allow much improved propel transfer times.

13

24

7)

The software holds two complete parameter sets. This allows propel to rather than

13

24

8)

The inverter capability to motor demand is much improved. The larger inverters can better cope with the momentary peaks, this should reduce machine fanlts.

13

27

a. Trouble

13

24

b. The PLC system has been updated to 5120 processor.

13 I'

(

9984b:wp:dml

Page 12 of 12

Updated March 10, 1999

0~~

~~

1999 08:41 FR B E SERVICE

~

BUCYRUS ,"-~.

414 768 4570 TO #331

I

.r-oo _ •.. _ P.02/02 _____

D

Page 1 of 1BI115345

SHOVEL

PRODUCT IMPROVEMENT ADVISORY 1:/

Q8 0 3z1

Swing Case Lower Bearing Bolts CHALLENGE: Devise a method to easily tighten the bolts.

SOLUTION:.

Utilize "Superbolt" products for effective bolt tensioning while employing readily obtainable hand tools.

Torquebolt

Swing pinion

This improvement applies to

39581 thru 49581: REF: UNIT 38582-01

Another design improvement from 8ucyrus International, Inc.!

This documeM is: prorecred under o.pplicable copywrire l3.wS to the extent available. Any unauthorized and unlawful reproduction,disuibuDon or other- usc sholl be subject [0 l.iabiUI)',~ 1998 BUC)TI1S International, Inc. AU righrs reserved.

**

TOTAL PAGE.02

**

SEP 08 1999 08:41 FR B E SERVICE

414 768 4570 TO

~331

P.01/02 BI115345

BUCYRUS INTERNATIONAL, INC. - FIELD SERVICE ENGINEERING P.O. Box 500, South Milwaukee, Wisconsin 53172-0500 Fax Number 414-768-4570 IF THERE ARE ANY PROBLEMS WITH THIS TRANSMISSION, PLEASE CALL 414-768-4574.

FACSIMILE TRANSMISSION DATE:

B

SEPTe Mt3e:R

1'(1'1 PAGE

OM

E

OF

FAX NUMBER: COMPANY:

FROM:

6u/!.."tp..u~

-C-EP

@

-ntJo

_..:!*!:....::3~;:;:.!.r_ _ _ __

6ILLE"te

vJ'L L..l.pRUt!'."=-

SUBJECT: .*******.***¥****************************************************

KD:FAX:994

I

PRODUCT IMPROVEMENT ADVISORY MASTER LIST

BI115345

Updated *October 2, 1998 MWH/CR

II

DESCRIPTION

~10897.,' House & Cab Door Latches 9108'08'

Boom Point Split Hubs

91080~,

Center Pintle Sleeve W/Buttress Threads

910810:

Drive Tumbler Shaft Inboard Hub Cap

91681{: "~'.. ' . " ' ,

Hoist Intermediate Shaft Seal

~J1081z,i

Propel 1st Intermediate Shaft w/dual seals

9108'\3

Crawler Link Pins w/Higher Hardness

.

.

.

'.'

910814

910815···· '......• >

Crowd Drum Bearing Rod Bolts Crowd Motor w/Coupling & Seals

. ....,".

.

Drive Tumbler Shaft Inboard Hub Cap

91,0816

Crawler Links W/Bushings 910818"

Two Piece Collector Ring Box

910819"

Center Pintle Sleeve W/Buttress Threads

910820······· . ... "

Crowd Blower Remote Location

910821 , ."

Crowd 1 st Intermediate Shaft

910822.

Propel 3rd Intermediate Shaft w/Larger Brgs

910823'

Crowd Rope Retainer On Crowd Sheave

910824

Hoist Rope Reeving Instructions

.

..

'

:,

.

.';

910825

Propel Tachometer Addition

9109,16/

Crowd 1 st Intermediate Shaft

;;"

.

91091"(;

"Tecspak" Crowd Cushion

911106

Operator Cab One Piece Front Window

911j 07, Dipper Trip Base w/Thicker Plates 911'108

Center Pintle Sleeve W/Buttress Threads

9897.1NDEX:DML:CR

Page No.1

PRODUCT IMPROVEMENT ADVISORY MASTER LIST

BI115345

Updated *October 2, 1998 MWH/CR

I

DESCRIPTION

911189')

Handle End Bumper

9,\1112:',

Padlock Rope Retainer

9h21'f;

Boom Point Sheaves w/larger

920305

A-Frame Rear Leg

920325 .;: ..

"-

Vertical Crowd rope Sheaves

9204;21

Crowd Sheave Anti-Friction

920~06

Propel 4th reduction Gear set

920601··

Hydraulic Retract Rope Take-up

920602

Propel 4th Reduction Gear set

920611

Hoist Motor Shaft Bearings

9.20617

Padlock Rope Guard

920716 . ..

Roof Access For Hoist 1 st Reduction

920729..

Crowd Blower Base

930819

Crowd 1 st Intermediate Shaft -Forged

930824

Crowd 1st Intermediate Shaft -

.

...

<

950417

Three Disc Hoist Brake

.

950428

Boarding Stairs Bumper

950722.

Encoder Gearbox

.'.

...

950723 ...

Boom Bumper Support

950724.

Upper Front Rails

.... :

950725.···

Lube Line Protection At Outer Drive Tumbler Hub

950726

Crawler Link Pin Hole Wear

.

.

...

950727 .• • UPS Noise Reduction 95012?

Safety Gate at Hoist Drum

950729·

Walkway Over Lube/Air Manifold

9897.1NDEX:DML:CR

Page No.2

PRODUCT IMPROVEMENT ADVISORY MASTER LIST

BI115345

Updated .October 2, 1998 MWH/CR

I

DESCRIPTION ~

.

95073'0'

Lower Rollers - Forged

9567~"

Hoist Pedestal Bolts

950801,·.···· .-

Crawler Link Pin Retainers

950802

L.H. Boom Stair Access

950803;

Upper Boom Stairs Supports

950804/

Gearcase Sealing

",'-

950e08 '....... Increased Latch Lever Life E-960403

Leather Boot for Joysticks

E-960404 Dipper trip motor junction box Ec 960405

Wire support for auxiliary collector rings

E:960406

UR U Series auxiliary collector rings

960617

Crowd drum w/dual ferrule buttons on retract

960618

Upper roller w/wide bushings

960619'-

Swing rack dust curtain

960620

Operator's Cab air conditioning ducting

960621.'

Crowd encoder relocation

960622

Crowd cushion blocking/deleting

,

..-

960623 .

Plastic vertical fan hoods

960624 . . .

House Pressurization- crowd panel

960625

Operator's cab Tenkay Filter

960626

Machine Access - Power Step

9666:27"

Machine Access - Rear Facing Stairway

..

960628,··.· Encoder Protective Step ,-' Forged vs. Cast Bogie Rollers 960629.

960630

Hoist motor pinion - Carburized

9897.INDEX:DML:CR

Page No.3

PRODUCT IMPROVEMENT ADVISORY MASTER LIST

BI115345

Updated *October 2, 1998 MWH/CR

!

INU~:ERI ,~.

-.

DESCRIPTION

-~:

9,~(r7cil

Hoist 2nd reduction pinion

960;7()2<

Dipper Trip Alignment

~60703

Padlock Pin - induction hardened

960704 ". , . '.

Roof Panel hold down bars

960705,

Take-up Axle dirt guard/seal

'

..

,

..

.:

'.'

~60706

..

'

.' Padlock/reeving Sign

~6()707.·.···.·.

Boom - Open inspection manhole

96~708

Hoist bearing cap drains

960709

Hoist motor shaft bearing piping

9SQ71!)

Crawler Frame to Truck Frame Weld Joint

9,60711.···

Add'i Vertical Fan Supports

960712 '.' Swing Rack - Spray Lube 960713

Swing Brakes- soft springs & dump valve ,

,

960714

Crowd lug reinforcing gussett at Rev. Frame

.

960715

Retract Take-up shims

960716:' . Crowd Drum bearing lubrication thru bearing block ".

960717' '. Boom Point & Crowd Sheave shimming 960718

Retract Rope Guides

.' .

.

960719 ."

Lower Roller - increased rim thickness

.... ,.:

96.0720

Saddleblock Liner w/manganese pads

9E)0721·'.••,

Dipper- latch lever w/increased section at latch bar

9701()1 . •. Crowd Half Sheave - dipper handle ." .'

970102

Planetary Swing

97()103 .'. ......'., 60" Crowd Drum .

.

.

970104

Single Part Dipper Trip Line

9897.INDEX:DML:CR

Page No.4

I

PRODUCT IMPROVEMENT ADVISORY MASTER LIST

BI115345

Updated *October 2, 1998 MWH/CR PIA l'IUMBER'

i

I

I

DESCRIPTION

Latch Lever to Suit Single Part Line '.<.".' •••..!'..,/

97M96

Dipper Door Sheave Bearing

9701(ri

Dipper Door Bumper

!:!7()108.

Forged Dipper Handle

., ... "-' :;

970109

Hoist Rollers

9701j(}

Ballast Checking Drawing

...........

97()111.···· Rebanded Swing Rack 970112

Crowd Rubber Skirt - House Pressurization

97()113

Dipper Door Elastomer Snubbers

970114

Operator's Cab Seat

!:l70115 ..... Drive Tumbler vs. Link Pitch Wear 970116

Boom Limit Switch Relocation

970117.

5 H.P. Reeving Winch

97()118

Propel Blower Lube Guard

970119<

Brake wear, release & temperature monitoring

'.'

.'

970902

Improved UPS door handle

980306" Handle end hub replacement

/

i

9803()9

Retract rope retainer block

980315

Boom bumper replacement

9803j8.

Shipper shaft material

980320.'

Stronger padlock sheaves

980323

Clad padlock pin

980324

Second intermediate crowd pinion

98()3?t{

Forged-welded hoist gear

980327·" Swing case lower bearing bolts 9897.INDEX.DML,CR

Page No.5

PRODUCT IMPROVEMENT ADVISORY MASTER LIST Updated ,*,October 2, 1998 MWH/CR

I

PIA NUMBER_

I

DESCRIPTION

~~O~30': . :;.-,-'.-.-

Crawler link pins with larger head

9$0;331j',

Propel brake drum balancing

, -

~80401 , .. Crawler link paddle bolts -

1~80402'

Upper center pintle nut 2nd reduction crowd gear

1~80404·· '::""":':'1.•

Carburized dipper trip pinion Truck frame structure Crowd and retract ropes

198()412·•.. , Boom lube hose kits Lube injectors for take-up tumblers

'9~{)4Hi . . . ,

Surface hardened swing pinion

19804161 Crawler belt tensioning ram 19804171 Boom Point Caps 1980420····., Boom Stair Handrails 1980421" '1 A-Frame Suspension Pin (Auto Lube) 1980422·1 Hoist Motor Mounting 1980423

I

Bearing Temperature Monitoring Hoist Gearcase Support

19~0821.··1

I· ·

Hoist Motor Coupling

·,.'1

II II 9897.INDEX:DML:CR

Page NO.6

BI115345

PRODUCT IMPROVEMENT ADVISORIES ELECTRIC MINING SHOVELS

(

BI115345

..

P.I.A. TOPIC

495-B

395-BIII

395-BII

395-BI

395-B

295-BII

LOWER WORKS Crawler Links Pin Hole Wear

950726

.....

.....

.....

.....

.....

Crawler Links with Bushings

910817

.....

.....

.....

.....

.....

Crawler Link Pin Retainer

950801

.....

.....

.....

.....

.....

Crawler Link Pins w/Higher Hardness

910813

.....

.....

.....

.....

.....

910810

.....

.....

.....

910816

.....

.....

.....

960629

.....

.....

.....

.....

Drive Tumbler Shaft Inboard Hub Cap Lube Line Protection @ Drive Tumbler

950725

.....

Lower Roller - Forged (Large Dia.)

950730

.....

Lower roller - Forged (Bogie)

.....

Lower Roller - Increased Rim Thickness

960719

.....

Crawler Frame to Truck Frame Weld Joint

960710

.....

Upper Roller - W/wide Bushing

960618

.....

pke-up Axle Dirt Guard/Seal

960705

.....

.....

.....

910812

.....

.....

.....

.....

920602

.....

.....

.....

.....

920506

910825

.....

Propel 1st. Inter. Shaft w /Dua1 Seals Propel, 4th Reduction Gearset

.

Propel Tachometer Addition Drive tumbler vs. Link pitCh wear

970115

Propel blower lube guard

970118

Crawler link pins with larger head

980330

Propel brake drum balancing

980331

Crawler link paddle bolts

980401

Truck frame structure

980406

Lube injectors for take-up tumblers

980414

Crawler belt tensioning ram

980416

.....

.....

.....

.....

.....

.....

.....

.....

.....

.....

.....

.....

.....

.....

.....

..... .....

.....

.....

... ...

... ...

UPPER WORKS· SWING Swing Rack Dust Curtain

960619

Swing Rack Spray Lubrication

960712

Swg. Brakes - Soft Springs & Dump Valve

960713

9897:D.\lL;CR

'*

=

... ... ...

Addition/Revision since April 1998

...

Pagc 1

...

October 2, 1998

PRODUCT IMPROVEMENT ADVISORIES ELECTRIC MINING SHOVELS

I'}

P.LA. TOPIC

495-B

BI115345

395-BIII

395-BII

395-BI

395-B

295-BII

.....

.....

Planetary Swing Gearcase

970102

Rebanded Swing Rack

970111

.....

.....

.....

Swing case lower bearing bolts

980327

......

......

......

Surface hardened swing pinion

980415

UPPER WORKS - HOIST

,

Hoist Intermediate Shaft Seal Guard

910811

Hoist Motor Shaft Bearing

920611

Hoist 3 Disc Brake

950417

Hoist Pedestal Bolts

950731

Safety Gates @ Hoist Drum

950728

Hoist Motor Pinion - Carburized

960630

Hoist Int. Shaft - Longer

960701

loist Motor Shaft Piping

960708

..... ..... ..... ..... ..... .....

Hoist Bearing Cap Drains

960709

.....

Roof Access for Hoist 1st Reduction

920716

.....

Hoist Rope Rollers

970109

.,....

Forged-welded hoist gear

.....

.....

..... ..... ..... .....

..... .....

..... ..... ..... .....

980422

.....

*Hoist Gear Case Support

980717

......

*Hoist Moltor Coupling

980821

.....

..... .....

.....

980325

*Hoist Motor Mounting

..... ..... ..... ..... .....

..... .....

.....

..... ..... .....

UPPER WORKS - CROWD Crowd Blower Remote Location

910820 920729

Crowd Blower Base

.....

.....

.....

.....

Crowd Motor with Coupling & Seals

910815

Crowd 1st Intermediate - Forged

930819 930824

. Crowd Drum - 60" Dia. Crowd Drum Bearing Rod Bolts w /Supernuts 9897:D~lL:CR

'*

=

970103

.....

910814

.....

Addition/Revision since April 1998

..... .....

Page 2

.....

.....

October 2, 1998

PRODUCT ]MPROVEMENli AD'VISORIES ELECTRIC MINING SHOVELS

',)

BI115345

495·B

395·BIIl

395·BII

395--BI

Crowd Encoder Relocation

960621

-t

-t

-t

Crowd Drum w/Dual Button Retract Rope

960617

-t

-t

'-t

Crowd Lug Reinforcement at Rev. Frame

960714

-t

-t

-t

Crowd Drum Bearing Lubrication

960716

-t

-t

-t

House Pressurization· Crowd Panel

970112

-t

-t

-t

Second intermediate crowd pinion

980324

2nd Reduction crowd gear

980403

P.I.A. TOPIC

395·B

295·BII

-t

911108

-t

-t

UPPER WORKS - MISCELLANEOUS Walkway Over Lubel Air Manifold

950729

-t

-t

-t

UPS Noise Reduction

950727

-t

-t

-t

Upper Front Rails

950724

......

-t

-t

950428

-+

-t

-+

\ ,-,enter Pintle Sleeve w IButtress Threads

910819

-t

Two Piece Collector Ring Box Cover

910818

-t

. Boarding Stair Bumper

,

.

Gear Case Sealing

950804

-t

-t

-t

Encoder Gear Box

950722

-t

-t

-t

Encoder Protective Step

960628

......

-t

-+

House & Cab Door Latches

910807

-+

-t

-t

-+

-t

911106

-t

-t

-t

-t

-t

-t

Operator Cab One·Piece Front Window Operator Cab Air Conditioning Ducting

960620

Operator Cab Tenkay Filter

960625

Ballast Check Drawing

970110

-t

-t

-t

-t

-t

Dual 5 HP Reeving Winch

970117

-t

-t

......

-t

-t

Operator's Cab Seat

970114

-t

-t

-t

Plastic Yenical Fan Hood

960623

-t

-t

-t

. ~ertical Fan Additional Supports

960711

-t

-t

......

Roof Hold Down Bars

960704

-t

-t

-+

9897:Dtv[LCR

'*' = Addition/Revision since April 1998

Page 3

Octobcr 2, 1998

PRODUCT IMPROVEMENT ADVISORIES ELECTRIC MINING SHOVELS

,

BI115345

/

...... !

P.I.A. TOPIC

495-B

395-BIII

395-BII

395-BI

Machine Access - Power Step

960626

-+

-+

-+

Machine Access - Rear Facing Stairs

960627

-+

-+

-+

Brake Monitoring

970119

-+

-+

-+

Upper center pintle nut

980402

.A-Frame Suspension (Auto Lube)

980421

-+

-+

-+

.Bearing Temperature Monitor

980423

-+

-+

-+

395-B

295-BII

-+

-+

FRONT END - BOOM Boom Limit Switch Relocation

970116

-+

-+

-+

Boom Bumper Support

950723

-+

-+

-+

LH Boom Stair Access

950802

-+

-+

-+

Upper Boom Stair Supports

950803

-+

-+

-+

911217

Boom Point Sheaves w/Larger Bearings

.

