CAT Electric Rope Shovel 7295 Electric Rope Shovel Service Manual

®

BI010935 October 2012

Service Manual 7295 Electric Rope Shovel 141403

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SAFETY.CAT.COM

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Front of Machine

Model Cross Reference Chart

Serial Number Plate

Model Plate

Bucyrus Model

CAT Model

182M

7182

295 HD

7295 HD

295 HR

7295

395 HR

7395

495 HD

7495 HD

495 HR 495 HF

2

2

7495 7495 HF

Amendments and alterations to this publication are not subject to notification. Caterpillar Global Mining LLC reserves all rights to this publication. Its content is protected by copyright laws.

No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Caterpillar Global Mining LLC. Caterpillar Global Mining LLC declines any liability for direct or indirect consequences of printing errors. © 2012 Caterpillar Global Mining LLC.

Table of Contents BI010936

Service Manual COVER

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DISCLAIMER

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TABLE OF CONTENTS

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SECTION S - SAFETY

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SECTION 1 - INTRODUCTION

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SECTION 2 - LUBRICATION

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LUBRICATION SPECIFICATIONS

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SECTION 3 - PREVENTIVE MAINTENANCE

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SECTION 4 - SERVICE PROCEDURES

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SECTION 5 - BRAKES AND COUPLINGS

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SECTION 6 - COMPRESSED AIR SYSTEM

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SECTION 7 - AIR FILTRATION

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SECTION 8 - ENGINEERING DATA

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SIDE VIEW

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DECK PLAN

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SCHEMATICS - OPEN GEAR LUBE

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SCHEMATICS - GREASE

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SCHEMATICS - AIR

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BACK COVER

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TOC - 1 October 2012

Table of Contents BI010936

TOC - 2 October 2012

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Safety BI010937

S

Safety

Always refer to the safety information in this section of this manual before starting any maintenance procedure on this machine.

Safety Symbols ........................................................................................................................... 3 Safety Precautions ...................................................................................................................... 5 General Precautions: ......................................................................................................... 6 Maintenance Precautions: ................................................................................................. 7 Operating Precautions: ...................................................................................................... 8 Fire Prevention ........................................................................................................................ 9 Fire Extinguisher Locations ...................................................................................................... 10

Common Safety Features ........................................................................................................ 11 Emergency Lighting ............................................................................................................... 11 Emergency Lighting Locations .................................................................................................. 11

Mine Signal ............................................................................................................................ 12 Mine Signal Switch ................................................................................................................... 12 Mine Signal Horn Location ....................................................................................................... 12

Dual Mirrors ........................................................................................................................... 13 Right Side Mirror ...................................................................................................................... 13

Propel Back-up Alarm ............................................................................................................ 14 Propel Back-up Horn Location ................................................................................................. 14

Emergency Stop Pushbutton .................................................................................................. 15 Emergency Stop Pushbutton Location ..................................................................................... 15

Vertical Boarding Ladder ........................................................................................................ 15 Cameras ................................................................................................................................ 15 Warning Signs and Decals ........................................................................................................ 16

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Safety BI010937

S-2 October 2012

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Safety BI010937

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

The safety alert symbols displayed here and throughout this manual are used to call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine.

Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions.

If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional service representative or the manufacturer.

The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.

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

This signal word denotes a hazardous situation which, if not avoided, could result in death or serious injury.

This signal word denotes a hazardous situation which, if not avoided, could result in minor or moderate injury.

This signal word indicates a situation related to protection of property. It is not directly associated with a hazard or hazardous situation and is not used in place of DANGER, WARNING, or CAUTION.

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

STORED ENERGY! These signal words are used when maintenance on or around indicated hardware and/or components could potentially release dangerous amounts of preloaded tension or pressure. Failure to properly support indicated components and/or release the preloaded energy could result in death, severe personal injury, or damage to the machine.

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

S-4 October 2012

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Safety Precautions

This manual provides information and data for the maintenance and/or operation of this machine. All electrical equipment must be serviced by qualified individuals who have been properly trained to work with high voltage systems and variable frequency AC drives. Failure to comply could result in personal injury or death.

Do not attempt mechanical or electrical maintenance on this machine without a full understanding of each component’s operation and function. Components utilizing electrical power, air pressure, hydraulic pressure and compression or tension springs for operation must be deactivated and isolated prior to disassembly.

The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.

HIGH VOLTAGE! The need for a power line grounding circuit adequate for the machine cannot be overemphasized. Without a good grounding system, high voltages exist between the machine and the ground. The portable trail cable and power lines supplying electric energy to the machine must have a ground wire, ample in capacity, running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult your local electrical supplier for details.

Due to the inherent dangers in the operation of high voltage electrical equipment, a safe grounding system is required that includes ground conductors in the cable, a neutral grounding resistor, and related relays and switchgear. A ground continuity check system is also recommended.

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General Precautions: •

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

•

Keep hands, feet and clothing away from rotating parts.

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

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

•

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

•

Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested method of cleanup.

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

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

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Keep your work area organized and clean. Wipe up oil or spills of any kind immediately.

Keep tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.

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

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Electrical cords and wet metal floors make a dangerous combination.

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Regularly inspect for any loose bolts or locking devices and properly secure them.

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

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Check limit switches for proper operation.

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

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Mechanical Brakes are designed for use as static holding brakes only. Use as a motion (dynamic) brake in emergency situations only.

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Use proper interior and exterior lighting.

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Install and maintain proper grounding and ground fault protection systems.

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

S-6 October 2012

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Maintenance Precautions: •

Do not wear rings, wristwatches or loose fitting clothing when working on machinery. They could get caught on moving parts causing serious injury.

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

•

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

•

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

•

Never utilize the machine air or hydraulic systems for support when working on the machine.

Deactivate or isolate the entire system prior to performing maintenance.

•

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

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Cranes and hoists must be of sufficient capacity to lift the heavier components (gearcases, etc.) Always work within the limitations of the equipment being utilized.

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

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

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

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

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

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When using an oxy/acetylene torch, always wear welding goggles and gloves. Keep a charged fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart.

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Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable.

Use hammers, punches and chisels only when absolutely necessary. Always be sure to wear safety glasses.

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

•

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

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

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

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Safety BI010937

•

Always wear approved rubber gloves and use insulated hooks or tongs when handling trail cable.

Operating Precautions: •

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

•

When in doubt about the noise level, wear approved hearing protection.

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

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

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Do not allow unauthorized personnel on board the machine while in operation.

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Use audible signals to warn of machine movements. A signal horn button is provided for this purpose.

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Do not propel until the travel route has been cleared of obstructions.

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Do not propel the machine on a slope greater than that specified in the Operator’s Manual SLOPE LIMITATIONS.

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

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Limit the amount of cable being pulled by the machine. Pulling too much cable will damage both the cable and the machine.

S-8 October 2012

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Safety BI010937

Fire Prevention •

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

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DO NOT smoke while handling flammables or when near batteries.

•

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

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

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

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

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

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

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

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

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

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

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Safety BI010937

Fire Extinguisher Locations

S - 10 October 2012

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Common Safety Features Most shovels can be equipped with the following safety features.

Emergency Lighting In case of a power failure, there are 11 emergency lights and 2 self-luminating exit lights located throughout the machinery house and near walkways similar to the figure below.

Emergency Lighting Locations

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Safety BI010937

Mine Signal A mine signal switch is located on either side of the machine at the back of the ballast box. A pull cord, which can be reached from the ground, activates an air horn located at the top of the lube room.

Mine Signal Switch

Mine Signal Horn Location S - 12 October 2012

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Safety BI010937

Dual Mirrors Dual convex mirrors are mounted outside right and left hand side of the operator’s cab. Mirrors can be mounted and adjusted for best operator’s viewing.

Right Side Mirror

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Safety BI010937

Propel Back-up Alarm In addition to propel warning lights, machines can be equipped with a propel back-up warning alarm.

The horn is usually mounted on the right side of the ballast box, bellow the deck extension.

Propel Back-up Horn Location

S - 14 October 2012

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Safety BI010937

Emergency Stop Pushbutton The machine stop/emergency stop pushbutton is located on the right operator’s console. It is used to remove power from the machine motions after the motions have been stopped in the normal manner. A second purpose of the pushbutton is to stop the machine under operational emergency conditions. For more information refer to the Operator’s manual.

Emergency Stop Pushbutton Location

Vertical Boarding Ladder The vertical boarding ladder is one of the means for boarding the machine, located on the left-hand side of the machine, at the rear of the machinery house. When the ladder is not latched in place the operator's controls are deactivated.

Cameras There are 4 cameras located on the machinery house and boom. Video camera monitors are located in the operator’s cab above the front windshield.

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Warning Signs and Decals The placards depicted are mounted on the machine as delivered from the manufacturer. These hazard warning placards convey information to operators, maintenance personnel, or anyone who will be on or near the machine. The information is designed to help prevent situations which may result in injury to personnel or damage to the machine.

DANGER TO PREVENT INJURY OR INJURY MAY RESULT FROM

DEATH CONTACTING ELECTRIC LINES

TO PLACE ANY PART OF THIS MACHINE OR LOAD WITHIN 10 FEET OF HIGH VOLTAGE LINES OF 50,000 VOLTS OR LESS FOR MINIMUM CLEARANCES OF HIGH VOLTAGE LINES IN EXCESS OF 50,000 VOLTS SEE YOUR LOCAL, STATE AND FEDERAL REGULATIONS 736444K1

TO BOARD MACHINE PULL CORD TO SOUND HORN. DO NOT LOWER BOARDING LADDER UNTIL MACHINE IS COMPLETELY STOPPED. C104093

DANGER

DANGER TO PREVENT INJURY

STAY CLEAR WHILE MACHINE IS OPERATING C102020

831905K1

TO PREVENT HEARING LOSS

TO PREVENT ACCIDENTS AND BODILY INJURY: THIS MACHINE SHALL ONLY BE OPERATED AND MAINTAINED BY TRAINED AND EXPERIENCED PEOPLE WHO HAVE READ AND UNDERSTOOD THE OPERATOR AND SERVICE MANUAL. IT IS THE USER’S RESPONSIBILITY TO FOLLOW THE MANUFACTURER’S INSTRUCTIONS ON MACHINE OPERATION AND APPLICATION AND TO OBSERVE ALL PERTINENT LAWS AND REGULATIONS.

WHEN EXPOSURE LIMIT IS REACHED FOR EXPOSURE LIMITS CONSULT LOCAL, STATE AND FEDERAL REGULATIONS 740168K1

signs_w

S - 16 October 2012

COPIES OF THE INSTRUCTION MANUAL MAY BE OBTAINED BY WRITING TO THE BUCYRUS INT. CO., SO. MILWAUKEE, WI 638669K1

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Safety BI010937

Stored Energy Decals

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S - 17 October 2012

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S - 18 October 2012

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Introduction BI010938

1

Introduction

Always refer to the safety information in this section of this manual before starting any maintenance procedure on this machine.

About This Manual ...................................................................................................................... 3 Purpose ................................................................................................................................... 3 Organization ............................................................................................................................ 3 Revisions................................................................................................................................. 3 Precautions and Disclaimers .................................................................................................. 3 Terminology ............................................................................................................................. 4 Contact .................................................................................................................................... 4 Safety - Swinging Restraint & Ballast Box Support ................................................................ 5 Ballast Box Support ................................................................................................................. 5 Swinging Restraint .................................................................................................................. 6 Machine Overview ..................................................................................................................... 8 Nomenclature .............................................................................................................................. 8

Lower Works ................................................................................................................................ 9 Truck Frame and Crawlers .......................................................................................................... 9

Crawlers ................................................................................................................................ 10 Crawler Assembly ...................................................................................................................... 10

Truck Frame .......................................................................................................................... 11 Truck Frame .............................................................................................................................. 11

Swing Rack ........................................................................................................................... 12 Swing Rack and Roller Circle ..................................................................................................... 12

Roller Circle ........................................................................................................................... 13

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Introduction BI010938 Roller Circle Assembly ............................................................................................................... 13

Propel Machinery ................................................................................................................... 14 Propel Machinery ........................................................................................................................ 14

Collector Rings ...................................................................................................................... 15 Rotating Deck ............................................................................................................................ 17 Revolving Frame ................................................................................................................... 17 Center Pintle .......................................................................................................................... 17 Deck Extensions ................................................................................................................... 19 Deck Extensions and Ballast Box .............................................................................................. 19

Ballast Box ............................................................................................................................ 19 Machinery House ................................................................................................................... 20 Boarding Stairs ...................................................................................................................... 20 RH Boarding Stairs .................................................................................................................... 20

Retractable Boarding Ladder................................................................................................. 21 A-Frame ................................................................................................................................ 22 A- Frame and Front End Support Components ........................................................................... 22

Hoist Machinery ..................................................................................................................... 23 Hoist Machinery - Plan View ....................................................................................................... 23

Swing Machinery ................................................................................................................... 24 Swing Machinery Components .................................................................................................... 24

Crowd Machinery .................................................................................................................. 25 Crowd Machinery Components ................................................................................................... 25

Operator’s Cab ..................................................................................................................... 26 Compressed Air System ....................................................................................................... 27 Automatic Lubrication System ............................................................................................... 28 Lubrication Room ....................................................................................................................... 28

Lube Reservoir fill / Overflow Plumbing ................................................................................. 29 Lube Reservoir Fill / Overflow Plumbing ..................................................................................... 29

Front End Equipment ............................................................................................................... 30 Suspension Strands .............................................................................................................. 30 Boom ..................................................................................................................................... 31 Boom Assembly ........................................................................................................................ 31

Running Ropes ..................................................................................................................... 32 Ropes - General Arrangement .................................................................................................... 32

Saddle Block ......................................................................................................................... 33 Dipper Handle ........................................................................................................................ 34 Dipper .................................................................................................................................... 35 Dipper Assembly ........................................................................................................................ 35

Padlocks................................................................................................................................ 36 Left and Right Padlocks ............................................................................................................. 36

Dipper Trip ............................................................................................................................. 37 Dipper Trip Motor and Dipper Trip Sheave .................................................................................. 37

General Estimated Component Weights ................................................................................ 38

1-2 October 2012

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Introduction BI010938

About This Manual Purpose This manual is designed to assist in the operation and maintenance of your machine. Inside, you will find the following information: guidance on machine operation, disassembly procedures, and maintenance procedures.

NOTE: This is not a parts book and cannot be used to order parts. A separate, detailed parts book for this machine has been supplied with the machine.

Organization •

A main table of contents (TOC) is your guide to topics and subtopics. It is located at the front of the manual. Main topics are listed as numbered Sections, with subtopics listed beneath (and indented). Subtopics include the main topic’s section number.

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Additionally, each section contains its own TOC.

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In the electronic version, all TOC items are hyperlinked to their respective topics.

Revisions This manual may be revised without notice. The most recent electronic version is available online.

Precautions and Disclaimers •

Carefully study and follow all procedures in this manual. Safety guidelines are intended to prevent accidents and are provided in the interest of all mine personnel. Overall safety depends on the use of good judgment and the alertness of the entire mining crew.

•

It is the owner/mine’s responsibility to perform the necessary risk assessment to outline proper safety precautions. A minimum of unplanned machine downtime and more reliable machine operation should result when a systematic and thorough maintenance/service procedure is adhered to for this machine.

•

It is the policy of the manufacturer to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations to install such changes on machines sold previously. Due to this ongoing program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve our machines.

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Introduction BI010938

Terminology •

The terms left, right, front, and rear refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.

•

On the cover and at the bottom of each page there is an alphanumeric code to identify the manual, formatted as follows: XXnnnnnn-YY • XX represents the manual type. Below is a list of all manual types.

• nnnnnn represents the serial number for machine-specific manuals, or a generic manual number intended for several machines.

• YY represents the language code. Below is a list of common language codes.

Code

Type

Code

Language

SM OM EM PM TM ZM AM VM MM

Service Operation Electrical Parts book Troubleshooting Electrical training Addendum Vendor Miscellaneous

EN ES FR PT

English Spanish French Portuguese

For example, manual code EM141455-ES is an electrical manual written in Spanish for machine #141455.

Contact Should you require additional information or factory service assistance, contact your regional service representative or: Caterpillar Global Mining LLC 6744 S. Howell Ave. Oak Creek, WI, USA 53154 Telephone (+1) 414.768.4000

1-4 October 2012

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Safety - Swinging Restraint & Ballast Box Support Ballast Box Support

Before performing any maintenance on the mining shovel, it should be resting on a firm, level surface.

Any mining shovel field work that requires the removal or lowering of the boom must incorporate additional support of the ballast box. The supports may be wooden cribbing or steel structures.

Two supports positioned side-by-side on level ground are recommended. These supports are intended to accept vertical loads only. To prevent machine rotation use the swing brakes, cable stays, welded ties, etc. Refer to “SWING RESTRAINT”.

When electric-powered, cable-style mining shovels are properly ballasted and operational, the center of gravity for the machine's upper works lies within the roller circle area. This assumes that the boom is attached to the machine and in its elevated, working position. As such, the machine should not be prone to tipping.

Boom removal or lowering will cause the center of gravity to shift toward the ballast box, decreasing machine stability. Stability is further dependent on the orientation of the upper works relative to the undercarriage. The machine may tip more easily over one of the four quadrants of the crawler mounting than it may over others.

Normally the machine is more likely to tip over the rear-most lower-roller than over the side of a crawler. Therefore, with the boom removed and the ballast box sitting over the rear of the crawlers, the machine may be unstable. Because ballast quantities differ from machine to machine and model to model, it is recommended that the ballast box be supported before beginning any procedure to lower and/or remove the boom.

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Introduction BI010938

Swinging Restraint

Before performing any maintenance on the mining shovel, it should be resting on a firm, level surface. A small ground slope is enough to cause the machine to freely rotate if the brakes are not set or other restraints are not used. Once moving, it will keep going.

The following shows the relation between an out-of-level or slope and the resulting difference in elevation over a 14 ft. swing rack: Slope

%

Difference in Elevation

0.25o

0.4%

0.75”

1.0o

1.7%

2.9”

5.0o

8.7%

14.7”

Where possible, all work on the swing brakes, motors, gearcases, or rack pinions should occur with the dipper attached to the machine and the full weight of the dipper on the ground. If the dipper is not resting firmly on the ground, then an external means of preventing machine upper works rotation is required. The preferred method to prevent machine rotation is to use a pair of one inch diameter steel cables to tie the upper works to the lower works. Other alternatives such as welded plates etc. can also be used. Contact your regional service representative or the manufacturer.

Mining shovels rotate using multiple swing units. Power is transferred from electric motors through individual gearcases, to pinions and into a fixed swing rack. Electric motor control prevents inadvertent machine rotation during operation. Should machine electric power be lost, spring-set brakes on the swing drive motors lock the geartrain to prevent machine rotation.

When working on the brakes, motors, or geartrains, it is an accepted practice to set the dipper on the ground. The weight of the dipper and handle will prevent machine rotation. EVEN IF ALL BRAKES, MOTORS, OR SWING GEARCASES ARE REMOVED the machine should not rotate.

In certain circumstances it may not be possible to rest the full weight of the dipper firmly on the ground. For instance, the dipper, handle or the boom may not be attached to the machine.

To prevent machine rotation, with any of the major structures removed, two swing motor brakes should be set. A single brake in good operational condition is acceptable. However, a minimum of two brakes is recommended due to the possibility that the proper operation of a single brake may be unknown.

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ON MACHINES USING PLANETARY DUAL-OUTPUT SWING DRIVES, BOTH SWING PINIONS PER DRIVE MUST BE ENGAGED WITH THE SWING RACK IN ORDER FOR THE SWING BRAKE TO BE EFFECTIVE. The internal differential drive in the gearcase allows one pinion to rotate, even if the brake is set, when the other pinion has been removed.

An external means of preventing machine rotation must be used - if the dipper is not resting firmly on the ground and if any of the following are true: •

Two brakes are not effectively set and coupled to the motors, or

•

The motors and geartrain are not fully coupled to the swing pinions, or

•

The swing pinions are not engaged to the swing rack.

The preferred method to prevent machine rotation is to use a pair of one inch diameter steel cables to tie the upper works to the lower works. Other alternatives such as welded plates etc. can also be used. Contact your regional service representative or the manufacturer.

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Introduction BI010938

Machine Overview This Electric Rope Shovel is designed and constructed to provide efficient service under the most severe conditions. The machine is built to the highest possible standards and will provide trouble free operation if properly maintained. This section of the manual introduces the machine and its functional capabilities and limitations.

Nomenclature

1-8 October 2012

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Introduction BI010938

Lower Works The lower works is comprised of the truck frame, right and left crawler frames, crawler belts, propel machinery, swing rack and roller circle.

Truck Frame and Crawlers

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Introduction BI010938

Crawlers This machine is provided with a crawler system composed of 2 independently-driven crawler frame assemblies, one on each side of the truck frame. Each crawler has its own belt driven by a sprockettype drive tumbler. Individual crawler links are heavy alloy steel castings connected by heat treated pins. Innovative drive tumblers made from large diameter steel castings have lugs extending beyond the tumbler rims. They are mounted on forged alloy steel shafts which turn on large anti-friction bearings mounted within the crawler frame. The sprocket type lugs provide a large area of contact against the crawler links, extending the life of both links and tumblers.

Lower rollers rotate on forged steel shafts mounted within the crawler side frames. Eight smaller rollers and 1 large roller per frame are specially suited to withstand the periodic single point ground reaction caused by uneven pit floors. Slide bars on top of each frame support the upper crawler belt, reducing propel friction and drag. These side frames are stress relieved weldments comprised of steel castings and cold weather steel plates. The crawler assemblies are bolted to the truck frame with large diameter rods and torque nuts. Each crawler belt can be independently adjusted for tension.

Crawler Assembly

1 - 10 October 2012

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Introduction BI010938

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

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

Truck Frame

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1 - 11 October 2012

Introduction BI010938

Swing Rack The swing rack is a large diameter external tooth gear mounted on the top of the truck frame concentric with the center pintle bore. The rack is a 4-piece gear bolted to the truck frame.

Swing Rack and Roller Circle

1 - 12 October 2012

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Introduction BI010938

Roller Circle The roller circle is composed of the upper rails, lower rails, thrust rails, 54 tapered rollers and inner/ outer roller cages. The lower rail segments are secured to the top surface of the swing rack forming a continuous rolling path for the rollers. The upper rails are attached to the bottom of the revolving frame, fore and aft of the center pintle. Upper rail ends are tapered to provide a smooth approach for the rollers. Rollers are tapered to ensure non-skid contact with rails. The rollers are spaced and aligned with pins and low maintenance polyurethane bushings.

Roller Circle Assembly

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7295 Electric Rope Shovel

1 - 13 October 2012

Introduction BI010938

Propel Machinery The propel machinery is driven by two AC motors, each horizontally mounted to the crawler frames.

Each motor is coupled to a right-angled planetary gearcase high up off the pit floor for protection from water and rock damage. One spring-set, air-released, disc brake is mounted to each of the two motors. The dual planetary configuration with separate drive motors permits straight ahead or reverse propel as well as counter rotation steering.

Propel Machinery

1 - 14 October 2012

7295 Electric Rope Shovel

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Introduction BI010938

Collector Rings High voltage collector rings between the revolving frame and truck frame transfer electric power from the truck frame to the rotating deck. Electric power enters the truck frame between the propel motors and is transferred by means of collector ring shoes to the collector rings. The shoes are mounted between the cast center pintle hub and the swing rack.

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7295 Electric Rope Shovel

1 - 15 October 2012

Introduction BI010938

The low voltage collector rings transfer power from the revolving frame back to the propel motors.

The propel collector rings provide control to the propel motors and power for the propel blower motor.

Collector Rings - Propel and Low Voltage (Rear Section View)

1 - 16 October 2012

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Introduction BI010938

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

Revolving Frame

The revolving frame is the main structural member of the rotating deck. It is a welded, stress relieved structure with integral lugs for mounting the A-frame, crowd machinery and boom. Provisions are made for mounting deck extensions, operator’s cab, ballast box and swing gearcases. Machined pads on the deck locate the hoist drive motor and machinery frames.

Refer to the following page for a view of the revolving frame assembly with deck extensions and ballast box.

The revolving frame is connected to the truck frame by the center pintle.

Center Pintle

HIGH VOLTAGE! EXTREME CARE MUST BE EXERCISED AT ALL TIMES WHEN PERFORMING MAINTENANCE IN THE CENTER PINTLE AREA. High voltage can cause serious or fatal injury. Installation, operation and servicing of components should be performed only by qualified personnel. ALWAYS DISCONNECT the electrical power BEFORE accessing the center pintle area.

The center pintle is a large diameter, hollow cylindrical forging with a flange at the top. It is threaded at the bottom with a lower locknut used to hold it in place. A bronze coated steel core spherical thrust washer between the lower locknut and the bottom surface of the truck frame provides a wear surface for pintle loads. The upper locknut at the top of the center pintle is doweled and bolted to the revolving frame to keep the center pintle from rotating.

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

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Introduction BI010938

1 - 18 October 2012

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Introduction BI010938

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

Deck Extensions and Ballast Box

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

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Introduction BI010938

Machinery House

The machinery house encloses the revolving frame, ballast box and deck extensions. It is constructed of self-supporting steel panels with built-in framing. Removable roof sections are provided over the swing machinery and to the side and rear of the A-frame. The house also provides mounting for the air ventilation and pressurization system. A separate electrical room is located over the ballast box.

Platforms and stairs facilitate access to the sides and tops of the house for inspection and maintenance purposes. Boarding stairs permit easy access onto the machine.

Boarding Stairs A set of boarding stairs is attached to the machinery house platform on the right side of the machine.

When lowered, the stairs allow entrance to the machinery house from ground level. To lower the stairs, a chord attached to the stairway is reachable from the ground. The stairs must be in the raised position to enable the operator’s controls.

STORED ENERGY! System may be under hydraulic pressure which can cause severe personal injury or death. Shut down pump and relieve system of all pressure before removing components.

RH Boarding Stairs

1 - 20 October 2012

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Introduction BI010938

Retractable Boarding Ladder A vertical, retractable boarding ladder is attached to the machinery house platform on the left side of the machine. After use, the ladder automatically returns to its stored position aided by two 200 lb. counterweights that move vertically inside the ladder’s channels.

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Introduction BI010938

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

A- Frame and Front End Support Components

1 - 22 October 2012

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Introduction BI010938

Hoist Machinery The hoist machinery consists of a motor coupled to two gear reductions which drive the hoist drum. A spring-set, air-released disc brake is mounted to the motor. A hoist rotary encoder limits hoist travel. The hoist motor is connected to the motor pinion shaft by a multiple coupling shaft assembly.

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

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

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

Hoist Machinery - Plan View SM141403-EN

7295 Electric Rope Shovel

1 - 23 October 2012

Introduction BI010938

Swing Machinery

Swing Machinery Components

The swing machinery is mounted on both the left and right sides of the revolving deck. Each machinery installation consists of a blower-cooled electric motor mounted vertically on top of the gearcase. The motor drives the gear system through a single input coupling. Each swing motor is equipped with a spring-set, air-released disc brake. The gearcase includes injectors that provide positive lubrication to the critical bearing surfaces of the gearcase. The gearcase transmits torque to a single pinion shaft. The pinion at the bottom of the shaft meshes with the swing rack on the lower works.

1 - 24 October 2012

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Introduction BI010938

Crowd Machinery The crowd machinery is located at the front, center of the revolving frame. It consists of a motor, spring-set, air-released disc brake, drum and gearing. A crowd limit switch prevents overtravel of the dipper handle. The entire machinery unit can be removed from the machine should maintenance or overhaul become necessary.

Crowd Machinery Components

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

A spring set, air released disc type brake is mounted to the RH gearcase and connected to the crowd motor using a motor coupling assembly.

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1 - 25 October 2012

Introduction BI010938

Operator’s Cab The isolated and elevated operator’s cab at the right, front of the machinery house provides a comfortable, safe and efficient working environment for the operator. Sufficient space is provided for the fully adjustable operator’s seat, a helper’s seat and the standard operator’s display panel.

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

A one-piece front window is supplied in a rugged, easy-to-change frame. Transparent sun shades are provided in front and side windows.

An air conditioner and pressurizing unit utilizes environmentally friendly 134a refrigerant in the cooling system. Interior ducting distributes the airflow to best suit the comfort of the operator.

1 - 26 October 2012

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Introduction BI010938

Compressed Air System The compressed air system consists of a rotary screw type air compressor, air receiver, air brakes, controls and center pintle air swivel. Hydraulic high pressure hose is used throughout. The air system is used to operate all machinery motion brakes and lubrication components and to perform various other functions.

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1 - 27 October 2012

Introduction BI010938

Automatic Lubrication System The lube system is located in an insulated, double wall, lube room which can be heated for cold weather operation. A one ton (907 kg) monorail-mounted electric chain hoist is provided to be used to raise supplies from the ground onto the left house platform and into the lube room. Lube points on the roller circle rollers, electric motors, suspension rope pins and some dipper pins are manually accessed. All other lube points are fed from the automatic system or by oil bath.

A single-line automatic lubrication system applies open gear lubricant (OGL) and grease via a programmable logic controller (PLC). The system has four lube pumps (two for OGL and two for grease), each feeding individual PLC controlled circuits. Lincoln 75:1 air powered pumps are mounted on each of the two 85 gallon reservoirs. High pressure hoses with reusable fittings are utilized.

Lubrication Room

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

1 - 28 October 2012

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Introduction BI010938

Lube Reservoir fill / Overflow Plumbing

Lube Reservoir Fill / Overflow Plumbing

The lube reservoir fill/overflow plumbing is located in the support structure directly below the lube room at the front, left side of the machine. Lubricants can be added at this location. The overflow connections are also located here. DO NOT plug the overflow connections.

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Introduction BI010938

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

Suspension Strands The suspension strands are designed to maintain the proper boom angle. These are fixed-length strands that support the entire weight of the boom and the load.

1 - 30 October 2012

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Introduction BI010938

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

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

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

Boom Assembly

The boom is supported by four pre-stressed suspension (structural) strands attached to equalizer links on the A-frame. These inherent long life structural strands carry the working loads of the front end equipment. A boom limit switch with soft setdown prevents boom jacking shock loads.

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7295 Electric Rope Shovel

1 - 31 October 2012

Introduction BI010938

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

Ropes - General Arrangement

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

1 - 32 October 2012

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Introduction BI010938

Saddle Block The saddle block is positioned between the boom side girders in the mid-section of the boom. It pivots on manganese-bronze bushings about the shipper shaft. It acts as a guide for the longitudinal movement of the dipper handle. The free-floating design of the handle in the saddle block eliminates handle torsion.

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1 - 33 October 2012

Introduction BI010938

Dipper Handle The dipper handle assembly is a weldment consisting of a large diameter tube and a handle end where the machine’s dipper is attached.

The handle has a take-up mechanism that removes slack from the retract rope during operation. At the rear of the assembly is a fixed half-sheave for the crowd rope. The dipper tube moves in and out within the saddle block during operation.

1 - 34 October 2012

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Introduction BI010938

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

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

Snubbers dampen the door’s swinging action.

Dipper Assembly

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Introduction BI010938

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

Left and Right Padlocks

1 - 36 October 2012

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Introduction BI010938

Dipper Trip The dipper trip is a wire rope activated dipper door trip mechanism driven by 2 electric motors through gear reduction mounted on the boom near the boom foot.

Dipper Trip Motor and Dipper Trip Sheave

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Introduction BI010938

General Estimated Component Weights

These are estimated weights only. Contact your service representative for the exact weight of components on your specific machine before rigging and lifting.

Quantity

Weight Each (U.S. Pounds)

Frame & Swing Rack Components Roller Frame Assembly Roller, Roller Frame Guard, Roller Circle Guard, Roller Circle Revolving Frame Center Pintle Support, Crowd Machinery Base, Crowd Motor Rail, Upper-Center Rail, Center-Upper Segment, Rail Rail, Upper End Rail, Upper End Pintle, Center Sleeve, Center Pintle Lock Nut, Lower, Center Pintle Thrust Washer, Center Pintle Lock Nut, Upper, Center Pintle Pin, Boom Foot Pin, A-Frame Swing Rack Assembly Swing Rack Rail, Lower Rail Segment Truck Frame Assembly Hub, Center Pintle Bushing, Center Pintle Cover, Bottom Plate Cover, Plate Cover, Manhole 1 - 38 October 2012

1 54 1 1 1 1 2 1 4 4 2 2 2 1 1 1 1 1 2 4 1 1 15 15 1 1 1 1 1 3

7295 Electric Rope Shovel

17,330 290 100 90 80,180 5,680 820 580 120 230 220 140 140 7,170 5,210 1,080 330 480 320 300 23,510 21,000 230 220 103,440 2,810 270 730 110 60 SM141403-EN

Introduction BI010938

Quantity

Weight Each (U.S. Pounds)

Propel Components Motor, Propel/Guards Assembly Propel Motor Propel Blower Brake, Propel Adapter, Propel Brake Coupling, Propel Guard, Propel Coupling Support, Propel Motor Duct Assembly, Propel Blower Inlet Guard Crawler Components Crawler Assembly Crawler Assembly, RH Crawler Assembly, LH Crawler, Frame Weldment, RH Crawler, Frame Weldment, LH Flange, Mounting Retainer Roller, Load, Rear Roller, Load, Assembly Roller, Front Idler Sprocket, Crawler Shaft, Roller, Front Shaft, Roller, Rear Adjusting Block Assembly Shaft, Idler Shaft, Main Propel Bearing, Roller, Crawler Sprocket Rod, w/Torquenut Assembly Gearcase Assembly, Propel Cabinet, Lube, Crawler Belt, Crawler Link, Crawler, 72 Inch

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1 2 2 2 2 2 2 2 2 2

17,130 4,000 230 490 230 140 80 2,960 220 130

1 1 1 1 1 2 2 2 16 2 2 16 2 4 2 2 2 40 2 2 2 96

217,630 93,990 93,990 57,910 57,910 2,680 190 2,230 1,440 3,480 4,980 410 530 460 1,060 3,180 340 80 12,600 330 68,950 1,370

7295 Electric Rope Shovel

1 - 39 October 2012

Introduction BI010938

Quantity

Weight Each (U.S. Pounds)

Operator Cab Components Operator Cab Assembly Operator Cab, FOPS Operator Cab Support Console, Operator Control Door & Frame Assembly Glass, Door Window, Front Assembly Base, Operator Seat Duct Assembly, Air Conditioner Air Conditioner Ducting, Air Conditioner

1 1 1 1 1 1 1 1 1 1 1

10,790 6,970 5,950 320 280 50 460 150 310 930 100

Collector Ring Components Housing, Collector Ring, Front Housing, Collector Ring, Rear Guard, Hose Support, Swivel Housing Air Swivel, 4-Line Ring, Collector Ring, Collector Ring, Collector Ring, Collector Ring, Collector Support, Shoe

1 1 1 1 1 1 1 1 1 1 2

140 140 90 710 150 130 100 80 60 150 60

Boom & Dipper Handle Components Boom Assembly, 59ft Hub, Shipper Shaft Foot, Boom Bushing, Tube Bumper Assembly, Boom Sheave, Boom Point Shaft, Boom Point Housing, Boom Point , RH Housing, Boom Point , RH Housing, Boom Point , LH Housing, Boom Point , LH

1 2 2 4 2 2 2 1 1 1 1

85,300 1,650 850 90 1,630 4,130 1,130 880 870 880 870

1 - 40 October 2012

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Introduction BI010938

Quantity

Weight Each (U.S. Pounds)

Boom & Dipper Handle Components (cont.)

Bearing, Boom Point Shipper Shaft

2 1

280 4,500

Dipper Trip Components Base, Dipper Trip Guard, Dipper Trip Drum Drum, Dipper Trip Gear, Dipper Trip Support, Deflector Support, Dipper Trip Pad, Mounting, Dipper Trip, Rear Pad, Mounting, Dipper Trip, Front Motor, Dipper Trip Rope, Dipper Trip

1 1 1 1 1 1 1 1 1 1

750 70 100 160 100 200 100 130 700 80

Swing Machinery Retainer, Bearing, Vertical Swing Shaft Pinion, Vertical Swing, Induction Gear, Swing Bearing, Taper Roller Bearing, Roller Guard, Swing Pinion Retainer, Bearing, Intermediate Shaft Pinion, Shaft, 2nd Reduction Bearing, Taper, Roller Gearcase & Cover Cover, Swing Gearcase Gearcase, Swing Hub, Swing Gearcase Gear, Intermediate Swing Shaft Motor, Swing Blower, Swing Motor Adapter, Swing Blower Swing Brake Adapter, Swing Brake

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

90 1,110 1,710 100 180 110 100 220 100 6,580 1,670 5,880 1,790 1,030 3,600 230 1,760 490 210

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1 - 41 October 2012

Introduction BI010938

Quantity

Weight Each (U.S. Pounds)

Crowd Machinery Crowd Frame Motor, Crowd Blower, Crowd Motor Duct Assembly, Crowd Motor Blower Brake, Crowd Crowd Drum Coupling, Crowd Input Shaft Rope, Wire, Crowd & Retract Gear,1st Reduction, Crowd Pinion, Shaft, 1st Reduction Guard, Pinion, Crowd Machinery Guard, Gear - Crowd Guard, Gear - Crowd Pinion, 2nd Reduction Shaft, 1st Intermediate, Crowd Machinery Bearing, Roller Pinion, Shaft, 3rd Reduction Gear, 2nd Intermediate Bearing, Roller Bearing, Roller End Cap Bearing, Spherical Roller Gear, Crowd Drum Cap, Bearing - Crowd Pin, Crowd, Front Guard, Crowd Whole Split Cover, Crowd Gearcase Cover, Plate

1 - 42 October 2012

1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 4 1 1 1

7295 Electric Rope Shovel

14,800 3,500 200 270 490 12,670 1,690 70 1,380 170 130 90 200 110 1,260 60 1,920 1,300 120 60 80 110 3,990 500 70 90 1,400 100

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Introduction BI010938

Quantity

Weight Each (U.S. Pounds)

Machinery House Components Machinery House Ballast Box Ballast Lube Room - Machinery House Lube Reservoir Lube Pump Heater, Lube Room Hoist, Lube Room Heater, Control Room Air Compressor Support, Auxiliary Winch Drum, Auxiliary Winch Rope, Wire Duct, Transition Bleed Duct Duct, Transition Duct, Cleanout Duct, Cleanout Filter, Air -15 Double Cell Filter, Air - 9 Double Cell Hood, Dual Fan Leg, Front, A-Frame Foot, A-Frame Pin, A-Frame Back Leg, A-Frame Platform Assembly, A-Frame Equalizer Link Rope Pendant

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1 1 1 1 2 4 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 2 1 2 4

7295 Electric Rope Shovel

10,830 100,660 352,000 6,550 330 70 80 190 160 1,100 750 210 210 140 60 380 340 460 2,050 1,330 800 16,550 700 300 4,030 3,120 940 1,700

1 - 43 October 2012

Introduction BI010938

Quantity

Weight Each (U.S. Pounds)

Dipper Components Dipper Assembly, 25yd Pin, Dipper Pin, Dipper Dipper Body, Weldment Latch Keeper Dipper Door, Weldment Latch Mechanism Lever, Latch Latch Bar Snubber Assembly, RH Snubber Assembly, LH Frame, Padlock Link, Padlock, RH Link, Padlock, LH Sheave, Padlock Bushing, Manganese Bushing, Manganese Pin, Padlock Frame Pin, Padlock Frame Pin, Clad Pitch Brace w/Manganese Bushing Pin, Pitch Brace Dipper Shrouds & Teeth Assembly

1 - 44 October 2012

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

7295 Electric Rope Shovel

61,190 290 240 44,270 1,060 12,310 1,050 260 500 1,190 1,190 1,480 750 750 750 90 50 370 250 370 320 170 10,020

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Introduction BI010938

Quantity

Weight Each (U.S. Pounds)

Hoist Components Cover, Bearing, Hoist Shaft & Pinion, Intermediate Bearing, Roller Bearing, Roller End, Plate Cover, Hoist Bearing, RH Pin, Bearing Housing Pin, Bearing Housing Retainer, Whole-Split Seal, Split Retainer, Hoist Drum, LH Retainer, Bearing, Hoist Drum Housing, Bearing, RH Housing, Bearing Spider, LH Gear, Hoist Drum Bearing, Roller Cover, Plate Cover, Gear, Front Cover, Gear, Lower Cover, Gear, Rear Cover, Gearcase Carrier, Intermediate Shaft & Pinion, RH Side Frame, Gearcase, LH Bolt, Rod Support, Drum, RH Guard, Hoist Coupling Drum, Hoist Brake, Hoist Hub, Horizontal Brake Adapter, Hoist Brake Motor, Hoist Blower, Hoist Motor Adapter Plate, Hoist Blower

SM141403-EN

1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1

7295 Electric Rope Shovel

210 2,150 120 410 170 250 470 210 170 120 200 260 2,830 2,780 5,390 8,560 510 290 600 1,160 710 3,240 1,280 12,640 60 5,400 100 16,700 1,030 140 420 15,180 430 260

1 - 45 October 2012

Introduction BI010938

Quantity

Weight Each (U.S. Pounds)

Hoist Components (cont.)

Rope, Wire, Hoist Gear, Hoist, 1st Reduction Coupling, Gear, Motor Pinion, Shaft, 1st Reduction Spider, RH

1 2 1 1 1

2,650 5,950 430 520 3,200

Dipper Handle Components Dipper Handle Assembly Handle, Lower End Dipper Handle Support, Take-Up Spreader, Retract Retract Take-Up Nut, Take-Up Cylinder, Hydraulic Take-Up Guide, Take-Up Cylinder Guard Support Guard, Shim Sheave, Half-Fixed, Crowd Saddle Block Retainer Seal, Saddle Block Sheave, Crowd Bearing, Tapered Roller Bushing, Saddle Block Collar, Whole-Split Bushing, Liner, Saddle Block

1 1 1 1 1 1 1 2 1 1 1 1 1 4 2 2 2 2 2

44,170 40,000 34,570 1,300 2,030 3,020 1,180 110 460 130 150 3,960 15,600 120 2,600 350 100 120 1,290

1 - 46 October 2012

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Introduction BI010938

Quantity

Weight Each (U.S. Pounds)

Electrical Components Skid, IGBT Drive Transformer, DPT Transformer, Auxiliary Power Switch, Disconnect, High Voltage Motor Control Center (MCC1) Fan, Intake, Front Fan, Intake, Rear Motor, Reeving Winch Transformer, CVT Transformer, DTT Transformer, LTT Duct, IGBT Skid Duct, IGBT Skid Fan, DPT Exhaust

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1 1 1 1 1 1 1 1 1 1 1 1 1 1

7295 Electric Rope Shovel

18,000 11,500 2,750 1,800 1,500 1,190 820 610 300 240 240 110 170 70

1 - 47 October 2012

Introduction BI010938

1 - 48 October 2012

7295 Electric Rope Shovel

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Lubrication BI010939

2

Lubrication

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Lubrication Principles ................................................................................................................. 3 Greasing Main A.C. Drive Motors ............................................................................................... 4 1. Type of grease ..................................................................................................................... 4 2. Initial commissioning ............................................................................................................ 4 3. Maintenance ........................................................................................................................ 4 4. Regreasing intervals ............................................................................................................ 5 Lubricant Selection ..................................................................................................................... 6 Gearcase Lubricant Replacement/Sampling ............................................................................ 7 Lubricant Change Cycle .......................................................................................................... 7 Automatic Lubrication System .................................................................................................. 8 Lube Room .............................................................................................................................. 9 Lubrication Room Details ........................................................................................................... 9

Lube Reservoir fill / Overflow Plumbing ................................................................................. 10 Lube Reservoir Fill / Overflow Plumbing .................................................................................. 10

Auto Lube Control Panel ........................................................................................................ 11 Lower Works Lubrication ....................................................................................................... 12 Revolving Frame Lubrication ................................................................................................. 13 Front End Lubrication ............................................................................................................ 14 Lubricant Injectors .................................................................................................................... 15 Lincoln Type SL-1 Lubricant Injectors .................................................................................... 15 SL-1 Lubricant Injector Operation .................................................................................... 17 Lincoln Type SL-V Lubricant Injectors .................................................................................... 19 Lubricant Injector (SL-V) .......................................................................................................... 20 SM141403-EN

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2-1 October 2012

Lubrication BI010939 Adjusting Injectors ................................................................................................................... 21

SL-V Lubricant Injector Operation .................................................................................... 22 Injector Advantages ................................................................................................................ 24 Propel Machinery Lubrication .................................................................................................. 25 Hoist Machinery Lubrication .................................................................................................... 26 Filter Element Cleaning .......................................................................................................... 27 Swing Machinery Lubrication .................................................................................................. 28 Swing Machinery MPG & OGL Lubrication Lines .................................................................... 28

Crowd Machinery Lubrication .................................................................................................. 29 Oil Pump ................................................................................................................................ 31 Air Compressor Lubrication ..................................................................................................... 32 ACSL - Air Compressor (Screw-type) Lubricant ...................................................................... 33

2-2 October 2012

7295 Electric Rope Shovel

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Lubrication BI010939

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

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

Some components, due to their location and function, can not be readily covered by the automatic lube system. You should become familiar with these points so you can service them properly at the intervals listed. A listing of the parts covered by the automatic lubrication system is included later in this section. The standard lubrication fittings used for manual service are the hydraulic type, push-on fittings having 1/8 inch or 1/4 inch NPT threads.