. ':Boom Point Split Hubs

980417

-+

-+

-+

Boom - Open Inspection Manhole

960707

-+

-+

-+

Boom Point & Crowd Sheave Shimming

960717

-+

-+

-+

Boom bumper replacement

980315

-+

-4

-+

Boom lube hose kits

980412

-+

-+

-+

.Boom Stair Handrails

980420

-+

-+

-+

910808

-+

-+

FRONT END - SADDLE BLOCK & HA.NDLE Crowd Half Sheave - Handle

970101

-+

-+

-+

-+

-+

Forged Dipper Handle

970108

-+

-+

-+

-+

-+

911109

Handle End Bumper

910823

Crowd Rope Retainer on Cushion Sheave

-+

920325

Vertical Crowd Rope Sheaves

960622

-+

-+

-+

tetract Take-up Shims

960715

-+

-+

-+

Retract Rope Guides

960718

-+

-+

-+

Crowd Cushion Blockout/De1etion

9S97:m.[LCR

-+

• = Addition/Revision since April

1998

Page 4

October 2, 1998

-+

PRODUCT IMPROVEMENT ADVISORIES ELECTRIC MINING SHOVELS

! .•• '

BI115345

495-B

395-BIII

395-BII

395-BJ

Crowd Sheave Shimming

960717

......

......

......

Saddle Block Liner w/Manganese Pads

960720

......

......

......

Handle end hub replacement

980306

......

......

Retract rope retainer block

980309

......

......

......

Shipper shaft material

980318

......

......

......

......

Crowd and retract ropes

980407

......

......

......

......

......

......

......

......

910824

......

P.I.A. TOPIC

"

395-B

295-BII

......

......

FRONT END - MISCELLANEOUS 911107

Dipper Trip Base w/Thicker Plates Hoist Rope Reeving Instructions Dipper Latch Lever

950808

......

......

......

......

......

Dipper Trip Alignment

960702

......

......

......

......

......

Padlock Pin - Induction Hardened

960703

......

......

......

,Jadlock Reeving Sign

960706

......

......

......

......

......

Padlock Rope Retainer

911 Il2

......

......

......

......

......

Single Part Line - Dipper Trip

970104

......

......

......

Latch bar to suit Single Part Line

970105

......

......

......

Dipper Door Sheave

970106

......

......

......

Dipper Door Bumpers

970107

......

......

......

Dipper Door Snubbers - Elastomer

970113

......

......

......

Stronger padlock sheaves

980320

......

......

......

......

Clad padlock pin

980323

......

......

......

......

......

Carburized dipper trip pinion

980404

......

......

......

......

......

I

ELECTRICAL Leather boot for Joysticks

E-960403

......

......

......

Dipper trip motor junction box

E-960404

......

......

......

......

......

\vire support for auxiliary collector rings

E-960405

......

......

......

......

......

"R" Series alL'(iliary collector rings

E-960406

......

......

......

......

......

i

"

9897:D\lL:CR

'*' = Addition/Revision since April 1998

Page 5

295-BIII

October 2, 1998

PRODUCT IMPROVEMENT ADVISORIES ELECTRIC MINING SHOVELS

i

P.LA. TOPIC

Improved UPS Door handle

n97:D~!L:CR

BI115345

495-B

395-BIB

395-BII

395-BI

395-B

295-BB

970902

->

->

->

->

->

'*' = Addition/Revision since April 1998

Page 6

Oclobcr 2, 1998

BI115345

Bucyrus International, Inc. p.o. Box 500 -1100 Milwaukee Aven.ue South Milwaukee, Wisconsin, 53172*0500, USA

(414) 768·4000' Fax: (414) 768·4474

October 16, 1998

To:

Field Salesmen Field Service Engineers Electrical Service Engineers Parts Depot Supervisors Subsidiaries Distributors

SUBJECT:

cc:

D. J. Behlendorf G. G. Dinkelman J. A. Elliott G. N. Feld P. Glapa W. R. Hildebrand P. Huber R. H. Jelinek D. L. Kanter J. M. Krogman D. M. Lang (2) D. M. Largent R. N. Massey

J. M. McMurray G. S. Miller C. W. Moser J. R. Oliver M. G. Onsager R. R. Palmtag T. B. Phillips R. G. Shomperlen L. P. Stojack T. W. Sullivan K. J. Terhaar T. M. Willgrubs

NEW SHOVEL PRODUCT IMPROVEMENT ADVISORIES

******************************************************************************************************

Attached please find one (1) reissue and seven (7) new Product Improvement Advisories for your information, along with a new six page index and a six page chart showing applicability to the various shovel models.

Copies of these PIAs are being sent to all of our shovel customers for their consideration, so please take the time to review these improvements with each customer.

If you require additional copies, please contact the writer.

Sincerely,

Fred Keip Technical Service Engineer - Shovels

SAM

ISO·9001 CERTIFIED

PIA-EMS-980401 BI115345 Page 1 of 1

~

Revised 7/98

SHOVEL

BUCYRUS

PRODUCT IMPROVEMENT

,~~.

ADVISORY

Crawler Link Paddle Bolts CHALLENGE: Improve the reliability of crawler link paddle bolt retention.

SOLUTION: Replace the .375" cotter pins with .500" cotter pins.

Cotter pin

o Paddle bolt

Crawler link

I hIS Improvement applIes to

395BI:Thru 495BI:

REF: PADDLE BOLT C111292-03 REPLACES C111292-01 PADDLE BOLT C111292-04 REPLACES C111292-02 UTILIZE A .50 X 3.0 COTTER PIN #03 128 440

(REV.) C111292-03 WAS C111929-03 (REV.) C111292-04 WAS C111929-04

Another design improvement from Bucyrus International, Inc.!

This document is protected under applicable copywnte laws !O the extent availible. Any unauthorized and unlawful reproduction distribution or other use shall be subject to liability.© 1998 Bucyrus International. Inc. All rights reserved.

PIA-EMS-980417 Page 1 ofBI115345 1

~

SHOVEL

BUCYRUS

PRODUCT IMPROVEMENT

"\~~.

ADVISORY

Boom Point Caps CHALLENGE: Simplify removal of the boom point shafts.

SOLUTION: Split the boom point hubs and incorporate bolt-on end caps to retain the shafts.

i

I

i ,I,

Boom point shaft Shaft retaining collar

--------------------------------1

--------------------------------~~~~-~~--~~-~~--~~-~~-~~-~~-~~-~~-~~--~~-~~,;-~--'

Shims

This improvement applies to

395BI:thru 495BI:AII

REF: UNIT 38S78-01

Another design improvement from Bucyrus International, Inc.!

This document is protected under applicable copywrite laws to the extent availible. Any unauthorized and unlawful reproduction distribution or other use shall be subject to liability.© 1998 Bucyrus International, Inc. All rights reserved.

PIA-EMS-980420 BI115345 Page 1 of 1

~

SHOVEL

BUCYRUS

PRODUCT IMPROVEMENT

,~~.

ADVISORY

Boom Stair Handrails CHALLENGE: Eliminate occasional cracking in the boom handrail posts.

SOLUTION: Increase the material wall thickness from .14" to .191"

Boom hand rails K-----~#'

Not all railings are shown.

This improvement applies to

395BI:thru 495BI:AII

REF: UNIT 38A98·05 (G.A E018156 & G.A. E018158).

Another design improvement from Bucyrus International, Inc.!

This document is protected under applicable copywrite laws to the extent availible. Any unauthorized and unlawful reproduction distribution or other use shall be subject to liability.© 1998 Bucyrus International, Inc. All rights reserved.

PIA-EMS-980421 BI115345 Page 1 of 1

~

SHOVEL

BUCYRUS

PRODUCT IMPROVEMENT

,~~.

ADVISORY

A-frame Suspension Pin (Auto Lube) CHALLENGE: Insure timely lubrication of the A-frame suspension pins.

SOLUTION: Incorporate an auto lube system.

"

I',I/1

\

Suspension pins

\"' ../'"Auto lube liues \

~

1/ ' \ (r!----------\~~~':"" ~"5> f;'r----------'''"',,'""=-~

I

:

\

\

\

I

'

1'~\ ,!"

~--------------a~

/

.'

.

;//

~-------=------- j/ This improvement applies to

395BI:thru 495BI:AII

REF: UNIT 38885-01 (G.A E018393).

Another design improvement from Bucyrus International, Inc.!

This document is protected under applicable copywrite laws to the extent availible. Any unauthorized and unlawful reproduction distribution or other use shall be subject to liability.© 1998 Bucyrus International, Inc. All rights reserved.

PIA-EMS-980422 BI115345 Page 1 of 1

~

SHOVEL

BUCYRUS

.•

PRODUCT IMPROVEMENT

,~~

ADVISORY

Hoist Motor Mounting CHALLENGE: Increase bolting clearances and accessibility and obtain correct nut torque using common hand tools.

SOLUTION: Replace standard mounting nuts with torquenuts.

Torquenut

This improvement applies to

395BI:thru 495BI:AII

REF: UNIT 38S84-01

Another design improvement from Bucyrus International, Inc.!

This document is protected under applicable copywrite laws to the extent avrulible. Any unauthorized and unlawful reproduction distribution or other use shall be subject to liability.© 1998 Bucyrus International, Inc. All rights reserved.

PIA-EMS-980423 BI115345 Page 1 of 1

~

SHOVEL

BUCYRUS

PRODUCT IMPROVEMENT

,~"".

ADVISORY

Bearing Temperature Monitoring CHALLENGE: Provide a means to monitor the temperature of selective bearings.

SOLUTION: Locate ports and install thermocouples connected to a supplied receiver which must be wired into the existing PLC.

Thermocouples

Il

.----r--.-----.-,-..

---------

I

I

~

-------

tt----- -t----·---f---·-·*"·-·_+-·

~~ ....----.......~

..

-.

-'-

j-Hf

-~.~ "

~ "

Bearings

Typical installation This improvement applies to

395BI:thru 495BI:AII

REF: UNIT 38C42-02

Another design improvement from Bucyrus International, Inc.!

This document is protected under applicable copywritc laws to the extent availible. Any unauthorized and unlawful reproduction distribution or other use shall be subject to liability.© 1998 Bucyrus International, Inc. All rights reserved.

PIA-EMS-980717 Page 1 ofBI115345 1

~

SHOVEL

BUCYRUS

PRODUCT IMPROVEMENT

"\~~®

ADVISORY

Hoist Gearcase Support CHALLENGE: Reduce deflection of the hoist gearcase to maintain alignment of the motor couplings.

SOLUTION: Install a support gusset below the gearcase, welded to the gearcase, revolving frame and L.H. deck extension.

Edge of revolving frame (ref)

This improvement applies to

495BI:AII before SN 192866 395BI,BII,BIII: All before SN 141081 REF: UNIT 38889-01

Another design improvement from Bucyrus International, Inc.!

This document is protected under applicable copywrite laws to the extent availihJc. Any unauthorized aod unlawful reproduction distribution or other lISC shall be subject to liability.© 1998 Bucyrus International, Inc. All rights reserved.

PIA-EMS-980821 Page 1 ofBI115345 1

~

SHOVEL

BUCYRUS

PRODUCT IMPROVEMENT

~,,~.

ADVISORY

Hoist Motor Coupling CHALLENGE: Provide more flexability in the hoist motor coupling to compensate for variable spacing between the motor and the gearcase. Reduce possibility of end loading of hoist motor bearings.

SOLUTION: Increase the horizontal travel of the coupling by installing a spacer between the coupling halves.

Gearcase Coupling with spacer, gaskets and mounting hardware.

This improvement applies to

495BI:All 395BI,Blll: All REF: DRAWING #C116208 AND COUPLING KIT #39017467

Another design improvement from Bucyrus International, Inc.!

This document is protected under applicable copywrite laws to the extent availiblc. Any unauthorized and unlawful reproduction distribution or other use shall be subject to liability.© 1998 Bucyrus Intemationul, Inc. Ail rights reserved.

PIA-EMS-970113 Page 1 ofBI115345 1

~

BUCYRUS

SIHOVEL

'""~.

PRODUCT IMPROVEMENT ADVISORY

Elastomer Snubbers for Dipper Door CHALLENGE: Create a snubber with increased capacity to reduce door impacting and extend door life.

SOLUTION: Replace the existing belleville washers with elastomer disks. The elastomer disks have a greater capacity. The disks do not relu over time like a belleville washer - more time utllweeu adjustments.

Elastomer Disks

Contact your loea! serviceman,

s~lM1l1An

or S,ervicp.

~ent.er

for further cletJl.il~

Another design improvement from Bucyrus International, Inc.!

REF:~66503

057, E01e896

**

TOTAL PAGE.02

**

BI115345

SEFUES PRODUCT IMPROVEMENT MANUAL 29(f.a

-.

ELECTRIC MINING SHOVELS-

r

".

~:

it

'is"I,

;'0

~:

:.,:

[':i :':.

i::;,

!;:

~ORKS

Padlocks

Crowd Cushion Boom Structure Boom Bumpers Boom Suspension Boom Point Sheaves Boom Optimization

FRONT END

To be added at later date

To be added at later date

Crowd Intermediate Pinion Add; tiona 1 Dynavane. Fi 1ter Crowd and Hoist Drum Flame Hardened Oead Hoist Swing and Crowd Brake Ooerators Cab Door Boarding Ladder lubrication SYstems

Swing Vertical Shaft and Spacer

Auxil iary collector Rings Center Pintle Steel Thrust Washer Collector Ring Shoes Hoist Intermediate Pinion Shaft Swina Intermediate Pinion Shaft

UPPER

~raDs

Pronel Final Drive Bushin.

Prone I Third Intermediate Shaft and Bearings Propel Clutch To be added at later date To be added at later date

Crawler Links and Keeoer Pins Track link Keeper Pins Drive Tumbler Huck Scraper Take·Uo Axle Fourth Reduction Propel Gearing

0

......

~

o.~ ~~ ~. . .

"

......

......

~

~O

......

~

0'\

0\

'tJo

~ ~ ~ ~

If)

......

......

......

•••

•

•••

......

Any actions taken as a result of comments contained in this Product Improvement Booklet are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

......

'Jj:jj.~ff~~r!!?~o~ ......" " " " ,,0/.~

"lQlOtoto~1\, ":i ......":i ......":i ......":i ......"0 ......"0 ...... ......

.~. . ~~ o?0 ......

THIS IMPROVEMENT SUPPLIED WITH MACHINES,

290·0 UPDATES MECHANICAL IMPROVEMENTS

~ t{%% ~11%«~

J

j,......

It is essential that all appropriate safety measures such as set forth in the applicable machine maintenance manual are followed during the performance of any work detailed in this Product Improvement Booklet.

26.0 27.0 28.0 29.0 30.0 31.0 32.0

11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0

LO~ER ~ORKS

,~,

,

BI115345

BI115345

MODEL

CUSTOMER I it

SIN

SHIP DATE

290-81 290-81 290-81 290-81 290-81

ENDAKO RESERVE RESERVE NORTHERN LIME WIDCO

136717 136899 136900 136940 136941

12/79 11/78 01/80 03/80 06/81

290-81 290-81 290-81 290-81 290-81

80LIDEN SHELL SNIM SNIM M08IL

137714 137715 137716 137717 140230

09/84 10/80 02/82 02/82 09/81

290-81 290-81 290-81 290-81

M08IL M08IL SNIM SNIM

140231 140557 140594 140595

10/81 08/82 11/82 12/82

290-82 290-82 290-82

CROWS NEST NORTH· ANTELOPE MRA

140448 140565 140578

·08/83 07/83

BI115345 290S·1.0·89

Copyright 1989 Bucyrus·Erie Company

......

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..

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BUCYRUS·ERIE

290 BI - BII

ELECTRIC MINING SHOVELS CRAWLER LINKS & KEEPER PINS The crawler links have been increased in material hardness, line bored and retoleranced to allow for more pin wear before link goes out of pitch with the drive tumbler. The crawler link pin retainers have been redesigned to utilize a drilled and tapped block with a capscrew. The new arrangement has more surface wear area and greater strength to maintain link pin position.

Applicable to all 290-BI, 290-BII

Follow Appropriate Safety Procedures.

See UPDATE Chart.

THIS IMPROVEMENT SUPPLIED

Copyright 1989 Bucyrus-Erie Company

2909-2_0-89 BI115345

BUCYRUS-ERIE

290B-SERIES TRACK LINK KEEPER PINS

Keeper pins have been improved to prevent bending. Material in the pins has been improved to increase hardness. The diameter changes from 1" to 1-1/8".

Part Number A000845-01 Applicable to all 290-BI, 290-BII

(

-17\

'Y-f---CJ)-----~

Follow Appropriate Safety Procedures.

See UPDATE Chart.

WITH MACHINES:

290B-3_0-89 BI115345

Copyright 1989 Bucyrus-Erie Company

290-B SERIES DRIVE TUMBLER - MUCK SCRAPER In mine applications where material build up on the drive tumbler results in over tightening of the crawler belts, a scraper is available to continuously clean the surface of the outer diameter.

This Improvement Applies to all 290-BI, 290-BII

Follow Appropriate Safety Procedures.

See UPDATE Chart.

WITH MACHINES:

BI115345

29.08- 4 _0.: 89 ...•. ,"":'<

.. >',':,';"'-"":"':"

:;':',,~','

··········DV,~ci~~· 290-811 SERIES TAKE-UP AXLE

Take up axle has been improved to increase strength 21%.

Improvements have been made in stub shaft radius from 1/2" to 1-1/2", material hardness, improved chemistry.

New Part Number C109283-02 (29C,e,.....) t I C!9<6bS" 02. ('2402, x)

Applies to all 290-BI, 290-BII ~

-----.------.------.--------

-~-- -;~~:~::~:~~~-~-~~::~~r-l ,

Follow Appropriate Safety Procedures.

THIS I.

(Ref, PRJ 89510014)

".

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See UPDATE Chart.

WITH MACHINES:

BI115345

290a-5_0-89 BI115345

Copyright 1989 Bucyrus-Erie Company

ADVISORY

[1',~~~j&L. __ ~;L ~L,::~;~;L'"::;;_;i:" i;L_"~:.c.,_,,·.~:;,,,j_c:!i,:j~,;:d_..' _,.;LL:~.• i

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====~==========~~~~~==============) 290-8 SERIES FOURTH REDUCTION PROPEL GEARING The fourth reduction propel gearing has been modified on tooth crowns and tapers to reduce backlash. The pinion teeth are now induction hardened and ground to provide for longer life. These changes were completed to correct the drive tumbler shaft angularity due to bushing wear.