Bushings and bearings operating in a highly contaminated atmosphere (dust, grit, etc.) should be lubricated until clean grease seeps out around the journal or seal, or comes out the purge fitting, if one is provided.

Overfilling an anti-friction bearing can cause it to run excessively warm. After lubricating antifriction bearings (those that are sealed such as in electric motors must use electric motor grease) remove the pressure fitting, or the relief plug when provided, allowing the bearing to purge itself of any excess lube during the first 10-15 minutes of operation. Replace the fitting or plug after that time. Grease in a bearing generally deteriorates gradually, not suddenly. Only a small amount needs to be added to it at regular intervals to maintain the proper lubricant level.

Adding a small quantity of grease to the bearing every 600 operating hours, unless otherwise specified, is adequate.

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

Contact with or ingestion of petroleum products can be harmful. Automatic lubrication systems operate under pressure. Before opening any lube supply line, relieve the system and that line in particular, of any residual pressure.

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Lubrication BI010939

Greasing Main A.C. Drive Motors Main drive motors are shipped from the factory with the bearings packed with grease. A lubrication information plate is mounted on each motor with greasing instructions and the correct quantity or grease to be added. Main drive motors for these machines have their inlet tube filled with greased and include nameplates attached to the motor indicating “grease inlet” and “grease drain”.

An improper greasing procedure will cause premature bearing failure. Mixing of non-compatible lubricants will result in lubricant breakdown and bearing failure. Proper lubrication is important for all aspects of bearing life.

NOTE: This information covers main drive motors manufactured by Siemens, Norwood, Ohio.

It does not apply to NMA style motors manufactured by Siemens Germany.

1. Type of grease NOTE: Motors are shipped with Mobil SHC 100 NLGI #2 grease installed in the bearings. This grease has a lithium complex soap thickener and a synthetic base fluid having a base oil viscosity of 40 cSt @ 40°C.

Do not mix greases with different thickeners since the greases may not mix properly and bearing failure may result.

2. Initial commissioning Prior to initial start-up, the bearings should be greased. The normal maintenance regreasing procedure, item 3, should be used except the quantities should be doubled.

3. Maintenance This procedure should be used for regular maintenance regreasing. Refer to the following table, item 4, and/or lubrication information plate on each motor for regreasing intervals and type and quantity of grease to be used. a.

Stop the motor and lockout the starter.

b.

Remove and thoroughly clean the grease inlet fitting or plug.

c.

Remove the drain plug and clean out any hardened grease.

d.

Determine the correct amount of grease required for the bearings.

NOTE:

The drive end bearing and the non-drive end bearings require different quantities of grease.

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e.

Slowly pump the correct amount of grease into the grease inlet.

f.

Reinstall the inlet plug that was removed.

g.

Clear the lockout switch and start the motor.

h.

Allow the motor to run at least for one (1) hour to vent the bearing housing and to allow the expulsion of any excess grease from the drain opening before reinstalling the drain plug. (If it is not practical to run the motor for one hour and then stop the motor, it is acceptable to reinstall the drain plug without damage to the bearings or seals.)

i.

Stop the motor and lock out the starter. Reinstall the drain plug.

j.

The motor is now ready to be put back in service.

4. Regreasing intervals The regreasing interval can be found in the following table. Follow either the recommended operating hours, or the time interval, which ever comes first.

Motor

Regreasing Interval

Drive End Grease Amount Grams (oz.)

Non-Drive End Grease Amount Grams (oz.)

Hoist motor

3000 operating hours or every 6 months

88 (3.1)

140 (5.0)

Propel motor

3000 operating hours or every 6 months

54 (1.9)

94 (3.3)

Crowd motor

3000 operating hours or every 6 months

54 (1.9)

94 (3.3)

Swing motor

1500 operating hours or every 3 months

54 (1.9)

80 (2.8)

NOTES: 1.

It is critical that the drainpipe not be allowed to become plugged with caked or contaminated grease. If it does, then the pipe must be cleared.

2.

A common mistake is over-lubrication of bearings. When grease is added without removing the drain plug, the excess grease can be forced into and through the grease seals leading to grease leakage along the shaft (out of the motor or into the motor and possibly onto the motor windings). Proper lubrication is desired, but some under-lubrication is less harmful than over-lubrication.

3.

PN: 59100651 is a 14 ounce cartridge of Mobilith SHC100 grease.

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Lubrication BI010939

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

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

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

Operation of this machine in extreme temperatures (below -20°F/-29°C or above 110°F/44°C) requires special lubrication. Note the temperature ranges on the following lubricant specification sheets. Contact your local supplier, your manufacturer representative, or the service department of you local manufacturer’s office for recommendations if you require additional information or advice.

•

STORE LUBRICATION DRUMS ON THEIR SIDE, WITH THE OPENING TOWARD THE TOP.

•

STORE ALL LUBRICANTS IN TIGHTLY COVERED CONTAINERS!

•

WIPE OFF COVERS AND SURROUNDING AREA BEFORE OPENING!

•

FILTER ALL OIL BEFORE ADDING IT TO THE SYSTEM!

•

USE ONLY CLEAN and PROPER LUBRICANTS!

•

DO NOT MIX TYPES or BRANDS of LUBRICANTS!

Even the best lubricants are less useful in preventing wear if they become contaminated by dirt or water due to careless handling or storage.

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Gearcase Lubricant Replacement/Sampling It is strongly suggested that the gearcase lubricant be part of a routine oil analysis program to forecast impending problems and thereby reduce the possibility of catastrophic failure. This analysis should take place every 500-1250 machine hours to ensure that properties are maintained and contamination is controlled to the following parameters: Viscosity: Within 10% of the specified, new oil viscosity; Water Content: Contain less than 0.05% (500 ppm); Spectrometric oil analysis: Monitor the elements listed in the following table, at a minimum: Element

Normal

Excessive

Critical

Iron

<400

400-700

>700

Copper

<25

25-60

>60

Chromium

<5

5-15

>15

Silicon

<40

40-60

>60

NOTES: 1. All values are Parts per Million.

2. Particle count may be higher during the initial run-in period.

3. The oil should be changed when any element value exceeds normal levels.

4. Maintain an analysis record using the gearcase serial number and machine operating hours.

5. In gear cases with closed loop filtration systems, clogged filters require investigation into the source of contamination.

Lubricant Change Cycle For all machinery motions - Hoist, Crowd, Swing & Propel - the gearcase lubricant should be first changed after approx. 500 machine operating hours.

Thereafter, the lubricant should then be changed every 6,000 hours or 12 months, whichever comes first. Flush the gearcase prior to refilling with new oil.

To fill the propel gearcase, remove the inboard plug at the center of the gearcase. Remove the oil breather at the top of the gearcase and fill the gearcase with oil until oil flows from the unplugged port. Replace the removed plug. Oil capacity is approximately 70 Gallons (265 liters).

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2-7 October 2012

Lubrication BI010939

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

STORED ENERGY! Automatic lubrication systems operate under pressure. Before opening any lube supply line, relieve the system and that line in particular, of any residual pressure.

NOTE:

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

Enclosed gearcases must have their recommended lubricant level maintained at the prescribed level. Check the lubricant level at the oil level plug or with the dipstick at least once weekly (every 150 hours). Inspect them daily (every 24 hours) for leaks. Change the oil in the gearcase at their recommended intervals while flushing each case with a light lube oil before adding the new gear oil. ALWAYS STORE THE USED OIL IN A SAFE CONTAINER UNTIL PROPERLY DISPOSED. DO NOT POLLUTE THE ENVIRONMENT! The manufacturer recommends that scheduled oil samplings from the enclosed gearcases and air compressor crankcase on this machine be taken and tested by an authorized, reputable lab to determine the contamination level of the sump oil. These samples should be obtained and tested every 30 operating days (600 hours). They should be taken when the oil is at its normal operating temperature and is well mixed in the case, so the samples are representative of actual conditions. This diagnostic maintenance procedure will permit you to determine the condition of internal components within the operating gearcases. Increases in the presence of certain metallic types can be analyzed with the manufacturer’s service personnel to determine the best time to change the oil, thus obtaining its best service life. This will simultaneously allow you to monitor the condition of the components and address situations in their infancy instead of after a catastrophic breakdown. This program will pay you dividends in the long run.

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

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

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Lube Room The lubrication room is located at the left front corner of the machinery house. The lube room can be accessed by external walkways. The lube room contains the pumps, tanks, transducers and the basic components associated with the automatic lubrication system of the machine.

Lubrication Room Details

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Lubrication BI010939

Lube Reservoir fill / Overflow Plumbing

Lube Reservoir Fill / Overflow Plumbing

The lube reservoir fill/overflow plumbing is located on the lube room apron at the front, left side of the machine. Lubricants can be added at this location. The overflow connections are also located here. DO NOT plug the overflow connections.

2 - 10 October 2012

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Auto Lube Control Panel The Automatic Lubrication Control Panel is mounted on the inboard most wall of the lubrication room. The panel provides the switches and override functions required to activate, reset and override the automatic functions.

POWER ON -

Allows electrical power to energize the system.

LUBE FAULT -

A light that, when lit, indicates that a fault is present in that system. Reset the fault by turning the affected system off and then on.

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

ON /OFF -

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Energizes the system for normal operation.

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2 - 11 October 2012

Lubrication BI010939

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

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

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

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

2 - 12 October 2012

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

Although the machinery contained within the house is not exposed to the extreme conditions of some other machine components, the loading and stresses exerted on this equipment are severe. Longevity of these components is largely dependent upon proper lubrication.

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2 - 13 October 2012

Lubrication BI010939

Front End Lubrication The front end equipment is exposed to the most extreme working environment of any part of the machine. The proper amount of lubrication and its quality is imperative to achieving a substantial service life from these components. Daily inspection and monitoring of the lubrication system will result in both parts durability and the reduction of machine downtime.

Boom Foot Pins:

Although not under constant movement during the operation of the machine, the boom point feet are subjected to high loads and oscillations in a variety of directions. Virtually all movement of the front end equipment will exert a load on the pins. OGL is introduced from the lube system to reduce wear.

Saddle Block:

The saddle block bears the brunt of movement from the dipper, dipper handle, attached equipment and any material being moved. The saddle block lube points need to be checked at least before each shift to avoid dry spots and accumulations of foreign material.

Sheaves:

Both fixed and rotating front end sheaves are subjected to loads introduced by the ropes as they move the larger components of the machine. The sheave bearings on the boom point, the crowd sheaves and the connection points of the structural strands are lubricated.

Wire Ropes:

Running and structural wire ropes have very specific requirements for lubrication in order to survive the difficult conditions they are forced to operate within. Without proper lubrication and maintenance the expected life from costly wire ropes will be seriously degraded. Refer to the ENGINEERING DATA section for general care and maintenance of wire ropes.

Suspension Ropes: The suspension ropes support the boom as well as the rest of the front end equipment. These ropes are under constant tension but also sustain additional loads during machine operation. Lubricate the suspension rope sockets approx. every 3 months or 1250 hours of machine operation.

2 - 14 October 2012

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Lubricant Injectors Lincoln Type SL-1 Lubricant Injectors These pressure-operating, spring-reset, series-installed injectors are supplied in banks mounted on manifolds or individually. Each injector expels a maximum of .08 cu. inch of lubricant from its outlet port each cycle. Dual outlet ports on each injector permit the injectors to be piped in series for increased lube supply to a common point. The quantity of lube to each point on this machine has been carefully designed by our engineers for proper coverage. Each injector output can be adjusted; however the manufacturer recommends that injectors initially be set and used at their maximum setting.

NOTE:

MAXIMUM Operating Pressure: RECOMMENDED Operating Pressure: MINIMUM Operating Pressure: MAXIMUM Recharge Pressure:

3,500 2,500 1,850 600

PSI PSI PSI PSI

STORED ENERGY! Contact with or ingestion of petroleum products can be harmful.

Automatic lubrication systems operate under pressure. Before opening any lube supply line, relieve the system and that line in particular, of any residual pressure.

To set an injector for maximum output:

1.

Loosen locknut.

2.

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

3.

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

4.

Tighten the locknut.

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Lubrication BI010939

To reduce an injector’s output:

1.

Loosen locknut.

2.

Turn adjusting nut clockwise (CW) until desired discharge rate is obtained. This forces the stem into the body, retarding the stem’s movement.

3.

Set the locknut.

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

2 - 16 October 2012

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SL-1 Lubricant Injector Operation STAGE 1 The injector piston is in its normal or reset position. The discharge chamber is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant, the slide valve is about to open the passage leading to the piston.

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

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

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

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

2 - 18 October 2012

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Lincoln Type SL-V Lubricant Injectors These pressure-operating, spring-reset, series-installed injectors are supplied in banks mounted on manifolds or individually. Each injector expels a maximum of .08 cu. inch of lubricant from its outlet port each cycle. Dual outlet ports on each injector permit the injectors to be piped in series for increased lube supply to a common point. The quantity of lube to each point on this machine has been carefully designed by our engineers for proper coverage. Each injector output can be adjusted; however the manufacturer recommends that injectors initially be set and used at their maximum setting.

NOTE:

MAXIMUM Operating Pressure: RECOMMENDED Operating Pressure: MINIMUM Operating Pressure: MAXIMUM Recharge Pressure:

3,500 2,500 1,850 600

PSI PSI PSI PSI

STORED ENERGY! Contact with or ingestion of petroleum products can be harmful.

Automatic lubrication systems operate under pressure. Before opening any lube supply line, relieve the system and that line in particular, of any residual pressure.

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Lubrication BI010939

To set an injector for maximum output:

Lubricant Injector (SL-V)

1.

Remove protective cap.

2.

Loosen locknut.

3.

Turn adjusting nut until there is a small gap at the top of the stem and the top of the adjusting screw during Stage 3 of the injector operation.

4.

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

5.

Tighten the locknut.

6.

Install protective cap.

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To reduce an injector’s output:

Adjusting Injectors

1.

Remove protective cap.

2.

Loosen locknut.

3.

Turn adjusting nut clockwise (CW) until desired discharge rate is obtained. This forces the stem into the body, retarding the stem’s movement.

4.

Set the locknut.

5.

Install protective cap.

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

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Lubrication BI010939

SL-V Lubricant Injector Operation STAGE 1 The injector starts in its normal or reset position. Incoming lubricant is directed through the slide valve to both sides of the piston. The pressure of the incoming lubricant acting on both sides of the piston causes the piston to move downward against the shoulder and fills the measuring chamber. The indicator stem is fully retracted away from the stop of the adjusting screw.

STAGE 2 A further increase in pressure causes the slide valve to move against the force of the springs. As the slide valve moves, it closes passage 1 and opens passage 2 to the outlet port. The pressure of the incoming lubricant is now acting only upon the bottom of the piston. The incoming lubricant displaces the piston which forces the lubricant in the measuring chamber to be dispensed through passage 2, through the slide valve and through the outlet port to the lube point.

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STAGE 3 The piston will dispense the lubricant until the indicator stem hits the stop of the adjusting screw.

The volume of lubricant dispensed can be adjusted by limiting the travel of the piston. The piston and slide valve remain in this position until lubricant pressure in the supply line is vented.

STAGE 4 As the pressure in the supply line vents to 1000 psig [69 bar], the slide valve moves downward and closes passage 2 and opens passage 1. The lubricant pressure in the supply line is now acting on both sides of the piston causing it to move downward. As the piston moves downward, a volume of the lubricant flows from the underside of the piston, past the slide valve, through passage 1 and to the upper side of the piston. Since the volume on top of the piston is greater than the volume under the piston, an additional volume of lubricant flows from the supply line to the upper side of the piston. This volume of lubricant leaving the supply line causes the pressure to drop very quickly. The piston may or may not fully return to the shoulder, depending on the volume of lubricant in the supply line. The injector is now ready for the next cycle.

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

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Injector Advantages

2 - 24 October 2012

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Propel Machinery Lubrication Propel planetary gearcases should be checked every 48 hours. Inspect the lubricant level with the machine on level ground and add the required amount of the recommended lubricant if necessary. If water has accumulated within the gearcases, remove the drain plug and drain into a container for waste removal, then refill with clean lubricant.

For gearcases with the input shaft rotated 10° from horizontal, check the propel gearcase oil level using the dipstick located at the top of the input shaft housing.

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

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Lubrication BI010939

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

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

2 - 26 October 2012

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Filter Element Cleaning The oil filter for the hoist gearcase oil cooler has a removable, wire mesh filter element that can be cleaned and reused several times. Use the following method: 1.

Clean any coarse dirt from the pressure side of the element with normal cleaning solvents and a smooth bristled brush (not a wire brush). This process can be done under a jetstream, not a bath, to help prevent the removed particles from reaching the clean side of the element.

2.

After cleaning, use compressed air to blow through the element from the clean side.

NOTE: Filter elements which are filtered from inside to outside must use a dirt pan as shown in the figure.

3.

Next dip the cleaned element in cleaning fluid to pick up any remaining dirt particles. Use compressed air to blow out the element as in step 2 above.

4.

Repeat the above steps until all dirt particles have been removed from the filter element.

NOTES: •

Handle the mesh of the element carefully to avoid damage through improper handling.

•

The filter element cannot be 100% cleaned. Therefore, the element should be cleaned a maximum of 3 times then discarded.

•

Filter seals should be inspected and replaced as required during filter cleaning and maintenance.

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Lubrication BI010939

Swing Machinery Lubrication The swing machinery is primarily composed of an enclosed planetary gearcase on either side of the machine’s swing rack. Lubricant levels should be checked at least every 48 hours with a visual inspection for leakage at the start of each shift.

Swing Machinery MPG & OGL Lubrication Lines

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

2 - 28 October 2012

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Crowd Machinery Lubrication The crowd machinery includes 2 gearcases. The crowd first and second stages of gear reduction are totally enclosed systems submerged in gear lubricant. The gearcase is provided with an oil level plug to check for adequate lubrication, and a filter breather. The third stage of gear reduction, the crowd drum gear, is lubricated with OGL. The bearings of the crowd drum, along with the shafts of the crowd reduction system are auto-lubricated with MPG.

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2 - 30 October 2012

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Oil Pump The heart of the power unit is the hydraulic pump. It is self-lubricating. Preventive maintenance is limited to keeping the system fluid clean. This is done by changing the filters frequently. The recommendations listed below are a minimum requirement.

All return line filters and pressure filters should be changed a minimum of two times per year or, upon the visual or electrical indicator signaling otherwise.

The suction strainer (immersed below the oil level in the reservoir) should be cleaned once a year or every 4000 operating hours. The suction strainer should be removed from the reservoir and can be cleaned with compressed air, blowing from the inside out. If there are holes in the mesh or if there is mechanical damage, the strainer should be replaced. It is especially important that the suction or inlet piping and fittings be tight and in good condition to prevent air from being drawn into the pump.

The reservoir air breather should be changed or cleaned once a year or every 4000 hours. The air breather filters all air drawn into the reservoir.

Failure to change or clean this filter can result in pump failure.

The electric motor requires very little attention when kept clean and dry.

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Lubrication BI010939

Air Compressor Lubrication The air compressor supplied with the machine has very specific lubrication needs. For the details of servicing, refer to the manufacturer’s instructions and the specific lubricant recommendations made later in this section. Also refer to the COMPRESSED AIR SYSTEM section in this manual.

2 - 32 October 2012

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ACSL - Air Compressor (Screw-type) Lubricant SCOPE:

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

These lubricant performance requirements for screw-type air compressors are only good for Sullair screw compressors. If the machine is equipped with air compressors manufactured by other than Sullair you must refer to the vendor’s maintenance information provided with the machine and LUBRICATION of this manual.

LUBRICANT RECOMMENDATIONS: The following are listed service requirements (including lubrication) of the Sullair Air Compressor: Ambient Temperature ----------------------10ºF to +90ºF (-23ºC to +32ºC)

Fluid & Filter Change Separator Change Lubrication Period (Hrs.) Period (Hrs.) -------------------------------- ---------------------------------- --------------------------------Sullube 8000 Hrs. 8000 Hrs. Sullair LLL-4-32 8000 Hrs. 8000 Hrs. SRF 1/4000 4000 Hrs. 4000 Hrs.

Air Filter Change Period (Hrs.) ----------------------4000 Hrs. 4000 Hrs. 4000 Hrs.

NOTES •

For additional information, refer to the vendor supplied manual provided. For additional questions, please contact either the vendor or the manufacturer.

•

For light-duty, high-humidity service where condensed moisture and emulsification may occur, the fluid change interval should be reduced to 300 Hrs. maximum. A nondetergent fluid with rust, oxidation and foam inhibitors, and good water separation characteristics should be used.

•

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

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®

BI010196 May 2012

Special Instruction Lubrication Specifications Electric Rope Shovels

AM11093-EN

SAFETY.CAT.COM

BI010196

Amendments and alterations to this publication are not subject to notification. Caterpillar Global Mining LLC reserves all rights to this publication. Its content is protected by copyright laws.

No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Caterpillar Global Mining LLC. Caterpillar Global Mining LLC declines any liability for direct or indirect consequences of printing errors. © 2012 Caterpillar Global Mining LLC. LatchFree™ and HydraCrowd™ © 2012 Bucyrus International, Inc.

BI010196

Table of Contents EGL - Enclosed Gearcase Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MPG - Multipurpose Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

AM11093-EN

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 9, 2012

OGL - Open Gear Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 9, 2012

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BI010196

Lubrication Specifications EGL - Enclosed Gearcase Lubricant SD4720 (March 2006) This specification covers the requirements for “Enclosed Gearcase Lubricant” used on models 7495, 7495 HF and 7495 HD Electric Rope Shovels and is also applicable to former models 495BII, 495HF, 495HR and 495HD. The materials furnished under this specification are intended to lubricate spur, helical and spiral bevel gears as well as anti-friction bearings at the interior of enclosed planetary and nonplanetary type gearcases (Hoist, Swing, Crowd and Propel).

This specification covers “Enclosed Gearcase Lubricants” that may be applied in service at temperatures ranging from –50ºC (-58ºF) to the highest ambient temperature conditions.

Guidelines for Selecting an Approved Lubricant 1.

Using Table 1, determine the recommended oil type (Mineral or Synthetic) based upon the anticipated ambient temperature range.

AMBIENT TEMPERATURE RANGE Ambient Temperature: The ambient temperature is defined as the air temperature in the immediate vicinity of the gearcase. a. b. c.

Use atmospheric temperature for gearcases located outside of the machinery house (Swing, Crowd and Propel Gearcases).

Use machinery house temperature for gearcases located inside of the machinery house (Hoist Gearcase) for some machines are equipped with machinery house heaters.

If the ambient starting temperature approaches the lubricant pour point, external heaters may be required to facilitate starting and ensure proper lubrication. Use oil temperature for gearcases having oil immersion heaters.

Table -1 - Guidelines for Selecting Approved Lubricant Ambient Temperature Range

ISO Viscosity Grade / Oil Type

14°F to 100°F (-10°C to 37°C)

ISO VG 320 / Mineral or Synthetic (poly-a-olefin) Oil

Less than 14°F to 120°F (Less than -10°C to 50°C)

ISO VG 320 / Synthetic (poly-a-olefin) Oil

Under normal circumstances, an ISO VG 320 oil viscosity is required for all Gearcases (Hoist, Swing, Crowd and Propel). For cold weather applications, an ISO VG 220 oil viscosity may be used for the Propel Gearcases to help ensure that the lubricant pour point remains below that of the ambient starting temperature. The pour point and flash point of individual brand name gear oils must be observed. Refer to the oil manufacturers technical data sheets for these properties.

2.

Select an approved lubricant for the Hoist, Swing, Crowd and Propel Gearcases from the Approved Lubricant Table 2 & Table 3.

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SCOPE

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APPROVED LUBRICANTS Lubricants that have been approved for use by the gearcase manufacturers are listed in the Approved Lubricant Table 2 & Table 3. The use of non-approved lubricants may invalidate the manufacturers product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/regulatory requirements.

Table -2 - Approved Mineral Oil Lubricants (ISO VG 320) Manufacturer

Product Description

Bel-Ray

Bel-Ray 100 Gear Oil 90

BP

Energol GR-XF 320

Castrol

Alpha SP 320 Alpha MAX 320 Optigear BM 320 Tribol 1100/320

Chevron

Chevron Ultra Gear Lube 320 Gear Compound EP 320

Esso

Spartan EP 320 (Only Product Originating from Europe)

Fuchs

Renolin CLP 320 Plus

LE (Lubrication Engineers)

Almasol 605

Mobil

Mobilgear XMP 320

Petro-Canada

Ultima EP 320

Shell

Omala F 320

Texaco

Auriga EP 320 Meropa 320 Meropa WM 320

Whitmore Mfg. Co.

Paragon 320

Shaded lubricants are approved for use in the Planetary Hoist, Swing and Propel Gearcases as well as the Non-Planetary type Crowd Gearcase.

Non-shaded lubricants are approved for use only in the Planetary Propel and Non- Planetary type Crowd Gearcase.

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Table -3 - Approved Synthetic (Poly-a-olefin) Oil Lubricants (ISO VG 320) Manufacturer

Product Description Synth. Gear Oil 6692

BP

Enersyn EP-XF 320 Enersyn HTX 320

Castrol

Optigear Synth. A 320 Optigear Synth. X 320 Alphasyn EP 320 Alphasyn T 320 Tribol 1510/320 Tribol 1710/320

Chevron

Tegra Synth. Gear Lube 320

Fuchs

Renolin Unisyn CLP 320

Mobil

Mobil SHC 632 Mobilgear SHC XMP 320

Petro-Canada

Ultima Synth. EP 320 Traxon E Synth. 80W-140

Shell

Omala HD 320

Texaco

Pinnacle EP 320

Whitmore Mfg. Co.

Decathlon F 320

Shaded lubricants are approved for use in the Planetary Hoist, Swing and Propel Gearcases as well as the Non-Planetary type Crowd Gearcase.

Non-shaded lubricants are approved for use only in the Planetary Propel and Non-Planetary type Crowd Gearcase.

Specification Revisions This specification is subject to change without notice.

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Bel-Ray

BI010196

MPG - Multipurpose Grease SD4711 (November 2011) PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 10, 2012

SCOPE 1.

2.

3.

4.

This specification covers “Multi-Purpose Grease”.

Materials furnished under this specification are primarily intended to lubricate heavy duty ball, roller, and plain bearings.

The material furnished under this specification must be dispensable through the distribution lines of a centralized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors or metering blocks.

The particular grade or consistency selected must perform within the specific temperature range in which it is utilized.

PHYSICAL CHARACTERISTICS 1.

2.

3.

4.

5.

6.

7.

8.

9.

Heat Resistance - Shall be thermally stable, should not flow or harden in service.

Retention - Shall not exhibit high leakage.

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

Water Resistance - Shall withstand water washout or leaching.

Reversibility - Shall be stable with repeated heating and cooling.

Pressure Separation - Shall resist oil-soap separation.

Extreme Pressure - Shall withstand heavy shock loading.

Compatibility a. Low temperature greases shall be compatible with mineral oil base greases. b. Grease must be compatible with oil seal lip materials (Nitriles, Viton), and all centralized lubrication system components (i.e. gaskets, o-rings, vent valves, etc.).

Reference ASTM D 4289-03.

Compounding a. Suitable for producing the extreme pressure characteristics (without inert fillers)

required for heavy duty ball, roller, and plain bearing lubrication.

b. c.

4 May 2012

Base fluid is to be mineral or synthetics which are compatible with mineral base.

Thickener types are to be of the following varieties: Aluminum, Lithium, or Calcium.

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MINIMUM PERFORMANCE REQUIREMENTS Property

Reference -1°C to +43°C (+30°F to +110°F)

-18°C to +27°C (0°F to +80°F)

Less than -12°C (Less than +10°F)

NGLI Consistency #

ASTM D-217

2

1

1, 0, 00 (See Note #2)

Dropping Point °C (°F) Minimum

ASTM D-2265

177 (350)

177 (350)

177 (350)

Timken O.K. load-lbs (kgf)

ASTM D-2509

50 (23)

50 (23)

50 (23)

Four Ball EP Load wear index (LWI) kg Minimum

ASTM D-2596

65

65

65

Load Weld kg Minimum

ASTM D-2596

400

400

400

Four Ball Wear Wear Scar mm Maximum 40KG for 1 hour @ 75°C @ 1200 RPM

ASTM D-2266

0.6

0.6

0.6

Copper Strip Corrosion 24 Hrs @ 100°C (212°F)

ASTM D-4048

2e

2e

2e

Rust Test

ASTM D-1743

Pass

Pass

Pass

Viscosity of Base Fluid Minimum

ASTM D-445

460cSt @ 40°C

220cSt @ 40°C

130cSt @ 40°C

Motormatic Grease Worker Mechanical Stability 10,000 strokes, Maximum change

ASTM D-217A

10%

10%

10%

Roll Stability Test Maximum change in 2 hours

ASTM D-1831

15%

15%

15%

Wheel Bearing Test 6 hours @ 104°C (220°F) Maximum loss

ASTM D1263

10%

10%

10% (NLGI #1 Only)

Water Washout Test Loss @ 38°C (100°F), Maximum Loss @ 80°C (175°F), Maximum

ASTM D-1264 5%

5%

5% (NLGI #1 Only)

15%

15%

15% (NLGI #1 Only)

Minimum

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Ambient Temperature (See Note #1)

Requirement

BI010196

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 10, 2012

Property

Reference

Requirement

Pressure Oil Separation

The Lubrication Engineers Manual (United States Steel).

U.S. Steel test method - Cake penetration not less than 25% of grease penetration.

Grease Mobility

The Lubrication Engineers Manual (United States Steel).

U.S. Steel method - not less than 0.10 grams flow per second at the lowest anticipated ambient temperature. (Testing temperature not less than -34°C/-30°F).

Pumpability, Lincoln Ventmeter

The Lubrication Engineers Manual (United States Steel).

To vent from 1800 psi (127 kgf cm^2) to less than or equal to 600 psi (42 kgf/cm^2) within 30 seconds at the lowest anticipated ambient temperature (Testing temperature not less than -25°C/-13°F).

Lubricating Solids (Molybdenum Disulfide, Graphite, Etc.) % by Weight

Less than or equal to 5%

Lubricating Solids (Molybdenum Disulfide, Graphite, Etc.) Particle Size, (Microns, max.)

10 Microns

NOTES: 1.

2.

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

Low Temperature Grease - For extended use in low temperature (-12°C to -46°C / +10°F to -50°F) areas, this product should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing. This product should meet the Mobility and Pump-ability criteria for the lowest anticipated ambient temperature. In order to minimize compatibility problems, it is desirable that the thickener and additive system be compatible with the additional grades that are suitable for the other ambient temperatures.

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LUBRICANTS

The use of lubricants not meeting this specification may invalidate the manufacturers product warranty obligation.

SPECIFICATION REVISIONS This specification is subject to change without notice. Please contact the following for the latest specification: Caterpillar Global Mining LLC 6744 S. Howell Ave. Oak Creek, WI, USA 53154 Telephone (+1) 414.768.4000

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Electric Rope Shovel

7 May 2012

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 10, 2012

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements. Lubricants shall be certified by their manufacturers as complying with this specification. Quality Control Documentation may be requested pertaining to viscosity, weld point and scar per batch to validate properties.

BI010196

OGL - Open Gear Lubricant SD4713 (June 2011) PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 10, 2012

SCOPE 3.

4.

5.

6.

This specification covers "Open Gear Lubricant."

Materials furnished under this specification are primarily intended to lubricate open gears, but may also be used to lubricate racks, bushings, rails, rollers, dipper handles and propel mechanism components.

The material furnished under this specification must be dispensable through the distribution lines of a centralized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors, metering blocks, or spray nozzles.

This specification covers open gear lubricants that may be applied in service at temperatures ranging from -50°C (-58°F) to the highest ambient temperature conditions.

The particular grade or consistency selected must perform within the specific temperature range in which it is utilized. The temperature may vary significantly between external components in cold climates and components located within heated enclosures and must be considered during lubricant selection.

PHYSICAL CHARACTERISTICS 1.

2.

3.

Materials furnished under this specification are produced with highly fortified blends of viscous fluids combined with additives to form stable, long lasting, high load carrying, wear resistant films that lubricate under mixed film and boundary conditions. Lubricants addressed under this specification may be defined by AGMA 6014-A06 Annex D as (1) Residual [asphaltic (bitumen)] compounds, (2) High viscosity oils, (3) Compounds or (4) Greases.

Open gear lubricants supplied under this specification must have excellent adhesive and cohesive qualities, must not chip or throw off, and must provide sufficient film thickness and scuffing resistance to prevent metal to metal contact between applications of the lubricant under all operating conditions. Therefore: (2) High viscosity oils are NOT recommended due to performance characteristics at relatively slow speeds and frequent stop/start application; and (4) Greases inherently provide marginal film thicknesses at low speed which requires properly designed additive packages and thickener selection, stringent break in procedures and more frequent lubricant intervals.

Various grades or consistencies of open gear lubricants may be required to provide proper lubrication and application properties over a wide range of ambient temperatures. The consistency of the lubricant as applied must be appropriate for the method of application, and the in-service consistency shall be appropriate for the lubricant to meet or exceed the minimum performance requirements listed in the "MINIMUM PERFORMANCE REQUIREMENTS" section.

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4.

6.

7.

8.

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PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 10, 2012

5.

Viscosity, a fluid's resistance to flow, is the principal physical characteristic of a fluid in terms of its ability to produce a lubricating film between two interfacing surfaces. All lubricating fluids possess a natural viscosity that may be altered (enhanced) by additives such as resins or polymers. Some "viscosity enhancers" are shear sensitive, which could result in insufficient protection of the lubricated components under high load, elevated temperatures and/or high shear conditions. The viscosity of the fluids utilized in the open gear lubricants shall be sufficient under operating conditions for the product to meet or exceed the performance requirements listed in the "MINIMUM PERFORMANCE REQUIREMENTS" section.

Open gear lubricants supplied under this specification must be specifically formulated to protect surfaces, reduce wear, and provide satisfactory service life under all anticipated operating conditions.

Open gear lubricants supplied under this specification must have excellent water tolerance and rust preventive qualities, as well as minimal dripping qualities for operation over wide temperature ranges.

Should the material furnished under this specification contain a diluent to improve dispensability, special care must be exercised to ensure its compatibility with all centralized lubrication system components, i.e., gaskets, o-rings, vent valves, etc., and oil seal lip materials (Nitriles, Viton). Reference ASTM D 4289-03.

For extended use in low temperature areas, open gear lubricants supplied under this specification should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing. In order to minimize compatibility problems, it is desirable that the thickener and additive system be compatible with the additional grades that are suitable for the other ambient temperatures.

BI010196

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 10, 2012

MINIMUM PERFORMANCE REQUIREMENTS Property Flash point of product as applied, minimum (base product with diluent) Ambient Temperature (See Note #1) -50°C(-58°F) to + 10°C (50°F) Above +10°C(50°F) Flash point of base fluid(s), minimum Rust protection Copper strip corrosion Maximum rating 24hr. @ 100oC (212oF) Four ball EP test weld point, minimum kgf (base product without diluent) Load wear index (LWI), minimum (base product without diluent) Four ball wear test 60 minutes @ 40 kgf.

Maximum scar, mm (base product without diluent) Adhesive properties Minimum Base Fluid Viscosity Ambient Temperature (See Note #1) All - Except Electric Mining Shovel Hoist Drum Gear (°F) °C (-58 to +50) -50 to +10 (-4 to +104) -20 to +40 (+50 to +122) +10 to +50 Minimum Base Fluid Viscosity Ambient Temperature (See Note #1) Electric Mining Shovel Hoist Drum Gear °C (°F) +10 to +35 (+50 to +95) +25 to +50 (+77 to +122) Pumpability, Lincoln Ventmeter

Molybdenum Disulfide Lubricating Solids (Molybdenum Disulfide, Graphite, Etc.) Particle Size

NOTE:

10 May 2012

Reference ASTM D92 / ISO 2592

Requirement 61°C (142°F) 80°C (176°F)

ASTM D92 / ISO 2592 ASTM D 1743 ASTM D 4048

140°C (284°F) Pass 2a

ASTM D 2596

800

ASTM D 2596

120

ASTM D 2266

0.7

Must adhere to surfaces at the lowest anticipated ambient temperature. (See Note) ASTM D 445 680 cSt at 40°C 1860 cSt at 40°C 3600 cSt at 40°C

ASTM D 445

3600 cSt at 40°C 5000 cSt at 40°C

To vent from 1800 psi (127 kgf/cm^2) to less than or equal to 600 psi (42 kgf/cm^2) within 30 seconds at the lowest anticipated ambient temperature.

2% Minimum 15 Micron Nominal 44 Micron Maximum

Ambient Temperature - The ambient temperature shall be the temperature at the point of lubricant application. The Electric Mining Shovel Hoist Drum Gear is enclosed in a heated machinery room which should not be below 10°C (50°F).

Electric Rope Shovel

AM11093-EN

BI010196

LUBRICANTS

The use of lubricants not meeting this specification may invalidate the manufacturer’s product warranty obligation.

SPECIFICATION REVISIONS This specification is subject to change without notice. Please contact the following for the latest specification: Caterpillar Global Mining LLC 6744 S. Howell Ave. Oak Creek, WI, USA 53154 Telephone (+1) 414.768.4000

AM11093-EN

Electric Rope Shovel

11 May 2012

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 10, 2012

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements. Lubricants shall be certified by their manufacturers as complying with this specification. Quality Control Documentation may be requested pertaining to viscosity, weld point and scar per batch to validate properties.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 10, 2012

BI010196

12 May 2012

Electric Rope Shovel

AM11093-EN

®

Amendments and alterations to this publication are not subject to notification. Caterpillar Global Mining LLC reserves all rights to this publication. Its content is protected by copyright laws.

No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Caterpillar Global Mining LLC. Caterpillar Global Mining LLC declines any liability for direct or indirect consequences of printing errors. © 2012 Caterpillar Global Mining LLC. LatchFree™ and HydraCrowd™ © 2012 Bucyrus International, Inc.

Preventive Maintenance BI010940

3

Preventive Maintenance

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Introduction ................................................................................................................................. 3 Preventive Maintenance Program ........................................................................................... 3 Elements Of An Effective Maintenance Program .................................................................... 4 Scheduled Preventive Maintenance Program ......................................................................... 5 General Safety Considerations ................................................................................................ 5 Maintenance During Machine Operation ................................................................................. 6 Maintenance Precautions .......................................................................................................... 6 Preventive Maintenance For Lubrication ................................................................................ 8 Lubricant Cleanliness .............................................................................................................. 9 Frequency Of Inspection And Maintenance ........................................................................... 10 Maintenance Schedules .......................................................................................................... 10 Maintenance Inspection Check Points................................................................................... 10 Daily ...................................................................................................................................... 11 Every 100 Hours, Or Weekly ................................................................................................. 15 Every 500 Hours, Or Monthly................................................................................................. 17 Every 1250 Hours, Or Quarterly ............................................................................................ 21 Every 2500 Hours, Or Semi-annually .................................................................................... 25 5000 Hours, Or Annually ........................................................................................................ 28 Major Component Locations ................................................................................................... 31 Machine Nomenclature ............................................................................................................... 31 Lower Works and Crawlers ......................................................................................................... 32 Crawler Assembly ...................................................................................................................... 33

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Preventive Maintenance BI010940 Crawler Link Assembly .............................................................................................................. 34 Propel Machinery ........................................................................................................................ 35 Roller Circle Section View .......................................................................................................... 36 Roller Frame Assembly .............................................................................................................. 37 Collector Rings .......................................................................................................................... 38 Center Pintle Assembly ............................................................................................................. 40 Revolving Frame Deck Extensions ............................................................................................. 41 Hoist Machinery ......................................................................................................................... 42 Swing Machinery ........................................................................................................................ 43 Crowd Machinery ........................................................................................................................ 44 Lubrication Reservoirs ................................................................................................................ 45 Operators Cab ........................................................................................................................... 46 Boarding Stairway ...................................................................................................................... 47 Machinery House Walkways and Platforms ................................................................................ 48 Front End Equipment ................................................................................................................. 49 Boom Support Ropes ................................................................................................................. 50 Boom Bumpers .......................................................................................................................... 51 Dipper Assembly ........................................................................................................................ 52

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SM141403-EN

Preventive Maintenance BI010940

Introduction This section of the manual describes those aspects of preventive maintenance on the machine such as inspection, adjustment and routine repetitive tasks. Information related to lubrication techniques, frequency and service points is also partially included. Further detailed information can be found in the LUBRICATION and SERVICE PROCEDURES sections of this manual.

Preventive Maintenance Program A Preventive Maintenance Program is a systematic series of operations performed periodically on equipment in order to prevent breakdowns.

Any breakdown WILL reduce productivity and increase overhead expense. Machinery is only new at one point in time. From that moment, the machinery begins to deteriorate through use and aging.

A well organized maintenance program will avoid unexpected high-cost breakdowns and will increase component life.

A systematic approach to the program should be followed and detailed records of all findings kept, to detect potential problem areas. Valuable time and effort can be saved if defects are corrected before they lead to a major breakdown. The records should be reviewed often and kept on file for future reference.

Personnel involved in the program should go through an established training program, to know WHAT to check and HOW to rectify any potential problem area. When personnel are able to do routine maintenance and normal repairs efficiently, downtime is reduced and machine productivity increased. Also, to keep the machine in good running condition, the necessary parts, tools and current information should be kept on hand.

Equipment maintenance is a science and its practice an art. This art can be divided into 6 types of operations - they are: •

Inspection is probably the most important operation. Careful observation is required of all parts of the equipment. Slight abnormalities may not interfere with the equipment performance BUT those that are a deviation from the normal should be discovered early. When inspecting, notice placement, state of cleanliness, color, etc. of part(s). (Discoloration indicates overheating). All guards and bolts in place and good housekeeping.

•

Cleaning and keeping clean is essential for good operation. Periodic cleaning should be more frequent on exposed parts than those that are contained within cabinets. Parts, connections and joints should be free of dust, corrosion and other foreign matter.

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3-3 October 2012

Preventive Maintenance BI010940

•

A Feeling operation is used more often to check guarded rotating machinery for vibration due to worn parts, lack of lubrication, overheating, etc. Feeling operation on electrical items should be performed as soon as possible AFTER power has been removed and the circuit grounded.

Feeling of excessive heat may indicate an overloaded condition and should be corrected.

•

A Tightening operation should be done on all connections that have worked loose due to vibration, etc. Loose parts are a definite hazard because they may fall out of place and damage nearby components. The importance of firm mounting and tight connections cannot be overemphasized. Always replace missing or broken bolts with proper size and use the correct tools.

•

Adjusting should be done when inspection indicates that it is required to maintain normal operating conditions. Specific adjustment is contained in the “Mechanical Adjustment Section” of this manual, the electrical manual or the component manufacturer’s manual.

•

Lubrication refers primarily to the application of CORRECT LUBRICANT in the CORRECT AMOUNT to bearings and other rotating parts. It also means the application of a light oil to door hinges or other sliding surfaces. Use only clean and proper lubricant.

Planned maintenance, common sense and good judgment is less costly and more effective than panic maintenance. Action taken by the maintenance department on the recommendations made on the following suggested inspection checklists should reduce repair and maintenance costs and increase production.

Replacing worn components with genuine manufacturer parts on a scheduled basis will avoid costly down times and emergency repairs. The cost of parts is small when compared to unscheduled breakdowns that result in excessive overtime man-hours and lost machine production.

Whenever a problem is indicated, the inspector should briefly explain it on the maintenance report (a suggested form is at the end of this section) along with his signature. Then, an authorized person should briefly explain a solution to the problem. Finally, CORRECT THE PROBLEM.

Elements Of An Effective Maintenance Program •

Preventive Maintenance Program.

•

Well Trained and Motivated Work Force.

•

Effective Communications.

•

Proper Equipment Selection and Procurement.

•

Meaningful Documentation.

•

Cooperation with the Operations / Maintenance Department.

•

Warehouse Support.

•

Good Shop Facilities.

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Preventive Maintenance BI010940

Scheduled Preventive Maintenance Program Economically maintaining the productivity and performance of a mining shovel requires maintenance and inspection activities in a scheduled manner. Manpower requirements and performance of needed maintenance during scheduled downtime dictates a system which recognizes the recommended inspection interval. For example, dipper and crawler assemblies are exposed to severe service and should be inspected every maintenance period, while other components can be reasonably expected to operate twice this interval before inspection. By staggering the inspection or servicing of these items, labor time and work-force size is balanced.

Maintenance and component inspection should be performed simultaneously during scheduled downtime. History of machine maintenance practices has shown that parts replacement and component rebuild in advance of destructive failure yields the lowest operating costs. Keeping good records is vital to support any preventive maintenance program. Early “change-out” reduces unscheduled downtime and prevents secondary damage. Record keeping should be an “easy to use” format and contain enough detail to isolate the function. For instance, shovel rope and dipper teeth wear will often directly relate to tons of material loaded, rather than machine operating hours.

However, power transmission shafting and bearings wear rates correspond closer to operating hours. Since basic machine life extends over thousands of operating hours, maintenance records can be utilized to forecast budgets for maintenance expenditures. This makes records a very valuable planning tool for mine management.

Use the maintenance program that is outlined here to formulate a schedule suited to the work-force and mining environment. Over a period of time, additional inspection or planned work may supplement the activities described in this manual.

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

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7295 Electric Rope Shovel

3-5 October 2012

Preventive Maintenance BI010940

Maintenance During Machine Operation Safety requirements dictate that all machines in active service be inspected at regular intervals for proper adjustment of operating mechanisms, excessive wear of components, system cleanliness and any other defects. Deficiencies during machine operation should be carefully investigated. It should be determined if a safety problem exists. Maintenance is vital to safe operation! It should be performed systematically by competent personnel.

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

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

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

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

2.

3.

4.

Set the dipper on the ground.

Set all brakes.

De-energize control functions.

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

HIGH VOLTAGE! IF POWER IS ESSENTIAL TO THE REPAIR, SUCH AS FOR TESTING, IT

SHOULD ONLY BE ENERGIZED WHEN ALL PERSONNEL ARE CLEAR OF ELECTRICAL AND MECHANICAL HAZARDS. The power should only be energized during the testing period and not when repair work is actually being done.

3-6 October 2012

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

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

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

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

Many of the components comprising the machine are heavy, bulky items. EXTREME CAUTION SHOULD BE USED WHEN LIFTING THESE ITEMS. PERSONNEL SHOULD BE CERTAIN OF THE WEIGHTS OF COMPONENTS BEFORE ATTEMPTING TO LIFT THEM, EITHER MANUALLY OR WITH A LIFTING DEVICE. ALL APPLICABLE SAFETY RULES MUST BE FOLLOWED WHEN USING A CRANE OR OTHER LIFTING DEVICE. Be aware of the load rating, lifting height and swing radius of the lifting device before lifting a load. Failure to follow all applicable safety rules when performing maintenance could result in serious injury, or death.

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3-7 October 2012

Preventive Maintenance BI010940

Preventive Maintenance For Lubrication Lubrication may well be the most important portion of a preventative maintenance program. Do not allow anything to interfere with the lubrication of the machine. Experience will dictate how to adjust the amount of lubricant to use at each servicing. The extra effort will result in a smooth running machine with less wear and breakdowns.

It is difficult to predict how much lubricant should be applied to a particular bearing. It varies with how hard the machine is being worked, how much the bearing has previously worn and the grade of lubricant being used. Watch all the bearings closely to ensure that the lubricant added with each servicing will last to the next.

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

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

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

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

The LUBRICATION section of this manual will provide more detailed and specific information on lubricants and their usage.

3-8 October 2012

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

Follow these points of good lubrication practice: •

Keep all oil and other lubricants in tightly covered containers.

•

Wipe off covers before opening containers.

•

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

•

Wipe off each fitting before attaching the lubricant gun.

•

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

Refer to the topic LUBRICANT BENCHMARKS in the LUBRICATION Section of this manual for an explanation of each type of lubricant required for servicing this machine. Make sure the lubricant was not dirty or of improper viscosity. When the machine is operated for more than one shift each day, all crews must cooperate on checking lubrication. This is to ensure that no lubrication point will be missed or over-lubricated. It is usually best to do this at the beginning of each shift. Reproducible service schedules are provided for recording service information.

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

When it is not possible to work on the machine with a safety harness, use a “cherry picker” or “man basket” when inspecting or servicing elevated areas. A slip or fall can result in severe personal injury or death.

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3-9 October 2012

Preventive Maintenance BI010940

Frequency Of Inspection And Maintenance The suggested maintenance schedule is developed on a planned usage of 5,000 operating hours per year. This is a planned reference only. The actual conditions within the mine site, operator’s abilities and habits, along with the quality of components and consumables will ultimately drive the inspection schedule used on the machine.

Care should be taken to properly evaluate the maintenance approach during the initial period after machine commissioning.

Maintenance Schedules The following maintenance schedule is based on a typical machine. Certain features or configurations may be different on a specific machine. This maintenance schedule is intended to outline the intervals for the various repetitive maintenance requirements. For any assistance, refer to the appropriate section in this Maintenance Manual.

For locations of the specified components, refer to the graphics at the end of this section.

Maintenance Inspection Check Points The recommended check point schedules in this section are scheduled inspection guides. Perform inspection based on hours of use or time lapse intervals, which ever comes first. To verify inspection, copy the schedule pages of this manual, check all items inspected. If needed, add comments to the Noted Discrepancy column.

3 - 10 October 2012

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Daily 1.

Check the areas under and around the crawlers for signs of oil leaks. If single droplets are noticed, leakage is minimal.

Determine the point of leakage and note it on the log sheet. If pooling of oil is noticed, determine the source and begin maintenance or repair activity immediately. Determine if loose hardware, a defective gasket, a combination of both, or a similar problem is responsible. Tighten hardware or replace defective gaskets.

2.

Crawler Belts - Inspect for missing links or lock pins, excessive belt sag, cracked shoes or other deterioration.

3.

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

4.

Propel Motor Couplings - Inspect for debris, adequate lubrication and evidence of damage. Apply MPG as required.

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

5.

Machinery House Exterior - Visually inspect for damage or evidence of internal leakage.

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3 - 11 October 2012

Preventive Maintenance BI010940

Daily Check Points (cont.)

6.

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

7.

Dipper Door - Inspect the door structure, hardware and bumpers (if included) for damage and excessive wear.

8.

Dipper Handle - Inspect the crowd and retract rope attachment points, take-up cylinders and spacers and dipper handle for damage, excessive wear and evidence of adequate lubrication.

9.

Boom Bumpers - Inspect for security and damage.

10.

Dipper - Inspect the dipper structure for cracks and deformations. Check the tooth adapters for security and excessive wear.

11.

Padlocks - Inspect for damage, wear.

12.

Ropes - Check both the running ropes and the boom structural strands for broken strands, loose sockets or any additional visual indications that would indicate a loss of structural integrity.

13.

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

14.

Gearcase Machinery - Visually inspect all machinery for loose bolts, nuts, clamps or unusual conditions. Repair as required.

3 - 12 October 2012

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Daily Check Points (cont.)

15.

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

16.

Hoist and Crowd Ropes - Visually inspect for wear, lubrication and evidence of birdcaging near the drum attachment beckets.

17.

Air Compressor(s) - Check the oil level, add ASCL if required.

18.

Air and Lube System Lubricators Check the lubricant supply level.

19.

Automatic Lubrication System - Inspect the central pumping stations for any signs of malfunctioning. Check the lubricant supply and refill tanks if required with OGL or MPG.

20.

Swing Brake Assemblies - Visually inspect for damage, wear and overheating.

21.

Crowd Brake Assemblies - Visually inspect for damage, wear and overheating.

22.

Hoist Brake Assemblies - Visually inspect for damage, wear and overheating.

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3 - 13 October 2012

Preventive Maintenance BI010940

Daily Check Points (cont.)

23.

Operator’s Cab - Check for cleanliness and the visual condition of the controls.

Check the location of special equipment that may be required by the mine site.

Check all operating controls for freedom of movement. The controls should move freely without binding.

24.

Operator’s Cab - Clean all windows.

25.

Walkways and Stairways - Inspect to ensure there are no obstructions, damage or fluids creating a safety hazard.

26.

Boarding Stairs and/or Boarding Ladders - Ensure all are raised and properly stowed and latched.

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

27.

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

28.

At the Cable Reel, if equipped, check the Hydraulic Fluid Reservoir for proper fluid level. Add fluid if required.

29.

Visually check the Cable Reel Hydraulic System for leaks. Tighten, repair or replace components as necessary.

3 - 14 October 2012

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Every 100 Hours, Or Weekly (WHICHEVER OCCURS FIRST) 1.

Hoist Drum Gear Pinion - Clean off lubricant and inspect the tooth condition of the gear.

2.

Hoist Drum Bearing Lube - Check the operation of the auto lube system for the bearings and open gears.

3.

Hoist Automatic Lubrication System Check the lube valves for bypassing in valves and injectors.

4.

Crowd Lube System - Check the operation of the injectors, condition and connection of all hoses, cycle each injector to ensure proper lubricant delivery.

5.

Gearcase Fluid - Check the fluid level, sample fluids for testing (viscosity and contamination).

6.

Gearcase Breathers - Clean, verify condition and security. Check both crowd and hoist gearcases.

7.

Lower Rail Lubrication - Verify the proper function of the automatic lubrication system.

8.

House Rollers and Rails - Verify roller axle lube and lube on the roller surfaces.

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3 - 15 October 2012

Preventive Maintenance BI010940

100 Hours Or Weekly (cont.)

9.

Automatic Lube System - Check all lube lines for damage and replace as required.

10.

Automatic Lube System - Check each lube injector for proper operation and adequate dispensing of lubricant.

11.

Boarding Stairs and/or Boarding Ladders - Check all components, including: safety chain and gate, mounting bolts, hydraulic line and fittings, cylinder pin, arm pins and pin retainers. Replace any worn or damaged components.

Lubricate the arm pins and cylinder pins.

Check the lock pin and lubricate as necessary.

3 - 16 October 2012

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Every 500 Hours, Or Monthly (WHICHEVER OCCURS FIRST) 1.

Hoist Brake - Check proper operation, lining wear and adjustment. Refer to section 6 in this manual - Brakes and Couplings, for adjustment procedure.

2.

Crowd Gearcase Lube - Check both gearcases for leaks, lubricant level and the condition of the gearcase breather.

Clean or repair as needed.

3.

Crowd Brake - Check operation, linings for excessive wear, quick release operation and solenoid valve operation.

4.

Crowd Auto Lube System - Inspect the lube injectors, fittings and hoses. Verify correct operation of the system.

5.

Swing Gearcases - Operate the machine while listening for unusual noises and vibrations. Contact the manufacturer if problems are encountered.

6.

Swing Gear Lubricants - Check levels and correct as required.

7.

Swing Brake - Check for proper operation, lining wear, proper release and solenoid operation.

8.

Air System Controls - Inspect all air gauges, regulators, filters and oil-to-air line lubricators.

9.

Air System Lines - Inspect all tubing, hoses and fittings for damage and leaks.

Repair all leaks.

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3 - 17 October 2012

Preventive Maintenance BI010940

500 Hours Or Monthly (cont.)

10.

Lube Lines - Inspect all lines and fittings.

Repair all leaks and damaged hoses.

11.

Auto Lube Control Panel, Lube Reservoirs - Check lubricant levels and re-service. Repair all leaks and clean up spillage.

12.

Boom Structure - Inspect the entire boom structure (man basket recommended) for damage, cracks repair immediately.

13.

Boom Foot Pins - Inspect the boom foot pins, clearance keepers and retainers for damage, repair or replace as required.

14.

Boom Ladders and Handrails - Inspect for damage and repair immediately.

15.

Front and Rear Legs - Inspect visually for cracks and indications of stress.

16.

Suspension Ropes - Check for broken wires. If 30% of the outer wires are broken, or 10% of the total wires are broken, replace suspension cable.

17.

Dipper Corner and Center Shrouds Check for tightness, repair as required.

18.

Dipper Tooth Points - Teeth should be tight to adapters or dipper lips. Rebuild or repair as required.

3 - 18 October 2012

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500 Hours Or Monthly (cont.)

19.

Dipper Lip, Front - Completely check the front structure for wear, rebuild as required. Inspect for cracks and pay special attention to weld joint areas, repair immediately.

20.

Dipper Back Structure - Inspect for cracks/damage, repair immediately.

21.

Dipper Door - Check for bushing and pin wear. Rebuild as required. Check the door structure for cracks or damage, repair immediately.

22.

Latch Bar/Mechanism - Inspect the latch bar for wear, rebuild as required. Adjust the mechanism for proper operation.

23.

Latch Bar Dutchman - Rebuild as required, replace after 3 rebuilds.

24.

Dipper Door Snubbers - Inspect the linkage, pins, bushings, replace as required. Adjust if door swings too freely or does not close completely.

25.

Dipper Heel Band - Inspect and record wear to assure proper rebuild timing.

26.

Dipper - Check wear internally to plans.

Correct rebuild timing. Refer to the manufacturer for reline recommendations.

27.

Dipper Connecting Bushings and Pins Inspect all connecting bushings and pins, replace as necessary.

28.

Dipper Pitch Brace (Adjustable) - Check for missing or loose bolts. Tighten or replace as required.

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3 - 19 October 2012

Preventive Maintenance BI010940

500 Hours Or Monthly (cont.)

29.

Crowd Rope - Inspect the ropes, replace badly worn, frayed or damaged ropes.

30.

Retract Rope - Inspect the ropes, replace badly worn, frayed or damaged ropes.

31.

Dipper Trip Rope - Inspect the ropes, replace badly worn, frayed or damaged ropes.

32.

Hoist Drum Lagging Grooves - Check for damage and excessive wear.

33.

Upper Rail Clamps - Tighten the clamps and verify the integrity of the rail end chocks.

34.

Propel Planetary Gearcases - Pull the bottom plug and collect a 1/2 gallon of lubricant. Inspect the sample for metal particles.

35.

Boarding Stairs and/or Boarding Ladders - Check all components, including: safety chain and gate, mounting bolts, hydraulic line and fittings, cylinder pin, arm pins and pin retainers. Replace any worn or damaged components.

Lubricate the arm pins and cylinder pins.

Check the lock pin and lubricate as necessary.

3 - 20 October 2012

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Every 1250 Hours, Or Quarterly (WHICHEVER OCCURS FIRST) 1.

Crawler Links - Adjust the tension as required.

2.

Take-Up Tumbler - Check the condition of the bushing.

3.

Lower Rollers - Check for cracks, unusual wear, O.D. of the rollers, bushing wear, seal leakage and proper lubrication.

4.

Crawler Links - Check the drive tumbler O.D. and the link pins for wear and/or an out of pitch condition.

5.

Gearcases - Check all covers and plugs for leakage - seal as required.

6.

Propel Brake Assembly - Verify proper brake operation. Replace worn friction linings as required. Check the air cylinder piston travel and the adjustment of the springs.

7.

Roller Circle Rollers - Verify roller integrity, replace broken or cracked rollers.

8.

Center Pintle - Verify the proper adjustment of the pintle locking nut and the security of the locking bars. Clean spent grease from under the lower nut.

9.

Center Pintle Lube - Verify for correct spherical washer and truck frame pintle bushing lubrication.

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3 - 21 October 2012

Preventive Maintenance BI010940

1250 Hours, Or Quarterly (cont.)

10.

Warning/Safety Placards - Replace all missing safety and warning signs.

11.

Left Hoist Drum Spider - Inspect the spider for cracks, the fit to the drum and bolt tension.

12.

Hoist Drum Assembly Bearings - Inspect the bearings, retainers and seals for damage and correct as needed.

13.

Hoist Motor Coupling - Inspect the coupling, replace as required.

14.

Hoist Motor - Inspect the mounting bolts for security, the blower duct work for damage and security.

15.

Hoist Brake Air System - Check the operation of the solenoid valve, release and set operations, hoses, fittings and quick release valve.

16.

Crowd Machinery Frame - Inspect for loose bolts or chock blocks, worn mount pins and cracks. Repair as required.

17.

Crowd Drum Bearing Journals - Inspect the retainer, bearing retainer bolts, seals and condition of bearings.

Bearing Cap Mounting Bolts - Check for tightness.

18.

19.

Crowd 1st Gear Reduction - Inspect the gear and pinion teeth for the proper wear pattern, excessive wear and alignment.

Correct as required.

3 - 22 October 2012

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1250 Hours, Or Quarterly (cont.)

20.

Crowd 2nd Gear Reduction - Inspect the gear and pinion teeth for the proper wear pattern, excessive wear and alignment.

Correct as required.

21.

Crowd 3rd Gear Reduction - Inspect the gear and pinion teeth for the proper wear pattern, excessive wear and alignment.

Correct as required.

22.

Crowd Machinery Bearings - Inspect the bearings, retainers and seals. Re-tighten the retainer bolts.

23.

Crowd Motor Coupling - Check for lubrication and wear.

24.

Air Compressor(s) - Change the crankcase oil, clean the intake filter and refill the anti-freezer with the required agent.

25.

Compressor V-Belts - Check the belt tension, readjust as required. Maintain belt/pulley alignment.

26.

Compressor Intercooler - Inspect the intercooler tubing, replace as required.

27.

Center Pintle - Inspect the upper end for leaking or broken fittings. Check the lube and air swivel for a worn spindle housing seal and/or bypassing. Repair immediately as required.

28.

Lube Pressure Switches - Verify that all pressure transducers operate properly per machine requirements.

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3 - 23 October 2012

Preventive Maintenance BI010940

1250 Hours, Or Quarterly (cont.)

29.

Boom Bumpers - Inspect and repair as required.

30.

Boom Point Machinery - Inspect both sheaves and bearings for damage, repair as required.

31.

A-Frame Legs - Check the mounting pins and retainers, replace worn parts.

32.

Suspension Links - Inspect the links for worn pins, cracks, replace as required.

33.

Boom Suspension Rope Sockets Inspect and lubricate the sockets at each end of each rope.

34.

Dipper Tooth Adapters - If used, check the fit of the adapters to the lip. Must be tight fitting, repair as required.

35.

Padlock Connection - Check the clearance in the dipper padlock bearing, replace worn parts as required. Check the padlock link-to-bucket pin for wear.

36.

Hoist Ropes - Inspect the ropes, replace badly worn, frayed or damaged ropes.

37.

Swing Motor - Regrease drive end and non-drive end bearings.

3 - 24 October 2012

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Every 2500 Hours, Or Semi-annually (WHICHEVER OCCURS FIRST) 1.

Crawler Link Pin Clearance - Check, record average link pin clearance as per Section 5 of this manual.

2.

Crawler Frames - Inspect the crawler frames for cracks in the wear plates and bottom plates of the crawlers. Also inspect the connection of the crawler frames to truck frame for loose and/or missing hardware.

3.

Lower Rollers - Check for wear and/or cracks.

4.

Propel Gearcases - Verify mounting bolt tension with a torque wrench.

5.

Propel Motor Coupling - Inspect the coupling gear teeth for wear, re-lubricate.

6.

Drive Tumbler - Check for presence of lube in the relief fitting.

Lube must be present! If fresh lube is not present, attempt to purge the lube through. If still no lube, remove the tumbler and shaft to investigate the problem.

7.

Propel Motor Bearing Lube – Relubricate.

8.

Propel Blower Mounts - Verify security and condition of the blower motor.

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3 - 25 October 2012

Preventive Maintenance BI010940

2500 Hours, Or Semi-annually (cont.)

9.

Truck Frame - Visually inspect the internal structure for cracks and damage. Repair as required.

10.

Roller Circle Assembly - Verify all frame splice plate bolts and roller pin bolts are tight.

11.

Propel Blower - Check the blower ducts and connections and clean the fan.

12.

Hoist Machinery Pedestals - Check the connection between the hoist gearcase and the revolving frame.

13.

Center Pintle Upper Box - Remove the cover and verify the condition of all lube and air lines through the center of rotation.

14.

Center Pintle Air Swivel - Check the test port for signs of air or lube leakage.

15.

Walkways/Ladders/Stairs, Hand Rails/ Skid Protection - Repair all damaged sections. Replace or repair all damaged hand rails, toe plates and skid protection.

16.

Hoist Drum Lagging Bolts - Check all bolts for tension and retainers. Hoist Drum Gear Bolts - Check bolts for tension and retainers on left and right sides.

17.

Crowd Bearing Case Bolts - Check the tightness of all bolts.

18.

Crowd Drum Lagging - Inspect the condition of the rope grooves and anchors for excessive wear and distortion.

19.

Crowd Auto Lube System - Check all valves and injectors for bypassing.

3 - 26 October 2012

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Preventive Maintenance BI010940

2500 hours, or semi-annually (cont.)

20.

Crowd Gears/Pinions - Photograph all crowd machinery gears/pinions for future comparison. Ensure all teeth are clean for photo. Record the date and machine hours.

21.

Swing Air System - Inspect all air lines and fittings for leaks. Repair as required.

22.

Swing Motor Mounting - Inspect and tighten all swing motor mounting bolts.

23.

Air System Pressure Switches - Verify the correct function and setting of switches and regulator.

24.

Lube Room, Air Control Valves - Inspect all valves electrically and manually for proper operation. Repair/replace as required.

25.

Lube Pump Stations - Verify that all pumps and controls are operating properly, repair as required.

26.

Boom Point Machinery - Check all bearings, adjustments, retainers, seals repair or replace as required.

27.

Suspension Sockets - Check for worn pins, lug ends. If wear exceeds 0.25 inch replace bridge pendant.

28.

Hoist Motor - Regrease drive end and non-drive end bearings.

29.

Propel Motor - Regrease drive end and non-drive end bearings.

30.

Crowd Motor - Regrease drive end and non-drive end bearings.

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3 - 27 October 2012

Preventive Maintenance BI010940

5000 Hours, Or Annually (WHICHEVER COMES FIRST) 1.

Propel Gearcase - Check for leaks, cracks - repair as required.

2.

Crawler Frame Underside - Check for wear, cracks, damage.

3.

Tighten all crawler frame connecting rod jack bolts per Section 5 in this manual.

4.

Propel motors - Verify motor coupling clearance and alignment using a dial indicator. (Refer to manufacturer’s information.)

5.

Propel Gearcase - Pull the bottom plug and collect a 1/2 gallon of lubricant.

Inspect the sample for metal particles.

6.

Final Drive Shaft Bearing - Lube must be present! If fresh lube is not present, investigate the problem.

7.

Swing Rack - Verify the tension of the rack-to-truck frame mounting bolts and the rack joint assembly bolts.

8.

Roller Circle and Rails - Check for wear.

Replace rails or rollers when wear exceeds 1/2".

9.

Center Pintle Bushing - Check the truck frame bushing and replace if required.

3 - 28 October 2012

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Preventive Maintenance BI010940

5000 Hours Or Annually (cont.)

10.

Center Pintle Upper Nut - Verify that the lock bars and retaining dowels are in place. Check that the nut is flush with the top of the pintle - if not, investigate the problem.

11.

Revolving Frame - Thoroughly inspect the revolving frame integrity. Repair damage from cracks and wear.

(Includes the ballast box weld joint and swing gearcase support welds.)

12.

Revolving Frame Extensions - Check the extension bolts for security and retension as required.

13.

Machinery House - Repair all damaged sections, panels, doors and latches.

14.

House Filtration - Clean the filter units, inspect the blowers and fan blades closely. Repair or replace damaged and worn parts.

15.

Hoist Motor Pinion Shaft - Inspect the bearings, retainers and seals for damage. Correct as needed. Inspect oil passages for obstructions.

16.

Hoist Drum Gear Cover - Clean out excessive OGL.

17.

Hoist Brake Mounts - Inspect the mounting bracket bolts for damage and alignment.

18.

Crowd Motor - Inspect the mounts, chocks, coupling and blower for damage or wear. Correct as required.

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3 - 29 October 2012

Preventive Maintenance BI010940

5000 Hours Or Annually (cont.)

19.

Crowd Brake Mounting - Inspect mounting bracket for security and damage.

20.

Crowd Machinery - Check the torque on the taper lock pin retainers on the crowd module-to-deck mounts. Lubricate with spray lube.

21.

Swing Brake - Inspect the mounting brackets and check the tightness on all mounting bolts.

22.

Lube System - Check all valves, injectors and pumps for proper operation and damage. Repair as required.

3 - 30 October 2012

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Preventive Maintenance BI010940

Major Component Locations

Machine Nomenclature

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7295 Electric Rope Shovel

3 - 31 October 2012

Preventive Maintenance BI010940

Lower Works and Crawlers

3 - 32 October 2012

7295 Electric Rope Shovel

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Preventive Maintenance BI010940

Crawler Assembly

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3 - 33 October 2012

Preventive Maintenance BI010940

Crawler Link Assembly

3 - 34 October 2012

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Propel Machinery

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3 - 35 October 2012

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Roller Circle Section View

3 - 36 October 2012

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Roller Frame Assembly

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3 - 37 October 2012

Preventive Maintenance BI010940

Collector Rings Propel and Low Voltage (Rear Section View)

3 - 38 October 2012

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3 - 39 October 2012

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Center Pintle Assembly 3 - 40 October 2012

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Revolving Frame Deck Extensions

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3 - 41 October 2012

Preventive Maintenance BI010940

Hoist Machinery

3 - 42 October 2012

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Swing Machinery

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3 - 43 October 2012

Preventive Maintenance BI010940

Crowd Machinery

3 - 44 October 2012

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Lubrication Reservoirs

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3 - 45 October 2012

Preventive Maintenance BI010940

Operators Cab

3 - 46 October 2012

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Boarding Stairway

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3 - 47 October 2012

Preventive Maintenance BI010940

Machinery House Walkways and Platforms

3 - 48 October 2012

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Preventive Maintenance BI010940

Front End Equipment

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3 - 49 October 2012

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Boom Support Ropes

3 - 50 October 2012

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Boom Bumpers

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3 - 51 October 2012

Preventive Maintenance BI010940

Dipper Assembly

3 - 52 October 2012

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Service Procedures BI010941

4

Service Procedures

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Lower Works ................................................................................................................................ 7 Truck Frame Assembly ............................................................................................................. 7 Truck Frame and Crawlers Assembly ........................................................................................ 7

Swing Rack Assembly .............................................................................................................. 8 Roller Circle ............................................................................................................................. 9 Roller Frame Assembly ............................................................................................................ 10

Roller Circle Repair .......................................................................................................... 11 Roller Circle ~Section View ..................................................................................................... 12 Roller Circle and Rails ............................................................................................................. 13 Roller Circle ~Exploded View .................................................................................................. 14

Crawler Belts ............................................................................................................................. 15 Crawler Belt Maintenance ...................................................................................................... 15 Crawler Belt Tension Adjustment ...................................................................................... 16 Crawler Belt Tension Adjustment ............................................................................................. 17 Correct Belt Tension ................................................................................................................ 18

Crawler Shoe Replacement ............................................................................................. 18 Crawler Belt Replacement ............................................................................................... 19 Crawler Belt and Shoe Replacement ....................................................................................... 19

Crawler Side Frame Assembly ............................................................................................... 20 Crawler Side Frame Maintenance .................................................................................... 20 Crawler Assembly - Right Shown, Left Opposite ..................................................................... 21

Slide Bar Rebuild ............................................................................................................. 22 Crawler Mounted Slide Bars .................................................................................................... 22 Crawler Front Idler Assembly .................................................................................................. 23 (Left Shown, Right Opposite) ................................................................................................... 23 SM141403-EN

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4-1 October 2012

Service Procedures BI010941

Crawler Front Idler Roller Assembly ................................................................................. 24 Front Idler Assembly - Section View ........................................................................................ 24

Load And Idler Rollers ...................................................................................................... 26 Roller Removal Or Replacement ...................................................................................... 28 Load Roller Removal ................................................................................................................ 28

Propel Assembly ....................................................................................................................... 30 Propel Drive Shaft Assembly - Exploded View ........................................................................ 30 Propel Drive Shaft Assembly - Section View ........................................................................... 31

Installation Notes ............................................................................................................. 32 Main Propel Drive Shaft Removal .......................................................................................... 33 Fixtures for the Main Propel Shaft ...........................................................................................

Propel Shaft Pilot Rod ..............................................................................................................

Propel Shaft End Support .........................................................................................................

Details for the Main Propel Shaft Fixtures ...............................................................................

34 35 35 35

Main Propel Shaft - Disassembly ..................................................................................... 37 Main Propel Shaft - Section View ............................................................................................ 39

Tumbler Rebuild Procedure ............................................................................................. 40 Crawler Tumbler Rebuild .......................................................................................................... 40 Crawler Drive Tumbler Rebuild Template ................................................................................. 41

Propel Machinery ................................................................................................................... 42 Propel Planetary Gearcase .............................................................................................. 44 Propel Gearcase Removal ............................................................................................... 44 Propel Gearcase Installation ............................................................................................ 46 Propel Motors .................................................................................................................. 47 Propel Motor Removal ..................................................................................................... 48 Propel Motor and Motor Support .............................................................................................. 49

Propel Motor Installation .................................................................................................. 50 Center Pintle .......................................................................................................................... 52 Center Pintle - Section Views .................................................................................................. 55

Center Pintle Adjustment .................................................................................................. 56 Center Pintle Sleeve Removal ......................................................................................... 57 Collector Rings ...................................................................................................................... 58 Collector Rings - Propel and Low Voltage ................................................................................ 58 (Rear Section View) ................................................................................................................. 58

Collector Ring Inspection ................................................................................................. 60 Collector Ring Repair ....................................................................................................... 61 Rotating Deck ............................................................................................................................ 62 Swing Machinery ....................................................................................................................... 62 Inspection ........................................................................................................................ 63 Swing Gearcase .................................................................................................................... 64 Swing Motor Removal ............................................................................................................ 65 Gearcase Cover Removal ................................................................................................ 67 View G ..................................................................................................................................... 67

Intermediate Shaft And Gear Assembly Removal .............................................................. 69 Intermediate Shaft And Gear Assembly Re-assembly ....................................................... 70 Vertical Swing Shaft And Pinion Removal ......................................................................... 73

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Vertical Swing Shaft And Pinion Re-assembly .................................................................. 76 Detail A ..................................................................................................................................... 76 Detail B .................................................................................................................................... 77 Detail C .................................................................................................................................... 77

Hoist Machinery ........................................................................................................................ 79 Hoist Machinery Assembly ...................................................................................................... 79

Hoist Motor Removal ............................................................................................................. 80 Hoist Gearcase, Coupling and Motor Assembly ...................................................................... 80 Hoist Motor Mounting - Side View ............................................................................................ 81

Hoist Gearcase Assembly ...................................................................................................... 82 Hoist Gearcase Assembly ....................................................................................................... 82 Hoist Gearcase Section View .................................................................................................. 83

Hoist Gearcase Cover Removal ............................................................................................. 84 Propel Gearcase Cover Mounting Flanges ............................................................................... 85

Hoist Motor Pinion Shaft Removal ......................................................................................... 85 Hoist Motor Pinion Shaft Section View .................................................................................... 87

Hoist Motor Pinion Bearing Installation .................................................................................. 88 View C ...................................................................................................................................... 88

Hoist Intermediate Shaft Removal .......................................................................................... 89 Hoist Intermediate Shaft Bearing Installation .......................................................................... 91 View C ...................................................................................................................................... 91

Hoist Drum Assembly ............................................................................................................. 92 Inspection ........................................................................................................................ 93 Hoist Drum Removal ........................................................................................................ 93 Hoist Drum Gear Replacement ........................................................................................ 95 Hoist Drum Bearing Removal ........................................................................................... 98 View A - Right Side Shown ....................................................................................................... 98 View B - Right Side Shown ...................................................................................................... 99

Hoist Drum Bearing Installation ...................................................................................... 100 View C .....................................................................................................................................100

Hoist Mounting Bolts ............................................................................................................ 101 Hoist Limit Switch................................................................................................................. 102 Crowd Machinery .................................................................................................................... 103 Gearcase Cover Removal .................................................................................................... 105 L.H. Gearcase Cover Mounting Flanges ................................................................................. 105 R.H. Gearcase Cover Mounting Flanges ................................................................................. 107

Crowd 1st Intermediate Reduction Gears............................................................................. 108 1st Intermediate Shaft .............................................................................................................109

1st Intermediate Shaft Bearing Installation ..................................................................... 112 View C ..................................................................................................................................... 112

Crowd 2nd Intermediate Reduction Gears ........................................................................... 113 2nd Intermediate Shaft ............................................................................................................ 114

2nd Intermediate Shaft Bearing Installation .......................................................................... 117 View C ..................................................................................................................................... 117

Crowd Motor Removal ......................................................................................................... 118 Top View of Crowd Motor, Motor Coupling and Brake ............................................................. 119

Crowd Motor Installation ...................................................................................................... 120

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4-3 October 2012

Service Procedures BI010941

Crowd Brake Removal ......................................................................................................... 121 Crowd Brake and Brake Guard ............................................................................................... 121

Motor Pinion Shaft Removal ................................................................................................ 122 Section View A - A (Top View) .................................................................................................124 Section View B-B (Top View) .................................................................................................. 124 Section View C-C (Top View) .................................................................................................. 125

Crowd Gear and Drum ......................................................................................................... 126 Crowd Frame & Drum - Right Side View ................................................................................. 126

Crowd Drum Removal .......................................................................................................... 127 Section View A ........................................................................................................................ 128

Machinery House .................................................................................................................... 130 Walkways, Stairways and Handrails ..................................................................................... 131 Boarding Stairs .................................................................................................................... 132 Retractable Boarding Ladder ............................................................................................... 134 Front End Equipment .............................................................................................................. 135 Front End Equipment .............................................................................................................. 135

Boom Assembly ................................................................................................................... 136 Boom Repair .................................................................................................................. 137 Boom Limit Switch Installation .............................................................................................. 138 Section A - A Boom Inductive Proximity Switch ......................................................................139

Boom Point Sheaves ........................................................................................................... 140 Boom Point Sheave Assembly (2 Places) .............................................................................. 140

Boom Point Sheave Removal And Disassembly ............................................................. 141 Boom Point Sheave Reassembly And Installation .......................................................... 143 Boom Bumper ...................................................................................................................... 145 Saddle Block ........................................................................................................................ 146 Saddle Block ........................................................................................................................... 146

Saddle Block Repair ...................................................................................................... 147 Saddle Block Removal ................................................................................................... 148 Saddle Block Sheave .............................................................................................................. 149

Dipper Handle ...................................................................................................................... 150 Handle Removal .................................................................................................................. 151 Retract Take-Up Mechanism ................................................................................................ 152 Front Stop & Spreader ......................................................................................................... 154 Spreader Repair ............................................................................................................. 155 Dipper Assembly .................................................................................................................. 156 Dipper Door Latch Bar and Lever ............................................................................................ 157 Section D ................................................................................................................................ 158

Latch Bar Adjusting Procedure ....................................................................................... 158 Dipper Removal & Installation ........................................................................................ 159 View A .................................................................................................................................... 160 View B .................................................................................................................................... 161 View C .....................................................................................................................................162 View D .....................................................................................................................................163

Dipper Door Snubbers ................................................................................................... 164 Snubber Adjustment ....................................................................................................... 165

4-4 October 2012

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Service Procedures BI010941 View A .....................................................................................................................................165

Dipper Pitch Brace ............................................................................................................... 166 Fixed Length Pitch Brace Assembly ....................................................................................... 166

Dipper Padlock .................................................................................................................... 167 Dipper Trip Assembly ........................................................................................................... 169 A-Frame ............................................................................................................................... 170 Auxiliary Winch .................................................................................................................... 172 Auxiliary Winch Assembly ...................................................................................................... 172

Boom Suspension Ropes..................................................................................................... 173 Wire Ropes .......................................................................................................................... 175 Wire Rope Inspection ..................................................................................................... 176 Hoist Rope Reeving & Replacement .................................................................................... 176 Shim for Hoist Rope Socket .................................................................................................. 180

Crowd Rope Reeving & Replacement .................................................................................. 181 Crowd Rope Reeving ............................................................................................................... 182 Crowd Rope Drum Reeving ..................................................................................................... 183

Retract Rope Reeving & Replacement ................................................................................ 185 Retract Rope Reeving .............................................................................................................186 Retract Rope Take-Up Mechanism ......................................................................................... 188

Retract Rope Tightening ...................................................................................................... 189 Dipper Trip Rope Reeving & Replacement .......................................................................... 190 Hoist and Crowd Limit Systems ............................................................................................ 191 Setting Rope Limits In The Hoist & Crowd System ............................................................... 192 View A - Calibration Limits Screen .......................................................................................... 193

Crowd Slowdown/Stop Limit ................................................................................................. 194 Retract Slowdown/Stop Limits .............................................................................................. 195 Lower Slowdown/Stop Limits ............................................................................................... 196 Hoist Slowdown/Stop Limits ................................................................................................. 197

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4-5 October 2012

Service Procedures BI010941

4-6 October 2012

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Service Procedures BI010941

Lower Works Truck Frame Assembly The TRUCK FRAME assembly consists of the bolt-on crawler assemblies with belts, truck frame structure, propel motors and planetary gearcases, center pintle, roller circle, swing rack and lower roller circle rails.

Truck Frame and Crawlers Assembly

The Truck Frame is the primary support structure for the machine. The two bolt-on crawler side frames each have a propel motor and planetary gearcase. This assembly provides the operator complete independent control of each crawler.

Both the Truck Frame and crawler structures should be inspected during each maintenance period for areas of distress. If cracks are found in any of the structural welds or plates these should be repaired during the next scheduled maintenance period.

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4-7 October 2012

Service Procedures BI010941

Each propel motor is equipped with a spring set, air released disc brake. These brakes require no adjustment. Inspect friction disc wear by removing the assembly cover and observe remaining amount of friction material on the disc. When wear reaches the change notch, replacement is required. Since these are holding brakes, wear rate will be slow. For brake maintenance, refer to the BRAKES & COUPLINGS section in this manual.

Swing Rack Assembly The swing rack assembly includes a 1-piece cast gear and 15 lower roller circle rail segments. A series of rail clamps and clamp bars secure the lower rail segments to the swing rack.

Capscrews fasten the swing rack to the truck frame structure.

Should the swing rack need to be replaced, it can be installed without complete separation of upper and lower frame structures. Maintenance inspection of the swing rack consists of a periodic check of torque on capscrews (semi-annual or 2500 hours, whichever comes first).

HIGH VOLTAGE! DO NOT ENTER THE TRUCK FRAME OR THE AREA BETWEEN THE REVOLVING FRAME AND THE TRUCK FRAME, UNLESS THE POWER SUPPLY TO THE MACHINE HAS BEEN DISCONNECTED. Isolate the machine from the mine substation and confirm that the collector rings have been grounded by a qualified electrician.

Failure to comply with these instructions could result in serious injury or death.

4-8 October 2012

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Service Procedures BI010941

Roller Circle

HIGH VOLTAGE! EXTREME CARE MUST BE EXERCISED AT ALL TIMES WHEN PERFORMING MAINTENANCE IN THE CENTER PINTLE AREA. High voltage can cause serious or fatal injury. Installation, operation and servicing of components should be performed only by qualified personnel. ALWAYS DISCONNECT THE ELECTRICAL POWER BEFORE ACCESSING THE CENTER PINTLE AREA.

Inspect the rollers and rails of the roller circle monthly for severe pitting or spalling. This will usually be an indication of non-uniform loading. Small incipient pitting is not unusual and is not harmful. If rollers are damaged to the extent that they retard the swing function, they should be replaced as soon as possible. The diameter of the replacement roller must be matched to the worn good rollers. Consult the manufacturer for the correct procedure.

NOTE: The machine can operate in an emergency with a few rollers missing - however the missing rollers must not be adjacent to each other and must be equally-spaced around the roller circle. The remaining rollers will be subjected to increased loading, resulting in a shorter roller life.

Inspect the inner and outer roller frame sections and the rollers weekly for broken bolts.

Normally the inside flange of the rollers contacts the inside edge of the lower rail. If they do not, a cracking or popping noise may be heard as the machine swings. This noise is caused by the rollers aligning themselves with the rails. Excessive popping requires a close inspection of the roller frame. Also, check the lubricant being used. Consult the manufacturer if noise is excessive.

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4-9 October 2012

Service Procedures BI010941

Check both the upper and lower rails to see that they are properly chocked and secured to the swing rack and the revolving frame. Check the rail clamp bolts and retighten as required. Also check the rail surfaces for pitting and spalling.

Roller Frame Assembly

4 - 10 October 2012

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Service Procedures BI010941

Roller Circle Repair To replace a roller, roller pin, frame or rail: 1.

Swing the machine until maximum access is available to the defective component.

Defective rollers should not be between upper and lower rails.

2.

Remove the splice plate bolts from each end of an outer frame section.

3.

Remove the nuts securing the roller pins to the outer frame section and remove the frame section.

4.

Remove the bolts from the roller pin and remove the defective roller with its pin.

If a lower rail segment must be replaced: 1.

Remove both inner and outer frame splice joints.

2.

Remove the chocks, clamp bar, and hardware securing the rail to the rack.

3.

Install a new rail segment. If required, install shims as needed to remove any spacing between rail segments.

If an upper rail segment must be replaced: 1.

Remove a frame and roller section.

2.

Swing the machine until the upper rail is over the gap.

3.

Remove the rail segment and install a new segment.

NOTES: •

Before replacing a new roller, contact the manufacturer for the procedure required to size the new roller to the old roller.

•

Install a new roller, roller pin or frame section as needed reversing the steps necessary for removal of the component.

•

Be sure to lubricate the roller pins and bushings and the roller when installing them.

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4 - 11 October 2012

Service Procedures BI010941

Roller Circle ~Section VIEW

4 - 12 October 2012

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Roller Circle and Rails

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4 - 13 October 2012

Service Procedures BI010941

Roller Circle ~Exploded VIEW

4 - 14 October 2012

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Service Procedures BI010941

Crawler Belts The Crawler Belts contact the ground and transfer the entire weight of the machine from the truck frame to the ground. Each belt is an endless shoe assembly that is moved by the propel machinery around the crawler side frame. One belt on each crawler consists of 48 cast alloy steel, non-cleated, double-pin connected shoes. The pins are retained in the shoes by lock bolts.

All the shoes assemble into the belt so that the male lugs on each shoe are toward the front of the machine when the shoe is on the bottom of the crawler frame.

Crawler Belt Maintenance 1.

Replace any missing or broken shoe pin lock bolts immediately.

2.

To remove old shoe pins - drive them out if possible, burn them out if necessary.

3.

Annually (5000 hrs.) remove any metal flow from the roller path on each shoe that interferes with belt motion. Use arc air to within 0.125 inch of final surface, then grind the remainder.

4.

Monitor the fit of the shoes or belt to the drive tumbler monthly (420 hrs.)

5.

•

Record wear rate.

•

Replace shoes or rebuild drive lugs as needed.

•

Replace the tumbler or rebuild wear areas as needed.

Replace or rebuild the slide bars on the crawler side frame BEFORE the drive lugs on the shoes touch the top of the crawler.

PROPERLY ADJUSTED BELTS REDUCE THEIR WEAR RATE AND PROLONGS THEIR SERVICE LIFE!

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4 - 15 October 2012

Service Procedures BI010941

Crawler Belt Tension Adjustment 1.

Propel the machine forward on level ground until most of the slack in the crawler belt is on top of the crawler.

2.

Safely park the machine. Remove the auto lube line from the end of the front idler shaft.

3.

Position 2 identical hydraulic jacks to the rear of the adjusting blocks on each side of the front idler in the crawler side frame. Seat the jack ram into the counterbore provided in the adjusting block.

4.

Remove the 2 shim retainer bars on each side to free the shims, and remove the shims from the storage space in front of each adjusting block.

5.

Extend both hydraulic jacks in unison to move the front idler assembly forward to tighten the belt. Do not permit the adjusting blocks to misalign in the side frame.

6.

Tighten the belt until the dimension measured from a straightedge on pins of one shoe to pins of adjacent shoe located between front idler and first slide bar is 0.75 - 1.0 Inch.

7.

Insert shims into the space on each side behind the adjusting blocks until a gap of 1.0 inch exists between the shims and the blocks.

NOTE: Shims of the same thickness and quantity must be used in the space on each side to maintain correct idler alignment in the crawler.

4 - 16 October 2012

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Service Procedures BI010941

8.

Release both hydraulic jacks and remove them from the crawler.

9.

Put the remaining shims in the storage space in front of each adjusting block. Reassemble the shim retainer bars to the crawler. Reconnect the auto lube line.

NOTE: Both crawler belts should be adjusted to the same tension and the same overall length.

This is to ensure that the machine will propel in a straight line. The machine will have a tendency to turn toward the shorter belt when propelling forward.

Crawler Belt Tension Adjustment

NOTE: Moving the adjusting blocks 1.00 inch results in a belt adjustment of 2.00 inches.

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4 - 17 October 2012

Service Procedures BI010941

Correct Belt Tension

NOTES:

•

BEFORE the drive lugs on the shoes touch the top of the crawler frame, replace or rebuild the slide bars to their original height.