Attached Service Bulletin 89-006 This Improvement Applies to All 290-BI, 290-BII

Follow Appropriate Safety Procedures.

See UPDATE Chart.

BI115345

,INBOARD BEARING

SE~\L_-a~~~~~t:~~YI~INTHSEAL _

OUTER SP,ACI,R

___":~~::lj

FRAME r--eIEA,RIING SPACER

~fi~~~~~ CI~'T~'~Ic:t'ARID BEARING

CDUPLING HUB RE"rAII~ER--....:'

f--lt--BEA;RING RE"rAINER

RE"r AINER a"',1 T_I

~::;~;;'~'T>I""'<A'''' COVER SEAL

TRANSVERSE SHAFT AND PINION

3UGfHUS-E:RIE

CO~,"'P.L',f'JY

SERVICE OEP,L',RTMENT So. MILW,6,UKEE, \iVIS. 5317:::> TELE:PHOi'·JE: 4']4-768-4000

BI115345

SERVICE BULLETIN Bulletin No.:

89-006 DATE: April 13, 1989 PAGE 1 of 3

SUBJECT:

ALL 290BI AND B2 SHOVELS PROPEL UPDATE FOURTH REDUCTION GEARING

NOTE: IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

Recent investigations into the design of our final (fourth) reduction propel gearing has developed new insight into this drive system and concurrently design changes which will enhance the life of the component.

, t,

The fourth reduction propel gear drive force configuration is different from a typical gear reduction drive in that as the drive tumbler shaft outer bushings wear the centers of the gear mesh tend to compress due to crawler belt pull.

The drive tumbler inner bushings wear in a more normal manner thus tending to extend the gear centers. As these two bushings wear, they tend to cross load the gear, thus increasing the stress on the gear train when propelling in either direction. If this wear is allowed to continue beyond cross loading, the drive will reach a condition where the pinion will actually bottom or wedge the gear mesh. The loadings produced on the gear and pinion from this wedging condition will cause the gear to split from the root of the gear tooth to the hub and the pinion teeth to break.

This was not a problem on the machines designed 30 to 40 years ago, as the gear and pinion were softer and would wear and plastically deform, thus preventing cross loading and bottoming. Improved lubrication and hardened gearing (which reduces wear) have contributed to the present condition. Once a problem is understood, then design changes can be implemented to correct conditions and thus improve component life.

All current models are now re-designed for optimum tooth tapers, tooth crowns and backlash. Material and heat treatment have been modified for the pinion, gear and bushings. The lubrication grooving on the bushings has changed.

General Comments New machines generally run 6,000 to 15,000 plus hours before these conditions (cross loading and tooth bottoming) lead to failure. The failure mode can be pinion tooth breakage, gear tooth breakage, gear splitting, and transverse shaft bearing failures.

Bullet:89-006

~-'-'--:--'-'--' ':'-'-'~-'-'-'

BI115345

All 290BI and B2 Shovels Propel Update Fourth Reduction Gearing April 13, 1989 89-006

BE CO Recommendations 1.

When replacing the fourth reduction p,n,on and/or gear, always replace the drive tumbler shaft bushings.

2.

Increase lube injector settings on the two drive tumbler bushings to maximum.

3.

a.

Use a good 240 wt oil in the gear case with a compatible Open Gear Lubricant on the drive tumbler shaft bushings and the transverse shaft bearings.

b.

Or use a good Open Gear Lubricant in the gear case on the bushings and on the bearings.

4.

Replace the drive tumbler shaft bushings at 10,000 hrs. interval will be increased with the redesigned parts.

Note:

This

Bushings are relatively inexpensive when compared with gear, pinion or bearing breakage and the resultant unscheduled downtime.

A. FOURTH REDUCTION PINION AND SHAFT (INTEGRAL) 1.

The final reduction propel pinion has been re-designed to modify pinion tooth crowns and to surface harden and grind the teeth.

2.

Large capacity bearings are available for all three bearings on this shaft. The propel gear cases and crawler side frames can be modified (rebored) to accept this modification for the inboard and outboard bearing. The larger capacity center bearing requires no modification.

3.

Some machines have reported bolt breakage on the outboard bearing to shaft retainer. These bolts should be checked periodically (every 4,000 hours). If failures continue, the bushings on the drive. tumbler shaft should be checked for wear and replaced if needed.

A thicker end plate is available and should be considered on any propel unit overhaul.

4.

Updating of this shaft is strongly recommended on the next scheduled propel gear case overhaul. This applies to all 290BI and B2 shovels except serial number 140578 which is already converted.

BECO will stock the latest shaft and associated parts.

Bullet:89-006

BI115345

All 290BI and B2 Shovels Propel Update Fourth Reduction Gearing April 13, 1989 89-006

B. FOURTH REDUCTION GEAR AND DRIVE TUMBLER SHAFT .1.

The drive tumbler gear has been redesigned to maintain alignment with more allowable bushing wear.

2.

The drive tumbler bushings will be machined with allowable wear indicators. Bushing material and future drive tumbler shafts will be modified to reduce wear.

BECO will stock only the latest parts.

C.

GENERAL 1.

Improved parts coverage can be provided if all modifications or updates on machines are reported to BECD by machine serial number at the time of implementation. BEeD records will then be updated (THIS IS VERY IMPORTANT).

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474

Bullet: 89-006

2908-6_0-89

Copyright 1989 Bucyrus-Erie Company

BI115345

290-8 SERIES PROPEL FINAL DRIVE BUSHINGS Drive tumbler bushings have been changed to improve lubrication delivery to the final drive shaft.

Lubrication grooves were changed on the 1.0. and 0.0. to achieve better placement.

Bushings have also been changed to a Manganese/Bronze for improved wear life. As a further enhancement wear indicators are also machined into the outer edges to determine when change out is required.

Applies to All 290-BI, 290-BII

Drive Tumbler Inner Bushing 544352KI Replace with CI08445-01 Drive Tumbler outer Bushing 54435314 Replace with C108444-01

C.AWLE'.FRAME

Follow Appropriate Safety Procedures.

See UPDATE Chart.

BI115345 2909-7_0-89

Copyright 1989 Bucyrus-Erie Company

290-B SERIES UPGRADE 3RD INTERMEDIATE SHAFT AND BEARINGS

The 3rd propel intermediate shafts have been upgraded to include induction hardened and ground pinion teeth with larger bearings to increase B-10 life.

Field machining of inboard hubs and crawler frame outer hubs is required, per B-E instruction on D012130.

Applies to All 290-B1, 290-B11

Follow Appropriate Safety Procedures.

See UPDATE Chart.

WITH MACHINES:

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BI115345

2908-8_0-89 BI115345

Copyright 1989 Bucyrus-Erie Company

~'-,' ,,,,'",,~-"''''',

","~

<f.·'>"'.... ... .;{'A'jf i · BUCYRUS-ERIE

290-8 SERIES PROPEL CLUTCH Propel clutch modified for cooling, higher temperature operation, and self purging of worn particles (clutch lining).

An adjustable pressure regulator is available to control maximum clutch torque transmitted to gear train.

This reduces dynamics on propel drive tumbler and crawler links.

Replace the propel clutches with account number 39 017 093, as shown on the Illustration below.

Be sure the air regulator is set for 60 PSI. The clutch regulator is now mounted as shown on Dwg D006820 attached.

This Improvement Field Adaptable to All 290-B Series Machines.

,

i:

2

Follow Appropriate Safety Procedures.

See UPDATE Chart.

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BI115345

Copyright 1989 Bucyrus-Erie Company

2908-11.0-89 BI115345

(

290-8 SERIES AUXILIARY COLLECTOR RINGS The auxiliary collector ring attachment to air swivel has been modified to improve performance and ease of assembly.

Locating set screws in unit have been moved to the top of the collector ring assembly.

This Improvement Applies to 290-BI, 290-BII This is a field alteration.

,

t

~i!'\';,:;~ f-.;)!.~!f~-@

Follow Appropriate Safety Procedures.

See UPDATE Chart.

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PLATE • . 375 TUBE, 3,5000 X ,120W BAR . . 25

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BI115345

BI115345 2908-12_0-89

Copyright 1989 BUcyrus-Erie Company

290-8 SERIES CENTER PINTLE STEEL THRUST WASHER

A new steel-center, bronze-clad center pintle thrust washer results in greater strength and improved service life.

Part Number D010876-01 This Improvement Applies to 290-BI, 290-BII

Follow Appropriate Safety Procedures.

See UPDATE Chart.

290B·13.0·89 BI115345

Copyright 1989 Bucyrus-Erie Company

290-B SERIES COLLECTOR RING SHOES

A. Propel B. High Voltage Graphite Impregnated Shoes For Longer Life.

New collector ring shoes have been created with dry-solid lubricated plugs for increased wear life.

544240(~) Replaces 54424Q'@

A.

Propel - New Part Number

B.

High Voltage - New Part Number 504837-02 Replaces 504837-01

This Applies to all 290-BI, 290-BII

;'

/

L __ _

E'~---~ L__

--=:J

I

L __

.

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Follow Appropriate Safety Procedures.

, --~'

\~___ _~'

""

See UPDATE Chart.

WITH MACHINES:

2908-14.0-89 BI115345

copyright 1989 Bucyrus·Erie Company

BUCYRUS-ERIE

290B-SERIES HOIST INTERMEDIATE PINION SHAFT To improve loading contact and extend service life, the intermediate hoist pinion-shaft is now induction.hardened and ground with radius crowns on the tooth face.

This Improvement Applies to all 290-BI, 290-BII

Follow Appropriate Safety Procedures.

See UPDATE Chart.

WITH MACHINES:

Copyright 1989

Bucyrus~Erie

Company

2908-15_0-89 BI115345

mEl _. (

BUCYRUS-ERIE

290·8 SERIES SWING INTERMEDIATE PINION SHAFT

To improve the service life of the intermediate pinion-shaft, the teeth are now induction hardened and ground.

Part Number C104077-02 Replaced by D012109-02 This Applies to all 290-BII

Follow Appropriate Safety Procedures.

See UPDATE Chart.

THIS IMPROVEMENT SUPPLIED WITH MACHINES: - - - - - - - 1 290-B2

B1,1

21

15.. 109

II

SUNor'E.I--1

---.rJ

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5CE II'DT£,2

S£l:TIOJ( S~B FDIt ASS£I'II'JLY OIUEKTAT/O....

OF FL.Ar SIP£ O~ #""051"'(/.

+fLU

SECTION

13

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S~M'"T

IHSTALLATIOH

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IIISTRUCTIOIi 11M>· oooao<te.:&

Naif..

3. ©

::;. I.V~RICATION

REFER -,;; SJ)BZD4 FDIt PIAlIt"" Fn- To> "'~TIN' SHAFT.

2_

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ITE,., IIi!. - /f'HEKIf S,«O'"'''''' .,."J..J" PEK"'ATIfJ( SEAL''''''' C"~_"KP, "HI"H TACII" " iJ"FS#A~I.E AP#ESI/I'G, TP "'AKE .TaINTS OIl. TIGIfJ; F"A .l." SFA;i.$, APPLY iJET""EE.If STI:EL CASE II"VSIAIG 8lJR£.

~

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NOTES:

JlL-~

REqUIRED TIU'Kllt5S FOR SPACER (tT-7s) TO BE lIlo.SUAED AT IIU,,"'L ASSE~Bt..Y "'Ill SPAtER THICIUIESS 6AOIIII1l TO SUIT.

1~112-S£f NOT! I

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ARE tJSEb WfTH

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MOTOR ONL.'I'.

(ITEMS '1',82,

MOTOR ADA"""~~ PL"TE (nn.. 5")

TIGHTEN lOWER 8"(;. Ht,vS//((; Ft.AAI(;E SIlt-7.$ (Ir~"'s "" -11111) VSI"'~ 7",£ "TIIRH "" n-& ,tlVT ,'UT"''''': Po'~. 7,,"7773_

WIT/( ,.,VJ..TJ -"v"I",,$E G"£A5£.

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MATERIALS,

;::..---=

~t 1llSHLL VERt: SI'''~' SII,IoFT fIT·") LOWER BEA"IrtS (IT °10) AC.C.ORDI"~ Yo '~l"'LV.TlOII INSTIIIlCTIOItS llWI> DOO&O,e,m £j ME,IoStJlIE GAP &ETVIEEII EHI! OF SH ...n AI1I! PE"UIIIER PlATE. I!T"Z5j TO *TE"!oII~e. REQVIIIUI ~1I1~ P,IoCK TlileKH£SS

VERT. 5 .... ,10;

or (SJEME.NS

~--=--:J

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5_ PACK SPACE" 8ETwE£N DP SEAt.S

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BILL

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FOR

SE:£ DW(fs'