•

To check for the correct belt tension - while propelling the machine ensure that the crawler shoes effectively engage the drive tumbler. This is achieved when there is a minimum of radial shoe movement as it enters the load area of the drive tumbler.

Crawler Shoe Replacement

STORED ENERGY! SECURE THE CRAWLER BELT BEFORE SEPARATING IT SO UNEXPECTED MOVEMENT UNDER ITS OWN WEIGHT IS PREVENTED. Failure to secure the belt could result in bodily injury or death.

1.

Park the machine safely on a level work area with the shoe to be replaced at the front idler at the belt separation point.

2.

Add blocking between the top of the crawler frame and the shoes to remove any slack in the belt.

3.

Using hydraulic jacks, remove any belt tension by removing the shims behind the adjusting blocks on each side of the front idler shaft.

NOTE: Propel the machine slightly back and forth to unseat the adjusting blocks rearward in the frame slots if they do not move on their own.

3.

Block or support the shoe below the one to be removed. To separate the belt, remove the pin locking hardware and the pin from 2 places on the bottom of the shoe to be removed.

4.

Sling and support the shoe to be removed and then remove the pin locking hardware and the pin from 2 places on the top of the shoe to be removed. Remove the shoe from the belt.

5.

Position the new shoe into the belt. To fasten one end of the new shoe to the belt, insert the pins and locking hardware in 2 places to secure one end of the shoe. Remove the sling.

4 - 18 October 2012

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Service Procedures BI010941

6.

Align the other end of the shoe to the existing shoe to close the belt. Install the pins and locking hardware in 2 places to secure the shoe. Tighten the capscrews retaining all 4 pins removed to 1045 Ft-Lbs.

7.

Remove the blocking and adjust the belt tension.

Crawler Belt Replacement 1.

Park the machine in a level work area. Assemble the new belt forward of the machine, in line with the one to be replaced.

2.

Add blocking between the top of the crawler frame and the shoes to remove any slack in the belt.

3.

Remove any belt tension. To separate the belt, at the lowest point forward of the front idler, remove the locking hardware and pin from 2 places on the shoe.

4.

Connect the new belt to the front shoe under the front idler roller at the separation of the old belt. Install both pins and their locking hardware and tighten the capscrews to 1045 Ft-Lbs.

5.

Attach a wire rope to the upper portion of the old belt at the separation point, then to a truck or dozer.

6.

Pull on the top portion of the old belt to maintain engagement with the shoe lugs on the drive tumbler and SLOWLY propel the machine forward until the new belt has replaced the old on the crawler. Park the machine.

7.

Disconnect the old belt from the new and remove it from the work area. Pin the new belt together at the front idler.

8.

Adjust the belt tension.

Crawler Belt and Shoe Replacement

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4 - 19 October 2012

Service Procedures BI010941

Crawler Side Frame Assembly The Crawler Side Frame assembly provides the motion path and support structure for each crawler belt. Each assembly bolts to the truck frame structure and contains the propel machinery to drive its respective belt.

Each side frame assembly consists of the following components: • 8 Load rollers which transfer machine weight to the belt.

• 1 Front idler roller.

• 1 Rear idler roller.

• Drive tumbler shaft.

• Planetary propel gearcase, totally enclosed with right angle input.

• Propel motor with a single-disc, spring-set, air-released brake.

• Heavy duty fabricated frame structure with slide bars to guide the belt.

Crawler Side Frame Maintenance Maintenance and inspection requirements for each crawler side frame includes: • Check the tension of the rod bolts joining the crawler side frame to the truck frame.

(Refer to PROCEDURE FOR USE OF MECHANICAL TENSIONER ON CRAWLER RODS in ENGINEERING DATA section of this manual.)

• Inspect the crawler side frame structure for cracks quarterly (1250 hrs).

• Inspect lubrication coverage daily.

• Check auto lube injector operation daily.

• Change the oil in the gearcase yearly (5000 hrs) or as determined by lab analysis of oil samples.

4 - 20 October 2012

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Service Procedures BI010941

Crawler Assembly - Right Shown, Left Opposite

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4 - 21 October 2012

Service Procedures BI010941

Slide Bar Rebuild The Slide Bars on top of the crawler side frame can be repaired by applying weld material to the top of the slide bar surface.

The procedure for welding is as follows: 1.

Prepare a template of the top slide surface. See figure below.

2.

Clean the slide bar of all spalled, mushrooming or loose material, grease and contaminants. Use grinder to remover imperfections. DO NOT USE A TORCH.

3.

Preheat the slide bar to 260oC (500oF).

4.

Use Hobart Tufanhard #375, McKay Hardalloy #48 or an equivalent electrode. Deposit welds using stringer bead technique. Thoroughly chip and clean between passes and layers.

5.

Postheat to 260oC. Hold for two hours and then slow cool.

6.

Grind slide surface of bar to final contour required to fit shoe surface.

Crawler Mounted Slide Bars

4 - 22 October 2012

7295 Electric Rope Shovel

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Service Procedures BI010941

Crawler Front Idler Assembly (Left Shown, Right Opposite)

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4 - 23 October 2012

Service Procedures BI010941

Crawler Front Idler Roller Assembly The front idler roller carries the machine weight in conjunction with the load rollers. The roller turns about the idler shaft on bronze bushings. The idler shaft mounting consists of a pair of adjusting blocks which can be moved to the front or rear to compensate for crawler belt wear.

Shims located on either side of each adjusting block are used to maintain the roller position. To remove the front idler: 1.

Park the machine level and leave several inches of clearance under the front idler.

2.

Rotate the revolving frame to provide crane access to crawler belt and idler.

Front Idler Assembly - Section View

3.

Remove the shim retainer bars, lube lines and shims ahead of the adjusting blocks.

4.

Using the jacks provided, push the adjusting blocks on both sides of the idler shaft forward to allow removal of the remaining shims.

4 - 24 October 2012

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Service Procedures BI010941

NOTE: When using jacks to move the adjusting blocks, pressurize and release both jacks at the same rate to prevent binding of the idler shaft.

5.

Release the belt tension by slowly releasing the jack pressure to allow the adjusting blocks to move to their rear-most position.

6.

Separate the crawler belt behind the top of the idler and lay the forward crawler shoes on the ground in front of the crawler.

SECURE THE CRAWLER BELT BEFORE SEPARATING IT SO UNEXPECTED MOVEMENT UNDER ITS OWN WEIGHT IS PREVENTED. Failure to secure the belt could result in bodily injury or death.

7.

Support the idler (approx. 3475 Lbs.) with a crane.

8.

Remove the split collars from both sides including shear pins.

9.

Remove thrust washers from both ends of idler shaft at adjusting blocks.

10.

Pull adjusting blocks off of both sides for bushing(s) replacement. Push/pull shaft out for replacement.

STAND CLEAR OF THE AREA AS THE SHAFT IS REMOVED. The Thrust Washers on each side of the Idler are loose. THESE PARTS MAY FALL OUT AS THE SHAFT IS REMOVED. 11.

Remove the thrust washers on each side of the idler. Lift the idler clear of the crawler frame.

12.

Inspect all parts for wear or damage. Replace or repair as required.

Installation of the front idler is the reverse of removal.

NOTES: - If removed, install the thrust washers with their lube grooves toward the adjustment block. Verify that the proper running gap exists between the thrust washer and the idler on each side of the idler.

- When repositioning the idler adjusting blocks, install with the tapped lube hole in the upward position.

- Outside thrust washers and bushings in adjusting blocks can be replaced without removing front idler roller and shaft from the side frame.

- After installation, lubricate and check auto-lube. Adjust belt tension. Refer to proper procedures in this section of the manual.

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Service Procedures BI010941

Load And Idler Rollers The Load and Rear Idler Rollers are located at the bottom of each crawler side frame. The load rollers and rear idler distribute the machine weight on the crawler belt.

Each of the load rollers and rear idler roller turn on a fixed shaft secured in the crawler side frame by a lock collar and pin. Each roller is fitted with a bronze bushing.

Thrust plates are located between the rollers and inner frame bosses to retain lubrication and prevent the entry of dirt.

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NOTE: Install plug for shipping purposes. Remove at field assembly when lube line is installed.

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Service Procedures BI010941

Roller Removal Or Replacement Since the rollers are captured between the sides of the crawler frame, removal or replacement requires the separation of the crawler belt and the lowering of the roller below the crawler side frame. This is best accomplished by digging a pit to the dimensions shown in the following chart: Pit Size

Height

Width

REAR IDLER

55 inches

79 inches

LOAD ROLLER

39 inches

63 inches

Load Roller Removal

To remove a roller from the crawler side frame: 1.

After a pit has been prepared, position a handling fixture under the roller for support when the shaft is removed.

2.

Propel the machine forward to a position where the roller to be removed is directly over the hole. Separate the belt by removing the lock bolts. Lower each end of the belt into the pit exposing the roller for removal.

3.

Disconnect the auto lube line from the end of the roller shaft. Plug the line to prevent dirt entry.

4.

Remove the shaft retaining bolt.

5.

Drive shaft out of the crawler frame, to the outside, being careful to support the roller on a handling fixture, jack or cribbing. Remove the thrust plates as they come free.

The same procedure can also be used to remove the rear idler roller.

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To install or replace a load or rear idler roller: 1.

Position the replacement roller in the pit on some cribbing, a handling fixture or jack.

2.

Start shaft through the outside crawler side frame member. When the shaft begins to exit the other side, install the thrust plate.

3.

Raise the roller or idler into position and continue to drive the shaft through the roller or idler.

4.

As the shaft exits the roller, install the other thrust plate.

5.

Continue to drive the shaft through the crawler frame until the bolt retainer aligns with the hole in the collar.

NOTES: - Install the load or idler roller shafts with their lube line lubrication holes toward the inside of the crawler.

- Install the load or idler roller shafts with their lubrication holes toward the front of the machine. The punch mark on the end of the shaft indicates the lube hole location.

6.

Install the lock bolt and nut with locking collar. Install pin through rear idler roller thrust plates to lock into position.

7.

Install and purge the automatic lube lines. Check the lube system operation and reinstall the guards.

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Service Procedures BI010941

Propel Assembly

Propel Drive Shaft Assembly - Exploded View

NOTE:

The 3 socket head capscrews in the bearing cartridge of the Main Propel Shaft are present only to hold the subassembly of the cartridge and bearing to the shaft. They are not to be removed after installation, or during removal of the Main Propel Shaft.

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The drive shaft transmits propel effort from the planetary gearcase to the crawler belt. Antifriction bearings support the assembly at each end.

Propel Drive Shaft Assembly - Section View

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Service Procedures BI010941

Installation Notes 1.

Install the retainer with the lube hole on the horizontal centerline of the propel shaft and in line with the access hole.

2.

After thorough cleaning, coat the exterior splines and interior mating surfaces with Optimoly grease paste (PN: 62042829).

3.

Pack the rear of the spline cavity with 1 pint of lubricant; grease paste (PN: MP480206), prior to installing the shaft assembly.

4.

Spray lip seal area with Molylube 1200AR (PN: MP170025).

5.

Shim Procedure For Gap “A”: A. After bearing installation, assemble the retainer to the shaft and tighten the capscrews to 100 Ft-Lbs for gap measurement.

B. Measure through the 3 small holes in the retainer with a depth micrometer to determine the distance from the outer face of the retainer to the end of the shaft.

C. Remove the retainer and measure the retainer thickness at the 3 small holes.

D. Take the average of the 3 measurements from Step B and subtract the average of the 3 measurements from Step C. From this difference subtract .001-.003 inch to obtain the shim thickness.

E. Install the shim and the retainer. Tighten the capscrews to 905 Ft-Lbs.

6.

Shim Procedure For Gap “B”: A. Install the retainer and tighten the capscrews to 100 Ft-Lbs for the gap measurement.

B. Measure the gap at 3 places equally spaced around the O.D. of the retainer.

C. Remove the retainer. Take the average of the 3 measurements and subtract .001-.003 inch to obtain the shim thickness.

D. Install the shim and the retainer. Tighten the capscrews to 905 Ft-Lbs. E. Fill the bearing cavity with Multiplex EP2 grease (PN: MP380900).

7.

If shim is in 2 halves, install with the split line horizontal and seal the split with Form-AGasket (PN: MP134562) at joint split only.

8.

Install the retainer with lube point on centerline of propel shaft and toward the front of the crawler.

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Main Propel Drive Shaft Removal 1.

Park the machine safely on a level work area.

2.

Rotate the revolving frame to gain access to the propel machinery.

3.

Release the tension in the crawler belt to unpin the belt.

4.

Have a qualified electrician disconnect the trail cable from the machine and move it out of the way.

HIGH VOLTAGE! Only qualified personnel are permitted to perform this operation.

Failure to comply could result in bodily injury or death.

5.

Remove the walkway from the front of the wing, above the propel machinery.

6.

Separate the belt on top of the crawler, forward of the drive tumbler.

Secure the belt before separating it so that it cannot move unexpectedly under its own weight. Failure to do this could result in personal bodily injury.

7.

Lift the belt from the drive tumbler and lay it on the ground.

8.

Mark the tumbler and the shoe under it with a visible mark (paint) so that the tumbler can be repositioned to the belt in same location.

9.

Remove the guard from the propel motor coupling and disassemble the coupling.

10.

Support the propel gearcase (approx. 12,600 Lbs.) with a crane.

11.

Unbolt the propel gearcase and remove it. Store in a clean area.

12.

Remove the lube line to the inboard propel bearing at the inside of the gearcase housing.

13.

Disconnect and plug the lube line to the outboard bearing retainer. Remove the retainer with its shim pack from the end of the main propel shaft. Support the tumbler with the crane.

14.

Pull the outboard bearing carriage from its bore using 3 of the retainer capscrews as jack screws in the tapped holes provided in the cartridge flange.

15.

Remove the retainer plate from the outboard end of the tumbler shaft.

16.

Use the spacer between the bearing race and shaft shoulder as a puller. Six tapped holes are provided in the spacer to attach the threaded rods and hardware required. Hydraulic expansion of the inner race is also provided to ease the pulling force. Attach the hydraulic pump provided with the machine to the .25 inch hole in the end of the drive shaft. Use hydraulic pressure and pulling force simultaneously to remove the bearing race.

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Service Procedures BI010941

17.

Remove the 18 - 1 Inch capscrews which secure the cartridge and retainer to the crawler.

DO NOT remove the 3 capscrews which secure the retainer to the cartridge.

18.

Attach end support to the outboard end of shaft and install a pulling eye in the tapped hole provided on the inboard end of shaft. Remove the drive shaft assembly toward the CL machine.

Fixtures for the Main Propel Shaft

19.

Lift the tumbler clear of the crawler after the shaft has been removed.

20.

Inspect all parts for damage or wear. Replace or repair as required. Refer to the “Main Propel Shaft” for disassembly and rework.

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Propel Shaft Pilot Rod

Propel Shaft End Support Details for the Main Propel Shaft Fixtures

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Service Procedures BI010941

Reassembly is the reverse of disassembly.

1.

Replace all seals and bearings.

2.

Coat the internal and external spline surfaces and all pilot surfaces with Optimoly grease paste (PN: 62042829).

3.

The inner race for the outboard bearing on the main propel shaft may be heated to fit it to the shaft. Use a dry heat source and do not heat the race over 250o F (121o C). Allow the race to cool to ambient temperature before installing the rest of the bearing.

4.

Lube access on both bearing retainers of the main propel shaft must be installed on a horizontal centerline toward the front of the crawler.

5.

Shim the gaps as indicated on the accompanying sketches.

6.

Pack the rear of the spline cavity in the propel gearcase for the main propel shaft with 1 pint of lubricant; grease paste (PN: MP480206).

7.

Fill the bearings and cavities manually with Multiplex EP2 grease (PN: MP380900) at assembly. Reconnect and purge the lube line.

8.

Observe the match marking when installing the tumbler and propel gearcase, and when assembling the propel motor coupling.

9.

Propel motor coupling reassembly can be assisted by releasing the brake with the manual override on the air control valve to allow the motor shaft to rotate freely.

10.

Reconnect the crawler belt and adjust the belt tension. Reinstall the walkway to the front of the wing.

11.

Have a qualified electrician reconnect the trail cable to the machine.

HIGH VOLTAGE! ONLY QUALIFIED PERSONNEL ARE PERMITTED TO PERFORM THIS OPERATION. Failure to comply, could result in bodily injury or death.

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Main Propel Shaft - Disassembly 1.

Remove 2 locking capscrews from the bearing nut, and unscrew the bearing nut from the shaft using the special wrench provided with the machine.

2.

Lift the lip seal from the back face of the bearing cartridge, if it is still in place.

3.

Remove 3 socket head capscrews holding the retainer to the cartridge.

4.

Remove the retainer and seal spacer from the shaft.

5.

Pull the cartridge from the bearing in the opposite direction.

6.

Use a bearing puller to remove the bearing from the shaft.

7.

Remove the bearing spacer from the shaft.

8.

Inspect the final spacer that may remain next to the splines on the shaft. Remove if required for replacement.

9.

Inspect all parts and replace as required.

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Service Procedures BI010941

Reassembly is the reverse of disassembly: 1.

Install the inboard spacer, bearing cartridge, bearing and spacer.

2.

The double tapered bearing may be heated for assembly to the shaft. Use a dry heat source and do not permit the temperature of bearing to exceed 300oF (149o C). Allow the bearing to cool to ambient temperature before assembling any other parts to it.

3.

Install the bearing retainer with new lip seal.

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Service Procedures BI010941

4.

Shim the gap at the bearing retainer using the following procedures: A.

Install the retainer and tighten the 3 socket head capscrews to 100 Ft-Lbs for gap measurement.

B.

Measure the gap at 3 places equally spaced around the O.D. of the retainer.

C.

Remove the retainer. Take the average of the 3 measurements and subtract .001.003 inch to obtain the shim thickness.

D.

Install the shims and the retainer. Tighten the 3 capscrews to 508 Ft-Lbs. If shim is in 2 halves, install with the split line horizontal and seal the split with Form-A-Gasket (PN: MP134562) at joint split only.

5.

Fill the bearing cavity with Multiplex EP2 grease (PN: MP380900) at assembly.

6.

Spray the lip seal area with lubricant (PN: MP170025) at assembly.

7.

Install outboard sleeve and bearing nut. Tighten nut snug against the spacer.

8.

Install 2 locking capscrews in bearing nut and tighten to 105 Ft-Lbs.

9.

Assemble the main propel shaft into the tumbler and crawler.

Main Propel Shaft - Section View

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Service Procedures BI010941

Tumbler Rebuild Procedure The drive tumbler can be repaired by a buildup of weld applied to the 9 drive lugs. To build up the lugs, proceed as follows: 1.

Prepare a template as indicated in the sketch below. The template can be made of sheet metal, wood or template paper. Contact the manufacturer for details.

2.

Clean the tumbler of all spalled or loose material, grease and contaminants. Use a grinder to remove imperfections. DO NOT USE A TORCH.

3.

Preheat the tumbler rim to 550 oF (273 oC). Keep the hub area below 200 oF (93 oC).

Maintain this temperature during welding.

4.

Hold a medium length arc - slight weaving action is permitted but keep it to a minimum to prevent local overheating. Weld beads must be applied adjacent to each other without removing the slag. This will result in a smooth overlay. Remove the slag between layers, maximum of 3 layers permitted.

5.

Weld to within .19 inch of the final contour with weld rod that conforms to AWS E-9018.

Use only low hydrogen electrodes.

6.

Finish contour the buildup using one of the following electrodes, or its equivalent: Hardalloy 40 TiC, Stoody 100HC 3/32 inch, Stoody 965 APG 0.045 inch. Use small diameter electrodes and deposit with stringer bead technique.

7.

Allow the tumbler to cool slowly.

8.

If needed, grind to a final lug contour.

Crawler Tumbler Rebuild

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Service Procedures BI010941

Crawler Drive Tumbler Rebuild Template

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Service Procedures BI010941

Propel Machinery The Propel Machinery is interchangeable between the left and right crawler assemblies. Both the planetary gearcases and motors mount inboard at the rear of the crawlers. Before installing a left gearcase onto a right crawler side frame, exchange the oil breather with oil drain and exchange eye bolt with screw plug. (As the same gearcase can be used on either the right or left side note that following the previous instructions, either hole can be used as an oil drain.) The drive motors are also interchangeable between the right and left crawler frames. A disc brake mounts on the rear of each motor frame.

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Service Procedures BI010941

General maintenance and inspection of the propel machinery includes: 1.

Inspection of the gearcase and electric motor mounting bolts.

2.

Check the gearcase oil level daily by removing the oil level plug in the gearcase.

3.

Change the oil in gearcase annually or as indicated by lab test analysis. Flush the gearcase before refilling with oil. (See Lubrication Section.)

4.

Inspect the motor coupling quarterly for lube level and keep full.

5.

Lubricate the motor bearings semi-annually with EMG (Electric Motor Grease). Application of grease should be performed by qualified personnel as an excess could cause motor failure.

6.

Inspect the operation of the brakes daily. Monitor wear rate of friction disc. Replace when lining is worn out. For more detailed information on the description and maintenance of the propel brakes, see the ENGINEERING DATA, section in this manual.

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Service Procedures BI010941

Propel Planetary Gearcase The propel gearcase assembly includes three reductions - a right angle spiral bevel 1st reduction, a planetary 2nd reduction and a planetary 3rd reduction.

STORED ENERGY! Gearing or drum must be blocked prior to performing maintenance in order to prevent unwanted movement. Death, serious injury, or damage to the machine can result in failure to take proper prevention measures.

To minimize down time, it is recommended that the gearcase be replaced as a complete unit, if a problem should develop within the case. If the case is to be disassembled, it should be taken to a maintenance shop for repairs.

NOTES: 1.

The reduction spiral bevel (palloid) gear & pinion are manufactured as a matched set. Do not interchange or order separately.

2.

When replacing the single row tapered bearings on the spiral gear shaft & pinion cartridge, the end play must be adjusted & new spacers ground to fit.

3.

Check the 1st reduction tooth contact when a new bearing & new gears are installed.

4.

Change the planet gears in sets of 3 only.

5.

FOR LUBRICANT REPLACEMENT, Refer to the LUBRICATION section in this manual.

Propel Gearcase Removal To remove the left or right Propel Gearcase use the following procedure: 1.

Park the machine on a level work area.

2.

Rotate the upper frame to gain access to the propel gearcase with a crane or hoist.

3.

Disconnect the trail cable from the machine and move it out of harms way.

HIGH VOLTAGE! A QUALIFIED ELECTRICIAN SHOULD DISCONNECT THE TRAIL CABLE. Failure to comply could result in bodily injury or death.

4.

Remove the cable reel if furnished with the machine.

5.

Drain the oil from the gearcase.

6.

Remove the guard from the propel motor coupling.

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Service Procedures BI010941

STORED ENERGY! Once grid is removed, machinery is free to rotate and brake will no longer hold. Gearing or drum must be blocked prior to doing any maintenance to prevent unwanted movement. Death, serious injury, or damage to the machine can result from failure to take proper measures to prevent movement due to release of energy.

7.

Open the propel motor coupling and remove the spring grid. Note the match marking on the coupling covers.

8.

Remove the inspection cover from the housing on the crawler bell housing for viewing the main propel shaft/gearcase junction.

9.

Support the gearcase (approx. 12,600 Lbs.) with a crane line through the lifting eye on the gearcase.

10.

Remove all 36 capscrews that fasten the gearcase to the crawler side frame bell housing.

Match marks on the gearcase and crawler bell housing flange are for coupling alignment assistance if the SAME gearcase is reinstalled.

11.

Use 3 of the removed capscrews in tapped holes in the flange of the gearcase as jacking screws to evenly withdraw the gearcase from the pilot bore in the crawler bell housing.

12.

Remove the gearcase from the splines of the main propel shaft and lift it away from the crawler to some cribbing.

13.

If a new or exchange gearcase is to be installed, use a bearing puller to remove the coupling hub from the input shaft.

NOTE: The planetary gearcase design requires close tolerances and special tools for disassembly and rebuild. DO NOT ATTEMPT TO DISASSEMBLE THESE UNITS WITHOUT A QUALIFIED FACTORY REPRESENTATIVE PRESENT.

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Service Procedures BI010941

Propel Gearcase Installation The installation procedure for the propel gearcase is as follows: 1.

Install the coupling hub onto the gearcase input shaft. The Coupling hub should be heated to assist installation onto the shaft. Use a dry heat source and DO NOT permit temperature of the hub to exceed 350o F (177o C). Allow the hub to cool to ambient before assembling any other coupling parts.

2.

Install the a new face seal onto the propel shaft as shown in the sketch.

3.

Pack the rear of the spline cavity in the propel gearcase for the main propel shaft with 1 pint of Molub-Alloy grease paste (P/C 480206-3) or equivalent.

4.

Coat the internal and external spline surfaces and all shaft pilot surfaces with Molub-Alloy grease paste or equivalent.

5.

Install the gearcase by engaging the splines of the gearcase with the main propel shaft and the pilot register of the gearcase with the crawler housing. Install the spacer and 36 fasteners and tighten to 4,990 Ft-Lbs.

NOTE: Align the match marks if the same gearcase is being reinstalled. This will minimize the time required to align the coupling. If a NEW gearcase is being installed, add new match marks after the gearcase has been installed and the coupling aligned.

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6.

Fill the gearcase with the proper lubricant to the specified capacity. Refer to the LUBRICATION section in this manual. Be sure to install the breather and case plugs.

7.

The reassembly of the propel motor coupling can be assisted by releasing the disc brake with the manual override on the air control valve. This will allow the rotation of the motor shaft.

8.

Align the motor coupling per the specifications in the BRAKES AND COUPLINGS section in this manual. Install the grids and cover.

9.

Fill the propel motor coupling to the recommended level with special long term grease (P/C 295148-7).

10.

Install the cable reel, if furnished with the machine and reconnect the trail cable.

HIGH VOLTAGE! RE-CONNECTION OF THE TRAIL CABLE SHOULD ONLY BE PERFORMED BY A QUALIFIED ELECTRICIAN. Failure to comply could result in severe bodily injury or death.

Propel Motors For lubrication of the drive motor, refer to GREASING MAIN AC DRIVE MOTORS in the LUBRICATION section of this manual.

STORED ENERGY! Gearing or drums must be blocked prior to performing maintenance in order to prevent unwanted movement. Death, serious injury, or damage to the machine can result from failure to take proper prevention measures.

Each Propel Motor is bolted to a mounting pad located inside each crawler side frame. The motor output shafts are coupled to the planetary gearcase with grid type couplings. Coupling alignment is assisted with jacking screws located at six positions on the motor mounting pads.

Each propel motor is equipped with a spring-set, air-released disc brake.

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Service Procedures BI010941

Propel Motor Removal 1.

Park the machine on a level work area and rotate the upper frame to gain access to the propel motor.

2.

Have a qualified electrician disconnect the power from the machine and wiring from the propel motor.

HIGH VOLTAGE! ONLY QUALIFIED PERSONNEL ARE PERMITTED TO PERFORM HIGH VOLTAGE ELECTRICAL SERVICE AND MAINTENANCE. Failure to comply could result in bodily injury or death.

3.

Remove any dirt guards and/or cable support from around the motor and brake assembly.

4.

Remove the guard over the motor coupling. Open the coupling and remove the grid.

NOTE: Match marking on the coupling covers is for use in reassembly.

5.

Disconnect and plug the air supply at the disc brake.

RELEASE THE AIR PRESSURE TO THE BRAKE BEFORE DISCONNECTING THE AIRLINE. Plug the line immediately after disconnecting. Failure to comply could result in personal injury.

6.

Support the motor (approx. 4,000 lbs.) with a crane.

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Propel Motor and Motor Support

7.

Remove the 4 capscrews and related hardware that fasten the motor to the motor support.

Lift the motor away from the machine to the cribbing. Secure the shims at the 4 motor mounting points at the time of removal so that they are available for reassembly.

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Service Procedures BI010941

NOTE:

If the motor is to be replaced, remove the coupling hub and the brake rotor hub from each end of the electric motor armature shaft. For further information and a complete description of the propel brakes, refer to the BRAKES & COUPLINGS section in this manual.

Propel Motor Installation The following procedure assumes that the propel motor being installed is new & that it has none of the additional parts required for the application.

1.

Install the drive coupling hub & brake rotor hub onto the motor shaft. The rotor hub installs on the commutator end of the motor. Follow the hub/gear installation procedure in the ENGINEERING DATA section of this manual.

2.

Install the brake assembly so that the air inlet is at the bottom after the motor assembly is installed onto the machine. Again, refer to BRAKES & COUPLINGS section of this manual for installation & adjustment.

3.

Install the motor and brake assembly onto the crawler frame. Check the coupling alignment. With the motor shaft at midpoint of its axial float, the gap, angular offset & radial offset must all be within specification. Refer to GRID COUPLINGS in the BRAKES & COUPLINGS section of this manual for specifications & mounting instructions.

4.

If alignment is required, use the 4 jacking screws & mounting bolts to move the motor horizontally & the 2 jack screws under the motor to move it vertically. Once aligned, determine the shim thickness required and install the shims.

5.

Install the 4 motor mounting capscrews and related hardware.

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6.

Re-check the alignment. Position chock and wedge blocks under the motor if required.

7.

Install all guards, air lines & wiring.

ALL WIRING MUST BE DONE BY A QUALIFIED ELECTRICIAN.

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Service Procedures BI010941

Center Pintle

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HIGH VOLTAGE! EXTREME CARE MUST BE EXERCISED AT ALL TIMES WHEN PERFORMING MAINTENANCE IN THE CENTER PINTLE AREA. High voltage can cause serious or fatal injury. Installation, operation and servicing of components should be performed only by qualified personnel. ALWAYS DISCONNECT the electrical power BEFORE accessing the center pintle area.

The center pintle is a large diameter, hollow cylindrical forging with a flange at the top. It is threaded at the bottom with a lower locknut used to hold it in place. A bronze coated steel core spherical thrust washer between the lower locknut and the bottom surface of the truck frame provides a wear surface for pintle loads. The upper locknut at the top of the center pintle is doweled and bolted to the revolving frame to keep the center pintle from rotating.

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

1.

To inspect for worn thrust washers, rails, or rollers proceed as follows: a.

Every 3 months, check the amount of lift of the revolving frame at the rear of the machine. Engage the dipper in the bank at near maximum reach and apply hoist power.

b.

Measure the distance between the upper and lower roller rails at the rear of the machine.

c.

Subtract from this measurement the measured distance at the rear between the upper and the lower roller rails with the dipper on the ground.

d.

If the difference in measurement is greater than 1/2 inch, the pintle lower nut must be adjusted to limit the amount of lift to between 3/16 and 1/4 inch. Refer to the CENTER PINTLE ADJUSTMENT in this section of the manual.

2.

The thrust washer, rails, or rollers may be worn sufficiently to require replacement rather than adjustment. If necessary, replace a worn thrust washer per the center pintle repair procedure and replace a worn roller and/or rail per the applicable repair procedure.

3.

Clearance for free rotation of the revolving frame must be provided between the truck frame bushing and the sleeve. Such clearance, however, cannot be excessive or premature wear of the truck frame bushing or sleeve will occur.

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Service Procedures BI010941

To determine this clearance, proceed as follows:

HIGH VOLTAGE! EXTREME CARE MUST BE EXERCISED AT ALL TIMES WHEN PERFORMING MAINTENANCE IN THE CENTER PINTLE AREA OF ELECTRICAL ENERGY. High voltage can cause serious or fatal injury. Installation, operation and servicing of components should be performed only by qualified personnel. ALWAYS DISCONNECT the electrical power BEFORE accessing the center pintle area. a.

Disconnect the power to the machine. Enter the truck frame through the bottom access opening.

b.

Remove the cover from the top of the truck frame and gain access to the space between the pintle and the rollers. Insert a feeler gauge between the sleeve and the bushing of the truck frame. Any measurement over 0.250" diametral clearance is considered excessive and replacement of the bushing and/or sleeve is necessary.

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Center Pintle - Section Views SM141403-EN

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Service Procedures BI010941

Center Pintle Adjustment To secure a loose center pintle sleeve which may be due to a worn thrust washer, roller, or rail, tighten the pintle lower nut as follows: NOTE: All adjustment of vertical clearance is to be made at the Lower Locknut. NEVER tighten to the point of removing all vertical clearance.

1.

Enter the bottom compartment of the truck frame which will give access to the pintle lower nut adjusting pin.

2.

Cut the lock wires and remove the capscrews attaching the lock bars to the lower nut.

Remove the lock bars.

3.

Pull down on the pin handle and rotate it 90° so that the pin can be moved into one of the slots in the lower pintle nut.

4.

To calculate the required rotation of the center pintle to keep lift at the rear rails within the allowable range of 0.18" to 0.25", use the following formula:

R = (M-.25)576° M = Measured lift at rear rails R = Rotation, in degrees, required at center pintle Example: If measured lift is .625", then R = (.625-.25)576° = 216° The actual adjustments must be made in 90° increments to allow reinstallation of the nutlock bars. After determining the required rotation, select the degree of turn closest to 90°, 180°, 270°, or 360°. In the above example 216° is closest to 180°. When there is a choice of selecting a higher or lower degree of turn from the formula’s result, always use the lower degree turn to prevent overtightening of the pintle nut.

5.

Install the lock bars and capscrews. Secure the capscrews with lock wire.

6.

Disengage the adjusting pin. Make sure the pin handle is turned parallel to the pin and locked in the slot on the pin to prevent the pin from accidentally reengaging the pintle lower nut.

7.

Apply power to the machine and check the lift as described in Inspection.

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Center Pintle Sleeve Removal Remove the center pintle sleeve and thrust washer through the top of the revolving frame as follows: 1.

Position the machine on a level work area with the dipper lip and front flat on the ground.

Set all brakes.

2.

Disconnect electrical power to the machine.

HIGH VOLTAGE! EXTREME CARE MUST BE EXERCISED AT ALL TIMES WHEN PERFORMING MAINTENANCE IN THE CENTER PINTLE AREA OF ELECTRICAL ENERGY. High voltage can cause serious or fatal injury. Installation, operation and servicing of components should be performed only by qualified personnel. ALWAYS DISCONNECT the electrical power BEFORE ACCESSING the center pintle area.

3.

Remove the coupling cover, the coupling, and shaft spacer. Disconnect, plug and tag all lube and airlines.

4.

Remove hose guard and collector ring cover. Disconnect and tag electric leads.

5.

Remove shoes, spacers and insulators from the collector ring housing.

6.

Remove the control collector rings from the swivel shaft. Remove the swivel assembly retainer. Lift the swivel assembly and disconnect and tag the air and lube lines. Remove the retainer with swivel assembly attached. Remove the collector ring support and remove the support and collector rings as a unit.

7.

Secure the swivel support at the top so that when it is removed it will not fall. Remove the access cover from the bottom of the truck frame and enter the truck frame. Disconnect and tag the electrical cables and tie them out of the way.

8.

Remove the swivel support base from the truck frame and lower the swivel support with base out of the truck frame.

9.

Remove the hoist drum shaft assembly. Refer to HOIST DRUM SHAFT in this section of the manual.

10.

Remove the lock bars, lower nut, and thrust washer from the lower end of the pintle sleeve.

11.

Install the lifting lug, supplied with the machine, to the top of the pintle and connect the auxiliary winch to the lifting lug.

Be sure to apply a load to the center pintle lifting lug sufficient to lift the center pintle before proceeding.

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12.

Remove the bolts, lockwashers and dowels that fasten the upper locknut to the revolving frame. Remove the upper lock bars and their hardware. Remove the upper locknut from the pintle sleeve.

13.

Using the auxiliary winch, lift the sleeve out of the revolving frame. Replace a worn or damaged sleeve with a new one. Check the pintle sleeve bushing for wear or damage.

Replace if required. Check the truck frame around the pintle structure for cracks. If the pintle structure area needs repair, contact the manufacturer for instructions.

Center pintle sleeve installation is the reverse of disassembly.

HIGH VOLTAGE! Be sure the electrical lines are correctly connected and all connections are tight. Also make sure that the air and lube lines are connected to the correct outlets in the swivel assembly and that the connections do not leak.

Collector Rings There are three sets of collector rings on the machine - low voltage, propel and high voltage. The low voltage collector rings transfer power from the revolving frame back to the propel motors.

The propel collector rings provide control to the propel motors and power for the propel blower motor.

Collector Rings - Propel and Low Voltage (Rear Section View)

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

Collector Ring Inspection Inspect the collector rings and shoes frequently for grease and contaminant accumulations on the rings, shoes, insulators and incoming wires.

Clean the collector rings and related parts with an approved solvent regularly to prevent high potential grounds. Make sure each shoe bears firmly against the collector ring. The shoes are spring-loaded to maintain constant contact.

Solvents may be toxic or flammable. Adequate ventilation must be provided to minimize fire and health hazards caused by using solvents for cleaning. Use away from sparks, heat or flame to prevent fire or explosion. Follow the manufacturer’s instructions.

Check the insulators for cracks or chipping and replace promptly if damaged. Verify that the screws securing the rings to the insulators do not protrude beyond the countersunk holes of the rings.

A cracked or chipped insulator or an excessive amount of contaminants may cause an electrical fault. This could result in death or serious injury.

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Collector Ring Repair Repair of the collector rings involves replacement of damaged insulators or defective shoes. The collector ring life expectancy exceeds the life expectancy of the machine. However, to replace the insulators or shoes: 1.

Disconnect electrical power to the machine.

HIGH VOLTAGE! Do not access the collector rings unless power to the machine has been disconnected and locked-out. Only authorized personnel should service the collector rings.

2.

Remove the attaching hardware securing the insulator or shoe to the mounting. Access to the shoes mounted to the truck frame is obtained by entering the truck frame through the bottom access opening.

3.

Install new insulators or shoes. Make sure all electrical leads are securely attached to the shoes and collector rings.

Do not attempt to inspect the underside of the revolving frame until power to the machine is disconnected.

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

Swing Machinery

The swing machinery is mounted on both the left and right sides of the revolving deck. Each machinery installation consists of an air-cooled electric motor mounted vertically on top of the gearcase. The gearcase transmits torque to a single vertical pinion shaft. The pinion at the bottom of the shaft meshes with the swing rack on the lower works.

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Inspection Check the area around the swing gearcases weekly for evidence of lubricant leakage. Check to make sure that all cover hardware is tight. Replace other defective seals.

Check the gearcase for cracks and other structural damage. Contact the manufacturers service department for repair procedures. Check the swing case breather filter frequently. Remove and clean with solvent and compressed air if dirty.

Solvents may be toxic or flammable. Adequate ventilation must be provided to minimize fire and health hazards caused by using solvents for cleaning. Use away from sparks, heat or flame to prevent fire or explosion. Follow the manufacturer’s instructions.

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Swing Gearcase

Repairs to the swing gear components are best done with the gearcase attached to the truck frame. However, it is possible to remove the entire swing gearcase (approximately 7,600 lbs.) after the swing motor has been removed. Contact the manufacturer for more information.

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Swing Motor Removal

NOTE:

Removal of the appropriate side roof panel is required for removal/replacement of either the left or right swing motor.

1.

Swing the machine until the pinion is at the front of the machine and will clear the truck frame when lowered.

2.

Position the machine with the dipper lip on the ground. Set all brakes.

STORED ENERGY! Release the air pressure to the brake before disconnecting the airline. Plug the line immediately after disconnecting. Failure to comply could result in personal injury.

3.

Disconnect the power leads to the swing motor that is connected to the shaft to be removed.

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BEFORE ATTEMPTING TO DISCONNECT ANY POWER LEADS, PRESS THE MAIN POWER OFF BUTTON AND TAG IT TO AVOID INADVERTENT ENERGIZING OF THE ELECTRICAL CIRCUIT. Electrocution or serious injury may occur if appropriate safety measures are not followed. Electrical connections should only be handled by trained electrical personnel.

4.

Release the pressure in the line to the swing brake and the lubrication line to the first intermediate shaft bearing and disconnect the airline. Drain the oil from the gearcase and lower swing bearing housing.

When working with compressed air, always wear safety glasses.

5.

Have a qualified electrician disconnect and tag the electrical leads to the swing motor.

6.

Remove the 8 - 1.00 inch capscrews and 1 inch thick spacers securing the swing motor to the swing gearcase cover. Attach a lifting device to the motor and swing brake. Using the lifting lugs on the swing motor, lift the swing motor from the gearcase cover.

7.

Check for loose motor pinion. If pinion is loose remove and clean it. Check bore and pinion shaft for matching tapers.

NOTE:

Once the motor has been removed, the vertical shaft and pinion may be removed without removing the gearcase cover. The top of the swing shaft is accessible beside the intermediate gearing.

Installation is the reverse of removal.

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Gearcase Cover Removal

View G Swing Gearcase and Cover

1.

Remove the dip stick and the cover.

2.

Drain the oil from the gearcase.

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3.

Remove the 6 - .62 inch socket head capscrews securing the upper bearing retainer of the intermediate shaft to the gearcase cover and separate the O-ring and lube fitting from the retainer.

4.

Remove the 26 - .75 inch capscrews and 4 - .88 inch body fit bolts securing the gearcase cover to the gearcase and remove the cover.

NOTE:

The bearing cage and seal will stay with the gearcase cover. Remove the intermediate shaft, upper bearing cage and oil seal from the gearcase cover.

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Intermediate Shaft And Gear Assembly Removal

1.

Remove the 8 - .75 inch capscrews and lockwire securing the lower bearing retainer to the gearcase. Separate the O-ring from the lower bearing retainer.

2.

Remove the 8 - .62 inch capscrews and lockwire securing the lower shaft retainer to the intermediate shaft. Also remove the 8 - .50 inch capscrews and lockwire securing the lower shaft retainer to the lower bearing spacer.

3.

Remove lower shaft retainer and shims. Reinstall the lower bearing retainer and snug up the bolts.

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4.

Using a suitable lifting device, lift the intermediate shaft and gear as a unit from the gearcase.

5.

Separate the upper bearing retainer, shims, bearing inner shaft race and upper shaft spacer from the shaft. Separate the lube fitting and upper retainer O-ring from the upper bearing retainer. The bearing inner race is interference fit to the shaft. Also remove the lower bearing spacer and lower bearing spacer key from the shaft. Press the gear from the shaft and remove the upper shaft key.

6.

Remove the lower bearing retainer from the gearcase. The lower bearing retainer and spacer can now be removed. Separate the lower shaft bearing from the lower bearing spacer. The bearing is interference fit to the spacer.

Intermediate Shaft And Gear Assembly Re-assembly

1.

Install the intermediate helical gear and upper shaft key on the intermediate shaft. The gear is interference fit to the shaft.

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2.

Install the upper shaft spacer, inner race, shims and upper shaft retainer on the intermediate shaft. Assemble the bearing as follows: a.

Dress the end of the shaft to remove all burrs.

b.

Preheat the bearing and spacer in an oil bath.

Use suitable protective equipment when handling the heated items. c.

Assemble preheated bearing components on the shaft snug against the locating shoulder. Preload the bearing components until the entire assembly has cooled.

d.

Remove the upper shaft retainer and measure Gap “X”.

e.

Assemble the shim pack with total thickness equal to gap “X”. “X” should be from .002 to .005 inches.

f.

Insert shim pack into gap “X”. Install the upper shaft retainer and the 4 - .75 inch capscrews. Tighten the capscrews (53 Ft-Lbs) using an alternating sequence.

g.

Continue to tighten capscrews in steps of 1/3 the proof load value (67 Ft-Lbs).

NOTE:

For each step, ensure all capscrews are at the same torque value before increasing torque level.

h.

Tighten all capscrews to torque value that gives 75% of proof loading (200 Ft-Lbs).

i.

Install lockwire. Refer to WIRE LOCKING CAPSCREWS in the ENGINEERING DATA section in this manual.

3.

Install the lower bearing, spacer, spacer key, shims and lower shaft retainer to the intermediate shaft using the procedure shown in steps 2a – 2i above.

4.

After the lower bearing assembly has cooled, remove the intermediate shaft and install the lower shaft bearing and lower bearing spacer into the gearcase. Support them in this position. Install the intermediate shaft in the gearcase and lower bearing spacer. Be sure that the spacer key is in place. Remove the support and install the lower bearing retainer and O-ring.

5.

Install the oil seal and bearing cage in the gearcase cover. Clean the flanges of the gearcase and cover with solvent. Install the gearcase cover sealant. For more information, refer to the GEARCASE SEALING procedure in the ENGINEERING DATA section in this manual. Position the cover on the gearcase. Install the upper shaft retainer and secure with capscrews and lockwire. Install the body fit bolts first and tighten, followed by the case cover capscrews, tightening them firmly.

6.

Install the upper bearing retainer to the gearcase.

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7.

Lower the swing motor and brake unit onto the gearcase, making sure it is positioned correctly. Install the motor mounting hardware and tighten it firmly. Refer to SWING MOTOR REMOVAL in this Section of the manual.

8.

Fill the gearcase and lower bearing housing to the recommended level. The gearcase capacity is approximately 83 gallons.

9.

Have a qualified electrician connect the electrical leads to the swing motor and the blower motor.

10.

Attach the air line to the brake cylinder and the lubrication line to the intermediate shaft retainer.

11.

Lubricate the bearing and the swing pinion.

12.

Re-install the lower pinion guard.

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Vertical Swing Shaft And Pinion Removal

BE EXTREMELY CAUTIOUS WHEN REMOVING THE SWING PINION SHAFT THROUGH THE BOTTOM OF THE REVOLVING FRAME. AFTER LOOSENING THE BEARING CARRIER BOLTS, THE SHAFT IS UNSUPPORTED AND MAY FALL.

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Service Procedures BI010941

1.

Remove the 3 - .75 inch capscrews securing the pinion guard to the bearing housing. Refer to View G in GEARCASE COVER REMOVAL in this Section of the manual.

2.

Support the swing shaft and pinion to be removed (approximately 1100 Lbs.) by using a jack or other suitable device beneath the pinion.

STORED ENERGY! Equipment must be blocked prior to performing maintenance in order to prevent unwanted movement. Failure to comply could result in death, severe personal injury, or damage to the machine. On machines using dual output swing drives, both swing pinions per drive must be engaged with the rack in order to be effective.

The internal differential drive of the gearcase allows one pinion to rotate, even if the brake is set, when the other pinion has been removed. Refer to Section 1 – Swing Restraint.

3.

Remove the 8 - .5 inch socket head capscrews that attach the vertical shaft cover to the helical gear and remove the cover.

4.

Loosen the 5 – 1.5 inch shaft retainer capscrews to obtain a .62 inch gap between the vertical shaft retainer and the bottom of the capscrew heads.

5.

Connect a hydraulic hand pump with 20 weight oil and a pressure gauge to the bearing removal pressure port at the bottom of the swing shaft.

6.

Pressurize the pump to a maximum of 10,000 psi. The spherical roller bearing should move down the taper. If so, proceed to step 9.

7.

If the bearing does not move or if pressure does not develop, use 140 weight oil.

Pressurize to a maximum 10,000 psi. The bearing should move down the taper. If so, proceed to step 9. If 140 wt. oil fails to develop pressure, grease may be substituted.

8.

If partial pressure develops, but bearing does not move, remove the pressure. Assemble a shaft puller. Tighten 6 - 1.25 inch capscrews and washers in the puller and pressurize the hydraulic pump. A sharp blow on top of the capscrews should help.

If the puller is used to remove bearing, the bearing will be damaged during removal and should be discarded.

9.

Remove the hydraulic pump, fittings and puller as required. Install blocking beneath the swing shaft to prevent it from dropping.

10.

Remove the 5 – 1.5 inch capscrews and lockwire securing the vertical shaft retainer and shims.

11.

Thread a 1.50 inch eye bolt into the center hole at the top of the vertical shaft. Using a suitable lifting device, support the shaft in position. Remove blocks or jacks, which were used to hold the shaft.

12.

Lower the vertical shaft and pinion to the ground, and set on cribbing.

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13.

If the two lower bearing spacers remained on the shaft, remove them.

14.

Remove the 12 - .75 inch bolts and lockwire securing the upper bearing carrier to the gearcase. Access to the bolts is through the elongated holes in the vertical swing shaft gear. Lift the vertical swing shaft gear, including the upper shaft bearing, upper bearing retainer, upper oil seal carrier, upper bearing carrier, oil seals, and O-rings from the gearcase.

15.

Remove and separate upper shaft bearing, upper bearing retainer, upper oil seal carrier, upper bearing carrier, garlock oil seals, and O-rings from the vertical swing shaft gear.

16.

While supporting the shaft sleeve with a crane to prevent the sleeve from dropping, remove the special capscrew and lift the vertical shaft spacer from the gearcase.

17.

Prior to removing the lower bearing retainer, ensure that the lower shaft bearing is securely blocked vertically. Remove the 6 - .75 inch capscrews that attach the lower bearing retainer to the bearing housing. Separate the lower bearing seal and the O-ring from the lower bearing retainer.

NOTE:

If pressurizing lower bearing outside of gearcase, (bench assembly etc.) it is necessary to install an adequate keeper to prevent bearing from coming off the top of the swing shaft (gearcase end).

18.

Run the cable down through the gearcase vertical shaft bore and attach the cable from the crane to a support bar under the lower bearing housing.

19.

Note the orientation of the bearing housing to the gearcase and the mounting hardware locations prior to disassembly. Remove the 13 - 1.5 x 7 inch capscrews and 4 - 1.5 x 4.5 inch capscrews with nuts that attach the lower bearing housing to the base of the gearcase.

20.

Lower the bearing housing only enough to disengage the boss on the housing from the gearcase. Slide the assembly away from the swing rack and lower to the ground. Separate the bearing housing O-ring from the gearcase and remove lower shaft bearing and bearing spacer.

21.

Inspect all parts. Repair or replace all oil seals, O-rings, gaskets or any other worn or broken components if necessary.

22.

Inspect the gears for pitting, abrasion, spalling and galling. Inspect all bearings for pitting, scoring and other damage. Replace damaged parts.

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Vertical Swing Shaft And Pinion Re-assembly 1.

Replace all oil seals, O-rings, gaskets, bearings or any other worn or broken components during re-assembly.

2.

Lubricate bearings at the time of installation. Also pack space between lips of oil seal with multi-purpose grease.

3.

Install the vertical shaft spacer in the gearcase vertical shaft bore. Refer to Detail A. Secure the spacer in place with the special capscrew.

4.

Assemble the upper bearing retainer, bearing retainer O-ring, upper shaft bearing and the upper bearing carrier on the helical gear and install the gear assembly in the gearcase.

Secure the upper bearing carrier to the gearcase through the elongated holes in the gear.

Detail A

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5.

If new bearing spacers are required, determine their proper thickness as follows: a.

Measure the bearing inner race width and the width of the vertical shaft spacer and record.

b.

Assemble the lower bearing lower spacer tight against the upper surface of the pinion. With the swing shaft and pinion in a vertical position, place the lower shaft bearing on the vertical shaft and pinion with only its own weight holding it in place.

c.

Measure the gap between the lower bearing lower spacer and the lower surface of the bearing, inner race at three equally spaced points; then calculate the average gap between the spacer and the bearing inner race. Refer to Detail B.

Detail B

d.

The required thickness of the lower bearing lower spacer is the average gap minus .162 inch. Machine the lower bearing upper spacer to this dimension plus or minus 0.005 inch.

e.

Subtract the width of the lower bearing inner race, and the widths of the lower bearing lower spacer and the lower bearing upper spacer from 10.925 inch.

f.

Machine the bearing spacer to this required dimension ±0.005 inch. Refer to Detail C.

Detail C

NOTE:

If lower bearing upper spacer is too short, build up of spacer may be required.

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6.

Assemble the oil seal, and bearing retainer O-ring to the lower bearing retainer.

7.

Assemble the lower bearing retainer assembly, bearing and lower bearing spacers, to the bearing housing. Set the bearing spacer on top of the bearing housing assembly. Run a cable through the base of the housing and spacers and attach a support bar to the cable.

Run the cable up through the vertical shaft bore and attach it to a crane. With the crane, raise the bearing housing assembly up to the top of the swing rack and slide the upper spacer and bearing housing into position in the gearcase. Be sure the boss on the bearing housing engages in the groove in the gearcase. Be sure the bearing housing O-ring is in place. Install and tighten new bearing housing bolts using the TURN-OF-NUT METHOD in the ENGINEERING DATA section of this manual.

8.

Screw an eyebolt into the end of the vertical shaft and pinion. Run the cable from the crane down through the bore in the gearcase and attach the cable to the eyebolt. Using the crane, lift the vertical shaft and pinion into the gearcase.

NOTE:

Apply Molykote to the taper journal and spline before assembly of vertical shaft and pinion.

9.

Securely block under the vertical shaft and pinion to prevent the shaft from falling. Remove the eyebolt and install the vertical shaft retainer and shaft retainer capscrews. Tighten to 20 Ft-Lbs.

10.

Measure the distance from the top of the shaft to the top of the vertical shaft retainer and record the measurement.

11.

To draw the vertical shaft and pinion into the tapered bore of the lower shaft bearing, tighten the upper retainer capscrews sequentially in a cross pattern. Nominal torque is approximately 650 ft.-lbs. The bearing is properly seated on the shaft and against the lower bearing lower spacer when a sharp increase in nominal torque is noticed and when the measurement in Step 10 is reduced by 0.162 inch.

12.

Measure the gap between the vertical shaft and pinion and the vertical shaft retainer.

Remove the retainer capscrews and the retainer and install a shim pack equal to the measured gap minus 0.002 to 0.005 inch. Re-install the retainer and capscrews and torque the capscrews to 100 Ft-Lbs.

13.

Re-install the vertical shaft cover and O-ring.

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Hoist Machinery

Hoist Machinery Assembly

The Hoist Machinery consists of: • A Large Diameter Hoist Drum, • Integral Single-Helical Hoist Gear, • Dual-Output Gearcase, • Hoist Motor with a spring-set, air-released disc brake.

Frequently check the hoist machinery for loose or missing hardware. At least once a month, check the hardware on the hoist motor, shaft, couplings and right and left pedestals for tightness.

Retighten or replace any missing hardware. Every 12 months remove the upper hoist gear guard inspection covers and the gearcase inspection covers and inspect the gear and pinions for pitting, abrasion, scratching, spalling, galling and/or other tooth wear. Check the gearcase for evidence of lubricant leakage. Replace any defective seals.

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Hoist Motor Removal For lubrication of the drive motor, refer to GREASING MAIN AC DRIVE MOTORS in Section 2 of this manual. If removal of the hoist motor is required, use the following procedure: 1.

Position the machine so that the dipper lip and front are flat on the ground.

2.

Remove the appropriate roof panels above the hoist motor.

BEFORE ATTEMPTING TO DISCONNECT ANY POWER LEADS, PRESS THE MAIN POWER OFF BUTTON AND TAG IT TO AVOID INADVERTENT ENERGIZING OF THE ELECTRICAL CIRCUIT. Electrocution or serious injury may occur if appropriate safety measures are not followed. Electrical connections should only be handled by trained electrical personnel.

3.

Disconnect and identify the electrical leads to the hoist blower motor and the hoist motor.

Hoist Gearcase, Coupling and Motor Assembly (Top View)

4.

Remove the hoist blower motor and duct as a unit from the hoist motor.

5.

Disconnect the piping to the hoist brake. Remove the brake from the motor. Refer to the BRAKES AND COUPLINGS section in this manual.

RELEASE THE HOIST BRAKE TO REMOVE ALL TENSION FROM THE HOIST DRUM BEFORE REMOVING THE BRAKE. 6.

Remove the motor coupling guard. The guard weighs approximately 115 Lbs.

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STORED ENERGY! Gearing or drum must be blocked prior to performing maintenance in order to prevent unwanted movement. Failure to comply could result in death, severe personal injury, or damage to the machine.

7.

Remove the coupling halves.

8.

Remove the attaching hardware.

Hoist Motor Mounting - Side View

9.

Using a suitable lifting device, lift the motor (approximately 13,000 Lbs) off the motor mounting pads, being careful not to damage the motor shaft and hub.

Installation of the hoist motor is the reverse procedure.

NOTES: • If replacing the original motor with a new motor, remove the alignment chocks and wedges from the motor mount, reinstall after setting and aligning the new motor.

• Align the coupling(s) using the procedure in the BRAKES AND COUPLINGS section in this manual.

• The hoist motor is fastened to its mounting pads using 2.0 inch hardware.

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Hoist Gearcase Assembly The Hoist Gearcase is a split-power gearcase. Power is transferred from the Hoist Motor through a single input shaft to dual helical output pinions mated to the main hoist gear. Repair of the hoist gearcase is best completed with the gearcase removed from the machine and in a shop environment. Basic “Level-1” repair involves replacement of seals and O-Rings in the pinion shaft area. Install oil seal with spring toward the bearing.

Hoist Gearcase Assembly

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Hoist Gearcase Section View

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Hoist Gearcase Cover Removal To remove the Hoist Gearcase Cover: 1.

Prior to removing the gearcase cover, drain the gearcase oil and disconnect the lube lines from the input shaft bearings as shown below.

2.

Attach a suitable lifting device to the gearcase cover's lifting lug. The cover weighs approximately 3,500 lbs.

3.

Remove the attaching hardware: •

Four 1.25 Inch Rod-Bolts

•

Two 1.75 Inch Rod-Bolts

•

Twenty-nine 0.75 Inch Cap Screws

NOTE: The four locating pins can remain in place if necessary.

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Propel Gearcase Cover Mounting Flanges

4.

Remove the 4 bearing covers on the outside ends of each shaft.

5.

Hoist the cover 4-5 feet, enough to safely clear the hoist gear. Relocate the cover to a clean work area.

6.

Thoroughly clean flanges with solvent prior to assembly.

Installation is the reverse of disassembly.

NOTE:

Apply RTV Sealant (PN:82833892) at assembly. Refer to GEARCASE SEALING procedure in the ENGINEERING DATA section.

Hoist Motor Pinion Shaft Removal The motor pinion shaft cannot be easily removed before first removing the intermediate shaft.

Refer to INTERMEDIATE SHAFT REMOVAL procedure in this Section of the manual.

STORED ENERGY! Equipment must be blocked prior to gearcase removal to prevent unwanted rotational movement. Failure to comply could result in death, severe personal injury, or damage to the machine.

NOTE: To perform this procedure, the motor coupling halves must be separated. It may be necessary to remove the hoist motor.

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To remove the hoist motor pinion shaft: 1.

Remove the gearcase cover, if not already done. Refer to HOIST GEARCASE COVER REMOVAL procedure in this Section of the manual.

2.

Remove the lockwire and 4 capscrews holding the LH bearing retainer in place. Remove the bearing retainer and any shims.

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Hoist Motor Pinion Shaft Section View

3.

Attach eyebolts to each end of the pinion shaft. Using a lifting sling and other additional rigging necessary, lift the pinion shaft (approximately 525 lbs.) just enough to support its weight.

4.

With the pinion shaft fully supported, remove the sleeve and spacers from the input end of the shaft.

5.

Remove the roller bearings and bearing spacers.

6.

Lift the pinion out of the hoist gearcase. Lower the pinion to the ground and lay it down horizontally on cribbing.

NOTE:

7.

The bearings and spacers are interference fit so they must be preheated in an oil bath prior to installation on the shafts. Refer to Bearing Installation procedure on the following page.

Inspect all parts. Repair or replace as required.

Installation is the reverse of disassembly.

NOTE:

Thoroughly clean or flush inside surfaces of gearcases and covers prior to assembly.

Upon completion, fill gearcases to proper level before operation.

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Hoist Motor Pinion Bearing Installation NOTE:

The bearings are assembled with an interference fit. Preheat the bearings in an oil bath to ease assembly.

1.

Ensure the ends of the drum shaft are free of any burrs prior to assembly.

2.

Assemble the preheated bearing on the shaft snug against the locating shoulder.

View C

3.

Assemble the bearing retainer to the drum shaft using 4 - 0.75 inch capscrews. Preload the bearing and allow the entire assembly to cool.

4.

Remove the bearing retainer. Measure the gap “X” as shown in View C.

5.

Assemble shim pack with thickness equal to the gap measurement (.002 - .005 inch).

6.

Assemble the bearing retainer and secure with 4 - 0.75 inch capscrews. Snug all capscrews to 53 Ft-Lbs using a STAR pattern.

7.

Continue to tighten capscrews using a STAR pattern until all capscrews reach a torque value 1/3 the torque value - approximately 67 Ft-Lbs.

8.

Continue to tighten capscrews using a STAR pattern until all capscrews reach a torque value 75% of proof load torque - 200 Ft-Lbs.

9.

Install lockwire to capscrews. Refer to Wire Locking Capscrews in the ENGINEERING DATA section of this manual.

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Hoist Intermediate Shaft Removal

STORED ENERGY! Equipment must be blocked prior to gearcase removal to prevent unwanted rotational movement. Failure to comply could result in death, severe personal injury, or damage to the machine.

To remove the hoist intermediate shaft: 1.

Remove the gearcase cover, if not already done. Refer to HOIST GEARCASE COVER REMOVAL procedure in this Section of the manual.

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2.

Attach a suitable lifting device and additional rigging necessary to safely remove the intermediate shaft, gear and all its components as a unit.

NOTE:

One eyebolt can be attached to each end of the intermediate shaft to help support the assembly during removal. DO NOT remove any additional capscrews used to secure the bearing retainers in place.

3.

Remove the intermediate shaft, gear and all its components as a unit.

4.

Disassemble the shaft as needed for inspection and replacement of parts.

5.

Clean and inspect the bearings for pitting, scoring, scratches, and other damage. Replace defective bearings. Check the seals for damage to the sealing surfaces. Replace seals and o-rings if necessary.

6.

Check the gears for broken teeth, pitting, abrasion, scratching, spalling and galling.

7.

Inspect all parts. Repair or replace as required.

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8.

If disassembled, reassemble the shafts. Some bearings and spacers are interference fit and must be preheated in an oil bath prior to insertion onto the shafts. Refer to Bearing Removal procedure on the following page.

Installation is the reverse of disassembly.

NOTE:

Thoroughly clean or flush inside surfaces of gearcases and covers prior to assembly.

Upon completion, fill gearcases to proper level before operation.

Hoist Intermediate Shaft Bearing Installation NOTE: The bearings are assembled with an interference fit. Preheat the bearings in an oil bath to ease assembly.

1.

Ensure the ends of the drum shaft are free of any burrs prior to assembly.

2.

Assemble the preheated bearing on the shaft snug against the locating shoulder.

View C

3.

Assemble the bearing retainer to the drum shaft using 6 - 1.50 inch capscrews. Preload the bearing and allow the entire assembly to cool.

4.

Remove the bearing retainer. Measure the gap “X” as shown in View C.

5.

Assemble shim pack with thickness equal to the gap measurement (.002 - .005 inch).

6.

Assemble the bearing retainer and secure with 6 - 1.50 inch capscrews. Snug all capscrews to 390 Ft-Lbs using a STAR pattern.

7.

Continue to tighten capscrews using a STAR pattern until all capscrews reach a torque value 1/3 the torque value - approximately 482 Ft-Lbs.

8.

Continue to tighten capscrews using a STAR pattern until all capscrews reach a torque value 75% of proof load torque - 1460 Ft-Lbs.

9.

Install lockwire to capscrews. Refer to Wire Locking Capscrews in the ENGINEERING DATA section of this manual.

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Hoist Drum Assembly The hoist drum uses a single-helical hoist gear fastened to a large-diameter drum with the hoist spider and rotates on double-row, tapered roller bearings.

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Inspection Check the drum spider mounting hardware monthly for loose or missing bolts and nuts. Do not retighten or re-use bolts or nuts. Replace bolts and nuts as required. Tighten the new bolts and nuts using the TURN-OF-NUT procedure in the ENGINEERING DATA section. Check the spider for cracks. Inspect the drum gear for tooth wear annually.

Hoist Drum Removal To disassemble the hoist drum: 1.

Place the dipper on the ground and remove the hoist ropes. Refer to HOIST ROPE REEVING & REPLACEMENT in this Section of the manual.

BEFORE PERFORMING ANY MAJOR MAINTENANCE ON THE HOIST MACHINERY, PRESS AND TAG THE MAIN POWER OFF BUTTON. Failure to comply may result in injury or death.

STORED ENERGY! Gearing or drum must be blocked prior to performing maintenance in order to prevent unwanted movement. Failure to comply could result in death, severe personal injury, or damage to the machine.

2.

Remove the appropriate roof panels above the hoist drum.

3.

Disconnect the lube lines from the drum gear and the drum shaft bearing caps.

4.

Remove the front and rear gear guards. The guards weigh approximately 700 lbs each.

With the weight of the guard supported, remove the hardware securing the guard. Repeat for the other gear guard.

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5.

Attach a crane to the drum. Remove the pins that hold the bearing blocks to the side frames; then lift the drum assembly from the side frames and out of the machine. If necessary, remove the outside covers and o-rings.

6.

Remove the retainer plates and slide the housings with bearings and inner retainers off the spider stub shafts. Remove the bearings, inner retainers and o-rings from the housings.

Remove the bearing inner spacers from the stub shafts.

7.

Inspect the bearings for pitting, scoring and other damage. Replace defective bearings.

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8.

If necessary, the drum gear can be replaced or reversed for extended use. Refer to the procedures in HOIST DRUM GEAR REPLACEMENT in this section of the manual.

9.

Re-assemble the drum, spiders and drum gear using new bolts and nuts. Prior to assembly, clean all threads with solvent.

10.

Lubricate the bolt threads with thread locking compound (PN:82833862). Tighten all 1.50 inch diameter bolts to 1,460 Ft-Lbs.

11.

Replace all o-rings and seals.

12.

Install the bearings and spacers.

NOTE:

The bearings and spacers are interference fit so they must be preheated in an oil bath prior to installation on the shafts. Refer to the ENGINEERING DATA section.

13.

Install the drum unit on the pedestals and insert the housing pins. Secure the pins with capscrews and lockwire together in pairs. See WIRE LOCKING CAPSCREWS in the ENGINEERING DATA section of this manual.

14.

Install the front and rear gear guards, bolting them together and to the gearcase.

15.

Lubricate the hoist drum gear and bearings.

16.

Install the hoist ropes. Refer to HOIST ROPE REEVING & REPLACEMENT in this Section of the manual.

Hoist Drum Gear Replacement The hoist gear can be reversed on the hoist spider to provide more useful life. To reverse or replace the hoist gear, the hoist drum shaft must be removed from the machine. Remove the drum assembly using the HOIST DRUM REMOVAL procedure in this section of the manual.

1.

Once removed, support the hoist drum assembly on cribbing in a vertical position, with the gear end down and the cribbing supporting the LH spider only. Ensure that the bearing housing on the gear end is not resting on the ground. This may require cribbing approximately 30 inches in height.

2.

Ensure the drum assembly is stable and fully supported with adequate cribbing.

3.

Using a suitable lifting device, attach a crane support to the drum gear so that it can be lifted in a horizontal position to the ground. The hoist gear weighs approximately 8,520 Lbs. DO NOT lift the gear until all the attaching hardware has been removed and the gear has been separated from the mounting flange of the spider.

4.

Remove all the hardware securing the hoist gear to the spider.

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NOTE:

5.

6.

Six 1.50 inch bolts (3.50 inch or longer) can be threaded into the tapped holes in the gear to help separate the gear from the spider mounting flange. The holes are equally spaced around the diameter of the gear.

Lift the hoist gear, removing it entirely from the drum assembly. Set hoist gear flat on the ground. a.

If the old gear is to be re-used, it can be flipped over (reversed) at this time. Reattach the crane support to the gear. Proceed to Step 6.

b.

If a new gear is to be used, attach a crane support to the drum gear.

Lift the gear high enough to clear the hoist drum assembly. Center the gear above the drum and carefully lower the gear onto the mounting flange of the spider.

NOTE:

Align the mounting holes of the spider and the gear before removing the lifting device.

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7.

Install new hardware using thread locking compound (PN:82833862). Ensure all bolts are equally tight, then install cotter pins.

NOTE:

ALWAYS use new bolts, steel washers, nuts and cotter pins.

See parts book for correct part numbers.

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Hoist Drum Bearing Removal To remove or replace the hoist drum shaft bearings, it is best to remove the drum assembly from the machine. Refer to HOIST DRUM REMOVAL in this section of the manual, then proceed as follows: 1.

Ensure the drum assembly is resting horizontally on cribbing (not shown).

2.

Remove the 6 - 1 inch hex screws that fasten each of the end covers to the bearing housings. See View A.

View A - Right Side Shown

3.

Mark then remove each end cover. Each cover weighs approximately 250 lbs each.

NOTE: These parts are not interchangeable. Inspect the O-Ring on the inside of each end cover. Replace if required.

4.

Remove the 6 - 1.00 inch hex screws that fasten each of the labyrinth seals to the bearing housings shown in View A.

5.

Using a suitable lifting device to support the weight of the bearing housing (approximately 2,820 lbs each), pull the bearing housings from the bearings.

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View B - Right Side Shown

6.

Remove the lockwire from the bearing retainer capscrews (not shown). Remove the 6 1.25 inch capscrews that fasten each bearing retainer. Refer to View B.

7.

Mark then remove each bearing retainers (approximately 175-200 lbs each). Tag and save the shim packs for later reuse.

8.

Use a bearing puller to pull each bearing from the shaft. Each roller bearing weighs approximately 510 lbs each.

Inspect the bearings, the spacer and seal remaining on the shaft ends, and the O-Ring on each seal. Repair or replace parts as needed.

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Hoist Drum Bearing Installation NOTE:

The bearings are assembled with an interference fit. Preheat the bearings in an oil bath to ease assembly.

1.

Ensure the ends of the drum shaft are free of any burrs prior to assembly.

2.

Assemble the preheated bearing on the shaft snug against the locating shoulder.

View C

3.

Assemble the bearing retainer to the drum shaft using 6 - 1.25 inch capscrews. Preload the bearing and allow the entire assembly to cool.

4.

Remove the bearing retainer. Measure the gap “X” as shown in View C.

5.

Assemble shim pack with thickness equal to the gap measurement (.002 - .005 inch).

6.

Assemble the bearing retainer and secure with 6 - 1.25 inch capscrews. Snug all capscrews to 224 Ft-Lbs using a STAR pattern.

7.

Continue to tighten capscrews using a STAR pattern until all capscrews reach a torque value 1/3 the torque value - approximately 277 Ft-Lbs.

8.

Continue to tighten capscrews using a STAR pattern until all capscrews reach a torque value 75% of proof load torque - 840 Ft-Lbs.

9.

Install lockwire to capscrews. Refer to Wire Locking Capscrews in the ENGINEERING DATA section of this manual.

10.

Ensure O-Ring is properly positioned against labyrinth seal. Using a suitable lifting device, assemble bearing housing (approximately 2,820 lbs each), to the roller bearings.

11.

Position O-Ring inside each bearing retainer. Assemble each outer cover using 6 - 1.00 inch hex screws.

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Hoist Mounting Bolts Use the following view to identify the correct installation of the mounting bolts for the hoist machinery.

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Hoist Limit Switch The hoist limit switch is used to prevent the padlocks on the dipper from being pulled into the boom point sheaves. The switch electrically cuts the reference signal. It is mechanically connected to the hoist drum shaft. It is composed of a gear reducer, an input shaft connected to the hoist stub shaft and an optical encoder. Setting the hoist limit switch is a function of the Operator’s Display in the operator’s cab. To set the hoist limit switch refer to SETTING ROPE LIMITS in this section of the manual.

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Crowd Machinery The Crowd Machinery is located on the deck at the front of the machine, forward of the center of rotation. This machinery consists of the crowd drum assembly for take-up of the crowd and retract ropes, a left and right gearcase and a motor with a spring-set, air-released disc brake.

Weekly, check both the crowd gearcases for lubrication leaks at all cover and case junctions and at the bearing retainers. Replace seals or rings if lubrication leaks are excessive. Replace sealant as required.

Weekly, check the electrical connection of the crowd motor and blower motor for tightness.

Tighten the connection hardware if necessary.

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Every six months remove the inspection cover of each gearcase and inspect the gears and pinions for pitting, abrasion, scratching, galling, spalling and other abnormal tooth wear.

Check the crowd machinery attachment pins for movement under load. Tight attachment pins reduces wear on the pins and pin holes. Check every 100 hours.

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Weekly, check the lubricant levels. Maintain the lubricant level at the sight glass. When lubricant sample tests prove it necessary, drain the gearcase immediately after operation; flush out the gearcase and refill with the recommended lubricant. Refer to the LUBRICATION section for the correct lubricant.

Gearcase Cover Removal To remove the LH Gearcase Cover: 1.

Prior to removing the gearcase cover, disconnect the 2 drain lines from the labyrinth seals.

2.

Attach a suitable lifting device to the gearcase cover's lifting lug. The gearcase cover weighs approximately 1,400 lbs.

L.H. Gearcase Cover Mounting Flanges (Top View)

3.

Remove 11 - .62 inch capscrews and lockwashers at the base flanges.

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4.

Remove the 2 - 1.75 inch rod-bolts.

5.

Remove the 2 - 1.25 inch rod-bolts.

NOTE:

The four locating pins can remain in place if necessary.

6.

Remove the 2 round cover plates on the outboard side of the gearcase.

7.

Hoist the cover 4-5 feet above the lower flange being careful not to contact the enclosed gears. Relocate cover to a clean work area.

8.

Thoroughly clean flanges with solvent prior to assembly.

Installation is the reverse of disassembly.

NOTE:

Apply RTV Sealant (PN:82833892) at assembly. Refer to GEARCASE SEALING procedure in the ENGINEERING DATA section.

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To remove the RH Gearcase Cover: 1.

Prior to removing the gearcase cover, disconnect the 2 drain lines from the labyrinth seals.

2.

Attach a suitable lifting device to the gearcase cover's lifting lug. The gearcase cover weighs approximately 1,400 lbs.

R.H. Gearcase Cover Mounting Flanges (Top View)

3.

Remove 14 - .62 inch capscrews and lockwashers at the base flanges.

4.

Remove the 2 - 1.75 inch rod-bolts.

5.

Remove the 2 - 1.25 inch rod-bolts.

NOTE:

The four locating pins can remain in place if necessary.

6.

Remove the 2 round cover plates on the outboard side of the gearcase.

7.

Hoist the cover 3-4 feet above the lower flange being careful not to contact the enclosed gears. Relocate cover to a clean work area.

8.

Thoroughly clean flanges with solvent prior to assembly.

Installation is the reverse of disassembly.

NOTE:

Apply RTV Sealant (PN:82833892) at assembly. Refer to GEARCASE SEALING procedure in the ENGINEERING DATA section.

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Crowd 1st Intermediate Reduction Gears

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NOTE:

Service and repair of the crowd reduction gears is basically a matter of component replacement. Both left and right gearcases should be thoroughly drained of oil before removing the gearcase covers.

To remove the 1st intermediate shaft and pinion: 1.

Remove both gearcase covers. Refer to GEARCASE COVER REMOVAL procedure in this Section of the manual.

1st Intermediate Shaft (Top View)

2.

Remove the lockwire and 6 - .62 inch capscrews from the labyrinth seals nested inside each geacase.

3.

Slide each of the labyrinth seals out of the gearcase to allow removal of the shaft as one unit.

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4.

Using a lifting sling and other additional rigging necessary, lift the shaft and gearing (approximately 3,000 lbs.) out of the crowd frame as a unit.

5.

Relocate the shaft and gearing to a clean work area. Provide adequate cribbing to safely support the entire shaft assembly.

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6.

Using a lifting sling and other additional rigging necessary, support the 1st intermediate gear (approximately 1,400 lbs.) before proceeding.

7.

Remove the lockwire and 4 - .75 inch capscrews securing the gear retainer in place.

Remove the gear retainer shown in Detail C.

8.

With the gear fully supported, remove the gear (approximately 1,400 lbs.) from the shaft being careful not to damage the splines. Relocate the gear to a clean work area.

9.

Remove the gear spacer. Remove the oil seal and bearing retainer.

10.

Remove the tapered roller bearing, labyrinth seal and bearing spacer from the shaft.

11.

Refer to the pinion end of the shaft shown in Detail D. Use a sling to support the 20 tooth pinion. The pinion weighs approximately 110 lbs.

12.

With the pinion supported, remove the lockwire and 4 - .75 inch capscrews securing the pinion retainer in place. Remove the retainer and any shims.

13.

Remove the pinion and seal retainer together.

14.

Remove the (6.5 inch ID) o-ring shown in Detail D.

15.

Remove the spherical bearing, labyrinth seal and bearing spacer.

NOTE:

16.

The bearings and spacers are interference fit so they must be preheated in an oil bath prior to installation on the shafts. Refer to 1ST INTERMEDIATE SHAFT BEARING INSTALLATION procedure in this Section of the manual.

Inspect all parts. Repair or replace as required.

Installation is the reverse of disassembly.

NOTE:

Thoroughly clean or flush inside surfaces of gearcases and covers prior to assembly.

Upon completion, fill gearcases to proper level before operation.

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1st Intermediate Shaft Bearing Installation NOTE:

The bearings are assembled with an interference fit. Preheat the bearings in an oil bath to ease assembly.

1.

Ensure the ends of the drum shaft are free of any burrs prior to assembly.

2.

Assemble the preheated bearing on the shaft snug against the locating shoulder.

View C

3.

Assemble the bearing retainer to the drum shaft using 4 - .75 inch capscrews. Preload the bearing and allow the entire assembly to cool.

4.

Remove the bearing retainer. Measure the gap “X” as shown in View C.

5.

Assemble shim pack with thickness equal to the gap measurement (.002 - .005 inch).

6.

Assemble the bearing retainer and secure with 4 - .75 inch capscrews. Snug all capscrews to 53 Ft-Lbs using a STAR pattern.

7.

Continue to tighten capscrews using a STAR pattern until all capscrews reach a torque value 1/3 the torque value - approximately 67 Ft-Lbs.

8.

Continue to tighten capscrews using a STAR pattern until all capscrews reach a torque value 75% of proof load torque - 200 Ft-Lbs.

9.

Install lockwire to capscrews. Refer to Wire Locking Capscrews in the ENGINEERING DATA section of this manual.

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Crowd 2nd Intermediate Reduction Gears NOTE:

Service and repair of the crowd reduction gears is basically a matter of component replacement. Both left and right gearcases should be thoroughly drained of oil before removing the gearcase covers.

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To remove the 2nd intermediate reduction gears: 1.

Remove both gearcase covers. Refer to GEARCASE COVER REMOVAL procedure in this Section of the manual.

2nd Intermediate Shaft (Top View)

2.

Remove the lockwire and 6 - .62 inch capscrews from the labyrinth seals nested inside each geacase.

3.

Slide each of the labyrinth seals out of the gearcase to allow removal of the shaft as one unit.

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4.

Using a lifting sling and other additional rigging necessary, lift the shaft and gearing (approximately 3700 lbs.) out of the crowd frame as a unit.

5.

Relocate the shaft and gearing to a clean work area. Provide adequate cribbing to safely support the entire shaft assembly.

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6.

Using a lifting sling and other additional rigging necessary, support the 1st intermediate gear (approximately 1,300 lbs.) before proceeding.

7.

Remove the lockwire and the 6 - 1.00 inch capscrews securing the gear retainer in place.

Remove the gear retainer shown in Detail E.

8.

With the gear fully supported, remove the 2nd intermediate gear (approximately 1,300 lbs.) from the shaft, being careful not to damage the splines. Relocate the gear to a clean work area.

9.

Remove the gear spacer, seal retainer and o-rings.

10.

Remove the spherical bearing, labyrinth seal and bearing spacer from the shaft.

11.

Refer to the static end of the shaft shown in Detail F. Remove the bearing and seal retainer if not already removed. Remove the oil seal.

12.

Remove the lockwire and the 6 - .75 inch capscrews securing the bearing retainer in place. Remove the retainer and any shims.

13.

Remove the spherical bearing and labyrinth seal from the shaft.

14.

Inspect all parts. Repair or replace as required.

Installation is the reverse of disassembly.

NOTE:

Thoroughly clean or flush inside surfaces of gearcases and covers prior to assembly.

Upon completion, fill gearcases to proper level before operation.

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2nd Intermediate Shaft Bearing Installation NOTE: The bearings are assembled with an interference fit. Preheat the bearings in an oil bath to ease assembly.

1.

Ensure the ends of the drum shaft are free of any burrs prior to assembly.

2.

Assemble the preheated bearing on the shaft snug against the locating shoulder.

View C

3.

Assemble the bearing retainer to the drum shaft using 4 - .75 inch capscrews. Preload the bearing and allow the entire assembly to cool.

4.

Remove the bearing retainer. Measure the gap “X” as shown in View C.

5.

Assemble shim pack with thickness equal to the gap measurement (.002 - .005 inch).

6.

Assemble the bearing retainer and secure with 4 - .75 inch capscrews. Snug all capscrews to 53 Ft-Lbs using a STAR pattern.

7.

Continue to tighten capscrews using a STAR pattern until all capscrews reach a torque value 1/3 the torque value - approximately 67 Ft-Lbs.

8.

Continue to tighten capscrews using a STAR pattern until all capscrews reach a torque value 75% of proof load torque - 200 Ft-Lbs.

9.

Install lockwire to capscrews. Refer to Wire Locking Capscrews in the ENGINEERING DATA section of this manual.

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Crowd Motor Removal For lubrication of the drive motor, refer to GREASING MAIN AC DRIVE MOTORS in the LUBRICATION section of this manual. If removal of the crowd motor is necessary, follow the instructions below.

1.

Park the machine in a stable, level area. Position the dipper flat on the ground.

2.

Remove appropriate roof panels above the crowd motor.

3.

Remove the crowd and retract ropes. Refer to the procedure CROWD ROPE REEVING AND REPLACEMENT in this section of the manual.

4.

Disconnect and identify the electrical leads to the crowd blower motor and the crowd motor.

BEFORE ATTEMPTING TO DISCONNECT ANY POWER LEADS, PRESS THE MAIN POWER OFF BUTTON AND TAG IT TO AVOID INADVERTENT ENERGIZING OF THE ELECTRICAL CIRCUIT. Electrocution or serious injury may occur if appropriate safety measures are not followed. Electrical connections should only be handled by trained electrical personnel.

STORED ENERGY! Gearing or drum must be blocked prior to removal of components in order to prevent unwanted movement. Failure to comply could result in death, severe personal injury, or damage to the machine.

5.

Block gearing and drum to prevent unwanted movement.

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6.

Remove the blower motor and duct as a unit from the crowd motor.

7.

Remove the motor coupling guard and separate the coupling.

Top View of Crowd Motor, Motor Coupling and Brake

8.

Remove the attaching hardware, securing the motor to the mounting pads. Chock and wedge bars may need to be removed.

9.

Attach a suitable lifting device to the crowd motor. The motor weighs approximately 4,000 lbs.

10.

Lift the motor, being careful not to damage the drive motor pinion.

11.

Relocate the motor to a clean work area.

12.

Inspect all parts. Repair or replace as required.

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Crowd Motor Installation 1.

Using a suitable lifting device, lower the crowd motor onto the motor mounting pads.

2.

Loosely assemble 4 sets of 1.25 inch attaching hardware. Do not tighten.

3.

Align the crowd motor to drive pinion. Shim motor if necessary. Refer to alignment procedure in the BRAKES and COUPLINGS section.

4.

Attach motor coupling, verify proper alignment.

5.

Tighten the attaching hardware in the sequence shown below. Weld chock and wedge bars to secure the crowd motor if previously removed.

6.

Attach the coupling guard.

7.

Re-connect blower duct work. Apply silastic sealant (PN:82833855) for air-tight seal.

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Crowd Brake Removal NOTE: 1.

Draining of the RH Gearcase oil is not necessary to remove the crowd brake.

Disconnect the piping to the crowd brake. Release pressure from the crowd brake.

RELEASE THE CROWD BRAKE TO REMOVE ALL TENSION FROM THE CROWD DRUM BEFORE REMOVING THE BRAKE.

Crowd Brake and Brake Guard

2.

Remove the 5 - .50 inch capscrews securing the brake guard to the outer gearcase flange.

Remove the brake guard.

3.

Using a suitable lifting device, secure the crowd brake (approximately 500 lbs.) prior to removal.

4.

With the crowd brake fully supported, remove the 12 - .75 inch socket head capscrews and locknuts.

5.

With the brake fully supported, remove the brake from the hub. Relocate the brake to a clean work area.

6.

Inspect all parts. Repair or replace as required.

For installation refer to CROWD BRAKE INSTALLATION in the BRAKES and COUPLINGS section in this manual.

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Motor Pinion Shaft Removal

NOTE:

To remove the motor pinion shaft, or bearings and seal replacement, the crowd motor must first be removed. Refer to CROWD MOTOR REMOVAL procedure in this section of the manual.

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To remove the motor pinion shaft: 1.

Drain the RH gearcase.

2.

Remove the crowd brake. The brake weighs approximately 500 lbs. Refer to the CROWD BRAKE REMOVAL procedure in this Section of the manual.

3.

Remove the brake hub, shown in Section View A-A. a.

Remove the lockwire and the 3 - .50 inch capscrews located on the outboard side of the motor pinion shaft.

b.

Remove the retainer plate holding the brake hub in place.

c.

The brake hub (approximately 45 lbs.) can now be removed. Use a puller if necessary.

4.

Remove the lockwire and the 3 - .50 inch capscrews and retainer plate that secure the motor coupling half to the inboard side of the drive motor pinion. Remove the motor coupling half shown in Section View A-A.

5.

Remove the coupling half from the pinion. For more information, refer to REMOVAL FROM A SHAFT procedure in the ENGINEERING DATA section.

6.

Remove the bearing and seal retainers attached to the inboard side of the gearcase.

Remove 2 oil seals and o-ring shown in Section View A-A.

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Section View A - A (Top View)

7.

Remove the spacer from the motor pinion shaft. The inboard roller bearing can be removed if necessary.

8.

Remove the bearing and seal retainers attached to the outboard side of the gearcase.

Remove both oil seals and the 7.0 inch diameter o-ring shown in Section View B-B.

9.

Remove the spacer from the motor pinion shaft .

Section View B-B (Top View)

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10.

Remove the 6 - .62 inch capscrews holding the bearing carrier in place. Refer to Section View C-C.

11.

Support the motor pinion shaft (approximately 170 lbs.) prior to removing the bearing carrier, roller bearing and shaft.

NOTE:

The motor pinion shaft can only be removed in one direction. Refer to Section View CC showing the proper direction of shaft removal.

Section View C-C (Top View)

Motor pinion shaft installation is the reverse of disassembly.

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Crowd Gear and Drum Inspect the drum gear-to-drum mounting hardware for loose or missing nuts and bolts. These bolts and nuts were tightened at the factory using Turn-of-the-Nut torque method. Loose bolts and nuts should not be retightened but replaced with new bolts and nuts. Tighten the new bolts and nuts using the Turn-of-the-Nut method per the ENGINEERING DATA section.

Crowd Frame & Drum - Right Side View

Check the drum for cracks. Check the drum grooves for rough edges and other defects which would damage the crowd and retract ropes. Check the retract rope for any damage. Inspect the drum gear teeth for pitting, abrasions, spalling, galling and other damage.

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Crowd Drum Removal If repair of the crowd drum is needed: 1.

Remove the crowd ropes and retract ropes from the drum. Refer to the FRONT END EQUIPMENT in this manual.

2.

Remove the upper and lower gear guards from the drum gear.

3.

Disconnect the lubrication lines at the shaft end covers. Remove the end covers.

4.

Remove the bolted-on crowd frame lower-front cross tie.

5.

Attach a crane to the drum (approximately 12,665 lbs.) and apply enough force to support the weight of the drum. Support the bearing caps (approximately 500 lbs.) separately.

6.

Loosen the torque nuts on the bearing caps. Refer to the procedures in the ENGINEERING DATA section. Remove the preload screws from each bearing cap.

7.

Remove the torque nuts and washers securing the bearing caps then carefully remove the bearing caps. The drum can then be lowered to the ground.

NOTE: The bearing cap rods are nested in the crowd frame with slotted hex nuts with cotter pins. These can remain in place.

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8.

Cut the lock wire and remove the 6 - 1.25 inch capscrews from each end of the shaft. See Section View A. Remove the bearing retainers. Remove the shim pack, bearings, bearing spacer and labyrinth seals and wire together for future use.

9.

If necessary, remove the hardware securing the drum gear to the drum and remove the gear. Consult the manufacturer for repair procedures for the drum and gear.

10.

Inspect the bearings for pitting, scoring, scratches and other defects. Replace defective bearings.

Section View A

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To reassemble the crowd drum: 1.

If removed, reinstall the drum gear to the crowd drum using new bolts and nuts.

2.

Tighten the nuts to 1,480 Ft-Lbs (lubed threads, 100% proof load) or tighten the nuts to 150 Ft-Lbs followed by 1/3 turn of the nut (dry threads).

3.

Let the joint set for 24 hours then loosen and retighten. When retightening use Loctite #277 on nuts.

4.

The bearings and spacers are interference fit and must be preheated in an oil bath prior to installation.

5.

Attach a crane to the drum unit and position it in the frame.

6.

Install the bearing caps. Preload the bearing caps against the front hook using 0.75 inch GR8 capscrews and hard steel flat washers. Lubricate threads and tighten to 385 Ft-Lbs.

7.

Secure the bearing caps in place with 2.00 inch torque nuts. Refer to the proper torque nut tightening procedures in the ENGINEERING DATA section.

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Machinery House The machinery house has separate structural members consisting of front and rear main truss and interconnecting beams. These form the permanent house structure.