Copyright 1989 Bucyrus-Erie Company

2908-16_ 0-89 BI115345

~~~==================================) 290-8 SERIES SWING VERTICAL SHAFT AND SPACER

An improvement in the swing vertical shaft to improve positioning of the lower bearing on to the shaft. When a new shaft (D008097-02) is ordered a new spacer (B004012-02) is required.

Assembly instructions are required for field installation purposes, reference drawing D008098.

This Applies to 290-B11

/ I

I

. I

I

Follow Appropriate Safety Procedures.

See UPDATE Chart.

WITH MACHINES:

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UPPER AND LOWER SPACER THICKNESS ! 7 "NO 111

tETERMlNING lHE REOUIRED

-

~ 12

_ __

7

1

12

L~.~'-',~

.

5. MEASURE wIr.TH OF" BEARIN:) IN"IER RACE. SUBIRACT HilS BEARING WIO;H AI\,'O THE VIeTH Of THE SPAC.£~ 11' J ttl StEI> • "NO THE '.... lOTH OF" SPliCER (l2) FROM 10.125".

BUlLO UP IF REUUIREI) .-.NO f'!A:HHlE UPPi::R SPACER \71 TO THIS REOUtPEr., D,I-:e:NStON t .005*.

4. THE REOUIPEO THIrl<NESS OF" SPACER (III IS II-'l AVERAGE G,\p tAT.NS .1&2'.

BUILD UP IF" REOUJ!.lEO ~t-U MACfIlNE SPAC::R 1 II, TO THIS REOU{J'EO DiMeNSION t.005*.

10-

~

3. ~!:'-'SURE CAP BETWEfN SPACER' 121 ANO LOWER SURFACE Of'" 8EARHJr, IN THR~~ Euu.-\lLY SPACED P'JINTS TO CAlcu..ArE hIE ,l..Y€;?AGE G,l..P.

2. WITH Sjo/l1G SHAn (I) STAN')ING vERTlC~LLY. PL'-'CE a~"RING tlOI TO REST 'IIlTH ONLY ITS WEIGHT ONTO TAPER.

I. ASSIOMBlE SPACER' 12) TIGHT AG"'INST uPPER Sl/I<fACE OF PINION ON \'E~ltCAL S"IING SHAn til.

~-

,-

'r/I-lEt~ REMOVHIG 8Ea.,'?!NG r:U:.TAINER 191 ALWAYS ENSURE T14Al LOWER E1EAPING '10) IS SECtJPEL Y BLOCKED V!;QTICALL Y.

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INSTALL SHIM 12J ANO TO!=IOUE CAP scf;ltw!'; 13' PER INSTRUCTIONS GIYEN ON GENERAL ARRANGEMENT AND SEn 100 f)QAwI1JGS OF O\FeoqOPIATE SWINr; UN! r

S.

11

9

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5

5. C"'JT{ON. IF" pCESSIJRIZ[NG LOWER SE"'i?tNS IAI ~D!C'-I ... SS<:Mi.'lLY, ETC.I CU,SlOE OF GC:AP':ASE IT SECO'ES NeCESSARY TO INS I A.!..'.. AN ADEOUATE K:"EPEI? iu PREVENT Si::ARtNG ~ROM SOI.fMING CF"F" TOP OF 5-4"1' T1r;EAR CASE END'.

RE~'OJE SI-I",q PUlLC:R IF" REOUIRED. BLuCK VERTICAL POSITION OF SWING S~,\Fr TO ,",PEVEtlt 1'01I0t4.. REMrJVE UP"ff? R[1AII'JER BOLlS I~I AJI<Q LF?ER RET"INER (4).

TH,.(£AO • , 12~ E'E BOLT IN UPPER END OF SHAQ ::>n,.,r r. H()LC 51-'A= I IN POSI lION WITH DE BOI...T At.t' f>!:.WJV;o mOCKS "'H1C.4 HOLD El-l.ln 1\1 POSItiON VERfIOL':...Y. LO''*£R $'-IAFT TO (;I::OUNO W1TH EYE 8OLT.

3.

TO DRAW SHAFT INTO TAP:;:.~EO BORE 0'LOflER eEAR;:-~1G TJGHTI:.N OP SCREWS 131 SEtJUE'lIIALLY IN A CROSS PATTERN. NOM:NAL TIGHTENING TORI1UE IS .... PPROXIMATiOLY 650 FT-U~S. THE SEARHIG IS PROPERLY SE \!'tiD AGAINST SPACEfI ! 1 t J "',lEN \ SHARP :NCREASE OVER NOMINAL TOROUE IS NOflCED AND W~'''N THE MEASUREMENT IN STEP 3 IS REDUCED fI( . If,2~ ..

5.

RE::ORO M<::ASUP.EI-lENT •

tAEASURE GAP 8ETWEEN TOf' OF SHAFT 11, ANO fOP OF" U'i>Ei? RET"INER I'" AN()

A.

SHAF"T (I), INSTALL THE U'PEP RETAINER(4) A:,j{) C.-\P SCREWS 131. T0l10liE TO 2(' FT*LBS.

J. WH!LE SUPPI)RTH!O THE wEIG:..n OF THE

PSI. 6EIIRH.JG SHOULD MO"E DOWN T.lPER, ~IWCEEI1 TO STEP 3.

IF" lAO "'EIGHI OIL '-AILS TO DEVELOP PRESSL<I?E GREASE MAY Elf SU6SBUT;:0.

IF l'EMP[tl; 1).1ES NOT MOVE ANOIOR IF FQESSIPE OO;::S NOr DEVELOP.

2. RAISE SIHNG Sl-'AF"T It) INTO HOUSING AF1ER THE FOLLOWING COMrONENTS. GEAR (5) ANO UPPEJ:> BEAR!NG ASSE!-tBLY SI'ACERS (61 ANO (7, BEARII'(; (10) RETAINER (91 ~RE ASSEMBLEO IN GERACAS( IS) ANO BEARING HOUSING (13).

'1. APPi.. Y A THIN COAl OF MOl YKOTE nPE G Gq~ASEIS047011 TO T "P!::RED PORTION Of" SWING SHAFT FJR LOWER BEARING (10).

INSTAlLAllON OF VERTICAL SWING SHAFT

r2----

USE lAO WEIGHT OIL ..

PQES<;lIRllE TO A MA)(IMlIM OF 10.000

D. IF PM,-rIAL PRESSURE DEVELOPES. SLIT 8E~RINIJ rlOES NOI .~VE. REMOVE PRESSUPE. ASSE'"'8LE SH.-.n PUlLER IC105410*01 I TIGHTEN! Ita'· CAP SCPEWS IN PULLER AU) PRESSliR17f. HYORIIUllC PUt"".

A SHAr'p r,' .. OW ON TUI' OF CAP SC"EWS S~IQULO '-'ELI'. I. ~IECO:;:SSAR)'.

C ..

B. PRESSL'RIlE TO A MAXIMUM OF 10,000 PSI PSt. BE.\RJro;G SHOl'lO MOYE DOWN lAflER. ;'ROCElO TO .3TEP 3.

2. ". lNSllILL A ~!Y~M},.. tC HAND PUMP ·.nTH 20 WEIGI-IT OIL ANO PRESSURE GAGE.

1. Sl;:T .620· GAP BEn:EEN UPPER RET"H~R IAI "HJ BOlT HEADS 131.

REMO\I\L OF VERTICAL SWING SHAFT

,,---'---'

~,

,

3

BI115345

Copyright 1989

Bucyrus~Erie

2908·17.0·89 .

BI115345

Company

BUCYRUS-ERIE

290-8 SERIES CROWD INTERMEDIATE PINION The 1st intermediate p~n~on has been upgraded to improve service life. The pinion now incorporates ground and crowned teeth to improve tooth life.

Part Number 739185-01 Replaced by C107851-04 This Applies to all 290-BI, 290-BII

,t:, 1'iJ INTER",·,EOI.b..TE ----s...,A.;::.-;

Follow AppropriQte Safety Procedures.

See UPDATE Chart.

THIS IMPROVEMENT SUPPLIED WITH MACHINES:

;1 (Ref PRJ 88510010

290B-18_0-89 BI115345

Copyright 1989 Bucyrus-Erie Company

290-8 SERIES ADDITIONAL DYNAVANE FILTERS Additional dynavane filter units available for machines that require increased air flow for cooling and dust suppression.

Following parts required.

Applicable to two filter unit 290-B1 Quantity Breaker contactor Size 2 Overload Size 1 Filter Fan unit start button stop button Start name plate stop name plate Heaters

1 1 1

1 1 1 1 1 3

Reference drawing 874797.

Follow Appropriate Safety Procedures_

See UPDATE Chart.

WITH MACHINES:

BI115345

.I I I

I

______ ____

i

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2908-19_0-89 BI115345

Copyright 1989 Bucyrus-Erie Company

BUCYRUS-ERIE

290-8 SERIES CROWD AND HOIST DRUM FLAME HARDENED DEAD WRAPS The hoist & crowd drum dead wrap grooving is now flame hardened.

This hardening results in extended wear life of the drum. A longer swaged ferrule button on the hoist & crowd rope ends is required. This ferrule button is available from most rope suppliers and will fit into the existing anchors on the drums.

This Improvement Applies to All 290-BI, 290-BII

SHIM .IF N!C!SSAAY)

I

(SUNDT£)

a~~ffi§i~~~~nRAULE BUTTON al!cxn SOCKET

PADLOCK

n

SHI!AV!S-_ _

LDTSJDI!

Follow Appropriate Safety Procedures.

See UPDATE Chart.

THIS IMPROVEMENT SUPPLIED WITH MACHINES:

Copyright 1989

(

Bucyrus~Erie

290B-20_0-89 BI115345

Company

BUCYRUS-ERIE

290-B SERIES HOIST, SWING, & CROWD BRAKE A.

ventilation Hoist, swing, and crowd brake modified for high thermal operation. Springs are insulated and pins provided with increased clearance for improved heat dissipation. ventilation thru brake improved by adding holes in motor mounting plate.

B.

New Brake Hardened Hub Drive Spline Parts: The drive splines on the brake hub are hardened to increase wear life.

Hoist Crowd Swing Propel

(

Brake Part Number

29190108

29190167

29190167

29190150

Brake Hub

82532846

82532855

82532847

82532814

Applicable to 290-BII only

Follow Appropriate Safety Procedures.

See UPDATE Chart.

WITH MACHINES:

(Ref PRI 85510030)

BI115345

BRAKe:

290B-21.0-89 BI115345

Copyright 1989 Bucyrus-Erie Company

UVULn.J..

~ m~miliw; .. UU

.

..

PRODUCT IMPROVEMENT ADVISORY··.·· ELECTRIC MINING SHOVELS OPERATORS CAB DOOR A new door reduces dust entry and helps keep the operator's environment clean. The door has a integral mounting frame, a rubber bulb seal between the door and frame, and a adjustable freezer style door latch. Upper and lower windows are supplied for operator visibility. This door/frame assemby will fit into existing operator's cabs with 23" x 6'8" door openings.

NOTE: Doorway clear width will decrease from 23" to 17" with the integral mounting frame.

The new door hinges are located on the left side of the operator's cab. The new door part number is D013304-02.

This Improvement Applies to all 290-BI, 290-BII

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SECTION 8 Follow Appropriate Safety Procedures.

See UPDATE Chart. .

THIS IMPROVEMENT SUPPLIED WITH MACHINES:

Copyright 1989 Bucyrus-Erie Company

2908-22_0-89 BI115345

BUCYRUS-ERIE

290-B

BOARDING LADDER

New Style boarding ladder features easy walk on/off ability. attached EMS-009 This Improvement Applies to all 290-BI, 290-BII

1-;

: /

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ini

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,

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r--L_.....:I1__.

Follow Appropriate Safety Procedures.

iUi

See UPDATE Chart.

THIS IMPROVEMENT SUPPLIED

-----

See

BI115345

EMS-009

LATEST STYLE BOARDING STAIRCASE 295-8 AND 395-8

* * *

EASY ON/EASY OFF LARGE ELECTRIC MINING SHOVELS. WALK ON AND OFF VS CLIMBING UP AND DOWN A LADDER. SKID RESISTANT STAIR TREADS FOR SAFETY.

5/89

BI115345

NEW STAIRCASE LETS YOU BOARD WITH EASE

, ' - - - - - - - - - - - - -- --hIi'Ii;;;;.;.;;

!r~il I

I

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I

DESIGNED FOR ADDED STRENGTH/REDUCED WEIGHT

* * * * * * *

ALL FABRICATED ALUMINUM STAIRCASE AND HANDRAILS. DESIGNED FOR RIGHT SIDE SHOVEL LOCATION (TOWARDS REAR).

STAIRCASE IS PITCHED AT A 60 DEGREE ANGLE. DESIGNED TO SUPPORT 1000 LBS. ON THE LOWER STEP. ROTARY LATCH HOLDS THE STAIRCASE IN RAISED POSITION. COUNTER WEIGHT LOWERS AND RAISES STAIRCASE. SKID RESISTANT TREADS ARE GRIP STRUT ALUMINUM.

ADVISE MACHINE MODEL AND SERIAL NUMBER WHEN PLACING YOUR ORDER. PLEASE CALL YOUR LOCAL BUCYRUS·ERIE PARTS SALES REPRESENTATIVE OR REGIONAL DEPOT FOR FURTHER DETAILS.

2908-23_0-89 BI115345

Copyright 1989 Bucyrus-Erie Company

(

.•

ioo~~~m~ri~)C ....,> .

DUCT IMPROVEMENTAI1VISORY

BUCYRUS-ERIE

~~====~®=====================================) 290·B SERIES LUBRICATION SYSTEM The lubrication system has been modified to lubricate all bushings with open-gear lubricant to achieve increased bushing life.

The boom point sheaves, saddle block crowd/retract sheaves, and propel transverse shaft bearings also receive open-gear lubricant.

This Improvement Applies to 290-BI, 290-BII

Follow Appropriate Safety Procedures.

See UPDATE Chart.

WITH MACHINES:

Copyright 1989 Bucyrus-Erie Company

(.)

290S·26.0·89 BI115345

BUCYRUS·ERIE

290-8 SERIES CROWD CUSHION The crowd cushion has been redesigned to greatly improve service life. The piston engagement with the cushion cylinder has been almost doubled. Tecspak polyurethane pads, guaranteed for 10,000 hours, replace the dynafloat pads previously used.

The new Tecspak unit is furnished as a pre-loaded assembly.

See attached PIA 295B-007 This Improvement Applies to all 290-BI, 290-BII

Follow Appropriate Safety. Procedures.

See UPDATE Chart.

BI115345

~~~~~m U;;Uill®[][]~~rnwW

BUCYRUS·ERIE

PRODUCT IMPROVEMENT ADVISORY

~~======®==========================================) P.I.A. 295-B-007

CROWD CUSHION IMPROVED DESIGN MODEL 19591, 29091, 2959, 29591, 295911, 3959 SHOVELS REDUCED MAINTENANCE AND DOWNTIME INCREASED LIFE AND PRODUCTION FEATURES Positive 3 (

.t

p 0 r t sin n s tea d 0 f qualizer

Reduces

c y 1 i nd e r 2 p 0 r t sin

year

Pre-assembled,

Pre-loaded

Pro v e n reI i a b i 1 i t y Guaranteed 10,000 hr, o

Lon g e r s 1 i din g sup p 0 r t 80% increase in area

Lubrication

Pads

operation

Improved Saddle Block Bumoers Same material cushion pads

Pads are made from a patented thermoplastic material. This material vill maintain its resilience and preload, consequently viII restrict the movement betveen cylinder and equalizer thereby increasing the year life.

Ports in cylinder eliminates fittings being damaged or misaligned.

o

Lengthened sliding engagement reduces vear.

as

BI115345

-!'ENEFITS Tyo to three ti~ the life of original components, reduced parts cost and decreased dovntime.

Improved design Crowd Cushion Package.

Kit consists of pre-assembled crowd cushion as shown including installation drawings. Excludes sheave and pin.

The estimated delivery of this product improvement is 22 yeeks.

Approximate installation time is:

2 men 1 - 8 hour shift.

The cushion pads may be replaced Yith the ney thermoplastic pads on your original design crowd cushion.

The kit consists of the cushion pads, special high strength retainer, assembly bolts and instruction drawings.

The estimated delivery of this product is 12 yeeks.

Approximate installation time is:

2 men 1 - 8 hour shift.

Be sure all safety measures.are followed in accordance with the assembly instructions.

PLEASE CONTACT YOUR LOCAL SALES/PARTS REPRESENTATIVE OR THE "BUCYRUS-ERIE" REGIONAL DEPOT FOR A FIRM PRICE AND DELIVERY AS IT PERTAINS TO YOUR SPECIFIC MACHINE, OR CALL: BUCYRUS-ERIE COMPANY SOUTH MILVAUKEE, VISCONSIN PHONE: #414-768-4000, TLX. #3797360, FAX. #41.4-768-4474

r-1ay 6,

1988

BI115345 2908-27_0-89

Copyright 1989. Bucyrus-Erie Company

BUCYRUS-ERIE

290-B SERIES BOOM STRUCTURE Improved transitions in the upper boom suspension lug area.

Reduces probability of cracking.

Applicable to all 290-BI, 290-BII This is a field alteration.

\:

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BY GR!}lOtNG, BLEND TRANSITION 0"SUSPE· ,seeN ANCi-:CR PLATES INTO 800M G[RD£~S. TYP a-PLACES.

Follow Appropriate Safety Procedures.

See UPDATE Chart.

WITH MACHINES:

Copyright 1989

Bucyrus~Erie

2908-28_0-89 BI115345

Company

,~'

BUCYRUS-ERIE

290-B SERIES BOOM BUMPERS Improvements made to eliminate Boom cracking @ Bumper attachments This Improvement Applies to all 290-BI, 290-BII

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\1 -

II

11-

\ ~-f.-

Follow Appropriate Safety Procedures.

,

' '"OM ;- \ _-'

<

--r'~,

\

See UPDATE Chart.

WITH MACHINES:

2908-29_0-89

Copyright 1989 Bucyrus-Erie Company

BI115345

BUCYRUS-ERIE

~~=======®==================================================~) ELECTRIC MINING SHOVELS BOOM SUSPENSION Boom suspension bridge strands are now available with socket pins drilled for lubrication.

This Improvement Applies to all mining shovels.

~.L

r,FTi+' ' I '

!

I~------P 2 <;c _~.ii-\,.=-_.J-------. _ ~ -I I,

z 2

Z ( Z

Z /?l

( /

2

Z~z::2I·

WI,

'~+F-,

Follow Appropriate Safety Procedures.

See UPDATE Chart.

THIS IMPROVEMENT SUPPLIED WITH MACHINES:

2908-30_0-89 BI115345

Copyright 1989 Bucyrus-Erie Company

BUCYRUS-ERIE

.1E:' ~~====~®======================================~) 290-8 SERIES 800M POINT SHEAVE A new heavy duty boom point sheave is available.

It incorporates a change to add a bead in the casting web hole to improve life.

The radius between the spoke and rim has also been" increased to reduce stress levels.

290BI 721799-01 290BII 735408K1

Replaced by C106297-01 Replaced by C106298-01

1".-. '"

( '-

-1

a

;z:.

CP

Follow Appropriate Safety Procedures.

See UPDATE Chart.

WITH MACHINES:

(Ref PRJ 87510007)

c'~-",,~"Z~":2~ _'_'_-~-~::':':-~""I

_ £. _;_;_:_:;::-"_:C::X:'0:~;;:' ".:.:".:.::__·S--':"l~

Copyright 1989 Bucyrus-Erie Company

2908-31_0-89 BI115345

,-=-: BUCYRUS-ERIE

~~======®======================================~) 290-8 SERIES

800M OPTIMIZATION By making the upper boom longer and adding additional ballast, the dipper size on the 290-BI, 290BII can be increased in the proportion of approximately 8%. This is an improvement, not a machine stretch.

Follow Appropriate Safety Procedures.

See UPDATE Chart.

Small investment, large return (

BI115345

Boom optimization • Increases shovel productivity Boom optimization for electIic mining shovels increases production as much as 22%. The substantial increase is realized with a relatively minimal conversion cost.

Amax Coal Company has realized this type of increase by optimizing ·a 1970's vintage BUCYRUS-ERIE 295-B ElectIic Mining Shovel operating in the Powder River Basin. Wyoming. Formerly equipped with a 22-cu.-yd. dipper. it is re-equipped with a 27-cu.-yd. i ~ 'iper. As a result of the optimiza'\lOn. 120-ton trucks at Amax load in 3 passes instead of 4. Load time

Diagram 1: The lengthening'of the boom by 12% changes dimensional relationships and increases the RSL and digging force.

decreases 30 seconds reflecting a possible 22% increase in productivity.

current market. The dividends multiply duIing years of service ahead.

Amax is achieving dramatic productivity increases as a result of boom optimization on a shovel that has significant years of useful life left ..

Long boom, higher RSL

Machine improvements such as boom optimization pioneered by B-E show a quick return on investment. easily justified in the

~

~

Bucyrus-EIie boom optimization is a result of a re-evaluation of engineeIing philosophy regarding electIic mining shovei front end geometry. PIior to the 1980·s. excavator design required the shorter boom length for the higher rated suspended load (RSL.) This

~.,.,

~

Bucyrus-Erie Company 1100 Milwaukee Avenue, P.O. Box 500, South Milwaukee, Wisconsin 53172 Telephone (414) 768-4000' FAX (414) 768-4474· TELEX 3797360

Diagram 2: An increase 01 11 % in maximum digging force is achieved with beam optimization. This benefit is achieved with a 12% increase in boom length.

Dipper is shown in the toe position.

philosophy changed in the early" 1980's.

B-E's engineering analysis showed that unique geometrtc relationships existed in electrtc mining shovels. Lengthening the boom and thereby changing the geometric dimensional relationship ( ,between saddle block/ dipper -'handle positioning actually increases RSL capabilities and increases digging force in the toe area of the bank where it is needed most. The saddle block and handle positions are unchanged. The new position of the

hoist rope attachment to the dipper and the new angle of the hoist rope in carrying the suspended load contrtbute to the favorable RSL and digging force, See Diagram 1.

Diagram 2 demonstrates the increase of 11% in maximum digging force resulting from a 12% increase in boom length.

Optimization of the future Boom optimization has been Incorporated on new shovels

since the early 1980's.

Shovels BI115345 commissioned in the 1970's, candidates for optimization. were sized to load 120-ton trucks popular at that time. The advent of 170-and 190-ton trucks in the 1980's meant increased passes to fill. Boom optimization was developed as a way to minimize passes and increase productivity for any size truck. For 295-B shovels. dippers are sized so that 170-ton trucks can be loaded in 4 passes and 190-ton trucks. in 5 passes.

In addition to lengthening the boom, a single gear ratio is changed in the hoist and additional ballast is reqUired to 'Complete the optimization.

Mining companies owning shovels commissioned in the 1970's may benefit greatly with boom optimization. A 10% increase in RSL with a commensurate increase in digging forces can be achieved in specific applications. Bucyrus-Erie Company's Engineering DepartI,TIent will rate your productivity potential with boom optimization specific to your application.

For a smaIl investment. boom optimization pays a quick retUITl with an outlook of many years of more profitable performance.