Roof panels are individually fastened to the interconnecting beams. Any panel can be removed separately to provide access to a machinery house unit. All roof panels are secured with hold down bolts on retainer bands. Vinyl tape weather stripping is installed between the retainer band and roof panel.

Shroud covers around the A-frame legs have vinyl tape between the leg and shroud. Shroud support joints are sealed with rubber cement or silicone caulking.

All mating surfaces of the machinery house wall panels are sealed with rubber cement or silicone caulking to ensure weather tight seal.

Frequently inspect all house panels and structural members for cracking. Include a close examination of all roof structures. Examine all struts, beams and braces used to reinforce the machinery house.

Always restore defective structural members to their original state by repair welding.

Periodically observe the hinges and closure mechanisms on all doors and windows to ensure they will remain closed during machine operation. Verify the sealing of the leg closures of the Aframe. Tighten all loose bolts and replace all missing hardware. The absence or looseness of these fasteners can result in excessive vibration and wear of house components. Individually, these faults can be considered minor, but taken collectively, they represent a major exposure of the electrical and mechanical elements of the house to dust and water.

Check the condition of the house paint. Paint is not impervious to deterioration. A well-painted machine is less susceptible to rust, corrosion and progressive failure.

Be sure the pressurization system is functioning properly to keep the house well-ventilated at a pressure higher than atmospheric pressure.

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Walkways, Stairways and Handrails Each day inspect all walkways, platforms, stairways and handrails on the machine. Maintenance personnel should do the inspecting. Should a structural member become damaged, repair or replacement may be necessary. Replace nuts and bolts where required or repair weld to restructure individual access members such as steps and railings.

Eliminate accumulations of wiping rags, oil and grease, dust and dirt and mislaid maintenance tools. They can create a safety hazard. Keep new and used wiping rags in barrel containers rather than draped or tied to railings. Clean off oil and grease in the primary walking and working areas to prevent workers from slipping. Maintain a tool bench and rack for the storage of all tools used in the machine upkeep. Do not let tools lie scattered upon walkways and stairways.

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Boarding Stairs A set of boarding stairs is attached to the machinery house platform on the right side of the machine. When lowered, the stairs allow entrance to the machinery house from ground level.

The stairs must be in their raised position to enable the operator’s controls.

Generally, very little maintenance is required for the boarding stairs. However, ensure that the flangette bearings on the pivot shaft are lubricated. See Section A-A.

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Verify that the boarding stair limit switch (located on the machinery house wall) is properly set.

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Retractable Boarding Ladder

After each use, the ladder automatically returns to its stored position aided by two 200 lb. counterweights that move vertically inside the ladder’s channels. If the ladder does not fully retract, inspect the 8 track rollers for damage or excessive wear. Replace if necessary. If problems persist and the ladder does not freely retract, lubricate the two counterweight rope sheave bearings located at the top of the ladder.

Verify the limit switch is properly set. The limit switch should be tripped when the ladder is 4.00 inches down from it’s fully retracted position.

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Front End Equipment

Front End Equipment

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Boom Assembly Maintenance of the front end equipment requires at minimum a weekly visual check for cracks or other damage to the boom structure. It will include checking the ladders and the boom point platform. Also, check for signs of wear and cracks on the sheaves. Replace, if necessary. There should always be a sign of fresh grease on both sheave bearing areas. Visually check sheave bearing retainer bolts. Inspect the boom foot lugs for any signs of cracking. Also check to see that the boom foot pins are being properly lubricated.

Unusual problems should be referred to the manufacturer for solutions.

STORED ENERGY! Removal of bolts and pins requires the attached items to have proper support to release the load. Failure to comply could result in death, severe personal injury, or damage to the machine.

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Boom Repair Repair of the boom is normally limited to very minimal additional damage sustained following the failure of an attached component. If any structural damage is found on the boom assembly contact the manufacturer immediately.

DUE TO THE HIGH LOAD CARRYING POSTURE OF THE BOOM ASSEMBLY, ANY QUESTIONABLE DAMAGE ON THE BOOM MAY SERIOUSLY ENDANGER HUMAN LIFE AND MUST BE INVESTIGATED BY QUALIFIED PERSONNEL BEFORE CONTINUED SERVICE CAN BE UNDERTAKEN.

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Boom Limit Switch Installation To adjust the Boom Limit Switch: 1.

Ensure that the machine is level, the dipper is resting on the ground, and that the hoist ropes are slack. The crowd must be allowed to unload all forces against the rack.

NOTE: Refer to Section - A on the following page.

2.

Loosen the .38 inch capscrews that fasten the proximity switch bracket to the mounting angle. The slotted holes in both pieces allow for both horizontal and vertical adjustment.

3.

Adjust the position of the proximity switch to the dimensions shown in Section A on the following page.

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Section A - A Boom Inductive Proximity Switch

Overall sensitivity can be further adjusted from this initial position to suit conditions.

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Boom Point Sheaves This machine uses 2 Boom Point Sheave assemblies to redirect the hoist ropes from the dipper padlock to the hoist drum. Check the boom point sheaves monthly for unusual wear. Check that the sheave bearings are receiving proper lubrication and that the lube lines are not damaged or crimped. For detailed sheave inspection procedure refer to INSPECTION OF SHEAVES AND DRUMS in the ENGINEERING DATA section of this manual.

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Boom Point Sheave Removal And Disassembly Use the following procedures to remove ONE Boom Point Sheave assembly: 1.

Position the machine in a clear and level area.

2.

It is not necessary to lower the boom when removing the boom point sheaves. However, lift the hoist ropes, with a suitable crane, and set them at the center of the boom away from the sheave assemblies.

THE HOIST ROPES MUST BE SECURED TO THE BOOM FOR SAFETY UNTIL THE REPAIR IS COMPLETED. USE BLOCKING BETWEEN THE ROPES AND THE BOOM STRUCTURE TO PREVENT DAMAGE TO THE ROPES.

ADEQUATE PRECAUTIONS MUST BE TAKEN TO ENSURE THE SAFETY OF PERSONNEL WHEN EQUIPMENT IS REMOVED AND REPLACED. USE EXTREME CAUTION AND PROPER SAFETY DEVICES WHEN WORKING AT THE BOOM POINT. 3.

Disconnect and plug the lubrication lines to the sheave pins.

NOTE: Use a suitable crane that will provide enough lift to remove and carry the weight of the boom point sheave assembly. The approximate weight is 7,000 Lbs. DO NOT APPLY TOO MUCH FORCE WITH THE LIFTING DEVICE. 4.

Secure the crane to one of the boom point sheaves.

5.

Ensure that the sheave assembly is supported with a sufficient sling or chain and remove the nuts and rod bolts that mount the bearing housings to the boom.

6.

Lift the sheave assembly away from the boom point and set on blocking.

7.

Remove the shaft retainer and shim pack.

8.

Attach a suitable lifting device to the eye bolt of the keyed bearing housing. The approximate weight is 870 Lbs. Slide the bearing housing from the boom point shaft and remove the key and bearing spacer.

9.

Use a crane to support the weight of the sheave and remove it from the shaft. Remove the remaining retainer and bearing housing from the shaft.

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To disassemble the boom point sheave: 1.

Remove the bearing retainers, oil seals and bearing.

2.

Inspect and repair all damaged or worn parts.

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Boom Point Sheave Reassembly And Installation 1.

Apply a thin coat of Molycote G to the shaft.

2.

Assemble the bearing, oil seals and bearing retainers to the sheave.

3.

Tighten the 0.75 inch capscrews in a criss-cross pattern to snug tight. Approximately 53 FtLbs. Continue to tighten the capscrews 1/3 of the required torque at a time until 75% proof load torque, 200 Ft-Lbs, is achieved. Lockwire in place.

4.

Using a crane to lift the sheave, install it onto the shaft. Ensure the bearing fits against the locating shoulder of the shaft.

5.

Using a suitable lifting device, install the outer bearing housing.

6.

Install the outer shaft retainer. Snug tight the 1.25 capscrews in a criss-cross pattern to 224 Ft-Lbs. Continue to tighten the capscrews 1/3 of the required torque at a time until 75% proof load torque, 840 Ft-Lbs, is achieved. Lockwire in place.

7.

Install the bearing spacer, shaft key and inner bearing housing. Use a suitable lifting device for the inner bearing housing.

8.

Install shim pack with thickness between .002 - .005 inch to fill the gap between inner bearing housing and inner shaft retainer.

9.

Install the inner shaft retainer with 1.25 inch capscrews. Snug tight the capscrews in a criss-cross pattern to 224 Ft-Lbs. Continue to tighten the capscrews 1/3 of the required torque at a time until 75% proof load torque, 840 Ft-Lbs, is achieved. Lockwire in place.

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To reinstall the boom point sheave assembly: 1.

Using a suitable crane, lift the sheave assembly into place at the boom point.

NOTE:

The sheave assembly must be oriented with the shaft key slot toward the center of the boom.

2.

With the shaft in place, attach the nuts and rod bolts that mount the bearing housings to the boom.

3.

Reconnect all lube lines.

4.

Using a crane, lift and set the hoist ropes back onto the sheaves. DO NOT CROSS THE HOIST ROPES. If required, refer to the proper reeving instructions in this section of the manual.

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Boom Bumper Regularly check the condition of the boom bumper and make repairs as required. Inspections should be conducted at minimum of once per operating shift. Additional inspections may be required. Operator’s style will affect bumper life. Repair of the boom bumpers consists of replacing common hardware and cushion material.

STORED ENERGY! Removal of bolts and pins requires that the attached items be properly supported to release their load. Failure to comply could result in death, severe personal injury, or damage to the machine.

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Saddle Block The saddle block should be inspected daily for signs of excessive wear. Make certain that it is being adequately lubricated and that the injectors are functioning properly. Also check the condition of the shipper shaft sheaves for signs of unusual wear. The lubrication lines which run up the boom should be checked for any signs of damage or crimping which could impede the flow of lubricant to the saddle block.

Saddle Block

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Saddle Block Repair The saddle block liners should be replaced either when the chamfer on the inside diameter flanged end of the liner has been worn off the inner bushings, or when the measured distance from one side of the handle to the lining is 0.12 inch or less - with the handle pushed to the same side of the liner. Measure the liners at 4 equally spaced points about its circumference. It may be possible to remove the liner capscrews and rotate the liner for additional wear. Replace the liners as follows: 1.

Remove the dipper handle per the procedures in Dipper Handle Removal.

2.

Secure the rear liner with a crane and remove the liner mounting bolts. Remove the liner from the saddle block.

NOTE: The liner was installed with Loctite. It may be necessary to heat the saddle block or to cut the liner in order to remove it. Discard after removal.

3.

When installing new rear liners, uniformly coat the mating surfaces of liner O.D. and saddle block I.D. with Loctite 680 immediately before installation. Use Loctite 227 on the liner bolts.

4.

Replace the front liners using the same procedures as above.

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Saddle Block Removal For any work to be done on the saddle block other than replacement of liners, the saddle block must be removed from the machine. Remove the saddle block as follows: 1.

Remove the crowd and retract ropes as described under Crowd & Retract Rope Removal.

2.

Remove the dipper handle as described under Dipper Handle Removal.

3.

Two cranes are required to remove the saddle block. One crane is used to support and remove the saddle block. The other crane is used to remove the shipper shaft.

4.

Separate and plug the lube lines to the saddle block.

5.

With a crane supporting the saddle block, remove the shipper shaft clamp collars and slide the shipper shaft to either side to remove it from the saddle block and boom. Lower the saddle block to the ground.

6.

Check the shipper shaft bushings in the boom and replace if required. Consult the manufacturer prior to starting repair.

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Saddle Block Sheave

7.

Inspect and replace any worn sheave bearings and seals or saddle block bushings.

Bearing retainer shimming instructions: a.

Install the spacer and the bearing on the saddle block. Install the seals and the seal retainers. Press the bearing tight against the spacer.

NOTE: Do not install the saddle block retainer. b.

Install the bearing retainer. Tighten just until snug, the socket head cap screws that hold the bearing retainer in place.

c.

Keeping the bearing tight against the spacer, measure the depth along the outer edge of the bearing retainer using the depth micrometer as shown. Remove the bearing retainer and measure the retainer thickness.

d.

Subtract the measured retainer thickness from the measured depth to calculate the gap and assemble the shim with the thickness equal to the gap thickness -0.002 to 0.005.

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e.

NOTE: 8.

Re-install the bearing retainer and snug-tighten the cap screws. All cap screws require retaining compound 82 833 859. Tighten in a sequence 180° apart in 3 steps adding 1/3 torque value each time.

All cap screws should be tightened to 146 Ft-Lbs.

Reinstall the saddle block in the boom. Reconnect the lube lines. Reinstall the dipper handle. Reeve the crowd and retract ropes on to the machine.

Dipper Handle The dipper handle should be checked regularly for cracking or bending. If cracking or bending is noticed, the handle should be removed and repaired as directed by the manufacturer. Check the handle for proper lubrication. Check condition of the crowd sheave and retract take-up mechanism.

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Handle Removal 1.

Lower the dipper to the ground.

2.

Remove the crowd and retract ropes.

3.

Remove the crowd half sheave.

4.

Secure a crane to the dipper handle.

THE SADDLE BLOCK MAY ROTATE SUDDENLY ONCE THE HANDLE IS REMOVED. The rigging from the crane must be securely fastened with additional rigging to prevent the crane cable from sliding away from the dipper end of the handle. Support the saddle block in a way that will prevent its rotation once the handle has been removed.

5.

While supporting the dipper handle with a crane, slowly back the machine up. The dipper handle will slide from the saddle block. Set the dipper handle on blocking and perform the required maintenance. While the handle is on the ground, the crowd half sheave (previously removed) and retract take-up mechanism should be inspected and repaired if required.

6.

Reinstall dipper handle in reverse of removal. Install the crowd cushion. Install the crowd and retract ropes.

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Retract Take-Up Mechanism The retract take-up mechanism of this machine provides the ability to remove slack and apply proper tensioning to the retract ropes of the mechanism.

1.

If the retract take-up mechanism must be repaired, lower the dipper so that the front of the dipper is flat on the ground.

2.

Remove the shim guard bolts and rotate shim guard out of the way.

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3.

Unload retract rope using hydraulic jacks to remove shims as follows:

Oil within the needle valves is under high pressure. STAY CLEAR OF TAKE-UP NUT, SHIMS AND CYLINDERS WHEN OPERATING NEEDLE VALVE, AS THESE ITEMS COULD MOVE UNEXPECTEDLY AND CAUSE SERIOUS INJURY. a.

Clean-up and grease sliding area on take-up nut, support and screw.

b.

Make sure the right needle valves are open and the left are closed.

c.

Extend cylinders by injecting hydraulic fluid into left fitting.

d.

Remove desired amount of shims from cylinder side of take-up nut and store on opposite side of nut.

e.

Slowly open left valve. Stay clear of take-up nut because weight of rope may jerk take-up nut when valve is opened. Close right valve.

4.

Release pressure from hydraulic jacks.

5.

Repair or replace all damaged parts.

6.

Retighten the retract rope as follows:

NOTE: Do not over-tighten the ropes. The ropes are properly adjusted when a very slight curvature is noticeable on the retract rope with a tight crowd rope. a.

Be sure that the right needle valve is open and the left valve is closed.

b.

Extend the cylinders by injecting hydraulic fluid into the left fitting.

c.

Shim the take-up nut at the desired position.

The take-up nut must be shimmed tight, both fore and aft, using all shims originally provided with machine. d.

Slowly open left valve to release pressure on cylinders.

Oil within the needle valves is under high pressure. Stay clear of take-up nut, shims and cylinders when operating needle valve, as these items could move unexpectedly and cause serious injury. STAY CLEAR OF TAKE-UP NUT, SHIMS AND CYLINDERS WHEN OPERATING NEEDLE VALVE, AS THESE ITEMS COULD MOVE UNEXPECTEDLY AND CAUSE SERIOUS INJURY. 7.

Close and secure shim guard.

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Front Stop & Spreader 1.

Lower the dipper to the ground.

2.

Back-off the retract rope as far as possible per step 3 of Retract Take-up Mechanism Removal.

3.

Remove the retract rope retainer bolts and retainers. Lift the retract rope out of the spreader grooves.

4.

Burn off the lower splice plate. Remove the upper splice plate.

5.

Attach a crane to one side of the spreader and remove the anchor bolt. Lift the spreader from the handle. Remove the other side in the same way.

6.

When re-installing the spreader, be sure it is aligned to the handle so that one side is aligned with the other side and each side is an equal distance from the handle.

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Spreader Repair NOTE: The following procedures involve burning and rewelding the spreader. Contact the manufacturer for the proper weld specifications for this item.

1.

Lower the dipper to the ground.

2.

Back-off the retract rope as far as possible. Refer to removal step 3 of RETRACT TAKEUP MECHANISM.

3.

Remove the retract rope retainer bolts and retainers. Lift the retract rope out of the spreader grooves.

4.

Carefully burn out the weld joining the cylinder guard support to one-half of the spreader only. The cylinder guard support can remain attached to the other half of the spreader.

5.

Burn off the upper and lower splice plates from one-half of the spreader. The splice plates can remain attached to the other half of the spreader.

6.

Attach a crane to one side of the spreader. Remove the anchor bolt attaching that side.

7.

Lift the spreader from the handle.

8.

Attach a crane to the remaining side of the spreader, remove its anchor bolt and lift it from the handle.

9.

Repair or replace any damaged parts.

10.

Reinstall each half of the spreader and their anchor bolts, but do not tighten the anchor bolts.

11.

Be sure the spreader assembly is aligned to the handle so that one side is aligned with the other side and each side is an equal distance from the handle.

12.

Contact the manufacturer for the proper weld specifications for the spreader.

13.

Tighten the anchor bolts, then tighten the retract rope using the procedure in RETRACT ROPE TIGHTENING later in this section of the manual.

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Dipper Assembly The dipper should be inspected before the start of each shift. The side and front surfaces provide critical reinforcement for the dipper. Consequently, they should be checked regularly for cracks and component wear. When wear spots develop in the side and front surfaces, the metal contour can be restored by building up the affected area. Contact the manufacturer for a specified welding repair solution.

THE DIPPER HANDLE WILL FALL ONCE REMOVED FROM THE SADDLE BLOCK IF IT IS NOT FULLY SUPPORTED. Removal of bolts and pins requires the attached items to have proper support to release the load. Failure to comply could result in death, severe personal injury, or damage to the machine.

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NOTE:

Do not apply hard-surfacing to steel side and front surfaces. This could promote the development of cracks. Where wear is excessive, mild steel plates can be welded in place and hard-surfacing applied to these additional plates with excellent results.

All lubrication points should be inspected and lubricated each shift. The dipper should be checked for missing or broken teeth, and for missing wedges. Replace these items as required before placing the dipper back into operation.

Dipper Door Latch Bar and Lever

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Check the latch bar and the latch keeper inserts for wear and replace if required.

Check the latch lever and latch keeper insert for proper adjustment. Adjust the latch bar to overlap insert by 1.25 inches as shown in Section D.

Section D

Latch Bar Adjusting Procedure 1.

Ensure door is stable so that it will not move during adjustment procedure.

2.

Use jack lever to rotate screw jack to raise latch lever and pivot bracket.

3.

Remove shim retaining bar and add or remove shims as desired.

4.

Install shim retaining bar.

5.

Lower screw jack with jack lever until it clears latch lever pivot bracket and bracket has solid contact with shims.

6.

Store jack lever in retaining hole provided.

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Dipper Removal & Installation

Before performing this procedure, ensure that the proper lifting devices are available and that you have a complete understanding of the removal process. DO NOT continue this procedure until you have read and fully understand the removal process.

Follow the procedure closely. As each set of pins are removed, specific dangers as well as changes in the dipper handle’s C.G. (center of gravity) can occur. Ensure that the components being removed are securely supported and the spotter (rigging crew) is in direct radio communication with the crane operator.

STORED ENERGY! Removal of dipper pins requires the attached items to have proper support to release the load. Failure to comply could result in death, severe personal injury, or damage to the machine.

To remove the dipper: 1.

Park the machine on a firm, level work surface. Position the revolving frame parallel with the crawlers, with the dipper over the front idlers. Allow approximately 75 feet of additional level work surface area behind the crawlers.

2.

Position the dipper with the floor flat on level ground. Ensure the base of the dipper is fully supported and level.

STORED ENERGY! If the dipper base is not fully supported and level, movement may result when the dipper is disconnected from the handle. Failure to comply could result in death, severe personal injury, or damage to the machine.

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3.

Clear the area of all personnel not directly involved in the process. Establish direct radio communication with the crane operator.

4.

Disconnect the dipper trip rope from the dipper door.

5.

Lower the hoist ropes slightly to allow for pin removal.

6.

Remove the padlocks one at a time using the following procedure:

STORED ENERGY! Removal of dipper pins requires the attached items to have proper support to release the load. Failure to comply could result in death, severe personal injury, or damage to the machine. a.

Using a suitable lifting device, raise the padlock (approx. 5,250 lbs) just enough to minimize the load placed on the dipper lug pin.

b.

Remove the T-bolts securing the dipper lug pin in place. See View A.

NOTE: An alternate; pin & collar clamp assembly may replace the T-bolts as a retaining mechanism. If so, remove the collar clamps and attaching hardware. c.

With a second lifting device, position a strap type sling under the dipper lug pin (approx. 400 lbs) to support the pin during removal. Remove the pin. Do not lower the pin at this time, it will be reinstalled.

View A

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7.

Raise the padlock from the dipper lug and reposition the padlock directly above the lifting lug of the dipper handle as shown in View B.

8.

Using the second lifting device, reinstall the dipper lug pin in the padlock link and secure the pin in place.

View B

9.

Attach a shackle (35-ton capacity) to the dipper handle lifting lug. Lock the shackle pin in place.

10.

Using a suitable wire rope sling, tie the padlock and shackle together.

11.

Repeat steps 6 through 10 for the opposite padlock. Ensure both slings (used to connect the padlock and shackle) are identical in length.

12.

Slowly raise the hoist ropes just enough to support the dipper handle and remove the load placed on the pitch brace pins. Ensure the load is evenly distributed between the two lifting points.

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13.

Using the hoist ropes to support the dipper handle, disconnect the pitch braces from the dipper handle using the following procedure: a.

Using a suitable lifting device with a sling-type strap, support the pitch brace (approx.

950 lbs) from falling forward when the upper pin is removed. Remove the collars from the upper pin. Refer to Section C-C. Using a second lifting device, remove the upper pitch brace pin (approximately 165 lbs).

b.

Lower the pitch brace so it rests on the dipper. See View C.

c.

Repeat steps A and B for the opposite pitch brace.

View C

14.

Raise or lower the hoist ropes just enough to support the weight of the handle and remove the load placed on the dipper handle pins. Remove the collars holding the dipper handle pins in place. Remove the dipper handle pins (approximately 375 lbs. each).

15.

Use the hoist ropes to raise the dipper handle just high enough to clear the dipper body as shown in View D.

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View D

16.

Carefully move the machine away from the dipper by backing up.

17.

When replacing dippers, ensure that the replacement dipper is resting on flat, level ground.

Carefully reposition the machine so the revolving frame is parallel with the crawlers and the dipper handle lined up with the dipper lugs.

Installation of the dipper is the reverse of removal.

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Dipper Door Snubbers The dipper door snubbers provide tension on the dipper door to prevent excessive speed and movement of the dipper door during closing. Check the door snubber periodically for proper tension.

STORED ENERGY! The snubber pads are under compression. Care must be taken during disassembly to avoid injury.

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Snubber Adjustment To adjust the dipper door snubbers: 1.

Lubricate bushings and pins to allow free movement and to ensure accurate addjustment.

2.

With each snubber assembly securely in place, adjust the spring housing nut and spring retainer to a depth of 6.50 inches as shown as Dim. Y in View A. Repeat for second snubber assembly, both snubbers must be adjusted equally.

3.

Re-adjust to suit operating conditions.

4.

As the linings wear, Dim. Z decreases. Increase Dim. Y by the same amount to maintain proper spring tension. Refer to the Snubber Geometry Chart below as reference.

View A

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Dipper Pitch Brace

Fixed Length Pitch Brace Assembly

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Dipper Padlock The padlock should be checked every shift to see that all pin mounting hardware is not loose or missing. Daily check for excessive movement at the pin joints which indicate bushing wear.

Replace worn bushings and pins. Check for cracking in the frames and links and make repairs when required.

STORED ENERGY! Removal of bolts and pins requires the attached items to have proper support to release the load. Failure to comply could result in death, severe personal injury, or damage to the machine.

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To Repair the Dipper Padlock: 1.

Place the dipper on the ground. Remove enough tension from the hoist ropes to remove the weight from the dipper lug pin, but not allowing enough slack to permit the weight of the padlock to rest on the pin.

2.

Remove the clamp collars from the lug pin, as shown in Section C-C. Remove the lug pin (approximately 450 Lbs.) with a suitable pulling device.

3.

Using the hoist ropes, lift the padlock from the dipper padlock lug and lower the padlock to the ground. Remove the thrust washers and the dowels from the lug.

4.

Remove the clamp collar from the link pin, as shown in Section B-B. Strike the clamp collar end with enough force to expose enough of the link pin head to secure a suitable pulling device. Remove the link pin (approximately 267 Lbs.) from the padlock frame and the link.

5.

Remove the bushings from the link and from the lower padlock frame. The bushings have an interference fit.

6.

Support the padlock frame and the sheave. Remove the T-bolts retaining the padlock sheave pin, as shown in Section A-A. Remove the sheave pin (approximately 366 Lbs.) with a suitable pulling device.

7.

Using a suitable lifting device, lift the padlock sheave from the padlock frame. Remove the thrust washers and the dowels from the sheave.

8.

Remove the hoist rope from the sheave. Remove the sheave pin bushings from the sheave and the frame. The bushings have an interference fit.

9.

Clean and inspect all parts. Repair or replace all damaged or worn parts.

10.

Reassemble in reverse of disassembly. Be sure all the dowels are flush with, or below, the surface of the thrust washers.

NOTE: The sheave pins and the lug pins are the same size but have different attaching hardware. Ensure they are replaced in the proper location during assembly.

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Dipper Trip Assembly The dipper trip can be disassembled in place on the machine or removed as a complete unit. In either case, the disassembly procedure is the same.

AVOID ANY METHODS WHICH ALLOW THE ROPE TO BECOME UNCONTROLLED AT ANY TIME DURING THE REEVING OPERATION. Death, serious injury, or damage to the machine will result should a rope become uncontrolled.

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1.

Remove the drum guard and trip rope from the drum.

2.

Open the gear and pinion guard.

3.

Remove the drum retainer and drum.

4.

Remove the bearing retainer and spacer on the drum side. Then remove the cover and bearing retainer at the other end of this shaft.

5.

Support the gear and slide the shaft from the gear and base on the drum side of the base.

Remove the gear, bearings, spacers and seals.

6.

Repair or replace all worn or damaged parts and reassemble in reverse order of disassembly. Lubricate the bearings.

7.

If the pinion was removed from the motor, when it is reinstalled, the motor shaft should be recessed inside of the pinion 1/16 inch.

A-Frame Periodically inspect the A-frame for signs of cracking or other damage. This check should include the mounting lugs and pins, the ladders and platforms, the equalizer links holding the boom structural strands and the leg shrouds on the machinery house roof. Make certain there are good seals around the leg shrouds.

If any repair welding is required, contact the manufacturer for a specialized repair process. For any other unusual problems consult the manufacturer.

Carefully inspect the mounting lugs and pins for cracks or other signs of wear or deterioration.

Lubricate these areas occasionally to prevent rusting. Check the leg shrouds both from the inside and on the top of the machinery house to see that a tight seal is maintained and there are no leaks. If there are any signs of leaking, reseal around the shrouds with a suitable caulking compound.

Make certain the ladders are securely mounted in good condition. Repair any cracks as soon as they are noticed.

Check the condition of the platforms to see that they are secure and safe. At the same time inspect the equalizer links and connections of the boom structural strands.

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STORED ENERGY! Removal of equalizer pins requires the attached items to have proper support to release the load. Failure to comply could result in death, severe personal injury, or damage to the machine.

Under normal circumstances the A-Frame of the machine will most likely not be removed until disassembly of the machine is required. Please contact the manufacturer should any unusual circumstances arise.

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Auxiliary Winch The auxiliary winch is attached to the hoist ropes to raise and lower the ropes during hoist machinery maintenance and change-out of hoist ropes. The winch consists of a drum and rope mounted to an electric gear motor.

Auxiliary Winch Assembly

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Boom Suspension Ropes Periodically inspect the outer layer of wires immediately adjacent to the sockets. If it is found that 30% of the outer wires are broken, or 10% of the total wires are broken, the strand must be replaced.

Lubricate the suspension rope sockets quarterly or after 1250 hours of machine operation.

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STORED ENERGY! Removal of equalizer pins requires the attached items to have proper support to release the load. Failure to comply could result in death, severe personal injury, or damage to the machine.

Additional, detailed information can be found in WIRE ROPE CARE AND MAINTENANCE in the ENGINEERING DATA section.

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Wire Ropes In designing excavating machinery, careful study of the size and operating speed of all sheaves and drums is conducted to determine the proper wire rope for each application. Continual contact with many machines in the field and repeated consultation with leading rope manufacturers permits the selection of the most satisfactory rope for each machine. To maintain the machine at its highest level of efficiency, purchase new ropes which conform to the manufacturer’s specifications, and thereby obtain the wire rope best suited for the particular application. Here are a few pointers relative to the proper inspection, lubrication and replacement of wire ropes on the machine.

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Wire Rope Inspection 1.

It is the operator’s responsibility to maintain drums and sheaves in good condition. Use ropes of proper size and construction. Examine ropes for signs of deterioration or damage in service, replace them when necessary.

2.

It is customary to work the running ropes almost to destruction in order to reduce the machine operating cost and downtime for replacement. When loading trucks, hoppers and the like, which would be damaged by a falling dipper, ropes should be inspected for signs of deterioration.

3.

Outer wires of the hoist ropes may be damaged or broken by falling rocks, by chafing over sharp rocks in the bank and by the presence of stones in sheave grooves. Rope life may be prolonged if broken wires are trimmed so that they do not cross over and cause additional damage to adjacent unbroken wires.

4.

The operator should always observe safety precautions.

5.

For more information refer to the WIRE ROPE CARE AND MAINTENANCE in the ENGINEERING DATA section.

Hoist Rope Reeving & Replacement It is highly recommended that hoist ropes be replaced in pairs.

NOTE: The procedure outlined in this manual assumes that the old hoist ropes are not broken or severely frayed, that the machine is equipped with an auxiliary rope winch and that all of the tools and supplies specified are on hand. THE HOIST ROPE MUST BE KEPT UNDER COMPLETE CONTROL AT ALL TIMES.

AVOID ANY METHODS WHICH ALLOW THE ROPE TO BECOME UNCONTROLLED AT ANY TIME DURING THE REEVING OPERATION. Death, serious injury, or damage to the machine will result should a rope become uncontrolled.

To replace the hoist ropes: 1.

The machine should be in a clear, flat area with sufficient room in front of the machine to work. All applicable safety regulations should be followed. Only personnel directly connected with replacing the ropes should be allowed on or near the machine.

ROPE END(S) WILL FORCEFULLY UNCOIL IN RELEASE OF ENERGY WHEN SHIPPING RESTRAINTS ARE REMOVED.

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The condition of the ropes may make it necessary to modify the procedures outlined, especially if the rope is broken or severely damaged. Be sure to always follow safety precautions when burning or climbing. Always keep the ropes under complete control.

2.

Lower the dipper to the ground. Position the dipper so that the padlocks are directly beneath the point sheaves. The hoist ropes will be vertical and the heel of the dipper will be on the ground.

3.

Position a person in the machinery house in a position to observe the hoist drum and ropes. Slowly rotate the drum in a lowering direction until all of the rope is spooled off of the drum and the rope sockets are in the bottom rear quadrant of the hoist drum.

Throughout this operation drum or rope positions must be communicated to the operator. Make sure that a system of signals is worked out in advance and that the line of communication is unbroken.

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NOTE:

Each hoist rope is a continuous length of rope.

•

The “LEAD ROPE” is the portion of rope from the hoist drum, over the outer groove of the point sheaves, and down to the back of the padlock. The socket on the hoist drum for this rope “LEADS” the socket for the “FOLLOW” rope.

•

The “FOLLOW ROPE” is the portion of rope from the front of the padlock, over the inner groove of the point sheaves, and back to the hoist drum.

4.

Attach an auxiliary winch line to each follow rope becket. Remove the keeper that attaches the follow ropes to the hoist drum.

5.

Pull the ferrules out of the becket receivers. Lower the auxiliary winch line until the hoist rope can be tied off. Tie-off the follow ropes.

6.

Carefully rotate the drum 180° in the LOWER direction to unwrap the remainder of the lead ropes from the drum.

7.

With the lead rope sockets in the lower rear quadrant of the drum, stop the drum.

8.

Attach the auxiliary winch line to each lead rope becket. Remove the lead rope keeper.

Payout the winch line until the lead rope can be tied off then tie it off.

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9.

Attach the follow ropes to the winch line.

10.

Attach a sling to the follow rope near the front of the padlock. Attach this sling to a ground vehicle.

11.

Slowly and carefully payout the auxiliary winch while pulling the hoist rope away from the front of the machine with the ground vehicle. Lower the hoist ropes until the winch line can be disconnected.

NOTE:

The ground vehicle is required to pull the weight of the hoist ropes over the boom point sheaves, and also help bend the ropes through the padlock sheaves.

12.

Rotate the hoist drum the lower direction until the lead rope keeper in is the lower rear quadrant.

13.

Attach a winch and lower the lead ropes in the same manner as that used for the follow ropes. When the ends of the lead ropes approach the padlocks, one rope must be removed from the winch line, the remaining lead rope lowered through the padlock, and then removed from the winch rope.

To install a new pair of hoist ropes: 1.

Place the new hoist ropes approximately 10 feet in from of the dipper. If the ropes are on reels, they should be located so that the ropes unreel from the bottom of the reel.

ROPE END(S) WILL FORCEFULLY UNCOIL WHEN SHIPPING CONSTRAINTS ARE REMOVED. 2.

Be sure a winch line runs through each padlock.

3.

Attach a winch line to one end of each new rope, making them the new lead ropes.

4.

Hoist the winch until the lead ropes have cleared the padlock. Attach the free end of each hoist rope to the winch line that its lead end is attached to.

5.

Pull both ropes over the point sheave, being careful to keep the lead rope (rear rope in

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padlock) on the outside groove of the point sheave.

6.

Continue pulling the ropes into the machinery house. When the ends of the ropes reach a point where the follow rope can be tied off, stop pulling, detach the follow rope from the winch line and tie it off.

7.

Pull the lead ropes until they are in a position to be placed in their becket resolvers. Place the lead rope ferrules in the resolvers, install the lead rope keeper and detach the winch line.

8.

Slowly rotate the drum 180° in the HOIST direction so that the follow ropes can be attached.

9.

Hoist the winch attached to the follow ropes until the ropes can be attached to the drum.

10.

Place the follow rope ferrules in the resolvers, install the lead rope keeper and detach the winch line.

11.

Slowly rotate the drum in the hoist direction until the hoist ropes are tight. Make sure the ropes stay in the proper grooves.

12.

Hoist the dipper approximately 1 foot off of the ground. Check to make sure the dipper hangs straight. If not, place shims between the ferrule and the ferrule socket on either the lead or the follow ropes on the side that the dipper hangs lower. If necessary, locally manufactured shims may be placed under both ferrules.

13.

Hoist and lower the dipper several times to seat the ropes. Make sure the dipper hangs straight. If not, shim as above. Reset the hoist and crowd limit switches.

Shim for Hoist Rope Socket

NOTE: The above steps are used to remove and replace 1 pair of hoist ropes. When replacing a single hoist rope, be sure to check the alignment of the dipper. Shim the old rope if required to level the dipper.

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Crowd Rope Reeving & Replacement NOTE:

To use the procedure below the old crowd rope must not be broken or severely frayed, the new crowd rope should be wound on a shipping reel with one ferrule button-end in and one ferrule button-end out, and all tools and equipment specified must be on hand.

AVOID ANY METHODS WHICH ALLOW THE ROPE TO UNWIND OR FALL UNCONTROLLED. An uncontrolled rope could cause death or serious injury.

NOTE: Should it be necessary to replace both the crowd and retract ropes, THE CROWD ROPE SHOULD BE REPLACED FIRST. The crowd rope has ferrules swaged onto the ends of the rope to the drum. These ferrules limit the amount of rope on the crowd drum in relationship to the handle position. Failure to install the crowd rope first may cause the ropes to be “out of time” and cause operating difficulties. Replacing both ropes simultaneously should not be attempted.

To replace the crowd rope: 1.

Check the new rope for the correct length. Measure to the inner ends of the ferrule buttons.

2.

The machine should be in a clear flat area with sufficient room to allow all of the steps in the procedure to be carried out. All applicable safety regulations should be followed. Only personnel directly connected with replacing the rope should be allowed on or near the machine.

The condition of the rope may make it necessary to modify the procedure described here, especially if the rope is broken or severely damaged. Be sure to follow all safety precautions when burning. Always maintain complete control over the rope and over any burned sections of rope.

3.

Crowd and lower the dipper simultaneously until the rear stop of the dipper handle contacts the saddle block and the dipper heel is resting on the ground as shown.

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Crowd Rope Reeving

4.

Set all brakes, shut the machine down and tag and lock all controls.

5.

Back-off the retract take-up adjustment to its complete limit.

6.

While using an auxiliary line to control the becketed end of the retract rope, remove the clamp and disconnect retract rope from left side of the crowd drum.

7.

Use an auxiliary line to pull the ferrule button-end of the retract rope sufficiently to permit the removal of the ferrule button from the ferrule socket on the right side of the crowd drum.

8.

Secure both ends of the retract rope away from the crowd drum.

9.

Remove locks and tags from the controls and, using the crowd motor, rotate crowd drum in the retract direction to unwind the crowd rope from the drum. When the crowd rope ferrule buttons are in position for easy removal from the sockets, stop rotating the crowd drum. Set the brakes and replace the tags and locks to the controls.

10.

Remove the crowd rope ferrule buttons from the ferrule sockets and allow the rope ends to hang vertically from the saddle block sheaves. Inspect the drum grooves for sharp edges and grind them as necessary.

11.

Position the reel of new crowd rope under the saddle block and in-line with the left saddle block sheave.

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ROPE END(S) WILL FORCEFULLY UNCOIL IN RELEASE OF ENERGY WHEN SHIPPING RESTRAINTS ARE REMOVED. If the old crowd rope IS NOT broken, attach the end of the new crowd rope to the end of the old crowd rope at the left side. Secure the end of the old crowd rope on the right side to a ground vehicle.

- OR If the old crowd rope IS broken and has to be removed in sections:

12.

a.

Inspect rope grooves and repair/weld as required.

b.

Reeve an auxiliary line up to and over the inner groove of the right side saddle block sheave, around the crowd cushion sheave, back over the inner groove of the left saddle block sheave, and down to the new reel of rope. Attach the auxiliary line to the becket loop of the new rope and the other end of the line to a ground vehicle as shown.

With the ground vehicle, pull the new crowd rope onto the machine until an equal amount of crowd rope hangs from each saddle block sheave. Secure the crowd rope and disconnect the auxiliary line.

NOTE: Liberally lubricate the grooves of the crowd drum to help prevent damage to the new crowd rope as it is pulled into position on the crowd drum.

Crowd Rope Drum Reeving

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13.

Bring the auxiliary line over the top of the crowd drum, through the crowd rope socket, around the rear of the drum and forward from the bottom of the drum to the corresponding end of the new crowd rope. Connect the auxiliary line to the corresponding end of the crowd rope. Release the corresponding end of the crowd rope from (Step 12) securing means, and with the ground vehicle still attached to the other end of the auxiliary line, pull the crowd rope onto the rope ferrule socket on the drum. Secure the crowd ferrule button into the drum ferrule socket. Release the auxiliary line from the crowd rope.

14.

Connect the other end of the crowd rope to the other corresponding crowd drum ferrule socket in the same way as described in Step 13.

15.

Remove the locks and tags from the controls and using the crowd motor, rewind new crowd rope onto the crowd drum by rotating the drum in the crowd direction. Make sure rope is seating properly in drum grooves and the inner grooves of the saddle block sheaves. Stop rotating drum when the crowd rope is tight. Set brakes and replace the tags and locks to the controls.

NOTE: The construction stretch may be out of the crowd rope when it becomes necessary to adjust the rope for about the third time. Therefor; after the third rope adjustment after replacement back off the adjustment by one 0.50 inch shim after obtaining a tight rope by pressurizing the cylinders and thus prevent working with an overly tight rope.

16.

With the ferrule button-end of the retract rope controlled by an auxiliary line to start with, reinstall the retract rope to the crowd drum by following Steps 11 through 17 of the RETRACT ROPE REEVING PROCEDURE in this section of the manual.

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Retract Rope Reeving & Replacement NOTE:

To use the procedure below the old retract rope must not be broken or severely frayed, the new retract rope should be wound on a shipping reel, and all tools and equipment specified must be on hand.

AVOID ANY METHODS WHICH ALLOW THE ROPE TO UNWIND OR FALL UNCONTROLLED. An uncontrolled rope could cause death or serious injury.

NOTE: Should it be necessary to replace both the crowd and retract ropes, THE CROWD ROPE SHOULD BE REPLACED FIRST. The crowd rope has ferrules swaged onto the ends of the rope to the drum. These ferrules limit the amount of rope on the crowd drum in relationship to the handle position. Failure to install the crowd rope first may cause the ropes to be “out of time” and cause operating difficulties. Replacing both ropes simultaneously should not be attempted.

To replace the retract rope: 1.

The machine should be in a clear, flat area with sufficient room to allow all of the steps in the procedure to be carried out. All applicable safety regulations should be followed. Only personnel directly connected with replacing the rope should be allowed on or near the machine.

The condition of the rope may make it necessary to modify the procedure described here, especially if the rope is broken or severely damaged. Be sure to follow all safety precautions when burning. Always maintain complete control over the rope and any burned section of rope.

2.

Crowd and lower the dipper simultaneously until the rear stop of the dipper handle contacts the saddle block and the dipper heel is resting on the ground as shown in the figure.

3.

Back off the retract take-up adjustment to its complete limit. Remove the rope retaining bolts on the take-up nut and the rope retainers on the front spreader.

4.

Remove the retract rope from the drum.

5.

Remove the old retract rope from the machine.

6.

Position the reel of new retract rope directly under the saddle block.

ROPE END(S) WILL FORCEFULLY UNCOIL IN RELEASE OF ENERGY WHEN SHIPPING RESTRAINTS ARE REMOVED.

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Retract Rope Reeving

7.

Reeve an auxiliary line under then over the crowd drum, up and over the outer groove of the saddle block sheave, through the rope guide on the front stop and around the retract takeup nut. Reeve it through the rope guide on the front stop on the opposite side of the handle, over the outer groove of the other shipper shaft sheave, down and over then under the crowd drum and secure the other end of the auxiliary line to the ground vehicle.

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NOTE:

Liberally lubricate the grooves of the crowd drum and the take-up nut to help prevent damage to the new retract rope as it is pulled onto the machine.

8.

With the ground vehicle pull the new rope onto the machine until an equal amount of the retract rope is on each side of the machine. Disconnect the auxiliary line from the retract rope.

9.

Reeve the auxiliary line, still attached to the ground vehicle, under the crowd drum up through the rope socket, down under then over the drum and secure it to the retract rope becket loop. With the ground vehicle pull the retract rope onto the drum and into the rope socket. Seat the becket within the drum receptacle.

10.

Install the other end of the retract rope in the crowd drum in the same way.

11.

Be sure the retract rope is seated in the outer groove of the shipper shaft sheaves and the rope grooves of the front stops. Re-install the take-up nut rope retaining bolts and front stop rope retainers.

12.

Take up any slack in the retract rope with the retract take-up mechanism. Refer to RETRACT ROPE TIGHTENING.

13.

Re-index the crowd limit switch.

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Retract Rope Take-Up Mechanism

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Retract Rope Tightening NOTE:

The constructional stretch may be out of the retract rope when it becomes necessary to adjust the rope for about the third time. Therefore, after the third rope adjustment or after replacement, back off the adjustment by one .5 inch shim after obtaining a tight rope by pressurizing the cylinders to prevent working with an overly tight rope.

NOTE:

Do not overtighten the ropes. The ropes are properly adjusted when a very slight curvature is noticeable on the retract rope (a 3 to 5 inch sag) with a tight crowd rope.

With the dipper resting on the ground, rotate the crowd drum in such a way as to tighten the crowd rope and provide slack in the retract rope. Retighten the retract rope as follows: 1.

Open the shim guard.

2.

Clean up and grease the sliding areas on the take-up nut, support and screw.