2908-32.0-89 BI115345

Copyright 1989 Bucyrus-Erie Company

BUCYRUS-ERIE

290-8 SERIES PADLOCKS A.

New padlocks are available that utilize a taper lock bushing assembly. This eliminates all wear on the hoist dipper lugs.

See attached PIA 295-B -006.

(

B.

Further enhancement provides dirt/rock covers over select shaft ends & locking assemblies.

Frames are structurally changed to prevent rock damage.

These will be supplied on future machines.

* Dipper attachment size must be verified before ordering.

These Improvements Apply to all 290-BI, 290-BII

Follow Appropriate Safety Procedures.

See UPDATE Chart.

/

,

i

Ref PRJ 89510013)

Cc""""","".c,,'"

y -- -__ -,-__:,~~__,~~~_~_:,__ _-:,,-:XX-_'::2~

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_ 'f:~;:,_-,,~':_~~:"::-~;~~':;~:::';;:;'..::'::~;:;~:~::~:'::~c;:;il- .:::,;-;.::" _.::XX!Ci:"::..:~c:'>:!c:::_ ~:::_-;:;,::::'_::I

BI115345

,

,

BUCYRUS-ERIE

~;;;;;;;~®================================~P~.IF..~AT.~2~95~B~-OOCO~6==~

PADLOCK, NEW GENERATION MODEL ·195BI, 29OBI, 295B, 295BI, 295BII, 395B SHOVELS NEW DESIGN UTILIZING TAPER LOCK BUSHINGS TRANSFERS WEAR TO EASILY REPLACEABLE AND INEXPENSIVE COMPONENTS A KAJOR IKPROVEMENT FROM THB OLD STYLE PINS AND BUSHINGS Sheave Heavy Rounded Edge ..._

.........

or Dipper

o J

( 1)

,

"

'

.. _---,-

,

,

( 7)

FEATURES The use of taper locks (1) between pin and component transfers wear to replaceable bushings.

SHEAVE PIN AND DIPPER LUG PIN

Pins (5) are held to padlock sheave, dipper lug and sleeve (3). Year is taken between the steel sleeve and heat treated aluminum bronze bushing (2).

PADLOCK PIN

The padlock pin (6) is held to the sheave frame lugs (7) with wear occurring between the high hardness pins (6) and aluminum bronze bushings (2). Pin drilled for bushing lubrication.

Lug

BI115345

BENEFITS BEARING AREA

50% increase in bearing area lowers loading and gives longer wear life.

SHEAVE FRAME

Rugged curved surface minimizes damage if frame contacts boom point sheaves. Removal of one bolt permits reeving of ferrule becket ends without padlock sheave removal.

ROPE LIFE

Open construction of padlock frame permits padlocks to tilt forward when the ropes are slack without "pinching" the hoist ropes. Open construction facilitates self cleaning.

LUBRICATION

Open gear lubricant recommended once per day for longer life.

RESULTS Proven reliability and performance on 295BII's.

Improved design extends wear life of components - two to three times the life of old style padlocks.

Extends rope life.

Reduced downtime.

BI115345

290-B SERIES ELECTRICAL UPDATES DC DRIVE SYSTEMS 1.0

Service Bulletin 89-020

Dig - Propel Contactor Adjustment and Maintenance

2.0

Service Bulletin 89-021

Low Voltage Collector Ring operation and Maintenance

3.0

Service Bulletin 89-022

Electric Motor Pinions and Couplings

4.0

Service Bulletin 89-026

General Electric MG Set Lubrication Procedures

5.0

Service Bulletin 89-027

Vibration Tolerances

6.0

Service Bulletin 89-023

Cleaning of Electrical Equipment Using Compressed Air From The Machine

7.0

Service Bulletin 89-024

Hoist and Crowd Controller Reversal

AC DRIVE SYSTEMS 1.0

Service Bulletin 89-025

Dig/Propel of Propel/Dig switching

2.0

Service Bulletin 88-4

Tachogenerator Inspection

3.0

Service Bulletin 89-016

Tachogenerator Maintenance

4.0

Service Bulletins 88-3, 89-017

Battery and Battery Charger Maintenance

5.0

Service Bulletin 88-024

Line Fault Monitoring

6.0

Service Bulletin 88-026

Swing Regulator Improvement

7.0

Service Bulletin 88-005

Improved Dipper Trip Mechanism

8.0

Service Bulletin 89-022

Electric Motor Pinions and Couplings

9.0

Service Bulletin 89-024

Hoist and Crowd controller" Reversal

LMB:MJC:9927

BI115345

DC DRIVE SYSTEMS

"_'_'___'_'_' __ " _' _____'_'-"__~_,_,_,_,____ '_'__~~_'2-

-;;----

BUCYRUS-ERIE COMPANY BUCYRUS-ERIE

SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172

•

TELEPHONE: 414-768-4000

BI115345

SERVICE BULLETIN Bulletin No.: 89-020 DATE: November 29, 1989 PAGE 1 of 9

SUBJECT:

NOTE:

LOWER WORKS PROPEL SHOVELS DIG/PROPEL CONTACTOR 290-Bl, Bll, 295-B, 295-Bl

IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

From time to time operational problems are encountered with the dig/propel contactor when attempting to transfer from dig to propel or vice versa.

In some instances the incorrect mechanical adjustment has been found to cause failure of the unlatching coil. There have been other failures due to a variety of causes. This bulletin is designed to clarify contactor adjustment and maintenance procedures.

CAUTION Before any adjustments, servicing, parts replacement or any other act is performed requiring physical contact with the electrical working components or wiring of this equipment.

ALVAYS DISCONNECT

THE POYER SUPPLY AND TAG The dig/propel contactor is operated by the dig/propel transfer switch in the operator cab. This switch is not a "toggle" switch. A toggle switch should not be used as a replacement SWitch, because such a device would keep power on the contactor coils continuously. The coils do not have a continuous rating.

If power is on the main contactor coil continuously, check the coil connection wiring. The wiring must be in accordant to the Bucyrus-Erie electrical I schematics for the serial number of the machine involved.

Coil Replacement:

'",

To remove the coils, Figure 1, just disconnect the coil leads. Then remove the assembly containing the magnet plate, cores and coils by removing the hardware a t "A", see Figure lC after the assembly has been removed from the con tactor, remove the coil mounting bolts.

Copyright 1989 Bucyrus-Erie Company

BI115345

89-020 Lower Yorks Propel Shovels Dig/Propel Contactor November 29, 1989 Page 2

1l!~r;:J"l------ARC CHUTE SUPPORT _~ARCING

ARC CHUTIE----:J::

BRACKET FOR CONNECTION STRAP ___ CONNECTION STRAP

~~~~~::::.

'~

--------------------~~I

STATIONARY TIP

AND BLOWOUT ASSEMBLY

::~SPACER

ASSEMBLY

, FRAME AND , ARMATURE ASSEMBL

PADS

"GFIOU'NDING STRAP

Vhen replacing the coils be sure to reinstall the coil-spring washer. The coil should then be placed on the core so that the coil flange seats properly on the milled step of the core. Align the core so that the core locating pin on the magnet 'plate, if present, will enter the hole provided in the core. Vhen tightening the coil mounting bolts, care should be taken to assure that the core pins are not flattened and that the coil flange is not broken.

Copyright 1989 Bucyrus-Erie Company

BI115345

(

89-020 Lower Yorks Propel Shovels Dig/Propel Contactor November 29, 1989 Page 3

After the assembly has been reinstalled on the contactor, check to see that electrical clearance exits between the coil terminals and the magnet frame post. Also check to insure that the armature seats against both cores.

SPACER ASSEMBLY CONTRACTOR BASE

SHIM

FLAT WASHER LOCKWASHER

STATIONARY

TIP

NUT

Slatia"ary a~i"g .a"lacl brackel.

Fig .• '-'

Fig. • B Slationary main.lip a • .ambIT.

Fig.

'Jt!

caNTA4:T"~

MOU.NT.O

Contactor Maintenance: Contact Yire and Gap: Vhen they are new, the arcing and main contacts should have wipes and gages as listed below. Refer to Figure 2 for location of item to adjust as per Table 2A.

INCHES

WIPE

:lH~

ARCING CONTACTS

1/2"

MAIN CONTACTS

19/64

~1/32

AT

GAP

Bucyrus-Erie Company

A . D ",

Arcing Main

1-1/8 3/4

C

Main/Arc Touching

3/16

TABLE 2A

19~9

AT

B

CONTACT WIPE AND GAP MEASUREMENTS

Copyright

INCHES

F

BI115345

89-020 Lower Yorks Propel Shovels Dig/Propel Contactor November 29, 1989 Page 4

MOVABLE

CONT:"""

Fie. 2

Contact adjullments.

ARCING TIPS JUST TOUCHING

SHIMS USED AS

R5:QUlREO TO OBTAIN

MEASUREMENT "C" ~~.E CONTACT

ARMATURE ~..ATED

AGAINST CORES

Contacts should be renewed When the wipe has worn to 1/4 inch or when the gap of the main contacts reaches 1/16 inch, with the arcing contacts just touching.

Renew the main contacts when their wipe has been reduced to 1/4 inch or before the silver face has been worn through. Silver contacts should not be filed.

Except for replacement when worn to prescribed limits, contacts will not, normally require attention while in service. Slight pitting and discoloration of the contacts is a normal occurrence in use.

Yhen replacing contacts the arc horn and arc chute must be removed first. moveable and stationary arcing contacts can then be removed, Figure 3.

The

Before removing the main moveable contacts measure the height of the springadjusting screws, Figure 3, above the armature-assembly casting and note the measurements for use in reassembly.

Copyright 1%9 Bucyrus-Erie Company

BI115345

89-020 Lower Yorks Propel Shovels DiglPropel Contactor November 29, 1989 Page 5

BLOWOUT ASSEMBLY

PIVOT PIN

;

,

-

~~~r- MOVABLE ARCING CONTACT (STATIONARY NOT VISIBLEl

ARCING HORN SET SCREW MAlN CONT'ACT SPRING ADJUSTING SCREWtSPRING NOT VISIBLE}

SHUNTS (MAIN

"n.IT",,,.,.,

SHUNT (ARCING CONTACT)

OVERLOAD RELAY

Remove the spring-adjusting screws (after loosening the setscrews) and springs to expose the moveable contacts. Remove both the moveable and stationery contacts by taking out their mounting bolts.

Install new contacts and reassemble the springs, adjusting screws and arcing horn. Place the adjusting screws at their original height setting and t~ghten the setscrews. Check that the wipe and gap dimensions are in accordanc,e.··with Table 2A. Verify that the stationery contact tips meet the requirement as shown in Figure 2. The contactor (de energized position) arcing horn for the arcing tip must be adjusted so that the gap between the moveable tip and the horn is 1/16 to 1/8 inch as shown in Figure 2. The arc horns and moveable contacts should be centered within 1/32 inch.

Copyright 1989 Bucyrus-Erie Company

(

BI115345

89-020 Lower Yorks Propel Shovels Dig/Propel Contactor November 29, 1989 Page 6

The contactor should' never be electrically operated without the arc chute in place and completely down on the stationary arching horn. Verify the contactor operates freely through the full stroke and the contacts do not touch the arc chutes.

Contact Force: The compression of the contact springs must be kept correct. If the force is too low, the contacts will overheat. If it is too high, the contactor may be prevented from completely closing. The compression springs should be checked periodically and the adjustment corrected when necessary.

To check the pressure on the arcing contacts, insert a strip of thin paper between the stop portion of the moveable arcing contact and the contact support of "B" (Figure 2). Attach the hook of a spring scale to the center of the ,arcing contact at G (Figure 2) and pull on the scale at right angles to the plane of contact. The pounds pull at the instant the paper can be moved is the initial contact force. If this force is outside the limits shown in Table 3, the arcing contact spring should be replaced.

TABLE 3 Arcing Contacts Main Contacts 14 - 18 pounds 33 - 41 pounds INITIAL CONTACT PRESSURE Check initial force of the main contacts in a similar way, by placing a strip of paper between the moveable contact and the stop at pin "c" (Figure 2) and pull at bolts "E" (Figure 2). Reset the spring-adjusting screw, if necessary, to bring the initial contact force within the limits shown in Table 3.

The contactors, dig and propel, have a mechanical link between them to prevent both contactors from being latched simultaneously. Yith either contactor latched closed the mechanical link must have 1/8 inch clearance to prevent reducing contact force.

19 • I 3Z-SZ INCHES

MOVABLE CCNT:'::T

q ~li~ t., I+I~ !

fa """--

~e·

-0 ~ INCHES

.! • .!.

S-:!Z .........

INCHES

• .,

mId

"G"

r

Fig.

2 Cont".t "J;unment..

ARCING TIPS JUST TCUCHING

SHIMS US::O AS REQUIRED TQ OeTAlN MtASUR~

"CO

MOVABL~ _'-:'.0

CCNTACT

~~.E CONTACT

I

ARMATURE SEAT£!) ~CORES

Copyr ght 1989 Bucyru

rie Compan

BI115345

89-020 Lower Yorks Propel Shovels Dig/Propel Contactor November 29, 1989 Page 7 -

Latch Assembly Adjustments: 1.

The antifriction bearings must not be jammed against the armature and must be free at all times.

2.

The latch blocks, which engage on the bearings, must be approximately centered on the bearings. Yashers may be used for centering the bearings and also for obtaining alignment. Table 4 shows latch assembly adjustments.

TABLE 4

LATCH ASSEMBLY ADJUSTMENTS

II

Gap

Ccmtactor

Arc Tip "A" (Inches)

~2.

Elcctrical Arc Tip ''B'' (Inches)

.

FJfZ.

Main Tip "C" (Inches)

Frf 19/64:1: 1/32

z.

Mechmical Maln Tip "D" (Inches)

FI12.

17/64:1: 1/64

M1n1mum

Blowout Assembly

3.

Maln Tip Arc Tip Touching (Inches)

3/4

Less

With Blowout Assembly

Maln Tip (Inches)

Wipet

1-1/8 Minimum

3/4 M1n1mum

3/16 M1n1mum

1 +1/16

2 -1/32

19/64:1: 1/32

17/64 MInimum

Electrical wipe is measured with the contactor coils energized and the armature not held-in with latches. It is recommended that the electrical wipe be set at about 11/32 inch (upper limit of "C" Figure 2 tolerance).

Then de-energize the contactor coil so that the contactor coil is held in by the latches. Adjust the latches (Figure 4A) for a mechanical wipe of 17/64" minimum. This allows for approximately 1/16" clearance between the antifriction bearings and the latches, which is a sufficient clearance for the latches to drop into position when the contactor is operated manually or electrically.

,

i

Copyright 1989 Bucyrus-Erie Company

BI115345

89-020 Lower Yorks Propel Shovels Dig/Propel Contactor November 29, 1989 Page 8

~

O.O~ MI~ @

0.06 (REF. ONLY) FiS.

Jill-.

•

FiS. l{8

Yith the two contactors mechanically joined together, it is imperative that the dimensions listed be as close to equal as possible for each of the contactors. If the adjustments are not equal, mechanical binding of the contactors will result.

4.

Mechanical wipe is measured with control voltage removed from the contactor coils, and the armature held-in. To equalize the mechanical wipe, adjust the latch block and tighten the jam nuts. All latches must be supporting the armature(s) in the latched position. To check this, carefully do the following: a.

In the latched position, raise each latch block slightly while observing the anti friction bearing.

b.

If anti friction bearing moves, then the latch is holding.

c.

Repeat "A" and "B" for each latching block.

d.

Adjust latching blocks if necessary.

The unlatching solenoid mounted on each latched contactor should be set for a gap of approximately 1/4 to 3/8 inch. Adjust by moving the solenoid bracket up or down as required. Yhen the contactor(s) are de-energized and the solenoid in the energized position, the gap between the antifriction bearing and the latch block should be .010 inch minimum as shown in Figure 4B.

Copyright 1989 Bucyrus-Erie Company

"-'-'-'-' '-'-'-' '_'_'_'_'_'_'-'_'_'_'_,_,_J__ '-'__ _, __ c['-

BI115345

89-020 Lower Works Propel Shovels Dig/Propel Contactor November 29, 1989 Page 9

After all adjustments have been made, it is advisable to drill and pin the operating arms to the shafts to prevent changes in their relationships.

Be sure all safety measures are followed.

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474

,,

Copyright 1989 Bucyrus-Erie Company

BUCYRUS-ERIE COMPANY

BUCYRUS-ERIE

SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172

•

TELEPHONE: 414-768-4000

BI115345

SERVICE BULLETIN Bulletin No.:

89-021 DATE: November 29, 1989 PAGE 1 of 7

SUBJECT:

NOTE:

MMD SHOVEL WITH LOWER WORKS PROPEL LOW VOLTAGE COLLECTOR RINGS MAINTENANCE AND OPERATION 290-B1, B11, 295-B SHOVELS IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN. THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE' FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

The low voltage collector rings for carrying power to the propel motor, blower motor, and pressure switches is located in the enclosure below the hoist drum.

This enclosure contains two ring assemblies. The rings which supply power to the propel motor armature or stator are manufactured by Bucyrus-Erie. The rings which supply auxiliary power are a purchased assembly. There have been reports from time to time covering a wide range of items on these rings which are discussed in the bulletin.

CAUTION BEFORE ANY ADJUSTMENT, SERVICING, PARTS REPLACEMENT OR ANY OTHER ACT IS PERFORMED REQUIRING PHYSICAL CONTACT VITH THE ELECTRICAL 'lORKING COMPONENTS OR VIRING OF THIS EQUIPMENT, THE POVER HUST BE DISCONNECTED. A.

,

\,

GENERAL DESCRIPTION The purchased collector rings are supplied with copper alloy rings that are finely machined finish to provide 100% brush contact. The insulators are of high dielectric strength. The brushes are copper graphite and are shunted for absolute electrical connection. All units use multiple brushes on each collector ring to insure best current collection. The present unit being furnished has double brushes. Early 295-B's had single brushes. The single brush units can easily be retrofitted to double brushes without additional pieces required. The new double brush unit is now a standard replacement part.

Copyright 1989 Bucyrus-Erie Company

BI115345

89-021 MMD Shovel Yith Lower Yorks Propel Low Voltage Collector Rings Maintenance and Operation All 290B1, B11, 295-B, and 295-Bl November 29, 1989 Page 2

The collector rings are designed with two separate components: the brush stud assembly and the slip ring core assembly. Bucyrus-Erie manufactures the pieces for mounting the collector ring assembly to the machine.

B.

OPERATION The collector ring is mounted with the drive collar assembly revolving with the upper works of the shovel. Conversely the brush stud assembly is tied to the lower works. It is important to remember that the wiring between the drive collar and the B-E collector ring box is clear of the brush stud assembly. These wires must also be a highly flexible wire such as hypalon insulated wiring with multiple stranding. Thermoplastic type wiring or single strand is too rigid and easily breaks in this application.

C.

, I

INSTALLATION 1.

Install the assembly onto the center of rotation air spindle and lock in position with the set screws in the drive collars.

2.

Verify the brushes are located in the center of the collector rings.

Brushes side should not contact the walls of the insulator ring. The brush stud assembly must rotate freely on drive collar assembly.

3.

Make the wire connections, as per schematic drawings for the shovel involved, at the lugs on the brush holder and the ends of lead wires or bus bar. Be sure connections on brush assemblies do not interfere or exert tension on the brush holders. It is recommended that soft (flexible) (B-E specified hypalon wire) will be used for brush and core terminations.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Yisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474

Copyright 1989 Bucyrus-Erie Company

BI115345

(

D. MAINTENANCE 1.

GENERAL (a) Periodic inspection and adjustment are essential to the maintenance of a collector ring assembly. Proper care of brushes, brush rigging, rings and current collection parts is a fundamental necessity for satisfactory performance of a collector ring assembly. (b) Environmental conditions affect the performance of the collector ring and these conditions should be considered in the enclosure design. Periodic inspection of the enclosure is essential maintenance of the collector ring assembly.

2.

COLLECTOR RING INSPECTION AND ADJUSTMENT (a)

Brush Rigging .

(1) Brush studs are supported between (2) outboard bearings. The brush studs extend through the outboard bearings and they are secured by a setscrew in the outboard bearing. The setscrews prevent rotation of the brush stud. The setscrews should be checked for tightness. Some collector ring assemblies are furnished with additional brush stud anti-rotation devices. These devices are located on the outboard side of the outboard bearings. They incorporate an additional setscrew to prevent brush stud rotation. The additional setscrew must also be checked for tightness.

(2)

(b)

The spacing between the outboard bearings is critical to assure the free rotation of the brush rigging. The brush stud insulator sleeves are cut to length in order to provide the proper spacing. The outboard bearings should be located snuggly against the insulator sleeve without any deformation of the materials. Hand tighten the outboard jam nuts and then secure the brush stud with the setscrews referred to in 2.(a)(1). Caution: Do not overtighten the outboard jam nuts. Overtightening can preload the bearings and cause excessive rotation friction.

Final check should be made to assure no binding of outboard brush rigging or binding of brushes with insulator barriers.

Brush Holders (1) Inspect brush holders for proper alignment. Brush holders should be located so that the entire brush contact surface rides squarelY,on the ring with the brush moving freely in the brush box. The top of the brush should be parallel with the top of the brush box.

(2)

Brush holder clamps should be checked for tightness. Clamp bolts should be set at a maximum of 75 inllbs. Loose clamps will allow the brush holder to rotate, causing the brush to lift from the surface of the ring. Brush lift will cause arcing and excessive heat concentration.

(3)

Brush ternunations at the holder should be inspected to assure that no external force is imposed on the holder that would cause rotation of the holder'on the stud.

Flexible or soft wire leads are recommended for these terminations. External clamps should be used to support the entire weight of the leads.

(4)

A

final check should be made to assure that the brush studs can not rotate. See 2(a).

Copyright 1989 Bucyrus-Erie Company

3

BI115345

(c)

(d)

(

Brushes (1) Inspect for wear. If the distance from the top of the brush to the top of the brush box is over half the depth of the brush box, the brush should be replaced.

(2)

Inspect brush contact surface by removing the brush and checking the brush surface for dirt, oxidation, pitting or other contaminants. Remove any large particles and follow seating instructions in paragraph 2.(c)(3).

(3)

Check brush contact surface for proper seating. If the seating is not proper, the contact surface will be tracked differently in different areas. To reseat the brushes, lay a piece of sandpaper between the ring and the brush. Install the brush in the brush holder in proper alignment and rotate the core while applying pressure on the brush. If the core cannot be rotated, the sandpaper must be pulled across the brush surface. Wrap sandpaper at least 180' around the ring to prevent rounding of the brush edges. Recheck the brush contact surface and repeat the sanding process if necessary until the entire contact surface appears uniform and without pits. Caution: Do not use emery paper or cloth to seat brushes since the emery will become embedded in the brush and continue the abrasive action against the ring and brush. Emery and many other abrasives are conductive and must not be used.

Brush Springs (1) Inspect and test springs for proper tension. The brush tension springs should be set at 1.5 lbs. per spring and as uniform as possible. Uniform settings for each brush prevent selective action by which certain brushes carry more or less than their share of the load. Insufficient brush pressure can cause loss of contact and overtension can cause excessive brush and ring wear.

(2)

The spring tension should be periodically tested on all brushes to assure uniform brush tension. Test for tension as shown in Figure 1. See paragraph 5(b) for spring tension adjustment. .

t

LIFT SCALE UNTIL SPRING JUST LIFTS OFF BRUSH SURFACE AND READ SCALE

I

m S LB. SCALE

WIRE LOOP (Approx •• 01" Music Wire)

BRUSH SPRI NG

BRUSH HOLDER

BRUSH ' \ - - - - RING

FIGURE 1 Copyright 1989 Bucyrus-Erie Company

4

BI115345

(e)

(f)

3.

Rings (1) Inspect the ring surface for dirt, oxidation or other contaminants. A properly operating ring will have a film that appears burnished in color where the brushes track with a darker surrounding color. If this condition does not exist, cleaning will be necessary.

(2)

The ring should be cleaned with a non-conductive abrasive such as Ideal Industries' Flexible Abrasive for collector rings. Hold the abrasive against the ring with a medium amount of pressure while turning the core. If the core cannot be turned, the abrasive must be rubbed over the ring. Continue this process until the ring surface is polished without any dirt or contaminants left on the surface. To prevent abrasive from being lodged in the brushes, they should be lifted off the ring.

(3)

Inspect rings for pitting. Pitting of the ring must be corrected since pits will produce arcing, leading to the development oflarger and more pits. Smell pits can be removed by hand stoning of the area. Iflarge pits and/or a considerable amount of pits are present on the surface, the surface must be machined. Machining is also necessary if concentricity of the surface is questionable. When stoning or machining rings, remove only enough material to eradicate the pits. Again, the brushes should be lifted from the surface when stoning or machining. Finish the ring surface to a 16-32 microfinish as described in 2(e)(2).

Electrical Connections (1) Inspect all electrical connections for corrosion and tightness. Clean corroded parts with a wire brush and/or muriatic acid. Loose and/or corroded terminations will cause a concentration of excessive heat.

ENCLOSURE INSPECTION (a)

(10)

( c)

Moisture is a major cause of collector ring deterioration. Corrosion of parts and insulation breakdown can be attributed to the presence of water. Dust and dirt present within the enclosure will affect the proper operation of the assembly. Most dusts cause excessive brush and collector ring wear and conductive dusts, if allowed to accumulate, wili . form a path for short circuiting.

Cleaning the collector ring assembly must be done "it:, care.

Contaminents cause abrasive wear to collector rings, brushes, and core assembly. If contamination is a lubricant (grease, OGL types), a suitable type of cleaning solvent must be used to avoid damage to brush stud and slip ring core assemblies.

An inspecti~n should be periodically perforned by removing the enclosure

and checking for condensation, water, and dust conditions. If contaminents are found, the enclosure and the assembly should be wiped with a lint free cloth. If the problem appears persistant, steps should be taken to remedy the leakage or condensation problem.

4.

FREQUENCY OF INSPECTIONS (a)

The first inspection should be made shortly after installation and before operation.

Continuing inspections should be made on a regular basis after every 200-400 hours of operation under normal conditions.

Copyright 1989 Bucyrus-Erie Company

5

BI115345

,

5.

REMOVING AND REPLACING BRUSHES AND SPRING TENSION SCREWS (a)

Brush Holders with non-adjustable spring tension (Figure 2) (1) Pull spring free end (B) out of brush holder recess and slide spring off offlXed hub (A).

(2)

Unscrew binder screw (C) and take off brush shunt connector (D) and remove brush (E).

(3)

Install new brush, reversing above procedure.

i---CLAMP BOLT

,

/

BRUSH STUD

FIGURE 2 (b)

Brush Holders with adjustable spring tension (Figure' 3) (1) Release spring tension on the brush spring by holding the spring tension screw with a screw driver at slot (A) and loosening spring tension nut on opposite side.

Do not completely remove the nut, just loosen. Screws can be adjusted with 9/32 wrench without removing from stud.

(2)

Puli spring (B) up and out of the way and unscrew binder screw (C). Take offbrush shunt connector (D) and remove brush (E).

(3)

Install new brush, reversing above procedure.

(4)

Tension is applied on brush spring by holding nut with wrench and turning screw with screw driven clockwise until inner coils are tight. Back off \10 turn, then tighten the nut. Spring should have a minimum of 1 pound pull at the brush. See paragraph 2.(d)(1).

Copyright 1989 Bucyrus-Erie Company

6

BI115345

(5)

To replace brush spring tension screw (A), simply take spring tension screw nut off and pull the screw and spring out of the holes in brush holder (F). Use above steps in reverse order to replace spring tension screw.

CLAMP BOLT

r---BRUSH STUD

FI GURE 3

E. STORAGE When not in use, the collector ring should be kept in a cl ean, dry place, protected and preferably at room temperature. Collector Ring Enclosures should be opened periodically to check for condensation. It is recommended that a self-contained or bagged absorbent material be placed in the Collector Ring Enclosure during extended periods of storage. Remove absorbent material before putting the collector ring into operation. .

Copyright 1989 Bucyrus-Erie Company

7

BUCYRUS-ERIE COMPANY

BUCYRUS-ERIE SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172

•

TELEPHONE: 414-768-4000

BI115345

SERVICE BULLETIN Bulletin No.: 89-022 DATE: November 29, 1989 PAGE 1 of 1

SUBJECT:

NOTE:

ELECTRIC MOTOR COUPLINGS/PINIONS MHO ALL SHOVELS

IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

There has been reported incidents where motor pinions have come loose from the shaft causing pinion and mating gear failure. In one case a motor shaft cracked as well.

On all machines there is a lock plate device which is required to keep the nut from turning once it is tightened. All motors have these listed on all AC and DC machines. The lock plate locks into the pinion/coupling as well as being bent over one flat of the nut - thereby locking it. Often in field replacement customer mechanics forget this device or possibly misunderstand its importance and throw it away. If this lock plate is omitted, the pinion or coupling will come loose.

Another point of importance is the matching tapers between the pinion/coupling and motor shaft. Always check the tapers with some type of blUeing or chalk, etc. to assure the tapers match.

The motors usually have a rounded keyway bottom toward the inner end of the key and sometimes the key tries to ride up this curve as the pinion/coupling is installed which possibly causes it to lockup before it is full sealed against the shaft taper. Be sure the key is fitted on the sides and has at least .003 clearance at the top (between the bottom of the keyway in the pinion and the top of the key).

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Yisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474 Copyright 1989 Bucyrus-Erie Company

~

..

BUCYRUS-ERIE

BUCYRUS-ERIE COMPANY SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172

•

TELEPHONE: 414-768-4000

BI115345

SERVICE BULLETIN Bulletin No.: 89-026 DATE: November 29, 1989 PAGE 1 of 8

SUBJECT:

NOTE:

HMO GENERAL ELECTRIC NEW MG SET LUBRICATION PROCEDURES 290-BI, BII, 295-B, BI SHOVELS

IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

After considerable dialogue General Electric has revised the lubrication procedures for MG sets with ball and roller bearings as well as sleeve bearings.

These are some important differences between previous recommendation and the following. I recommend careful reading because General Electric has addressed many of the problems in the previous procedures.

LUBRICATION BALL AND ROLLER BEARING LUBRICATION Ball and roller bearings use the oil from the grease at a rate that is dependent on bearing operating temperature, operating time and speed, and bearing load.

Machines exposed to high temperatures use up grease (oil) faster. Machines operating at high speeds use up grease faster and continuous operation uses grease faster than intermittent operation.

Motors and generators are shipped with enough grease to run for at least six months without relubrication. For most equipment, GE grease D6A2C5, which is a high quality ball bearing grease, should be used. It is suitable for excavator service except in cold weather areas. For the cold weather areas where o 0 temperatures are consistently below 0 F (-18 C) for the winter season, GE grease D6A4, which is a low temperature ball bearing grease, should be used.

IF REPLACING GE GREASE D6A2C5 WITH "COLD WEATHER" GREASE (i.e. D6A4, D6A15) THE OLD GREASE MUST BE REMOVED. LUBRICANTS CONTAINING EXTREME PRESSURE ADDITIVES MAY CAUSE INSULATION FAILURES. THESE LUBRICANTS PROVIDE A CONDUCTIVE CONTAMINANT WHICH CAN PENETRATE INSULATION AND PRODUCE SHORTS AND GROUNDS. NO LUBRICANT CONTAINING EXTREME PRESSURE ADDITIVES SHOULD BE USED IN ANY DC MACHINE OR BE ALLOWED TO COME INTO CONTACT WITH THE WINDINGS. Copyright 1989 Bucyrus-Erie Company

BI115345

89-026 MMD General Electric New MG Set Lubrication Procedures 290-B1, BII, 295-B, 295-BI Shovels November 29, 1989 Page 2

The recommended regreasing period for CDS320-680 frame size generators is 6 months and 3 months for the CDS5000-8000 frame sizes.

Be sure grease fittings are clean. Remove grease relief plug and clean out relief hole. Pump in new grease with a hand-operated grease gun until the new grease comes out the relief hole. Then run the machine for a few minutes to purge excessive grease before replacing the plugs.

Grease condition on CDS580-8000 frames can be checked by removing a bearing cap.

Remove the bolts in the bearing cap and slide the cap back along shaft. Remove the two 1/4 inch screws holding the metering plate to the bearing cartridge and pull the metering plate back. The grease near the bearing should have some free oil, it should not be much darker in color or much different in consistency when compared to new grease. Dry, crumbly grease is definitely beyond any use.

Old grease can be cleaned out of the bearing and bearing cap by wiping with a clean cloth. An oil can filled with solvent may be used to flush the bearing, 1£ desired. New grease can be added by "buttering" the bearing lightly, replacing the grease metering plate and then filling the bearing cap full of new grease.

TABLE I

BEARING GREASES KNOYN SOURCES OF GE GREASE D6A2C5: ATLANTIC 54 GE SHELL ALVANIA NO.2 TEXACO REGAL AFB-2 ==================================

KNOYN SOURCES OF GE GREASE D6A4: (LOY TEMPERATURE) HUMBLE OIL BEACON 325 SHELL AREOSHELL GREASE NO. 7 ==================================

KNOYN SOURCE OF GE GREASE D6A15A1: (SYNTHETIC HYDROCARBON GREASE ALL TEMPERATURE) MOBIL GREASE 28 ==================================

EQUIVALENT AND COMPATIBLE GREASES MAY ALSO BE AVAILABLE FROM OTHER VENDORS ==================================

Copyright 1989 Bucyrus-Erie Company

BI115345

89-026 MMD General Electric New MG Set Lubrication Procedures 290-B1, BII,. 295-B, 295-BI Shovels November 29, 1989 Page 3

Sleeve-Bearing Lubrication Machines equipped with sleeve bearings are shipped from the factory without oil in the bearing pedestals. Oil should be added so that the level is in the center of the two marks on the sight glass. llith the bull's eye type gage, the oil level should be maintained at the center of the gage. Oil level measurements must always be taken with the shaft at standstill and excavator level. To maintain proper lubrication, it is preferred to operate with oil level between the top mark and the center of the two marks. Never allow the oil level to fall below the bottom mark for any reason as the oil delivery to the bearing will not be adequate and the bearing failure may result.

An opening is provided in the pedestal cap for the purpose of adding oil and for inspection of the oil rings. Oil should be added only when the shaft is at standstill and the excavator is level so that the level in the sight gage properly shows the immersion of the oil rings in the oil. When the oil level is below the bottom mark on the sight gage and the machine is run, the inner surface of the oil ring is not wetted and oil is not delivered to the bearing.

When the machine is running, the opening in the pedestal cap allows viewing of the oil rings to be sure they are turning freely. The outer surfaces of the oil rings throw off a lot of oil even when the level is dangerously low. Thus, observing the oil spray is not indicative that oil is being supplied to the bearing.

All pedestals since mid 1976 should be equipped with.25 inch (6.35mm) thick leather seals to prevent pedestal oil leaks. If oil leaks should continue after the installation of the leather seal, the following steps should be taken to stop the leakage: 1)

Remove bearing and inspect the size of the drain slot in the bottom half of the bearing. the effective width of the drain slot must be at least 125 inch (6.35mm).

2)

Install a new leather seal on the pedestal. Be sure the leather seal fits tightly between the pedestal and shaft to insure that the leather seat will rub on the shaft.

"

Copyright 1989 Bucyrus-Erie Company

''-'.,'u'.'.,,'/,

-----------

-,

",'

.,-,-,,-

----------~

BI115345

I,

89-026 MMD General Electric New MG Set Lubrication Procedures 290-B1, BII, 295-B, 295-BI Shovels November 29, 1989 Page 4

For excavator machines the recommended oil is either light turbine oil as shown in Table II. The light turbine oil is recommended for climates where the ambient temperature ranges from _18 0 e (OoF) to 40 0 e (104 0 F). The medium oil is

~~s~m(~~~ij~)~orI~l!::t:=b~~~~et!~;e~=~~~~ti~e~~~~~~~r~h~:~g~~s~~~mO~o~f(~~:~!

to

are unusual operating conditions, consult your General Electric representative for lubrication specification.