3.

Be sure that the right needle valve is open and the left needle valve is closed.

4.

Extend the cylinders by injecting hydraulic fluid into the left fitting.

5.

Shim the take-up nut at the desired position.

The take-up nut must be shimmed tight, both fore and aft, using all shims originally provided with machine.

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6.

Slowly open the left needle valve to release the pressure on the cylinders.

Oil within the needle valves is under high pressure. STAY CLEAR OF TAKE-UP NUT, SHIMS AND CYLINDERS WHEN OPERATING NEEDLE VALVE, AS THESE ITEMS COULD MOVE UNEXPECTEDLY AND CAUSE SERIOUS INJURY. 7.

Close and secure the shim guard.

Dipper Trip Rope Reeving & Replacement 1.

Use steps one and two from Hoist Rope Reeving. In this procedure the on-board auxiliary winch is not used.

2.

Trip and lock the DTB breaker in the MCC cabinet.

3.

Crowd the dipper handle to unwind the trip rope from the reel. Lower the dipper to the ground and retract it slightly to get some slack in the trip rope. Remove worn rope from dipper door.

4.

Open the drum guard on the dipper trip and remove the rope and wedge from the drum.

Attach a work line to the trip rope. Pull the trip rope over and off of the trip rope guide sheave and lower to ground. The work rope will remain on the guide sheave and will be used to pull the new trip rope on.

NOTE: Do not use new trip rope which is longer than specified. Increasing length adds layers of rope on the drum which decreases trip torque.

5.

Reeve one end of the new trip rope under the guide roller, around the latch lever sheave and secure it to the rope socket with the rope socket wedge on the dipper door.

6.

Attach the other end of the new trip rope to the work line still in place on the guide sheave.

With the work line, pull the trip rope onto the guide sheave and up to the dipper trip. Secure the trip rope to the drum with the rope wedge. Close the drum guard.

7.

Remove the lock that was previously placed on the DTB breaker in the MCC cabinet and reset the breaker.

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Hoist and Crowd Limit Systems All electric rope shovels incorporate a PLC-based limit position system that permits the setting of the Hoist/Lower and Crowd/Retract operational limits. Hoist and crowd encoders send digital signals to the PLC relative to the hoist crowd motor positions. The setup of the hoist and crowd limits is accomplished through the operator’s display terminal by following the instructions provided here in this manual along with those on the operator’s display. When encoder calibration and hoist/crowd positional limits have been properly set the system will prevent the dipper handle from hitting its end stops and will prevent the padlocks from being pulled into the boom point sheaves.

Hoist/Crowd encoder calibration provides the limit system a reference point for tracking both the hoist and crowd positions. Performing the encoder calibration sets all the hoist and crowd limits to their previously set values in order that the actual limits do not require reset after initial commissioning.

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Setting Rope Limits In The Hoist & Crowd System The hoist and crowd limits may be changed as often as desired without encoder recalibration providing the ropes have not been replaced. The individual limits may be set in any order.

Suggested slowdown and stop points are shown as a guide only, and must be adjusted to suit local operation.

NOTE: Hoist and crowd limits should be set with care, as the limits will affect the digging range of the machine. After the motion limits have been set initially, it is necessary to calibrate the encoder if the ropes have been replaced, or if the encoder has been replaced.

Performing the encoder calibration will reset the motion limits to their previous positions.

NOTE: The slowdown limits reduce handle speed to 20% of maximum prior to reaching the stop limit. Because the drive requires a discrete distance to stop that is different at all positions, it is recommended that the slowdown limit be tried several times. Increase speeds from minimum to maximum to determine if sufficient distance is available in the limits as set to stop without impacting the mechanical stops.

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To calibrate the encoder: 1.

Go to the Calibration Limits screen on the operator display shown in View A.

S-CL_295HR

View A - Calibration Limits Screen

2.

Raise the dipper to the maximum point (just touching boom point sheaves).

3.

Extend the handle to its crowd end stop.

4.

Press the CALIBRATE button on the operator display. This calibrates the rope lengths prior to setting limits. This is required only after changing the ropes, or if the encoder has been replaced.

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Crowd Slowdown/Stop Limit To set the crowd slowdown and stop limits: 1.

With the handle horizontal, position the handle approximately one foot from the rear end of the saddle block.

2.

Press the CROWD STOP LIMIT button on the operator display.

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3.

Retract the handle until the crowd stops are approximately 2 feet from the saddle block.

Press the CROWD SLOWDOWN LIMIT button on the operator display.

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Retract Slowdown/Stop Limits To set the retract slowdown and stop limits: 1.

Position the handle vertically. Retract the handle until the retract stops are approximately 18 inches from the front end of the saddle block.

2.

Press the RETRACT SLOWDOWN LIMIT button on the operator display.

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3.

Position the handle with the retract stops approximately 6 inches from the saddle block and press the RETRACT STOP LIMIT button on the operator display.

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Lower Slowdown/Stop Limits To set the lower slowdown and stop limits: 1.

Position the handle vertically with the dipper teeth just touching pit floor and the hoist ropes tight. Press the LOWER SLOWDOWN LIMIT button on the operator display.

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2.

Keeping the handle vertical, let the padlocks fall forward until the padlocks contact the dipper.

3.

Press the LOWER STOP LIMIT button on the operator display. The lower stop limit helps prevent rope from spooling off the hoist drum.

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Hoist Slowdown/Stop Limits To set the hoist slowdown and stop limits: 1.

With the handle at full crowd extension, hoist the dipper so the padlocks are approximately one foot from the boom point sheaves.

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2.

Press the HOIST STOP LIMIT button on the operator display.

3.

Lower dipper until the padlocks are three feet from the boom point sheaves. Press the HOIST SLOWDOWN LIMIT button on the operator display.

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5

Brakes and Couplings

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Brakes .......................................................................................................................................... 3 Machine Motion Brakes ..................................................................................................... 3

Disc Brake Operation .............................................................................................................. 4 Maintenance ............................................................................................................................ 4 Brake Adjustment Specifications ............................................................................................. 4 Brake Adjustment Chart .................................................................................................... 4

Hoist Brake .............................................................................................................................. 5 Hoist Brake and Motor Location ........................................................................................ 5

Hoist Brake Adjustment ..................................................................................................... 7 Hoist Brake Installation ...................................................................................................... 9 Crowd Brake ......................................................................................................................... 10 Crowd Brake Location ...................................................................................................... 10 Section View B-B ............................................................................................................. 11

Crowd Brake Installation .................................................................................................. 13 Propel Brake .......................................................................................................................... 14 Propel Brake and Motor .................................................................................................... 14 Section View C-C ............................................................................................................. 15

Swing Brake .......................................................................................................................... 16 Location of Swing Brakes and Motors ............................................................................... 16 Section View D-D (Swing Brake) ....................................................................................... 17 View D (Swing Brake) ....................................................................................................... 17

Swing Brake Installation .................................................................................................. 18 View G ............................................................................................................................. 18

Swing Brake Burnishing .................................................................................................. 20 Spring Replacement — All Brakes ........................................................................................ 21 SM141403-EN

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Friction Disc Replacement — All Brakes .............................................................................. 23 O-ring Replacement — All Brakes ........................................................................................ 25 Couplings .................................................................................................................................. 27 Grid Couplings ....................................................................................................................... 27 Lubrication ....................................................................................................................... 28 Coupling Disassembly And Grid Removal ....................................................................... 28 Grid Coupling Installation ................................................................................................. 29 Seal Replacement Without Hub Removal ....................................................................... 32 Grid Coupling Alignment .................................................................................................. 34 Grid Coupling Data ........................................................................................................... 34

Gear Couplings ..................................................................................................................... 35 Installation ........................................................................................................................ 35 Gear Coupling Alignment ................................................................................................. 38 Gear Coupling Data .......................................................................................................... 38

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Brakes This machine uses spring-set, air-released disc brakes on the HOIST, CROWD, PROPEL and SWING motions.

In the event of a power failure or loss of air pressure, the brakes will automatically set to stop the machinery motion. Pressure switches located near each brake control valve monitor air pressure at the brake. The brakes cannot be released for operation until the air pressure reaches the operating pressure.

Each brake is fitted with a proximity sensor to monitor lining wear and a limit switch to monitor the brake set or released position. When the lining wear limit is reached, it is announced on the operator’s display terminal. The brake position is announced in the operator’s control screen.

Machine Motion Brakes

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Disc Brake Operation When air is exhausted, the spring force “clamps” the rotor between the friction discs or the mounting flange and pressure plate. To disengage the brake, air enters through the end plate into the diaphragm cavity. As air pressure increases, the end plate moves away from the stationary spring housing.

The pressure plate is bolted to the end plate and travels in the same direction compressing the springs and releasing the brake.

PRIOR TO INSTALLATION OR MAINTENANCE ON A BRAKE, MAKE SURE THAT MACHINE OR MACHINERY IS BLOCKED TO PREVENT MOVEMENT. Failure to do so could result in serious personal injury or machine damage.

Protective means must be used to prevent oil or grease from coming into contact with the disc(s) or the friction discs. Oil or grease will significantly reduce the torque capacity of the brake and decrease its ability to hold the machinery in a safe position. DO NOT RISK INJURY!

DO NOT OPERATE THE MACHINE WITHOUT ALL BRAKE GUARDS INSTALLED.

Maintenance •

No lubrication is required.

•

Replace friction disc(s) when worn to the step on the friction disc O.D.

Brake Adjustment Specifications

Brake Adjustment Chart

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Hoist Brake

Hoist Brake and Motor Location

The hoist brake is located on the right side of the hoist motor. An internal tachometer is located between the brake and the motor (inside the brake adapter). The hoist brake is spring set, air released and contain three friction discs; refer to Section View A-A. Visual inspection of the brake’s internal components can be made after removing the brake guard. Periodically inspect the brake friction disc, wear plate, pressure plate and center plates for signs of uneven or excessive wear. If found, disassemble brake to determine the extent of damage. The friction discs must be replaced if they become contaminated with oil/grease or are worn out.

PRIOR TO INSPECTION OR MAINTENANCE ON A BRAKE, MAKE SURE THAT MACHINE OR MACHINERY IS BLOCKED TO PREVENT MOVEMENT. Failure to do so could result in serious personal injury or machine damage.

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Brake wear can be extended with proper adjustment. Once the piston stroke has reached a specified point, an adjustment shim can be removed to bring the piston stroke into the safe operating limits.

Refer to the Brake Adjustment Chart in BRAKE ADJUSTMENT SPECIFICATIONS. A friction disc must be replaced if it has become contaminated with grease, oil or foreign material. Refer to the FRICTION DISC REPLACEMENT procedure in this section of the manual.

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Hoist Brake Adjustment The hoist brake is equipped with 3 adjustment shims to compensate for lining wear. This brake should be checked daily for lining wear and proper piston travel. If out of adjustment it will not be able to support a fully loaded dipper.

To inspect for excessive disc wear, use a depth micrometer as shown in View A. The reading must be taken from the same location with the brake engaged and released.

NOTE: The brake will be fully released once air pressure exceeds 65 PSI on a properly functioning brake. However, air pressure in excess of 125 PSI could damage the internal seals of the piston.

Due to the tapered surface of the pressure plate, care must be taken to duplicate the position and process as closely as possible. Friction disc adjustment must be performed when the total wear reaches 0.38 inch.

NOTE: Adjustment shims are split for ease of removal and installation. DO NOT DISCARD shims after removal during brake adjustment. These shims will be required when reassembling the brake following a friction disc replacement.

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1.

When wear has reached 0.38 inch, remove a single shim. Loosen the “X” stud nuts enough to slide the assembly back approximately 0.06 inch. Do not completely remove the stud nuts.

2.

Spread one shim at the split line and remove it from the brake, taking care not to bend or spring the shim. For ease of removal, the shims are split radially.

3.

Tighten outer cylinder nuts to 110-120 Ft-Lbs.

Tighten the stud nuts as per the instructions on the brake drive ring to a maximum of 120 Ft-Lbs Excessive or improper tightness can cause the drive ring to become deformed and seriously reduce the effectiveness and life of the brake assembly.

4.

Re-check the piston stroke. If the piston stroke is greater than 0.25 inch, place the unit back into service.

If the brake has already had a single shim removed, a second adjustment is possible. If the brake movement is greater than 0.38 inch the second shim may be removed.

NOTE: If friction disc(s) show signs of uneven wear, move the inner friction disc to outer location and the outer disc to the inner location to equalize wear. Ensure the side of the disc with the machined step “Z” faces the motor.

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Hoist Brake Installation The speed sensor, furnished with the hoist motor, must be installed before installing the brake assembly.

1.

Install the drive hub and keyway on the motor. Refer to PINION & HUB INSTALLATION in the ENGINEERING DATA section.

2.

Install motor shaft nut and secure to shaft with Loctite.

3.

Install brake adapter onto the motor and secure with hardware. Use care to align the access slots in the adapter for future speed sensor inspections.

4.

Lubricate the hub and friction disc splines with a light coat of Teflon grease (PN:59100650) or anti-seize compound.

5.

Install the friction discs and center plates onto the shaft adapter in the required order before sliding on the brake assembly. Tighten the drive ring hardware and install the brake guard.

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Crowd Brake

Crowd Brake Location (TOP VIEW of CROWD MACHINERY)

The crowd brake is located on the right side of the crowd motor. The crowd brake contains a single friction disc and is non adjustable; refer to Section View B-B. Once the stroke reaches 0.20 inch, the friction disc must be replaced. Visual inspection of the brake’s internal components can be made after removing the brake guard. Periodically inspect the brake friction disc, wear plate, pressure plate and center plates for signs of uneven or excessive wear. If found, disassemble brake to determine the extent of damage.

PRIOR TO INSPECTION OR MAINTENANCE ON A BRAKE, MAKE SURE THAT MACHINE OR MACHINERY IS BLOCKED TO PREVENT MOVEMENT. Failure to do so could result in serious personal injury or machine damage.

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Section View B-B (Crowd Brake)

The crowd brake is non-adjustable. Once the piston stroke has reached a specified point, the friction disc must be replaced. Refer to the Brake Adjustment Chart in BRAKE ADJUSTMENT SPECIFICATIONS. A friction disc must be replaced if it has become contaminated with grease, oil or foreign material. Refer to the FRICTION DISC REPLACEMENT procedure in this section of the manual.

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Crowd Brake Installation 1.

Lubricate hub spline and brake disc spline very lightly with Teflon grease (PN:59100650) prior to assembly. DO NOT use heavy grease or anti-seize type greases.

2.

Using a lifting device, place the brake assembly onto the drive hub and lower while aligning the splines in the drive hub with those in the brake disc.

3.

Apply at least 36 PSI compressed air to release the brake. Verify piston stroke.

NOTE: The brake will be fully released once air pressure exceeds 36 PSI on a properly functioning brake. However, air pressure in excess of 125 PSI could damage the internal seals of the piston.

4.

Release the air pressure from the brake piston to relax the internal springs.

5.

Tighten the drive ring for final installation.

6.

Apply at least 36 PSI compressed air to release the brake. Verify that the proper gap remains between the pressure plate and friction surface of the disc.

7.

Install safety guard around the brake assembly.

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Propel Brake

Propel Brake and Motor

The two propel brakes are located at the rear of the machine, installed in front of each propel motor.

Each propel brake is spring set, air released and contains a single friction disc, refer to Section View C-C. Visual inspection of the brake’s internal components can be made after removing the brake guard. Periodically inspect the brake’s friction disc, wear plate, pressure plate and center plates for signs of uneven or excessive wear. If found, disassemble brake to determine the extent of damage. The friction disc must be replaced if they become contaminated with oil/grease or are worn out.

Brake wear can be extended with proper adjustment, refer to the PROPEL BRAKE ADJUSTMENT procedure in this section of the manual.

PRIOR TO INSPECTION OR MAINTENANCE ON A BRAKE, MAKE SURE THAT MACHINE OR MACHINERY IS BLOCKED TO PREVENT MOVEMENT. Failure to do so could result in serious personal injury or machine damage.

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Section View C-C (Propel Brake)

The propel brake is non-adjustable. Once the piston stroke has reached a specified point, the friction disc must be replaced. Refer to the Brake Adjustment Chart in BRAKE ADJUSTMENT SPECIFICATIONS. A friction disc must be replaced if it has become contaminated with grease, oil or foreign material. Refer to the FRICTION DISC REPLACEMENT procedure in this section of the manual.

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Swing Brake

Location of Swing Brakes and Motors

A swing brake is located on top of each of the two swing motors. An internal tachometer is installed on one of the two swing motors (inside the brake adapter). Due to the mechanical coupling of the motors and the gearcases, both motors will operate at the same speed. Each swing brake contains a single friction disc and is non adjustable; refer to Section View D-D. Once the stroke reaches 0.20 inch, the friction disc must be replaced. Visual inspection of the brake’s internal components can be made after removing the brake guard. Periodically inspect the brake friction disc, wear plate, pressure plate and center plates for signs of uneven or excessive wear. If found, disassemble brake to determine the extent of damage.

PRIOR TO INSPECTION OR MAINTENANCE ON A BRAKE, MAKE SURE THAT MACHINE OR MACHINERY IS BLOCKED TO PREVENT MOVEMENT. Failure to do so could result in serious personal injury or machine damage.

Swing brakes are unique because of their horizontal operation which requires an additional burnishing procedure when new or relined brake discs are installed. For additional information, refer to the SWING BRAKE BURNISHING procedure in this section of the manual.

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Section View D-D (Swing Brake)

The swing brakes are non-adjustable. Once the piston stroke has reached a specified point, the friction disc must be replaced. Refer to the Brake Adjustment Chart in BRAKE ADJUSTMENT SPECIFICATIONS. A friction disc must be replaced if it has become contaminated with grease, oil or foreign material. Refer to the FRICTION DISC REPLACEMENT procedure in this section of the manual.

View D (Swing Brake)

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Swing Brake Installation The tachometer, furnished with the electric motor, must be installed before installing the swing brake assembly.

NOTE: Tachometer will only be installed on one of the two swing motors. Due to mechanical coupling the 2 swing motors and gearcases will operate at identical speeds.

1.

The tachometer is to be oriented as shown in View G. Reposition if necessary.

View G

2.

Install the drive hub and keyway on the motor. Refer to PINION & HUB INSTALLATION in the ENGINEERING DATA section.

3.

Install motor shaft nut and secure to shaft with the lockwasher by bending tabs over flats.

4.

Install brake adapter onto the motor and secure with hardware. Use care to align the access slots in the adapter for future tachometer inspections.

5.

Lightly coat the splines of the drive hub with a Teflon grease allowing only a thin film of lubricant to remain on the splines. Excess grease will be thrown outward by centrifugal force and have a degrading effect on the brake.

6.

Using a lifting device and the holes provided in the outer portion of the drive ring, place the brake assembly (approx. 500 lbs.) onto the drive hub and lower while aligning the splines in the drive hub with those in the brake disc.

7.

Apply at least 24 PSI compressed air to release the brake.

NOTE: The brake will be fully released once air pressure exceeds 24 PSI on a properly functioning brake. However, air pressure in excess of 125 PSI could damage the internal seals of the piston.

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8.

Install shims, as required, to achieve a gap of .015 - .030 inch between the brake disc and the pressure plate. Refer to View D.

A minimum of 24 PSI must remain applied to the brake while this dimension is determined. The brake must remain fully disengaged!

9.

Release the air pressure from the brake piston to relax the internal springs.

10.

Tighten the drive ring for final installation.

11.

Apply at least 24 PSI compressed air to release the brake. Verify that the proper gap remains between the pressure plate and friction surface of the disc.

12.

Install brake guard.

13.

If previously removed, install the wear/release switches and brackets for the wear and release indicators.

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Swing Brake Burnishing The swing brake on this machine is a “single disc assembly” consisting of a ductile iron disc to which multiple metallic lining segments are riveted. The burnish-in procedure for a new or relined disc brake initiates a controlled wear process to develop the maximum contact area between braking surfaces. The burnish-in process will also start the formation of an oxide layer on the surface of the linings to stabilize and to establish the coefficient of friction.

Prior to beginning the burnish-in procedure check and record the brake pressure plate temperature with a hand held temperature measuring device. Between each stop, continue monitoring the pressure plate temperature. Do not allow the pressure plate temperature to exceed 300° Fahrenheit (149°C).

NOTE: Check the temperature of each brake on the machine. If the temperature exceeds 300°F (149°C) stop the burnishing procedure and allow the brakes to cool to 200°F (93°C). If overheated or malfunctioning brakes are found, check if the brake is releasing properly. It is normal for a small amount of disc particles to be ejected from the brake and for sparking to occur during this operation. Large amounts of either situation may indicate overheating or improper release and should always be corrected prior to continuing.

BURNISH-IN PROCEDURE (DIPPER EMPTY) # of Stops at Speed

Time Between Stops

4 stops/1/4 speed

1 minute minimum

8 stops/1/2 speed

2 minutes minimum

Perform one additional full load, 3/4-speed stop with the dipper handle in the horizontal position and the hoist rope vertical on the swing motion. This will ensure that the brakes are functional. Record the swing stopping times and angles. Forward these recorded readings to the manufacturer.

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Spring Replacement — All Brakes To replace the brake springs, disassemble the brake as follows: 1.

Follow steps one through five of the Replacement of Friction Discs procedure.

2.

Remove the cylinder stud nuts.

NOTE: It is recommended that the piston cylinder, pressure plate and drive ring be marked so that the same studs pass through the same bolt holes at reassembly.

3.

Remove the piston with cylinder and pressure plate as a complete assembly from the studs and place on a clean level working area.

4.

Slowly open the temporary shut-off valve and release pressure from the piston with cylinder and pressure plate assembly.

The brake springs are under compression. Care must be taken when removing piston bolts in order to avoid injury.

5.

Remove all piston bolts except for four located at 90° from one another.

NOTE: Reinstall one piston bolt to the right of each of the four remaining piston bolts, turning each of the reinstalled piston bolts two turns. These bolts act as a safety stop during the removal of the four remaining piston bolts 90° from each other.

6.

Carefully loosen each of the four remaining piston bolts two turns each in a pattern 180° opposite each other until all four piston bolts have been loosened two turns. Repeat loosening each of the four piston bolts in the above manner until the brake spring compression has been fully released at all four remaining piston bolts.

Tap the piston to make sure it has not bound against the cylinder. Care must be taken when loosening piston bolts so that the piston does not bind against the cylinder.

7.

Remove the four remaining piston bolts and the safety stop bolts and lift the cylinder with piston off the pressure plate and brake springs.

8.

Remove all brake springs and insulating washers.

NOTE: The springs are equipped with insulated fiber washers. Be sure the washers are in place at reassembly.

9.

Place new insulating washers, then new springs into the counterbores of the pressure plate. Reposition the cylinder with piston onto the springs taking care that each spring end properly seats into each counterbore of the brake cylinder.

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10.

Using piston bolts, assemble the cylinder with piston to the pressure plate and springs by reversing step 4 above. Tighten all piston bolts to 200-220 Ft-Lbs in a pattern 180° apart.

11.

Close the temporary shut-off valve. Reconnect the auxiliary airline to the temporary shut-off valve and follow steps four and five of the Replacement of Friction Discs procedure.

12.

Slide the pressurized piston with cylinder and pressure plate assembly onto the cylinder studs. (When applicable, make sure cylinder shimming is in place between the cylinder and drive ring.) Secure the assembly in place with the stud nuts. Tighten the nuts in a diametrical pattern to 90-100 Ft-Lbs.

Do not over tighten the stud nuts as this will cause drive ring distortion leading to excessive wear on brake disc and mating surfaces.

NOTE: Observe the temporary regulator pressure gauge. If the pressure has dropped, the piston O-Rings may need replacement.

13.

Open the temporary shut-off valve and release the brake pressure. Remove the temporary regulator with gauge and the shut-off valve from the brake inlet and reconnect the brake airline to the brake inlet.

14.

Reinstall the brake guard, the tach supports, the tach and the tach cover.

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Friction Disc Replacement — All Brakes The friction disc(s) will require replacement when excessively worn or when contaminated by grease, oil or other foreign materials.

Major damage will occur to the components of the brake assembly if the friction disc is not replaced when worn. The result of “pushing” will result in metal-to-metal contact that will cause extremely expensive repairs and a seriously degraded braking system.

Do not remove the socket head capscrews near the bore of the piston as this will release the spring pressure within the brake assembly and make re-assembly much more difficult.

1.

Remove the brake guard as required.

2.

Release air pressure and remove the air line from the Air INLET to the brake.

3.

Install a ball or gate valve into the air INLET. This valve will be used to capture pressure within the piston during removal.

4.

Reconnect the air source and pressurize the brake to the full released position. Close the valve, and then remove the air lines. At this point the brake is disengaged and not connected to an air source.

NOTE: The cylinder, piston and pressure plate may be removed as a single unit.

5.

Remove the outer cylinder stud nuts at this time and the lift the entire brake assembly off the top of the studs as a unit. Once removed from the motor the pressure may be removed from the cylinder.

6.

Slide the friction disc(s) and center plate (for multiple disc brakes) up and off of the hub adapter splines and free it from the assembly. Do not remove the studs and collars retaining the separating springs, they will lift out with the plates.

7.

Clean the area where the friction disc resides and lightly coat the splines with fresh Teflon lubricant.

8.

Install the replacement friction disc ensuring that the machined step “Z”, near the center, is facing downward - toward the motor.

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Brakes and Couplings BI010942

9.

Carefully align the splines between the hub and the disc and allow the new disc to rest.

Install brake specific spacer or shims. Refer to specific BRAKE ADJUSTMENT procedure.

10.

Reinstall the piston and pressure plate onto the top of the friction disc and align the pneumatic fitting, access holes and studs accordingly. Pressurize the piston once more to minimum pressure allowing complete disengagement of the components.

11.

Replace the stud nuts and tighten to 90 - 100 Ft-Lbs.

Tighten the stud nuts as per the instructions on the brake drive ring. Excessive, or improper, torque application can cause the drive ring to become deformed and seriously reduce the effectiveness and life of the brake assembly.

12.

Ensure the air line and wear/release switches are properly reconnected. Refer to BRAKE WEAR & RELEASE SWITCHES in this section of the manual.

5 - 24 October 2012

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O-ring Replacement — All Brakes With machine parked on flat level surface, with dipper heel resting on the ground, the O-Rings may be replaced by disassembling the brake as follows: 1.

For the propel brake, remove the tachometer, tach supports and the brake guard as required.

2.

For hoist, crowd or swing brakes, remove the wear and release switches along with the mounting bracket and hardware. Remove the brake guard.

3.

Release air pressure to the brake. Disconnect the air line to the brake inlet. Install a temporary pressure regulator with gauge and a closed shutoff valve to the brake inlet.

NOTE: The pressure regulator with gauge should be located between the brake and the shutoff valve.

4. Remove the capscrews attaching the piston to the pressure plate. Remove the piston.

Do not remove cylinder stud nuts securing cylinder to pressure plate as this will release the brake springs and make reassembly difficult.

NOTE: It is recommended that piston and cylinder be marked so that the piston bolts pass through the same piston and pressure plate bolt holes at reassembly.

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Brakes and Couplings BI010942

5.

Inspect O-Rings for cleanliness, wear, deterioration, or cracks. Clean each as required and replace old or damaged O-Rings. Dress out any nicks or grooves in the cylinder wall with a fine stone and finish with a fine emery cloth prior to installing the new O-Ring seals.

6.

Lubricate the O-Rings and grooves generously before assembly. Install the O-Rings in grooves as they would lie naturally. Do not nick, pinch, or twist O-Rings.

NOTE: It is a good practice to coat the inner surfaces of the piston and cylinder with a Teflon type lubricant. This coating of lubricant acts as a final filter to remove air system dust particles which could damage the O-Rings.

7.

Reassemble the piston to the pressure plate with 12 capscrews. Tighten in a star tightening pattern to 200 - 220 Ft-Lbs.

8.

Pressurize the piston to a minimum of 30 PSI as needed to disengage the brake. Close the valve, and then remove the airlines. At this point the brake is disengaged and not connected to an air source.

9.

Observe the pressure gauge. If no pressure drop is observed, continue to Step 10. If pressure drops, the seals are not properly seated. Release any remaining air pressure and go to Step 4.

10.

Release the brake pressure by opening the temporary shutoff valve. Remove the temporary regulator and shutoff valve from the brake inlet. Reconnect the brake air line to the brake inlet.

11.

For the propel brake, reinstall the tach supports and the tachometer.

12.

For hoist, crowd or swing brakes, reinstall the wear and release switches along with the mounting bracket and hardware. Refer to BRAKE WEAR & RELEASE SWITCHES in this section of the manual.

13.

Reinstall the brake guard.

5 - 26 October 2012

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Couplings Grid Couplings

These instructions apply to Tapered Grid Couplings. They are designed to operate in either the horizontal or vertical position without modification. However, for vertical applications, the match mark shown above, must be up. The performance and life of the couplings depend largely upon how they are installed and serviced. Carefully follow these instructions for optimum performance and trouble-free service.

All coupling parts have identifying part numbers. When ordering parts, always SPECIFY SIZE and TYPE. Cover halves have 1/8 NPT lube holes. Use a standard grease gun and lube fitting.

For Long Term Grease (LTG) use part no. MP295148.

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Brakes and Couplings BI010942

Lubrication Adequate lubrication is essential for proper operation of the coupling. Refer to the table “Grid Coupling Data” for the amount of lubricant required. It is recommended that the coupling be checked once a year and lubricant added if required. For extreme or unusual operating conditions, check more frequently. Grid couplings initially lubricated with LTG will not require re-lubrication until the connected equipment is stopped for servicing.

Coupling Disassembly and Grid Removal

STORED ENERGY! Once grid is removed, machinery is free to rotate and brake will no longer hold. Equipment must be blocked prior to doing any maintenance to prevent unwanted movement. Death, serious injury, or damage to the machine can result from failure to take proper measures to prevent movement due to release of energy.

Whenever it is necessary to disconnect the coupling, remove the cover halves and grid. A round rod or screwdriver that will conveniently fit into the open loop ends of the grid is required. Begin at the open end of the grid section and insert the rod or screwdriver into the loop ends. Use the teeth adjacent to each loop as a fulcrum and pry the grid out radially in even, gradual stages, proceeding alternately from side to side.

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Grid Coupling Installation Only standard mechanics tools, wrenches, a straight edge and feeler gauges are required for installation. For instructions on mounting to a drive motor, refer to the appropriate motor shaft installation instructions in this manual.

1.

Mount Seals and Hubs

Clean all parts. Heat hubs in an oven or use suitable dry heat. DO NOT rest gear teeth on container bottom or apply flame directly to gear teeth. DO NOT heat hubs over 275oF (135oC) for mounting.

Lightly coat seals with grease and place them on shafts BEFORE mounting hubs. Mount hubs on their respective shafts so the hub face is flush with the end of its shaft.

2.

Gap and Angular Alignment

Use a spacer bar equal in thickness to the gap specified. Insert the bar, as shown here, to the same depth at 90o intervals and measure clearance between bar and hub face with feelers. The difference in minimum and maximum measurements must not exceed the ANGULAR limit specified.

NOTE: The motor shaft must be at the mid-point of its end play when measuring the gap.

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Brakes and Couplings BI010942

3.

Offset Alignment

Align hubs so that a straight edge rests squarely (or within the limit specified) on both hubs as shown here. Check at 90o intervals with feelers. The clearance must not exceed the OFFSET limit specified. Tighten all foundation bolts and repeat Steps 2 and 3. Realign coupling if necessary.

NOTE: Use a dial indicator for more accurate alignment.

4.

Insert Grids

Pack gap and grooves with specified lubricant before inserting grids. Install grid segments so that all cut ends extend in the same direction; this will assure correct grid contact with non-rotating pin in cover halves. Spread grid segments slightly to pass over the coupling teeth and seat with a soft mallet.

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5.

Pack with Grease and Assemble Covers

Pack the spaces between and around the grid with as much lubricant as possible and wipe off excess flush with top of grid. Position seals on hubs to line up with grooves in cover. Position gaskets on flange of lower cover half and assemble covers so that the match marks are on the same side as shown above. If shafts are not level (horizontal) or coupling is to be used vertically, assembly cover halves with the lug and match mark up, or on the high side. Secure covers halves with fasteners and tighten to torque specified in the coupling data table. MAKE SURE LUBE PLUGS ARE INSTALLED BEFORE OPERATING! 6.

Periodic Lubrication

Remove both lube plugs and insert a lube fitting. Fill with recommended lubricant until an excess appears at hole opposite; then insert plug. Lubricate couplings at least once ever year. Lubricate more frequently when exposed to excessive-moisture, extreme temperatures, rapid reversing or shock loads or excessive misalignment. It is not necessary to re-lube couplings filled with Long Term Grease (LTG) until disassembled for service to attached components.

For Long Term Grease (LTG) use part no. MP295148.

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Brakes and Couplings BI010942

Seal Replacement Without Hub Removal The instructions below offer additional procedures that may be useful when replacing seals on an existing installation.

Replacement seals are continuous, one piece members. Unless the connected machines are being moved from their foundation for some other reason you need not disturb the existing mountings to get the new seals in place. The following cut and cement procedures offer a simple way to install new seals without moving machines or pulling coupling hubs.

Falk Steelflex and gear couplings are lubricated shaft connectors. In both designs, a metallic cover and elastomer seals contain the lubricant. Refer to the applicable Installation, Maintenance and Lubrication Instructions furnished with each coupling when replacing worn or damaged seals.

To install a new coupling seal without hub removal: 1.

Cut the coupling seal using a clean, sharp utility knife.

NOTE: The following illustrations show O-Ring seals. The same procedures apply when replacing U-shaped or trapezoidal- shaped seals.

2.

Lightly dress both cut surfaces on a grinding wheel. The resultant square evenly roughened seal ends provide excellent bonding surfaces. Thoroughly clean and degrease the cut ends.

3.

Apply adhesive to the seal ends as instructed by the adhesive manufacturer.

Use Masterbond EP21TDC-7, Loctite Superbond or Loctite 414 Superbond for Viton Seals.

5 - 32 October 2012

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4.

Place the split seal around the shaft and carefully align the two seal ends.

5.

Carefully press and hold the joint together. Do not attempt to stretch the joint seal over the hub for several additional minutes. Refer to the adhesive manufacturer’s instructions for procedure and drying time.

6.

Carefully position the fused seal in place on the coupling hub.

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Brakes and Couplings BI010942

Grid Coupling Alignment

Grid Coupling Data

Coupling

Crowd

Propel

*Part No.

C111270-02

S045329

Type

Grid

Grid

Motor Frame

812

812

8

8

0.75

0.75

Torque (in lb.)

NA

1800

Torque (Ft-Lbs)

NA

150

Max. Parallel Offset (in.)

NA

0.003

Max. Angular Limit (in.)

NA

0.018

Min. End Gap Limit (in.)

NA

0.25

Grease Wt. (Lbs.)

NA

0.6

# Bolts Dia. (inch)

NOTES: • Bolts are NOT Standard Fasteners. Values indicated are for clean, dry threads.

• * Use Parts Book to verify Part Number.

DO NOT SUBSTITUTE STANDARD FASTENERS FOR COUPLING BOLTS.

5 - 34 October 2012

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Gear Couplings Installation

1.

Clean all parts. Heat hubs in an oven or use suitable dry heat. DO NOT rest gear teeth on container bottom or apply a flame directly to gear teeth. DO NOT heat hubs over 275oF (135oC) for mounting. Refer to motor shaft installation for hubs mounted on drive motors.

Pack sleeve teeth with grease and lightly coat seals with grease BEFORE assembly. DO NOT DAMAGE THE SEALS.

Use a dial indicator to align dynamically balanced couplings and assembly parts with mating match marks aligned. Mount the indicator on one hub and take readings for the OFFSET check on the O.D. of the other hub. The difference between the minimum and maximum readings DIVIDED by two should not exceed the values in the table. For ANGULAR check, take readings on either face of other hub. The difference between the minimum and maximum readings should not exceed the values in the gear coupling data table.

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Brakes and Couplings BI010942

2.

Mount the flanged sleeves, seal and hubs. Place the flanged sleeves WITH the seal rings on the shafts before mounting the hubs.

DO NOT DAMAGE THE SEALS. Mount the hubs on their respective shafts, as shown, so that each hub is flush with its shaft end. Position the equipment in approximate alignment with the approximate gap specified in the table.

3.

Gap and Angular Alignment - Use a spacer bar equal in thickness to gap specified in Table.

Insert bar, as shown, to same depth at 90o intervals and measure clearance between bar and hub face with feelers. The difference in minimum and maximum measurements should NOT exceed the ANGULAR limit specified in the table.

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4.

Clamp a dial indicator to the rigid hub as shown and rotate the rigid hub one complete turn.

The total indicator reading DIVIDED by two must not exceed the OFFSET limit specified.

Tighten all foundation bolts and repeat Steps 3 and 4. Realign coupling if necessary.

Grease the hub teeth.

5.

Insert gasket, DO NOT DAMAGE the GASKET, between flanges. Position flanged covers with lube holes at 90o and draw flanged cover into position. Use bolts, nuts and lockwashers furnished with couplings.

Tighten the flange bolts and nuts to the torque specified in the table.

6.

For TYPE G couplings, fill with recommended grease until excess appears at the open hole; then insert plug. For TYPE GV couplings, proceed as outlined above. IN ADDITION, when flex hub is on TOP, vent by inserting a .010 thick SMOOTH feeler gauge between seal and hub. Fill until excess appears at feeler. Repeat at 90o intervals.

Make certain all plugs are inserted after lubricating.

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Brakes and Couplings BI010942

Gear Coupling Alignment

Gear Coupling Data

Coupling

Hoist

*Part No.

C111561-01

Type

Gear

Motor Frame

820

# Bolts

14

Dia. (inch)

0.875

Torque (in-lb)

3756

Torque (Ft-Lbs)

313

Max. Parallel Offset (in.)

0.003

Max. Angular Limit

0.024

Min. End Gap Limit (in.)

0.344

Grease Wt. (lb.)

1.6

NOTES: • Bolts are NOT Standard Fasteners. Values indicated are for clean, dry threads.

• * Use Parts Book to Verify Part Number.

DO NOT SUBSTITUTE STANDARD FASTENERS FOR COUPLING BOLTS.

5 - 38 October 2012

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6

Compressed Air System

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Air Compressor - Dual ................................................................................................................ 3 Air Compressor Location ............................................................................................................. 3 Air Compressor Assembly .......................................................................................................... 4

Compressor Start-up Procedure ............................................................................................. 5 Compressor Shutdown Procedure ......................................................................................... 6 Compressor Fluid Level Check ............................................................................................... 7 Recommended Lubrication Guide ........................................................................................... 8 General Compressor Maintenance ......................................................................................... 9 Fluid & Fluid Filter Change Procedure ............................................................................... 9 Air Filter Maintenance ...................................................................................................... 11 Air / Fluid Separator Element Change ............................................................................. 12 Lockout Valves .......................................................................................................................... 13 Lockout Valve Locations ............................................................................................................ 13 Lube Room Lockout Valve ......................................................................................................... 14

Safety Warnings ........................................................................................................................ 15

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Compressed Air System BI010943

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Air Compressor - Dual This machine uses dual air compressors mounted in a welded frame assembly on the left side of the machine inside the machinery house. High pressure air is used to operate machinery brakes, lubrication and various other functions.

Each of the rotary screw compressors is driven by a 10HP electric, air cooled motor. Each unit has a control box containing a motor start and manual reset switch and two gauges to monitor air system pressure and discharge pressure. Check fluid level visually using the sight glass. Complete replacement of the fluid, fluid filter and separator element are recommended every 8,000 hours of operation. Replace the primary air filter as needed.

STORED ENERGY! Air under pressure will cause severe personal injury or death. Shut down compressor and relieve system of all pressure before removing components such as valves, plugs, fittings and bolts.

Air Compressor Location

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Compressed Air System BI010943

Air Compressor Assembly

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Compressor Start-up Procedure NOTE: Prior to start-up, check the compressors fluid level in the sight glass located on the compressor’s bell housing. The fluid should cover 3/4 of the sight glass when not in operation.

1.

Open the shut-off valve to the service line.

2.

Start the compressor motor by turning the selector switch to MANUAL START or AUTOMATIC START/STOP.

3.

When the compressor is running, observe the instrumentation. Discharge temperature should never exceed 200° F (93°C).

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Compressed Air System BI010943

Compressor Shutdown Procedure 1.

Turn the selector switch located on the control box to OFF/RESET position.

2.

Close the shut-off valve to the service line.

NOTE: Allow the unit to cool and ensure that the line pressure gauge on the control panel indicates “zero” pressure prior to performing any maintenance.

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Compressor Fluid Level Check

A sight glass is located on the bell housing.

•

WHEN NOT IN OPERATION, the fluid should cover 3/4 of the sight glass.

•

DURING OPERATION, the fluid should cover 1/4 to 1/2 of the sight glass.

If the fluid level is low, shutdown the compressor. Add fluid as necessary to bring the fluid level in the sight glass cover 1/4 to 1/2 of the sight glass during operation. DO NOT OVERFILL. DO NOT mix other fluids within the compressor!

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Compressed Air System BI010943

Recommended Lubrication Guide For longest uninterrupted service, the compressor is factory filled with Sullube, a long life lubricant.

For light-duty high humidity service where condensed moisture and emulsification may occur, the fluid change interval must be reduced to 300 hours maximum. A non-detergent fluid with rust, oxidation and foam inhibitors and good water separation characteristics should be used.

DO NOT mix other fluids within the compressor. Contamination of non-detergent mineral fluids with traces of ATF or detergent motor fluids may lead to operational problems such as foaming, filter plugging, orifice or line plugging. Complete flushing is required if changing to a different lubricant.

Lubricant

Fluid Change

Fluid Filter Change

Separator Change

Sullube

A, E

G, C

A, D

SRF 1/4000

B, E

G, C

B, D

24KT

F, E

G, C

A, D

A - 8,000 Hours or once a year.

B - 4,000 Hours or once a year.

C - When measured pressure loss exceeds 20 psig (1.3 bar).

D - When measured pressure loss exceeds 10 psig (0.7 bar).

E - When required by fluid analysis or known contamination.

F - Does not require replacement during normal service conditions.

G - Every 1,000 hours.

6-8 October 2012

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General Compressor Maintenance

STORED ENERGY! Air under pressure will cause severe personal injury or death. Shut down compressor and relieve system of all pressure before removing components such as valves, plugs, fittings and bolts.

Fluid & Fluid Filter Change Procedure When the compressor fluid is ready to be changed, the compressor needs to be shutdown with the power to the compressor disconnected.

NOTE: For long uninterrupted service, the compressor is factory filled with Sullube, a long life lubricant. Under normal service conditions the fluid should be changed every 8,000 hours of operation or once a year. Compressors using SRF 1/4000 fluid should be changed every 4,000 hours. Anytime measured pressure loss exceeds 20 psig (1.3 bar) the fluid should be changed.

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Compressed Air System BI010943

1.

Drain the fluid from the compressor using the fluid drain cap located at the bottom of the compressor.

NOTE: Complete flushing is required if the fluid has been contaminated, or when changing to a different lubricant.

2.

Remove the old fluid filter and gasket. Clean the gasket seating surface. Apply a thin coat of fluid to the new gasket and hand tighten new fluid filter until gasket is seated. Continue tightening an additional 1/2 to 3/4 turn.

3.

Remove the fill plug on the bell housing and fill with clean Sullair fluid. Sump capacity is 4.6 quarts (4.35 liters).

4.

Check the fluid level in the sump. When not in operation, the fluid should cover 3/4 of the sight glass. DO NOT OVERFILL.

5.

Tighten the fill plug. Restart the compressor and check for leaks.

6 - 10 October 2012

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Air Filter Maintenance NOTE: Under normal service conditions air filter maintenance should be performed every six months, more frequently when operating in extreme conditions. Care should be taken so no dirt or debris is allowed to enter the intake housing during the procedure below.

1.

Clean the exterior of the filter cover, removing any loose dirt or debris.

2.

Remove the wing nut holding the air filter cover in place.

3.

Remove the element and base. Clean the base and cover with a damp cloth.

4.

Reposition the base to the compressor. Place a new air filter element onto the base.

Replace the pre-filter and cover. Tighten wing nut securely in place.

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6 - 11 October 2012

Compressed Air System BI010943

Air / Fluid Separator Element Change NOTE:

Under normal service conditions the air/fluid separator element should be changed every 8,000 hours of operation or once a year. Compressors using SRF 1/4000 fluid should be changed every 4,000 hours. Anytime measured pressure loss exceeds 10 psig (0.7 bar) the air/fluid separator element should be changed.

1.

Insert a 1/4" diameter pin through the hole in the separator cap. Remove the cap.

2.

Using channel lock pliers, remove the old separator element. Remove old o-ring from the separator cap.

3.

Clean separator cap and install new o-ring. Install new o-ring to new separator element.