An optional feature that can be provided" for climates where winter temperatures are constantly below _18 0 e (OoF) is pedestal oil heaters. These heaters are located below the oil sump. The heaters are controlled so that the oil sump temperature is always above _18 0 e (OoF). The light turbine oil is recommended for all applications where the pedestal oil heaters are used.

Copyright 1989 Bucyrus-Erie Company

BI115345

89-026 MMD General Electric New MG Set Lubrication Procedures 290-B1, BII, 295-B, 295-BI Shovels November 29, 1989 Page 5

TABLE II OIL SPECIFICATION CHART For Normal Excavator Service and for Cold Climate Service Light Turbine Oil

For Warm Climate Service-Medium Turbine Oil

================================================================================

GE Spec. *Ambient Temp.

Range For Safe Operation Flash Point, Min. Viscosity, Saybolt Seconds Pour Point, Max.

D6B6A

D6B6B

_18°C to 40°C (OoF to 104°F) 330 F

OoC to 50°C (320F to 122°F) 350°F

140-170 at 100°F 20°F

270-325 at 100°F 25°F

°

================================================================================

*The use of pedestal oil heaters is recommended if the winter temperatures are consistently below _20°C (_4°F).

KNOWN SOURCES OF GE MATERIAL D6B6A: AMOCO NONPAREIL MEDIUM ATLANTIC IDEAL S150 CHEVRON OC TURBINE OIL 32 CITGO PACEMAKER T-32 GULF CREST 32 MOBIL DTE NO. 797 SHELL TURBO OIL 32 SUNVIS 916 TEXACO REGAL (R & 0) 32 ==================================

KNOWN SOURCES OF GE MATERIAL D6B6B: ATLANTIC IDEAL S315 CHEVRON OC TURBINE OIL 68 CITGO PACEMAKER T-68 GULF HARMONY 68 MOBIL DTE HEAVY MEDIUM SHELL TURBO OIL 68 SUNVIS 931 TEXACO REGAL (R & 0) 68 ================================

Copyright 1989 Bucyrus-Erie Company

BI115345

(

89-026 MMD General Electric New MG Set Lubrication Procedures 290-B1, BII, 295-B, 295-BI Shovels November 29, 1989 Page 6

During cold weather when the machine has been idle, the oil in the sump cools and is viscous. The colder the oil, the more viscous or resistant to flow it becomes. On start up under these conditions, the oil may not flow to wet the inner surface of ·the oil ring, especially if the oil level is below the bottom mark. This can cause lack of lubrication of the bearing resulting in a bearing failure.

If the power to the excavator has been off, the sump oil temperature may fall below _18 0 C (OoF). When power is restored the pedestal heaters should be 0 energized and the oil should be heated so that the temperature is above -18 C (OoF) before staring the MG Set. The time required to heat the oil depends on the ambient temperature. At _40 0 C (_40 0 F) the oil should be heated for about three hours before starting the MG Set. In starting an MG Set during cold weather, the sleeve bearings can wipe due to lack of lubrication. During a shutdown, all the oil drains from the gearing leaving metal-to-metal contact. The start up of the MG Set will not damage the bearings if the relubrication is established under the following conditions: i

I

1)

Use the proper type of oil. turbine oil.

For cold climate service this is light

2)

Have the proper oil level.

3)

Have the oil temperature above the minimum recommended ambient temperature in Table II. In cold climates, the pedestal oil heaters are recommended.

4)

Start the MG Set.

Lubrication of Flexible Couplings Flexible couplings are normally lubricated with a semi-fluid grease or an oil.

The coupling manufacturers' instructions should be followed in choosing a lubricant and setting relubrication intervals. General Electric ball-bearing grease D6A2C5 is a suitable lubricant for flexible couplings in most agplicatAons. For could weather areas where temperatures are consistently below o F (-18 C) for the winter season, GE grease D6A4, which is a low temperature ball bearing grease, should be used. ,

Copyright 1989 Bucyrus-Erie Company

BI115345

89-026 MMD General Electric New MG Set Lubrication Procedures 290-B1, BII, 295-B, 295-BI Shovels November 29, 1989 Page 7

Flexible couplings which join a small machine to a large one may have two different size coupling halves joined by an adapter plate. Couplings of this type have a separate lubricant supply for each half, so that both halves must be lubricated separately.

IF REPLACING GE GREASE D6A2C5 llITH "COLD YEATHER" GREASE (i.e. D6A4, D6A15) THE OLD GREASE MUST BE REMOVED. CAUTION:

LUBRICANTS CONTAINING EXTREME PRESSURE ADDITIVES MAY CAUSE INSULATION FAILURES. THESE LUBRICANTS PROVIDE A CONDUCTIVE CONTAMINANT llHICH CAN PENETRATE INSULATION AND PRODUCE SHORTS AND GROUNDS. NO LUBRICANT CONTAINING EXTREME PRESSURE ADDITIVES SHOULD BE USED IN ANY DC MACHINE OR BE ALLOYED TO COME INTO CONTACT llITH THE llINDINGS.

Copyright 1989 Bucyrus-Erie Company

BI115345

89-026 MMD General Electric New MG Set Lubrication Procedures 290-Bl, BII, 295-B, 295-BI Shovels November 29, 1989 Page 8

TABLE III METRIC CONVERSION FACTORS To convert from

To

Multiply By

================================================================================

pounds i.nches cubic inches ounces pound-feet tons pounds per square inch degree F

kilograms millimeters cubic centimeters grams newton meters kilograms kilo pascal degrees C

0.4536 25.4 16.387 28.35 1.356 907.2 6.89 deg. C=deg.F-32 1.8

These instructions also apply to older machines.

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Yisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474

Copyright 1989 Bucyrus-Erie Company

BUCYRUS-ERIE COMPANY SERVICE DEPARTMENT

BUCYRUS-ERIE

So. MILWAUKEE, WIS. 53172

(

TELEPHONE: 414-766-4000

BI115345

SERVICE BULLETIN Bulletin No.: 89-027 DATE: November 29, 1989 PAGE 1 of 2

SUBJECT:

NOTE:

MMD GENERAL ELECTRIC NEW VIBRATION TOLERANCES 290-BI, BII, 295-B, AND 295-BI SHOVELS IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

Often we have been confronted with various forms of vibration analysis and requests as to what is the allowable frequency and velocity for a given displacement.

In response to these questions, General Electric has released the following allowable tolerances.

Noise and Vibration New machines may sometimes smell warm or have the odor of varnish but should not smell scorched.

The vibration of the MG Set should be measured at each bearing on either the bearing cartridge for anti-Friction bearings or the pedestal for sleeve bearings. The vibration data should be taken with all the generators running no load and should include horizontal, vertical, and axial readings. The guidelines that are recommended for evaluating allowable vibration on excavator MG Sets are listed in Table I. TABLE I VIBRATION NEV EQUIPMENT

Displacement Veloci ty

1000 90 3.6 (4.8) .19

Copyright 1989 Bucyrus-Erie Company

RPM 1200 80 3.0 (4.8) .19

1500 60 2.4 (4.8) .19

1800 50 microns 2.0 mils (4.8) mm/sec .19 in/sec

'/

BI115345

OLD EQUIPKENT

Displacement Velocity

120 4.8 (6.4) .25

100 4.0 (6.4) .25

80 3.2 (6.4) .25

70 microns 2.6 mils (6.4) mm/sec .25 in/sec

240 9.6 (13) .51

200 8.0

160 6.4 ( 13) .51

130 microns 5.3 mils (13) mm/sec .51 in/sec

MAINTENANCE REQUIRED

Displacement Velocity Note:

25.4 microns

(13)

.51

=1

mil Micron displacements above are rounded to the nearest tenth

Excessive vibration can be caused by a number of reasons. The most likely causes of excessive vibration in a new MG Set are as follows: 1) 2) 3) 4)

Coupling misalignment Damage in shipment Loose coupling bolts Loose foot bolts or base tie-down bolts

It should be noted that /

!,

Vhen vibration peak-to-peak amplitude readings at operating speed are within the acceptable limits in Table I no further action is needed.

If the amplitude readings are in excess of the acceptable limits, first check possible causes (1) thru (4). Vith a new MG Set, dirt accumulation should not be a source of unbalance.

If vibration amplitude is still excessive, it is necessary to go from simple surveillance using only amplitude readings, to diagnostic techniques with more sophisticated instruments. Refer to the General Electric Company Direct Current Motor and Generator Department or Installation and Service Engineering Division.

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Visconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474

Copyright 1989 Bucyrus-Erie Company

BUCYRUS-ERIE COMPANY

BUCYRUS-ERIE

SERVICE DEPARTMENT So. MILWAUKEE, VVIS. 53172

~

TELEPHONE: 414-768-4000

BI115345

SERVICE BULLETIN Bulletin No.: 89-023 DATE: November 29, 1989 PAGE 1 of 1

SUBJECT:

NOTE:

CLEANING ELECTRICAL EQUIPMENT AND OTHER EQUIPMENT USING COMPRESSED AIR FROM THE MACHINE FOR ALL SHOVELS

IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

We have received reports of DC generator and motor commutation problems which were the result of commutating film contamination. Many drills, shovels and draglines have air control systems that have either air dryers or tanner gas system in line with the air receivers. Air dryers contain silicon oxides and/or aluminum oxides among other things. These items can have negative effects on commutating film. Therefore, it becomes very important that customers who have Bucyrus-Erie equipment, that have air dryers or tanner gas systems be made aware of the potential commutation problem. It is not recommended to use air for blow down purposes when it is taken after either one of these devices. Tapping into a system before these devices is permissible.

Another point should be made concerning "air blowing" around electrical equipment. Use of air pressures above 30 PSI can cause serious damage to generator and motor coils due to the air pressure lifting and/or causing the insulation to crack and allow contaminants to enter which in turn can cause shorted turns, grounds, etc. All air should be dried air, such as used on paint spray equipment.

We strongly recommend the use of a vacuum type device for cleaning electrical equipment. Blowing tends to move the dirt around instead of removing it.

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474

Copyright 1989 Bucyrus-Erie Company

BUCYRUS-ERIE COMPANY BUCYRUS-ERIE

SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172

•

TELEPHONE: 414-766-4000

BI115345

SERVICE BULLETIN Bulletin No.: 89-024 DATE: November 29, 1989 PAGE 1 of 1

SUBJECT:

NOTE:

HOIST AND CROWD CONTROLLER REVERSAL ON ALL SHOVELS IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

From time to time we hear that someone wants to set up his machine for pull on the hoist to hOist, and push to lower the dipper. Usually, the rational given is to have uniform controller movement across all the shovels in that particular mine or else someone learned to operate that way. Rarely, we hear that someone wants the crowd controller reversed.

Officially, we at Bucyrus-Erie would like to have the controller movements as prescribed on the prints; but we also understand the owner/user problem of uniformi ty.

The procedure for changing controller direction is a simple mechanical change.

Remove the cover from the controller in question. Looking inside, remove the Allen head caps crews from the half bevel gear and reverse it to the opposite side of the pinion. This reverses the mechanical direction of the switch.

Electrically, NOTHING needs to be reconnected.

Recently a controller was reversed by just reconnecting the motor field wires only. Yes, this effectively reverses the required motion of the master switch (pull to hoist or pull to crowd) but could have just as easily caused a motor and generator armature failure, costing up to 50,000 to 60,000 dollars because the field strengthening contactor was not correct for this controller movement, the plugging relays were backward, etc. the wiring schematics were not per machine control, which can cause all sorts of hassles. The high costs of repairs was potential loss of generator and motor armature.

DO NOT REVERSE CONTROLLER HOTION BY ELECTRICAL CONNECTION !

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Yisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474 Copyright 19d9 Bucyrus-Erie Company

BI115345

( '.

AC DRIVE SYSTEMS

BUCYRUS-ERIE COMPANY

BUCYRUS·ERIE

SERVICE DEPARTMENT So. MILWAUKEE, WIS, 53172

(

•

TELEPHONE; 414-768-4000

BI115345

SERVICE BULLETIN Bulletin No.: 89-025 DATE: November 29, 1989 PAGE 1 of 2

SUBJECT:

NOTE:

DIG TO PROPEL OR PROPEL TO DIG SWITCHING TROUBLESHOOTING ON ALL SHOVELS

IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

LIST OF WHAT TO LOOK AT IF YOU CANNOT TRANSFER FROM DIG TO PROPEL OR PROPEL TO DIG

To transfer either way: A)

Hoist on and

B)

HPATD must be dropped out (N.O. contact) in MRC cabinet.

C)

HIP on relay (HRSA) must be dropped out.

D)

~ropel

on lights on cabinet door must both be off.

1.

LED #6 (7th one down) must be out.

2.

Pin 29 HRSA (M2S1L) must be a "1".

"0" on Pin 29 prevents transfer and lighte LED #6.

NSGA in Row 1 and Row 2 must have SP28 LED off.

1.

Pin 33 on both cards should be a "1" since they are tied 'together on connector JPB an "0" on either side will prevent transfer. ';

2.

Pins 68 and 70 on each card should be "0" 28V at this point indicates a failed KIP relay.

3.

No gating LEDS should be on the can v or Inv firing boards.

Copyright 1989 Bucyrus-Erie Company

BI115345

89-025 Dig to Propel or Propel to Dig Switching Troubleshooting November 19, 1989 Page 2

E)

KIP coil should be de-energized.

1.

Pin 64 on both NSGA boards "0" picks up KIN relay and a. b. c.

=

"1" (5V) to D.O. KIP.

Applies 28V to conv and inv gating CKTS Turns on SP28 LED Puts a "0" on Pin 32 to prevent transfer

If KIP relay is failing, why does it apply to P28V properly for gating when moved to another motion?

If NSGA pins 68 and 70 = "0" and Pin 32 = "0" then either the inverter has failed or something on the output is loading it down. Watch for a "strange" voltage like 3.5V on Pin 32.

If NSGA Pins 68 and 70 = 28V and Pin 64 = "1" (5V) then the relay has

failed (KIP) and the SP28 LED should still be on.

The object of this is to identify the reason behind the frequent problems of this nature which can be solved by moving the NSGA in Row 1 of HIP to another motion. If the relay (KIP) contact has failed, it should still be failed when moved to another motion. Hopefully this list of what must occur before the transfer can take place will help in identifying where we actually are losing the signal.

Any actions taken'as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474

Copyright 1989 Bucyrus-Erie Company

BI115345

BUCYRUS-ERIE COMPANY BUCYRUS-ERIE

SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172

•

TELEPHONE: 414-768-4000

SERVICE BULLETIN Bulletin No.:

DATE: PAGE:

January 14, 1988 1 of 2

SUBJECT:

88-4

Tachogenerators on B.E. Machines

Tachogenerators are utilized as primary speed feedback sources on various drives on all B.E. product lines. The continued optimal performance of a tachometer controlled drive is largely dependant on the condition of the tachometer and its coupling. Please include in your preventive maintenance a careful check and repair of the following areas.

1)

2)

3)

Coupling: a. ·Is the stub shaft firmly seated in the motor shaft?

Insure that there is no play in this fit. b.

Is the coupling itself in optimal condition?

Insure that leaf springs are integral, rubber parts are undamaged, bolts are tight, and again no play on the shaft fits.

c.

Is the guard mounted properly?

Insure that while fully protecting the coupling it does not interfere with the free rotation of the unit.

Mechanical: a.

Is the base solidly mounted?

On pedestal mounts, insure that tacho is secure to its pedestal which again must be secure to the bracket. All bolts must be tight. b.

Are the shafts in alignment?

Where dowelled, insure dowel pins are all installed.

Note: The' better this alignment the longer each of the components will last, the longer the gear train will last, and the better the performance.

c.

Is the cable routed and clamped properly?

Electrical: i a.

Generally the signal cable to the tachogenerator is shielded. This electrical shield is grounded to the machine at the control cabinet side. It is to be grounded in only one place, therefore, if insulation is damaged replace the cable.

, Copyright 1989 Bucyrus-Erie Company

I

,

.....•..THE LONGEST'; LINE.

EARTH.....

.

BI115345

Tachogenerators on B.E. Machines Page Two

b.

Insure connections are properly made, lugged where possible, and tight. Frayed wires and "birds nest" connections are not acceptable.

c.

Insure brushes ate of the correct type, correct length, (trim as necessary), have completely free movement, are properly seated and are clamped by a good spring. Vhere adjustable, utilize the highest brush spring pressure.

d.

Brush pigtails must be routed clear of all metal supports particularly in the old style Hubner devices with screw in brush covers. Pigtails must not accidentally touch ground.

NOTE: NEV TACHOGENERATORS PRESENTLY IN STOCK CAN HAVE THEIR BREAK IN PERIODS SHORTENED BY RUNNING ON A 48 VOLT D.C. POVER SUPPLY FOR A PERIOD OF TIME (48 HOURS' HUBNER, 7 DAYS BC42).

A little extra ca~e of these devices will result in measurable benefits to your company. Do not allow brackets to be utilized as steps, anchors, or winch points, inspect casually on an intermittent bases. Thoroughly check each device at least once per month.

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

For further -information, consult your service manual or contact: Bucyrus-Erie Company 1100 Milwaukee Avenue . South Milwaukee, VI 53172 Phone: 414-768-4000

GB: 9996: BULLETIN

Copyright 1989 Bucyrus-Erie Company [

"

BUCYRUS-ERIE COMPANY

BUCYRUS-ERIE

SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172

(

•

TELEPHONE: 414-768-4000

BI115345

SERVICE BULLETIN Bu lIatin No.: 89-016 DATE: October, 1989 PAGE: 1 of 2

SUBJECT:

Note:

SIEMENS ACUTROL TACH-GENERATOR MAINTENANCE

It is essential that all appropriate safety measures, such as set forth in the applicable machine maintenance manual, are followed during the performance of this work.

The tach-generator on the acutrol machine is the speed feedback for the regulator.

In the regulator it is used to generate the torque command and the actual stator frequency.

The tach has to be doing precisely what the motor is doing.

There can be no backlash. ,.

Problems with tach show up as a large increase in over current trips isolated to one motion. Slow or jerky operation are also possible. Gear train noise may also accompany problems.

Maintaining tachs can prevent machine problems. Tachs are mounted on the brake end of the motors. They are coupled to the motor via a stub shaft. To obtain zero backlash the stub shaft must be tight to the motor shaft and locked in place.

The coupling between the tach and stub shaft must be tight and rigid. No broken springs or bolts. Tach mounting bolts must be tight as well as mounting brackets. Alignment is critical and must be maintained for proper operation and longevity of components.

The tach itself is a measuring instrument and should be treated accordingly. Rough handling can change the output.

All connections should be tight.

Brushes should be set for highest spring force, if adjustable. They should move freely in the brush holders and have 75% or more contact to the commutator.

Proper maintenance of the tach-generators and couplings keep machine operating properly. All connections and mounting hardware must be tight. Tach must duplicate motor rotation exactly.

Copyright 1989 Bucyrus-Erie Company

BI115345

Bulletin 89-016 Siemens Acutrol Tach-Generator Maintenance page two

Any actions taken, as a result of comments contained in this Service Bulletin, are undertaken at your own expense. These actions shall not be subject to reimbursement from BucyrusErie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact: Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, WI Telephone: 414-768-4000 Facsimile: 414-768-4474

\:

Copyright 1989

Bucyru~

Erie Company

BUCYRUS-ERIE COMPANY

BUCYRUS-ERIE

SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172 TELEPHONE: 414-768-4000

BI115345

SERVICE BULLETIN Bulletin No.:

DATE: PAGE:

January 14, 1988 1 of 3

SUBJECT:

88-3

SIEMENS ACUTROL BATTERY CHARGERS

A six battery deck is utilized on subject machines to provide continuous power to the regulators during low line conditions and for a short time in the event of a line fault. The batteries are continuously under float charge in order to ensure their optimal condition at all times. Damage, including both fuse and thyristor loss in the drives, will result when even a momentary battery power loss occurs. Please include in your preventative maintenance a careful check and repair of the following areas: 1)

2)

Inside battery cabinet: a.

As the sulfuric acid electrolyte works it gives off a gas_ This gas is vented by the battery cabinet blower_ Insure that the blower is functioning properly, and is properly fastened. b.

The connections to the batteries are of paramount importance. They must be cleaned and checked regularly.

On reassembly, apply grease on both sides of the lug. (Replace lug if corroded or wires are frayed.) Note: Yire B8 = +48 VDC, BIO = +24 VDC, B12 = 0 VDC or M Buss, B14 = -24 VDC.

c.

Make certain the batteries are clean and dry so there is no potential for tracking across the batteries or to ground.

Inside battery charger: a.

Battery cables are connected to buss bars in lower right hand side of cabinet on X4, X5, X6 and X7. These connections must be solid and tight. Do not stack more than two lugs to a bolt, drill more holes if necessary. b.

Fuses or breakers F41, F42, F43 carry rated charge current_ Insure that terminals and lugs are properly tightened to avoid overheating. If signs of overheating occur, replace lug and or,wire.

Check the fuse connections for good contact.

J

c.

Reactor chokes L31, L32, L33 also carry the full charge current, check screw lugs for heat effects and firmness. Check also the mounting of these heavy reactors_ A mechanical brace has been added across the front (top) face of the three units on most machines. The reactors must be firmly mounted.

Copyright 1989 Bucyrus-Erie Company

BI115345

Siemens Acutrol Battery Chargers Page Two

3)

Electrical: a.

The charger output voltages measured between X13-X14, X23-X24, X33X34, with the battery charger switched to "charge" must read 27.2V .± 0.1 VDC. If not, the adjustment labeled "U" on the control card is to be used in order to correct this value. When the charger is switched to "operate", the voltage should not collapse below 26.5 volts with nominal line conditions. The nominal output voltage should be checked monthly. b.

Continued maximum output currents from any of the chargers can significantly affect battery charger component life. The maximum charger current must be measured with a fully charged good set of batteries connected.

CAUTION: WHEN DOING A LOAD TEST WITH LEAD ACID STORAGE BATTERIES, TESTS SHOULD ONLY BE PERFORMED BY PERSONNEL KNOWLEDGEABLE AND TRAINED TO WORK WITH THESE BATTERIES. NEVER MAKE OR BREAK AN ELECTRICAL CONNECTION AT THE BATTERY WHILE THE CONNECTED WIRE IS CARRYING A LOAD CURRENT. THE RESULTING SPARK MAY CAUSE AN EXPLOSION. / I.

A load is switched onto the batteries with the battery charger in charge and all breakers in the back of the MRC off. This load must be able to draw more than 50 AMPS (Le., less than 0.5 ohms) for up to a minute. Current is measured at X11-X12, X21-X22 or X31-X32, depending on which charger is in test. The max currents are set with adjustment labeled "I" on the control card and are set to: XII - X12.(48mv X21 - X22 (45mv X31 - X32 (48mv

= 20 amps) = 30 amps) = 20 amps)

When this test is complete, allow batteries to recharge for at least 10 minutes prior to putting machine back into operation. Once set, the charger current should not need re-calibration for at least a year unless repairs or adjustments are made for other reasons.

Attention to these details on a regular basis will measurably increase the reliability of the equipment and will avoid costly electrical failures such as fuse loss and thyristor loss.

NOTE: Under normal conditions the batteries should not require replacement more than once per year.

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

Copyright 1989 Bucyrus-Erie Company

BI115345

Siemens Acutrol Battery Chargers Page Three

For further information consult your service manual or contact: Bucyrus-Erie Company Service Division 1100 Milwaukee Ave. South Milwaukee, VI 53172 Phone: 414-768-4000

GB: 9997: BULLETIN

Copyright 1989 Bucyrus-Erie Company

.E:a: _ BUCYRUS-ERIE COMPANY BUCYRUS-ERIE

SERVICE DEPARTMENT SO. MILWAUKEE, VJIS. 53172

•

TELEPHONE: 414-768-4000

BI115345

SERVICE BULLETIN Bulletin No.: 89-017 DATE: October, 1989 PAGE: Page 1 of 2

SUBJECT:

SIEMENS ACUTROL

BATTERY CHARGER MAINTENANCE Note:

It is essential that all appropriate safety measures, such as set forth in the applicable machine maintenance manual, are followed during the performance of this work.

Battery charger and batteries in acutrol machines require regular preventative maintenance to provide proper operation.

They supply power to the regulator and thyristor gate firing.

Neglect of this area can cause fuse loss and extensive inverter component damage.

Fuse loss will be random in motions or all motions simultaneously. Proper machine operation is possible only if batteries and charger are maintained.

Batteries should be lead-calcium, side terminal, maintenance free, heavy duty automotive type batteries.

(B-E part number 17026103). Connections should be checked bi-weekly. Corrosion should be removed with wire brush. Reassembly with corrosion inhibitor, such as petroleum jelly is recommended.

Fluid level in batteries must be above plates. Battery replacement is recommended ev.ery 12 months.

Battery charger cabinet connections should be checked bi-weekly. All terminal board connections should be tight.

Connections to relays should be checked. Particular attention should be paid to the buss bar connections in lower right area of cabinet (X4, X5, X6, X7). M-buss connections (X5) should be distributed the length of buss bar, not all at one point.

Corrosion inhibitor is recommended. Connections to fuses F41, F42 and F43 should also be checked, as well as the fuses and fuse holders themselves.

Battery charger voltages should be 27.2V ± 0.2V. If adjustment is necessary it should be rechecked within 2 days.

If further adjustment is necessary evaluation of charger and batteries is necessary to find and repair cause of drift.

Proper maintenance of battery charger and batteries can prevent damage to other components in the acutrol system. Connections are the most important item, all must be clean and tight.

Reliable operation of· the acutrol machine can be maintained when the battery charger and batteries are properly taken care of.

BI115345

Bulletin 89-017 Siemens Acutrol Battery Charger Maintenance page two

Any actions taken, as a result of comments contained in this Service Bulletin, are undertaken at your own expense. These actions shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise. .

If there are any questions concerning this procedure; contact: Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, WI Telephone: 414-768-4000 Facsimile: 414-768-4474

('

'=_~_~_-

BUCYRUS-ERIE COMPANY BUCYRUS-ERIE

SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172

(--

TELEPHDNE: 414-768-40.0.0.

BI115345

SERVICE BULLETIN Bulletin No.:

*REISSUED 4/12/1989 *ADDED A LINE IN SUBJECT

SUBJECT:

*

DATE: PAGE:

88-024 March 27, 1989 1 of 1

LINE FAULT MONITORING IMPROVEMENT FOR SIEMENS A.C. DRIVES ON DRAGLINES AND SHOVELS

NOTE: IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

An apparent potential for losing drive fuses on some particular line fault conditions has been recently investigated. It was found that time delay introduced in the line voltage monitoring circuit by a filter could result in a delayed shutdown in the event of an actual fault. The delayed shutdown could allow time for a fault as per above to occur. The original purpose of this filter was to eliminate sporadic nuisance tripping. The nuisance tripping can be eliminated in a better manner by protecting the latch gate of the monitor circuit. To accomplish this, two changes must be made on the 9210 card. This change is best done by a qualified electrical service engineer or as part of an electrical service call.

Change #1

Remove Cll from 9210 card.

Change #2

Connect a 12 or 15 nano farad capacitor from V56 pin 12 on 9210 to M buss 9210.

Note:

On some, particularly high impedance, distribution systems a small This must be less than 0.47 UFo

Cl1/9210 may remain necessary.

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Yisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474

Copyright 1989 Bucyrus-Erie Company 88-024

BUCYRUS-ERIE COMPANY

BUCYRUS-ERIE

SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172

(

•

TELEPHONE: 414-768-4000

BI115345

SERVICE BULLETIN Bulletin No.:

88-026 DATE: May 1, 1989 PAGE 1 of 4 SUBJECT:

SWING REGULATOR PERFORMANCE IMPROVEMENT ON P.W.M. ACUTROL SHOVELS AND 680-W DRAGLINES

NOTE: IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

(

The current design of the speed regulator in swing incorporates a speed ramp of nominally 1.5 seconds. In the event that an operator coasts the machine at some speed less than 100% and then accelerates in the same direction, it is possible that the machine will develop a noticeable regenerative torque prior to accelerating in the commanded direction. This can cause unstable and erratic machine performance. The reason for this is: the speed regulator compares N* wi th N and develops an M* which is the difference of these two. If the operator coasts for a period of time longer than the speed ramp the N* can become less than the N which switches the M* to regenerative until the speed ramp allows N* to climb over N following a speed command. This is illustrated in the chart following.

In the swing drive, which is torque regulated and speed clamped, there is no need for a speed ramp. As a direct result of this there is also no need for a speed ramp clamp. This service bulletin advises how this improvement can be accomplished.

1.

Following all normal procedures remove the 9215 card from the swing row only.

2.

Remove R18 entirely.

3.

Remove R145 entirely.

4.

Change R16 from 330K OHM to 3.3K OHM.

5.

Reinsert 9215 into swing row and startup normally.

·Copyright 1989 Bucyrus-Erie Company

88-026

BI115345

88-026 Swing Regulator Performance Improvement May 1, 1989 Page 2

Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474

_

Copyright 1989 Bucyrus-Erie Company

88-026

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Copyright

1~89

Bucyrus

Company Page 4

BUCYRUS-ERIE COMPANY

BUCYRUS-ERIE

(

•

SERVICE DEPARTMENT So. MILWAUKEE, \1\115. 53172 TELEPHONE: 414-768-4000

Revised: May 12. 1988 Part Number Corrected to 12580031 SUBJECT:

BI115345

SERVICE BULLETIN Bulletin No.: 88-005 DATE: March 22, 1988 PAGE 1 .of 3

IMPROVED DIPPER TRIP MECHANISM FOR MINING SHOVELS

It is essential that all appropriate safety measures such as found in the relevant machine maintenance manual are followed during the performance of this work.

Extensive field testing has shown that it is largely motor inertia which opens the dipper latch bar lever when dumping. The latch bar lever disengages the latch Within 0.3 seconds and strikes the upper limit Within 0.5. seconds. As a result of this, an electrical circuit has been developed to shut off the dipper trip motor prior to reaChing the upper limit. The benefits to the shovel operator are: 1)

reduced dipper trip rope wear, therefore extended life

2)

reduced mechanical wear on latch mechanism

3)

Eliminates dipper trip motor failure due to extended time at stall

(

Attached is the appropriate electrical schematic for your machine (using D.C. motor trip). You Will require one additional relay, B-E part number 12580031.

Although the installation is straightforward we recommend you enlist the services of your assigned Bucyrus-Erie Service Representative.

( Copyright 1989 Bucyrus-Erie Company

88-005

BUCYRUS-ERIE COMPANY BUCYRUS-ERIE

SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172

•

TELEPHONE: 414-768-4000

Revised: May 12. 1988 Part Number Corrected to 12580031 SUBJECT:

BI115345

SERVICE BULLETIN Bulletin No.: 88-005 DATE: March 22, 1988 PAGE 1 .of 3

IMPROVED DIPPER TRIP MECHANISM FOR MINING SHOVELS

It is essential that all appropriate safety measures such as found in the relevant machine maintenance manual are follo~ed during the performance of this ~ork.

Extensive field testing has sho~ that it is largely motot inertia ~h1ch opens the dipper latch bar lever ~hen dumping. The latch bar lever disengages the latch Il1thin 0.3 seconds and strikes the upper limit Il1thin 0.5 seconds. As a result of this, an electrical circuit has been developed to shut off the dipper trip motor prior to reaChing the upper limit. The benefits to the shovel operator are: 1)

reduced dipper trip rope ~ear, therefore extended life

2)

reduced mechanical ~ear on latch mechanism

3)

Eliminates dipper trip motor failure due to extended time at stall

Attached is the appropriate electrical schematic for your machine (using D.C. motor trip). You Il1ll require one additional relay, B-E part number 12580031.

Although the installation is straightfo~ard ~e recommend you enlist the services of your asSigned Bucyrus-Erie SerVice Representative.

Copyright 1989 Bucyrus-Erie Company

88-005

.----------_

...

.

BI115345

DIPPBll TIIIP AS BunT 101. VAlID LBOIWUl IfACHINBS

KODIPIlm DIPPBll TIIIP

TIM

Copyright 1989 Bucyrus-Erie Company

88-005 March 22, 1988 Page 2 of 3

BI115345

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11"

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Copyright 1989 Bucyrus-Erie Company

88-005 March 22, 1988 Page 3 of 3

SCBBKATIC

PP. 832-28

BUCYRUS-ERIE COMPANY BUCYRUS-ERIE SERVICE DEPARTMENT

: 'E:, ,;:

•

So. MILWAUKEE, WIS, 53172 TELEPHONE: 414-768-4000

BI115345

SERVICE BULLETIN Bulletjn No_.: 89-022 DATg:- November 29, 1989 PAGE 1 of 1

SUBJECT:

ELECTRIC MOTOR COUPLINGS/PINIONS MMD ALL SHOVELS

IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK. There has been reported incidents where motor pinions have come loose from the shaft causing pinion and mating gear failure. In one case a motor shaft cracked as well.

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On all machines there is a lock plate device which is required to keep the nut from turning once it is tightened. All motors have these listed on all AC and DC machines. The lock plate locks into the pinion/coupling as well as being bent over one flat of the nut - thereby locking it. Often in field replacement customer mechanics forget this device or possibly misunderstand its importance and throw it away. If this lock plate is omitted, the pinion or coupling will come loose.

Another point of importance is the matching tapers between the pinion/coupling and motor shaft. Always check the tapers with some type of blueing or chalk, etc. to assure the tapers match.

The motors usually have a rounded keyway bottom toward the inner end of the key and sometimes the key tries to ride up this curve as the pinion/coupling is installed which possibly causes it to lockup before it is full sealed against the shaft taper. Be sure the key is fitted on the sides and has at least .003 clearance at the top (between the bottom of the keyway in the pinion and the top of the key), Any actions taken as a result of comments contained in this Service Bulletin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474 Copyright 1989 Bucyrus-Erie Company

BUCYRUS-ERIE COMPANY

BUCYRUS-ERIE

SERVICE DEPARTMENT So. MILWAUKEE, WIS. 53172 TELEPHONE: 414-768-4000

BI115345

SERVICE BULLETIN Bu lIetin No.: 89-024 DATE: November 29, 1989 PAGE 1 of 1

SUBJECT:

NOTE:

HOIST AND CROWD CONTROLLER.REVERSAL ON ALL SHOVELS IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

From time to time we hear that someone wants to set up his machine for pull on the hoist to hoist, and push to lower the dipper. Usually, the rational given is to have uniform controller movement across all the shovels in that particular mine or else someone learned to operate that way. Rarely, we hear that someone wants the crowd controller reversed.

Officially, we at Bucyrus-Erie would like to have the controller movements as prescribed on the prints; but we also understand the owner/user problem of uniformi ty.

The procedure for changing controller direction is a simple mechanical change.

Remove the cover from the controller in question. Looking inside, remove the Allen head caps crews from the half bevel gear and reverse it to the opposite side of the pinion. This reverses the mechanical direction of the switch.

Electrically, NOTHING needs to be reconnected.

Recently a controller was reversed by just reconnecting the motor field wires only. Yes, this effectively reverses the required motion of the master switch (pull to hoist or pull to crowd) but could have just as easily caused a motor and generator armature failure, costing up to 50,000 to 60,000 dollars because the field strengthening contactor was not correct for this controller movement, the plugging relays were backward, etc. the wiring schematics were not per machine control, which can cause all sorts of hassles. The high costs of repairs was potential loss of generator and motor armature.

DO NOT REVERSE CONTROLLER MOTION· BY ELECTRICAL CONNECTION

Any actions taken as a result of comments contained in this Service Bull~tin are undertaken at your own expense and shall not be subject to reimbursement from Bucyrus-Erie as a warranty claim or otherwise.

If there are any questions concerning this procedure, contact Bucyrus-Erie Company 1100 Milwaukee Avenue South Milwaukee, Yisconsin 53172 Phone: 414-768-4000 Facsimile: 414-768-4474 Copyright 1969 Bucyrus-Erie Company