Lightly lubricate to make installation easier.

4.

Insert and push the new element in place.

5.

Reinstall the cap using the 1/4" diameter pin inserted in the separator cap. Remove the pin and store for later use

6 - 12 October 2012

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Lockout Valves A series of lockout valves are provided to enable maintenance personnel to isolate and remove compressed air from the swing, crowd, hoist and propel brakes should they require maintenance.

This permits airflow to continue to the other brakes and features of the machine.

Isolating only one feature of the machine will not eliminate the danger of machine motion while maintenance is being performed. The user is responsible to ensure that all proper precautions, including lock-out/tag-out, bracing and any other necessary precautions have been taken, so that no unanticipated machine motions will occur.

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Compressed Air System BI010943

Lube Room Lockout Valve

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Safety Warnings Ensure all personnel are aware of, and adhere to the instructions of the following safety warnings.

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Compressed Air System BI010943

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Air Filtration BI010944

7

Air Filtration

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

House Filter Fans ....................................................................................................................... 3 Lubrication ............................................................................................................................... 4 Dynavane Air Cleaner .............................................................................................................. 4 Filter Components Overview ........................................................................................................ 5

Air Conditioner ............................................................................................................................ 6 Specifications .......................................................................................................................... 7 Air Conditioner - Block Diagram .................................................................................................. 7

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Air Filtration BI010944

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House Filter Fans Check the blades for grease and/or dirt accumulation. Clean if necessary. Blades should rotate freely without binding.

If vibration is detected, check the following: 1.

Bearing and drive alignment

2.

Shaft straightness

3.

Wheel or sheaves loose on shaft

4.

Loose or worn bearings

5.

Loose mounting bolts

6.

Motor out-of-balance

7.

Sheaves out-of-balance

8.

Nose cap loose on wheel

9.

Worn or corroded wheel

10.

Accumulation of material on the wheel

11.

Cracks on blades and/or at the hub

12.

Worn fan blades and hubs

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Air Filtration BI010944

Lubrication All bearings are pre-lubricated and sealed at the factory. Under normal temperature conditions (-20° to +150°F), when the fans are circulating clean air, the bearings are considered lubricated for life and additional lubrication is unnecessary.

If the fans are circulating contaminated air, or operating at elevated temperatures, periodic lubrication is required. For normal temperatures, a high quality, light, neutral mineral grease is used. It is free of abrasive fillers and highly resistant to oxidation. When fans are operating at elevated temperatures (166°F or higher), silicone or lithium soap base grease should be used. This high temperature grease should have a breakdown point above 350°F. Use a low pressure grease gun for fan bearings. Either the gun or the fitting should be vented. To prevent overfilling apply a small amount of grease. This is especially important when extended lubrication piping is used and the bearing cannot be observed.

Dynavane Air Cleaner Dynavane air cleaners are self-cleaning and do not require the routine service typical of air filters which collect and hold the dirt removed from the air. There are a few maintenance procedures which should be observed.

•

The air entering the side of the cells should be kept free of rags, leaves and papers to assure free airflow. Applications exposed to this type of material should have intakes covered with a course mesh (5 mesh) screen to prevent entry of material larger than the bleed slot.

7-4 October 2012

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Filter Components Overview

•

Check the bleed system to make sure nothing has impaired bleed airflow.

•

The cells should be examined for buildup of deposits on the blades. A light coating of dust is normal and will not impair the operation or efficiency of the cell. Occasionally, due to the presence of oil mist or similar vapors in the air, heavier surface accumulations will occur and the cell will require cleaning. Cleaning the cells can be accomplished by brushing the surface of the blades or blowing down with compressed air.

•

Another method of cleaning the Dynavane filters is to reverse the direction of fan rotation.

This creates reverse air pressure which helps free up the dirt. The units can be removed for a more thorough cleaning.

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Air Filtration BI010944

Air Conditioner SIGMA MPV9 climate control units are heavy duty systems providing superior performance in a variety of climate and environmental conditions.

Air is drawn from beneath the unit, passes over the heat exchanger coil and the heating elements into a double-wheel fan where it is discharged through the base of the unit into the conditioned space below.

The refrigerant is metered by an externally mounted TX valve, and is cut off by a liquid line solenoid valve. The heat exchanger is large, constructed of heavy gauge tubing with a coarse fin pitch to reduce clogging. The fan motor is a large shaft, totally enclosed unit that is air cooled.

All pressure controls within the evaporator unit are fully sealed, preset and O-ring connected.

The compressor is a heavy duty, fully sealed scroll-type device. The unit is mounted in flexible mounts in an effort to reduce noise and vibration. All connections are either soldered, O-ring type or rotalok.

A large liquid drier is placed within the liquid line to filter moisture from the refrigerant. The condenser operates at a single speed only.

7-6 October 2012

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Specifications Nominal Cooling Capacity

31,000 Btu/hr@460V/60Hz

Power requirements

380V/3ph/50Hz

415V/3ph/50Hz

460V/3ph/60Hz

17.5 Amps

19.0 Amps

21.0 Amps

Refrigerant

HFC 134a – 24 lbs.

Oil

POE Variety Mobil Arctic EAL22CC or ICI Emcarate RL32CF

Compressor

Fully sealed, scroll type

Condenser Coil

5 row, 3/8 inch copper tube with 8 aluminum fins/inch

Evaporator Coil

4 row, 3/8 inch copper tube with 10 aluminum fins/inch

Detailed information on the MPV9 can be found in the vendor’s documentation that accompanied the machine and the General Arrangement drawings provided by the manufacturer.

Air Conditioner - Block Diagram

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8

Engineering Data

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Capscrew (Bolt) Grade ............................................................................................................... 3 Bolt Tightening ........................................................................................................................... 4 Torque Wrench Method ........................................................................................................... 4 Table 1 - Lubricated or Plated Threads or with Hardened Washers .............................................. 4 Table 2 - Dry Threads .................................................................................................................. 5

Turn-of-nut Method .................................................................................................................. 6 Table of Snug Tight Torque Values ............................................................................................. 6

Split Flange Assembly Procedure ............................................................................................. 8 Torque Table For Split Flange Assembly .................................................................................... 10

Wire Locking Capscrews ......................................................................................................... 11 Patterns for Wirelocking Capscrews .......................................................................................... 11

Procedure For Use Of Mechanical Tensioner On Crawler Rods .......................................... 12 Connecting Rods - Crawlers to Truck Frame .............................................................................. 13

Torque Nut Removal Procedure ............................................................................................. 14 Thread Lubrication................................................................................................................. 14 Torque Nut Helpful Hints ......................................................................................................... 15 Locking Assemblies .................................................................................................................. 16 Locking Assembly Removal .................................................................................................. 18 Pinion And Hub Installation ...................................................................................................... 19 Removal From A Shaft .......................................................................................................... 19 Mounting A Pinion Or Hub On A Shaft .................................................................................... 19 Hub Adapter Pre-heat Advance Requirements ................................................................ 22 Motor Coupling Pre-heat Advance Requirements ............................................................ 23 SM141403-EN

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Maintenance Welding ............................................................................................................... 24 Welding Electrodes ............................................................................................................... 25 Repair Welding Of Cracks .................................................................................................... 26 Joint Preparation for Repair of Cracks ....................................................................................... 26

Preheat ............................................................................................................................ 27 Welding Technique .......................................................................................................... 28 Repair Welding Of Broken Parts ........................................................................................... 29 Repair Welding Swing Rack Teeth ........................................................................................ 30 Preparation ...................................................................................................................... 31 Swing Rack Welding Electrodes ..................................................................................... 32 Preheat ............................................................................................................................ 32 Welding Procedure .......................................................................................................... 33 Welding And Cutting Equipment ............................................................................................. 35 Stress Relieving & Temperature Measuring Equipment ..................................................... 36 Wire Rope Care And Maintenance .......................................................................................... 38 Storage .................................................................................................................................. 38 Checking Diameter ................................................................................................................ 38 Correct Method for Checking Wire Rope Diameter ..................................................................... 38

Handling Wire Rope .............................................................................................................. 39 Improper Methods for Uncoiling Wire Rope ................................................................................ 40

Seizing Wire Rope ................................................................................................................ 41 End Preparations/Terminations ............................................................................................. 43 Wire Rope Clips .................................................................................................................... 44 Wire Rope Clip Application .............................................................................................. 45 Wedge Sockets ............................................................................................................... 47 Inspection of Sheaves and Drums ........................................................................................ 48 Examples of Sheave Groove Conditions ..................................................................................... 48 Groove Gauge for New or Re-Worked Sheaves .......................................................................... 49 Inspecting for Worn Sheave ....................................................................................................... 50

Breaking In A New Wire Rope ................................................................................................ 50 Inspection Data ..................................................................................................................... 50 Guideline to Inspections and Reports .............................................................................. 51 Wire Rope Stretch vs. Rope Life ................................................................................................55 Examples of Broken Wires ........................................................................................................ 58

Seals ........................................................................................................................................... 59 Seal Installation ..................................................................................................................... 59 Split Seal Installation ................................................................................................................. 60

Gearcase Sealing .................................................................................................................. 61

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Capscrew (Bolt) Grade The grade classification of a capscrew (bolt) is identified by the marks on the head as shown below:

Use the SAME GRADE washer and nut as the capscrew. NEVER SUBSTITUTE A LESSER GRADE CAPSCREW IN PLACE OF THAT WHICH IS SPECIFIED.

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Bolt Tightening Torque Wrench Method The following tables show torque values for bolt grades 2, 5 and 8 with UNC threads only. Table 1 lists torque values for lubricated or plated threads and for using hardened washers. Table 2 lists those for dry threads.

Table 1 - Lubricated or Plated Threads or with Hardened Washers

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Table 2 - Dry Threads

The bolts should be tightened to the specified total value in increments, alternating from bolt to bolt to assure gradual, even pull-up of mating parts. Tightening should progress systematically from the most rigid part of a joint to its free edges.

Circular bolt patterns should be tightened in a diametric crosshatch pattern while applying torque in increasing values to ensure proper pull-up of parts.

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Turn-of-nut Method

THIS TIGHTENING PROCEDURE IS ONLY APPLICABLE FOR BOLT GRADES 5 AND 8 WITH UNC THREADS. For bolts with other than UNC threads, contact the manufacturer.

NOTE: When using this procedure the bolt threads and the surfaces under the bolt head and nut must be lubricated. This procedure is applicable only if the joint and under head surfaces for bolt and nut are machined for parallelism.

1.

The bolts should be brought to a “snug tight” condition to ensure that the parts of the joint have good contact with each other. “Snug Tight” is defined as the tightness attained by torquing a bolt to the value specified in the table on the following page. Snug tightening should progress systematically from the most rigid part of the joint to its free edges while alternating from bolt to bolt to assure gradual even pull up of the mating parts. After all bolts have been snugged, the first bolts tightened at the most rigid part of the joint should be rechecked for proper torque retention. If these bolts are loose due to pull up of the joint, the snug tightening sequence should be repeated for all bolts in the connection. This rechecking and re-torquing procedure should be repeated as many times as is required until the joint is completely pulled up and all bolts are at the specified “snug tight” torque.

Tightness of the mating surfaces of the joint should then be verified by using feeler gauges.

Table of Snug Tight Torque Values

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2.

The nuts and bolts should then be matched marked by center punching the bolt end and nut. On rod bolts match mark both rod ends and nuts. The bolts and nuts should then be tightened additionally by the applicable amount of nut rotation as specified in chart above. It is not necessary to follow any particular bolt to bolt sequence during this portion of the “turn of the nut” tightening.

NOTE: Nut rotation is read between the punch mark on the bolt and the punch mark on the nut.

For rod bolts, nut rotation is the cumulative total rotational movement between punch marks on both ends of the rod bolt.

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Split Flange Assembly Procedure

The 4 bolt split flange connection consists of four main components.

— Body of Flange Head (part of hose or tube) — O-Ring — Pair of Split Flange Clamps — Bolts and Lockwashers To assemble split flange connection: 1.

Ensure that all sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

2.

Lubricate the o-ring with light grease or oil and insert into groove.

3.

Position flange head and clamp halves.

4.

Apply retaining compound to the bolt threads. Place lock washers on bolts and insert through clamp halves.

5.

Hand tighten bolts.

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NOTE: Refer to the TORQUE TABLE for proper torque values. All torque values apply to Grade 5 (Metric Grade 8.9) hardware or above with lubricated threads.

6.

Tighten all bolts in a diagonal sequence in three incremental steps. Use the appropriate torque value specified in the TORQUE TABLE.

7.

Clean components before marking, then apply a legible mark with a permanent marker or paint across each bolt and clamp.

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Torque Table For Split Flange Assembly

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Wire Locking Capscrews Wire locking of capscrews is used when maximum lock assurance is required when periodic visual inspection is not possible.

The illustrations below show the recommended wire locking methods for various right hand thread capscrew patterns. For patterns not shown, wire lock the screws “in pairs”. For odd numbered patterns, wire lock the screws in pairs except the remaining 3 capscrews wire lock together

Patterns for Wirelocking Capscrews

Use 14 gauge soft annealed lock wire. Thread the wire through the capscrew head so that tightening stress on the wire will exert a tightening torque on the direction of capscrew thread. (The illustrations show lock wire threading for right hand threaded capscrews. Reverse the lock wire patterns shown for left hand capscrews.)

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Procedure For Use Of Mechanical Tensioner On Crawler Rods NOTE:

Steps 2 - 5 are to be done in the rod sequence pattern shown below.

1.

Lubricate the threads and spin the tensioner onto the main thread until it seats against the washer (supplied with the torquenut).

2.

Tighten 4 jackbolts at 90° apart as indicated in Sequence Fig. 1 on all studs with a partial torque (88 Ft-Lbs). This serves to seat the flange. If using an air impact, use a reduced setting or lightly pulse the trigger at the full setting.

3.

At 100% target torque, (175 Ft-Lbs), tighten the same 4 jackbolts on all the studs.

4.

At 100% target torque, (175 Ft-Lbs), tighten all the jackbolts in a circular pattern as shown in Sequence Fig. 2. Tighten jackbolts on all the studs.

5.

Repeat Step 4 until all jackbolts are stabilized (less than 10° rotation). This usually requires 2-4 additional passes. If using air tools, switch to a torque wrench when socket rotation is small. Use the torque wrench to stabilize at the target torque (175 Ft-Lbs).

6.

Repeat Step 5 for all studs after 20 hours of digging operation.

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Connecting Rods - Crawlers to Truck Frame

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Engineering Data BI010945

Torque Nut Removal Procedure

THE PROPER REMOVAL OF TORQUE NUTS REQUIRES FOLLOWING STRICT PROCEDURES. LONGER ANCHOR BOLTS AND RODS REQUIRE GREATER CARE. If some jackbolts are completely unloaded prematurely, the remaining jackbolts will carry the entire load of the fastener. This may cause the jackbolts to become extremely hard to turn or even deformed.

NOTE: It is a good practice to spray the entire fastener and jackbolts with a penetrating type lubricant prior to attempting removal. This step will be critical if rust exists on the components.

1.

Turn the first jackbolt counter-clockwise until it feels loose, but no more than 1/2 turn.

2.

Repeat the loosening with the rest of the jackbolts. Use the reverse of the star pattern used to tighten the jackbolts. This will minimize loading on the last few jackbolts.

3.

Repeat the entire loosening pattern, turning each jackbolt no more than 1/2 turn at a time, until the torque nut can be spun off the rod or bolt by hand.

After removal of the torque nut: •

Remove all jackbolts from the torque nut. Clean, inspect and lubricate the toque nut, hardened washer and the jackbolts for later reassembly.

NOTE: On smaller torque nut fasteners it may be possible to utilize impact tools to speed removal after performing step 2 above. However, DO NOT USE IMPACT TOOLS FOR THE INITIAL LOOSENING PROCEDURE. Longer anchor bolts may require several repetitions of the initial loosening process prior to switching to impact tools for assistance.

Thread Lubrication For the main studs of torque nut fasteners any standard anti-seize compound may be used. A thin, brush-on type application, or aerosol spray lubricant is acceptable.

Jackbolts are pre-lubricated from the factory with either moly or graphite lubricants depending on the intended use. Ensure lube is present on these surfaces and apply additional lube (PN: MP390331) as needed. Similar lubricants may be used on the jackbolt tips and hardened washer during installation.

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Torque Nut Helpful Hints Prior to Tightening: 1.

Threads: Check all threads of the main stud to verify that the torque nut will spin on freely prior to installation. If a restriction is found, use a lapping compound on the main threads or chase the threads in either the torque nut or the main stud using a good die or tap. THE UNRESTRICTED MOVEMENT OF THE torque nut ON THE MAIN STUD IS CRITICAL IN THE INSTALLATION PROCESS.

2.

Spacers: The torque nut should be positioned at the end of the main stud when installation is complete in order to minimize exposed threads which could be damaged. This will also serve to minimize any difficulty in reaching the jackbolts and avoid the need for thinwall, or deepwell sockets. A spacer or stacked washers can be used beneath the hardened washer to accomplish this. The spacer will also allow a step-over of a damaged area on stud from repeated installations.

3.

Gaps: Back off the torque nut to provide a gap of 1/16 to 1/8 inch between the torque nut and the hardened washer prior to beginning the torque application process. This will allow additional jackbolt extension which provides easy access for jackbolt tip lubrication prior to removal. When closing a gap between flanges, or where long fasteners are used, there may be insufficient jackbolt stroke to allow this step.

4.

Sockets: Use only six-point quality sockets in good condition. Worn sockets will eventually round out the corners of the jackbolts possibly causing damage or injury.

While Tightening: 5.

Do not tighten a jackbolt completely prior to moving on to the next jackbolt. As the torque nut is tightened, the first jackbolt that was tightened in that sequence will have a tendency to loosen. It will be faster to make multiple passes by moving quickly between jackbolts.

6.

Overshoot the Target Torque as indicated PRIOR to the final tightening. This will quicken the tightening sequence by stabilizing previously tightened jackbolts sooner. BE CERTAIN NOT TO “STABILIZE” THE JACKBOLTS AT THIS HIGHER TORQUE VALUE!

While Removing: 7.

Removing the jackbolts too quickly during disassembly may increase the removal torque of the remaining jackbolts. If a jackbolt should become jammed, re-tighten several jackbolts to either side to even the tension on the torque nut.

8.

If a jackbolt tip “mushrooms” its tip must be cut off with a cutoff wheel or abrasive disc, then the jackbolt removed.

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Locking Assemblies To install a locking assembly:

1.

Clean and lightly oil all parts of the locking assembly, the shaft or pin and the housing bores.

Be sure the bores to be connected are properly aligned.

2.

Loosen all socket head capscrews on the locking assembly.

3.

Install the locking assembly and the shaft or pin into the housing. Carefully note any measurements required to align the locking assembly.

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4.

Tighten the capscrews of the locking assembly evenly. Do not tighten each screw all at once. Instead, gradually tighten each one and proceed with the entire set, using a crisscross pattern, and repeat until all screws are tight. Refer to the proper section of the maintenance manual for the specific torque required.

Where pilot bushings are used: 1.

Insert the locking assembly as stated above - except remove all socket head capscrews.

2.

Insert 3 pilot bushings, equally spaced. Insert the longer capscrews supplied with the pilot bushings.

3.

Tighten the capscrews using the same procedure required for the locking assembly capscrews.

4.

Once the pilot bushing is has been properly tightened, remove the longer socket head capscrews and the pilot bushings. Replace the capscrews in the locking assembly with the socket head capscrews that came with the locking assembly.

5.

Tighten all capscrews using the procedure above. Retain the pilot bushings and longer capscrews for future use.

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Locking Assembly Removal

For series 1015 assemblies with a center collar: 1.

Loosen all capscrews on the locking assembly by at least 2 turns in 1/4 turn increments.

2.

Transfer all the capscrews to the push-off threads provided in the clamp collar and in the center collar.

3.

Progressively tighten all screws in a diametrical pattern - except the screws adjacent to the slit in the clamp collar - these should be tightened one after the other.

For series 4000 assemblies with NO center collar: 1.

Loosen all capscrews on the locking assembly by at least 2 turns in 1/4 turn increments.

2.

The locking assembly incorporates a self-releasing taper, which should allow the assembly to be removed. However if the thrust rings jam, tap on the heads of 3 equally spaced capscrews to positively release the connection.

3.

Insert pullout screws in the threads under the cadmium plated locking screws to remove the assembly.

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Pinion And Hub Installation Removal From A Shaft

A properly mounted pinion, brake drum or coupling will have an interference fit with the shaft causing it to release suddenly and violently when broken loose. Loosen the shaft nut just enough to allow the pinion, brake drum or coupling to free itself. The shaft nut will stop the pinion or coupling and avoid injury to personnel.

NOTE: When removing the pinion, brake drum or coupling from a motor shaft, always use a suitable puller to avoid causing damage to either the pinion, coupling, motor frame, bearings or shaft. Do not heat the pinion, brake drum or coupling before pulling and do not use wedges between them and the bearing cap. To prevent damage to the antifriction bearings, avoid the use of a sledge hammer on the puller.

Mounting A Pinion Or Hub On A Shaft Successful operation of the gearing largely depends on the proper mounting of the pinion, brake drum or coupling on the shaft.

NOTE: Mounting pinions, brake drums or coupling by heating them in boiling water and driving them on the shaft with a blow from a heavy sledge hammer is not recommended. This results in uncontrolled advance of the pinion or coupling on the shaft. Too great an advance can cause breakage of the pinion, brake drum or coupling core, while insufficient advance can cause slippage and wear in spite of the presence of the key. In addition, hammer blows can injure the finished surface of the anti-friction bearings.

Pinions, brake drums or couplings must be mounted to a definite advance on the shaft, without hammer blows. This requires heating them to a higher temperature than is obtainable with boiling water, and is based on a difference in temperature between them and the shaft. The following is the recommended method for mounting pinions, brake drums or couplings: 1.

Thoroughly clean the pinion, brake drum or coupling seating surface on the shaft and the bore of the pinion, brake drum or couplings. Use toluol or percholoethylene; do not use kerosene.

Solvents may be toxic or flammable. Adequate ventilation must be provided to minimize fire and health hazards. Use away from sparks, heat or flame to prevent fire or explosion. Follow the manufacturer’s instructions.

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2.

Remove any scoring from either part. Spot the cold pinion, brake drum or coupling on the shaft by hand to obtain at least a 75% fit. Check the fit with bluing. Remove the pinion, brake drum or coupling.

3.

Break all sharp edges of the key and the keyway with a fine file, so there will be a radius of about 1/64 inch at each edge. Fit the key to the shaft, taking care to avoid upsetting the metal of the shaft adjacent to the key. If previously upset, file lightly, checking the fit with bluing until a 75% fit results. Try the pinion, brake drum or coupling on the shaft to make certain it does not bind on the key.

4.

Mount the pinion, brake drum or coupling cold by placing it on the shaft and snapping it into position by hand. Measure the “cold” position of the pinion, brake drum or coupling using a micrometer depth gauge. Mark the places where the depth gauge was resting so measurements can be made from the same position after the pinion, brake drum or coupling has been mounted. The following figure illustrates the method of using the depth gauge.

5.

Remove the pinion, brake drum or coupling from the shaft and heat it in a suitable oven to the temperature specified. If the pinion, brake drum or coupling is heated in oil, the bore must be thoroughly cleaned before mounting. To avoid the cleaning, the use of an oven is recommended.

Use suitable protective equipment when handling hot items.

The pinion, brake drum or coupling temperature is indicated as a temperature difference between the shaft and pinion; this temperature difference is estimated only and can be adjusted to maintain the specified advance. Heat the pinion, brake drum or coupling in the oven until the temperature is uniform at the required number of degrees above the shaft temperature. For example, if the shaft temperature is 25oC (77oF) and the estimated difference is 125oC (225oF), heat the pinion, brake drum or coupling to 150oC (320oF) for mounting.

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Pinion, brake drum or coupling temperature must never exceed 190oC (374oF).

Some accurate method must be provided for quickly measuring the temperatures of the pinion, brake drum or coupling and shaft before mounting them. This is best done with a hand pyrometer (refer to the figure). When a hand pyrometer is not available, a centigrade thermometer can be used by placing putty over the bulb to hold it against the pinion or coupling. Heat the pinion, brake drum or coupling a few degrees above the desired temperature before removing it from the oven. Wait until it has cooled to the temperature desired, remove the thermometer and quickly mount the pinion, brake drum or coupling as described below.

6.

After making sure the bore is clean, quickly mount the hot pinion, brake drum or coupling on the shaft. When it is nearly engaged with the taper fit (but not actually in contact), snap it forcible into place with a quick push. It is important that the hot pinion, brake drum or coupling be instantly snapped into position before it has cooled appreciably; otherwise it will immediately “freeze” to the shaft and cannot be adjusted further.

7.

Check the “hot” or shrunk-on position of the pinion, brake drum or coupling on the shaft, using the micrometer depth gauge. The actual advance is the difference between depth gauge readings at the hot and cold positions. To control the stresses in the pinion, brake drum or coupling, the advance must be within the limits specified in the table below.

If the advance is not within the limits given, the pinion, brake drum or coupling should be pulled and remounted.

8.

Assemble the lockwasher and nut, tighten firmly and lock. Where a lockwasher is not used, retaining compound must be used to keep the nut tight during operation.

When a lockwasher is used, the nut must be firmly tightened against it, then the tab on the lockwasher must be bent against the flat of the nut. This is required to keep the nut tight during operation.

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Hub Adapter Pre-heat Advance Requirements

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Motor Coupling Pre-heat Advance Requirements

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8 - 23 October 2012

Engineering Data BI010945

Maintenance Welding These recommendations for repair welding apply to the major structural members of the machine.

The high cyclic loading characteristics of the machine are considered in the design and material selected for the construction of the machine. However, due to unusual operational conditions that may be encountered and to the great number of cyclic loadings that may be applied to the machine, fatigue cracks or other abnormalities may occur. Early detection of these conditions through regular machine inspection helps to avoid problems or emergency breakdowns.

Maintenance welding is applied to the repair of cracked or broken structural components.

Reconditioning of broken parts by the application of heating, cutting and welding processes requires attention to a number of details, careful adherence to the repair procedure and observance of federal, state and local safety regulations.

WELDING AND THERMAL-CUTTING OF METALS INVOLVE THE GENERATION OF TEMPERATURES UP TO THOUSANDS OF DEGREES AT WHICH METALS MELT AND VAPORIZE. When proper precautions are taken to protect personnel and property against the heat, evolved gases and fumes, electric shock and radiation, no harm will result either to personnel or property. In gas heating and cutting, the handling and storage of compressed gases present other hazards that also must be protected against to provide a safe working environment.

Safety precautions should conform to the latest edition of ANSI standard Z49.1, Safety in Welding and Cutting, published by the American Welding Society.

Reconditioning of failed members requires attention to a number of details and careful application of the repair procedure. Only in certain cases is it necessary to strengthen members by added reinforcement.

REINFORCING STRUCTURAL MEMBERS SHOULD BE MADE ONLY UPON RECOMMENDATION BY THE MANUFACTURER. IMPROPERLY APPLIED REINFORCEMENTS CAN HAVE AN ADVERSE EFFECT ON THE PERFORMANCE AND LIFE OF THE STRUCTURE. A broken member is best repaired by making a complete penetration weld, preferably by welding from both sides, using the correct welding electrode and observing all precautions such as preheat, back-gouging, etc. The complete penetration groove weld should be ground flush with the base metal on both sides to remove all surface irregularities. An alternate procedure incorporates backup bars to ensure sound, complete penetration welds in the repair area. Be sure to follow all applicable safety measures and federal, state and local regulations.

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A complete penetration weld repair conditioned by grinding instead of adding reinforcement is favored to maintain the original pattern of stress flow designed into the structural members. Addition of reinforcement which is not part of the design can reduce fatigue strength because of the change in geometry from the original structure.

Effective repair welding of cracked, broken or bent structural members of the machine involves knowledge of the types of steel used, proper welding electrodes and recognized good welding practice. The chemical composition, mechanical properties and thickness of the steel determine the welding electrode to be used and the preheat temperature required.

Welding Electrodes With the exception of the boom, weld repairs on the various structures of the machine can be made with two basic classifications of shielded metal arc electrodes: E7018 and E8018-C1. Both are low hydrogen electrodes which deposit weld metal having excellent properties at strength levels with 70,000 to 80,000 PSI, and impact properties from -20o to -75oF. These are all-position electrodes which produce high quality welds for repairing the structural components of heavy machinery.

NOTE: Although these electrodes are of superior quality, care must be exercised in their application. Low hydrogen electrodes are highly susceptible to moisture pickup after removal from sealed containers. To maintain low hydrogen, crack-resistant properties, they must be stored in electrode ovens at 250oF up to the time of use. Small portable rod ovens at the welder’s side are ideal. Use of dry low hydrogen electrodes cannot be over-emphasized.

Cracks caused by hydrogen are extremely fine and occur invisibly below the surface in the base metal heat affected zone, as shown. Therefore, they are not detectable at the time of welding.

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These cracks can propagate in service and lead to ultimate failure of the part. It is necessary to adhere strictly to recognized good welding practice regarding the handling, storage and use of low hydrogen electrodes. To avoid underbead cracks, remove all oil or grease or other contaminates from the surface and be sure the steel is dry.

Preheat to the required temperature. Use only dry electrodes taken from the electrode oven. After exposure to the air, the electrodes must be returned to the oven. Time limit outside the oven is four hours for E7018 and two hours for E8018-C1 electrodes.

Repair Welding Of Cracks

Joint Preparation for Repair of Cracks

Remove the entire crack by arc air-gouging or grinding. Prepare a V-groove of approximately 4560o included angle for rewelding. If cracked through the full thickness and if it is possible to make the repair from both sides, a double V preparation is preferred. When welding from both sides, back-gouging for complete penetration is always recommended.

When it is not physically possible to back-gouge and weld the second side, an alternate approach must be taken. Sometimes it is possible to gouge through to completely remove the crack, then fit a backup bar on the underside to facilitate making a complete penetration weld.

NOTE: The backup bar must fit tightly to the underside otherwise poor welding conditions conducive to cracking may occur.

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When it is not possible to fit a backup due to limited accessibility to the underside, it is advisable to remove a portion of the defective plate and weld in a new piece, using back up bars on all sides to ensure complete penetration welds.

A further alternative is to gouge through, removing the crack, and then weld small stringer beads to close the gap and prepare a groove for a repair weld. In this case, the repair weld will be essentially full penetration, but will be less than perfect on the under side. The other methods are preferred in the order described, that is, welding both sides, welding against a backup bar, or completely replacing a section of plate.

Preheat When preheating, apply heat to a broad, general area surrounding the repair location. A soaking heat that penetrates the material through its full thickness is preferred to high surface temperature quickly applied. Electrical resistance or radiant heating is suggested since the heat source can be left operating during welding to maintain the minimum preheat temperature. Preheat temperatures up to 400oF, depending upon the steel analysis, are adequate under most conditions for major repairs. As previously stated, preheat temperatures are determined by the type of steel in the structure. Temperatures should be measured with temperature indicating crayons.

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Welding Technique

Maximum electrode sizes are 1/4 inch for flat position, 3/16 inch for horizontal position and 5/32 inch for vertical and overhead positions. Use a split weave as soon as bead width is large enough to accommodate beads side by side. Throughout all welding be certain thorough fusion with the base metal and adjacent weld beads is obtained on all weld passes. Clean off all slag between passes and all craters before starting the next electrode.

Inspect closely for cracks, undercut or overlap of beads, and gouge out or grind flaws where they occur before continuing. It is very important on highly loaded parts, particularly members subject to cyclic or dynamic stresses, to obtain sound repair welds.

The presence of any stress risers on the surface of a part is detrimental to fatigue life and can result in future cracking. Therefore, it is essential that the finished repair be smooth and well blended into the base metal. Repair weld any undercuts, grind off overlapped weld beads and blend out any notches or gouges. The best condition in a repair weld location is provided by grinding the repair smooth and flush with the surface of the base metal. Final grinding direction is to be identical with the direction of applied load on the structure. Refer to the figure.

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Repair Welding Of Broken Parts All recommendations given for repair of cracks apply to repair of broken parts, with additional corrections. Depending on the size and cross-section of the part, a specific sequence of welding procedures may be required in making the repair. These techniques include back-step welding sequence, block welding sequence, alternating from side to side, welding simultaneously on opposite sides, etc. All of these precautionary measures are intended to minimize shrinkage stresses and subsequent distortion or cracking during welding. The method to follow should be determined after a careful analysis of the situation and by approaching the problem with common sense. Generally a procedure which has proven successful in previous experience could logically be applied in most cases.

Use of doubling plates, stiffeners or other reinforcements to strengthen a member which has cracked in service, must be carefully considered before that repair measure is decided upon. Additional material added for strengthening alters the configuration and geometry of the member, possibly with a pronounced effect on the fatigue life of that structure. Many times, such attempts at strengthening by adding plates only serves to “chase the crack someplace else.” The stress flow in the part has been altered, creating a location for stress concentration. Attachments requiring fillet welds across a tension member for example, are poor repair methods. A sound repair weld, carefully made and smoothly blended into the base metal on all sides, is preferable to additional reinforcements. Any application of reinforcements requires careful consideration regarding total overall effect on the structure during service, and should be done only after consulting the manufacturer.

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Repair Welding Swing Rack Teeth The following is a suggested method for the repair of cracked or broken swing rack teeth. The repair method should produce satisfactory results and provide a serviceable swing rack, provided the procedure is carefully followed in all details. The welding procedure is essentially the same for the three conditions shown.

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Preparation 1.

Clean off the swing rack in the area of the tooth to be repaired to remove all traces of grease, oil or dirt. Wash down thoroughly with a solvent cleaner and wipe dry with clean rags.

2.

Grind to completely remove the crack and prepare a groove for welding as shown in the figures.

3.

Dye penetrant test for complete crack removal.

4.

In the case of a broken tooth, grind the fracture surface on the swing rack smooth and round off edges as shown.

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Swing Rack Welding Electrodes 1.

All welding is to be done using oven dry E11018-M low hydrogen electrodes. Connect an electrode drying oven as close as possible to the work area. Set the oven temperature at 300oF. As sealed containers of electrodes are opened, place the entire contents of the container in the oven. Remove no more electrodes than can be consumed in one-half hour.

If all electrodes are not used in 1/2 hour, return them to the oven. Discard any electrodes which have been wet.

Preheat 1.

Two levels of preheat are required for tooth repair, 250oF minimum for butter welding and 175oF minimum for filling in the groove. Temperatures should be measured with temperature indicating crayons.

2.

Preheat will be difficult to maintain because of the mass of metal in the swing rack to draw the heat away from the repair area. It is therefore recommended to apply heat to a large section of the swing rack to offset this quench effect. A section covering at least 3 teeth on either side of the tooth being repaired should be heated so that the minimum preheat temperature is obtained at the repair location. It is suggested that electrical resistance heaters be applied behind the teeth as shown, if such physical arrangement is possible. If the repair area cannot be heated to the required minimum temperature by this arrangement, supplementary heat must be applied from the tooth side of the swing rack.

Electrical resistance heaters can be applied, or heat provided by oxy-propane torches.

Adjacent areas of the swing rack should be covered with heavy insulation to avoid heat loss.

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NOTE:

Contract services are available for field application of resistance heating equipment.

Suggested source: Stresstech Box 11 Red Wing, MN 55066 (612) 388-7117

3.

During welding, the repair area must be continually checked with temperature indicating crayons to be sure that the minimum temperature is being maintained. Do not weld at temperatures below the specified minimums.

Welding Procedure 1.

Refer to the previous butter-welding figures. The purpose of the butter weld layer is to provide a buffer between the weld required to fill the groove and the alloy cast steel. This technique is essential in preventing heat affected zone cracking in the cast steel which otherwise is likely to occur due to the shrinkage of the weld as the groove is filled. Butter welding permits the repair weld to be made at the preheat temperatures specified. Much higher temperature would otherwise be required for crack free welding.

2.

Butter welding is done using 1/8 inch diameter E11018-M electrodes at a minimum preheat temperature of 250oF. (See section under WELDING ELECTRODES regarding use of the electrode drying oven.) Horizontal weld beads are applied to completely cover the cavity or surface to be welded. The edges of the butter weld must overlap the adjacent surface about ½ inch. This is to prevent subsequent welding from impinging upon the cast steel.

3.

Before starting the butter weld, position a piece of thin mild steel plate under the bottom end of the tooth. This is to provide a shelf for starting the weld and to avoid irregular weld beads at the bottom which would become stress risers to cause cracking when the tooth is loaded in service.

4.

Apply the butter weld, progressing with horizontal beads from bottom to top. Use care to keep the butter weld layer as smooth and regular as possible. When finished, remove all slag and grind any high spot which could trap slag when welding to fill the groove. In the case of repairing a broken tooth the prepared tooth segment is butter welded separately before positioning for final welding in place.

5.

Filling the groove is done with 1/8 inch or 5/32 inch E11018-M electrodes at a minimum preheat temperature of 175oF. (See section under WELDING ELECTRODES regarding the use of the electrode drying oven.) Weld vertically up using a split layer technique as soon as the groove is wide enough to accommodate 2 or more beads. Refer to the butterweld figures for the approximate weld bead sequence.

6.

For replacing a tooth segment as shown, it will be necessary to prepare a tooth profile template. The template must be carefully made to fit the rack teeth as accurately as possible. Use the template to position the tooth segment prior to tack welding. When welding the tooth segment in place alternate welding from side to side to control distortion.

Check frequently with the template.

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7.

When groove welding is finished check carefully for low spots and fill in as required. Grind the weld smooth and flush with the adjacent tooth surfaces. Use the tooth profile template to check grinding of a welded-on tooth segment. Grinding of the radius at the root of the tooth is very important. Avoid any nicks, gouges or grinding marks in a vertical direction.

Grind a smooth radius using small diameter (peanut) grinders. Failure to achieve a smooth, notch-free radius may result in future cracking at the root of the tooth.

8.

After the swing rack has cooled to ambient temperature, dye-penetrant test the repaired tooth for soundness.

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Welding And Cutting Equipment The welding and cutting equipment needed for general repair welding is listed below.

WELDING MACHINES, Arc - 600 ampere (for Welding and Air Arcing) OXY ACETYLENE TORCHES with Gauges - 150' Long Hoses HEATING TORCHES, Butane (for Boom Welding) ARC AIR ATTACHMENTS (for use with 600 Ampere Welding Machines) WELD RODS - E7018, E8018, E11018 - 1/8", 5/32". 3/16", 1/4" C02 - Welding Grade - 45oF Max. Dew Point OXYGEN - Cutting, and Heating ACETYLENE WELD FLUX CHIPPERS - Pneumatic with Chisels and Spare Parts BLOWERS, Ventilating (for Compartment Welding,) GRINDERS, Wheel - Air Powered w/Wheels TARPAULINS - Fireproof (for Boom Welding Shelters) HIGH TEMPERATURE GLOVES CUTTING GOGGLES, Dark SOAPSTONE MARKERS ANTI-SPATTER COMPOUND TEMPILSTIKS - 200o and 400o

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Stress Relieving & Temperature Measuring Equipment The equipment recommended for stress relieving, after repair welding, is listed below.

TEMPERATURE MEASURING EQUIPMENT SPEEDOMAX, “W” Multipoint, Potentiometer Recorder POWER REQUIREMENT - 120 Volts, 60 or 50 Hz. RANGE - 0 to 1500oF CALIBRATION - Chromel-Alumel Thermocouple Wire ACCURACY RATING - 0.3% of Electrical Span CHART SPEED - 2" per Hour THERMOCOUPLE SELECTION - Six (6) Points FLUORESCENT LIGHTING MANUFACTURER - Leeds & Northrup Company THERMOCOUPLE EXTENSION WIRE DUPLEX WIRES - Chromel-Alumel - Type K - 16 AWG Stranded LENGTH - Total External Resistance for both Wires including Thermocouple not to exceed 2500 Ohms or 410 Feet.

WIRE RESISTANCE - Nominal Resistance, Ohm per Foot at 20oC (66oF) - Chromel - Ohms Alumel - .0683 Ohms.

WIRE INSULATION - each Conductor Enamel, Asbestos (Twisted Pair) Overall Asbestos Braid WIRE CODE -Alumel, Negative Wire (Red); Chromel, Positive Wire (Yellow) OVERALL COLOR - Yellow CATALOG No. 16-59-17 POLARITY DISCONNECT CHROMEL-ALUMEL COMPENSATED CONNECTION JACK Color Code (Yellow) - Catalog No. 040419 PLUG Color Code (Yellow) - Catalog No. 040434 CABLE CLAMP - Catalog No. 072513 ADAPTER - Catalog No. 076794 THERMOCOUPLE ELEMENT CHROMEL-ALUMEL - Type K - Swaged One (1) Inch Stripped CHROMEL POSITIVE WIRE Color Code (None) ALUMEL NEGATIVE WIRE Color Code (Red)

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CATALOG No. 8784-K-1-3-12"-D 1.

588003 Kaopak Flex Heaters

2.

588004 Kaopak Collector Streamer Type

3.

Kaopak Blankets 3, 5, or 6 Pocket Size as needed for Size Pipe being Stressed Relieved

Thermocouple Assembly, Complete Catalog No. 8784-K-1-3-12"-Q Temperature Indicating Pellets (Tempil° Pellets) Indicating Temperature: 1050°F, 1100°F, 1200°F, and 1250°F. (Several of each temperature)

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Wire Rope Care And Maintenance Storage Reels of wire rope stock may be kept on hand for a considerable length of time. This is particularly true of slow-moving special ropes that may not be disposed of completely for several years.

Consequently, wire rope should be stored in an area that is well-ventilated and stable with regard to temperature and humidity.

Do not store rope in contact with the bare ground or expose it to the elements. Excessive atmospheric vapors will condense moisture on the rope causing corrosion. If exposed to the direct sun, next to a boiler or in similarly warm conditions, the original lubrication will dry out and lose its preservation properties.

Similarly, storage in a dusty or chemical laden environment may coat the surface of the rope with corrosive materials or even deteriorate the fiber core. If it should be necessary to store rope outside, the reel should be set on blocks or raised off the ground, and covered with a waterproof covering.

Checking Diameter It is critical to check the diameter of the delivered rope BEFORE installation on the machine. This is to ensure that the rope diameter meets the specified requirements for the given machine or equipment. An UNDERSIZE diameter rope will bring about a condition where stresses are exceeding design limitations. This will increase the possibility of injury or machine damage as the chances of breaking the rope will be increased. Use of an OVERSIZE diameter rope will bring about premature wear of that rope. The rope constantly being pinched and compressed in the grooves of the sheaves and drum causes this.

Correct Method for Checking Wire Rope Diameter

When checking it is imperative that the actual rope diameter is measured. This is defined as the diameter of the circumscribing circle, or its largest cross-sectional dimension. To ensure accuracy this measurement should be made with a wire rope caliper to obtain the outside dimension of 2 diametrically opposing strands of the rope. When measuring a rope with an odd number of outer strands, special techniques must be employed. Refer to the manufacturer of the product for accurate information.

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Handling Wire Rope When re-reeling wire rope from a horizontally supported reel to a drum, keep in mind that a wire rope has a “memory” to be considered. If at all possible, it is preferable for the rope to travel from the top of the reel to the top of the drum during this process. The same would hold true for the bottom of the reel to the bottom of the drum. Re-reeling in this manner will avoid putting a reverse bend into the rope as it is being installed. If a rope is installed so that a reverse bend is induced, it may cause the rope to become “cranky” and, consequently, more difficult to work with.

There are several methods, which can be used to uncoil rope from a spool or coil. The particular situation, or application, will determine the method used.

One method begins by placing the coil or spool on a vertical unreeling stand. The stand consists of a base with a fixed vertical shaft. On this shaft there is a “swift” or rotating sleeve” consisting of a plate with inclined pins. This is positioned so that the coil or spool may be placed over them allowing the coil or spool to rotate in the horizontal axis. The whole swift and coil then rotate as the rope is pulled off without adding twist or the possibility of kinks. This method is particularly effective when the rope is to be wound on a vertical drum.

The most common, and the easiest uncoiling method is merely to hold one end of the rope while rolling the coil along the ground like a hoop.

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NOTE: Avoid unreeling and uncoiling methods that are likely to provide kinks. Such IMPROPER procedures should be strenuously avoided in order to prevent the occurrence of loops.

These loops, when pulled taut, will inevitably result in kinks. No matter how a kink develops, it will damage strands and wires, resulting in a kinked section that must be cut out. Proper and careful handling will keep the wire rope free from kinks.

Improper Methods for Uncoiling Wire Rope

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Seizing Wire Rope While there are numerous ways to cut wire rope, in every case, certain precautions must be observed. It is critical that before any cut is made proper seizings must be applied on both sides of the location where the cut is to be made. Carelessly or inadequately seized, ends may become distorted and flattened. This will also prevent the strands at the ends from loosening or fraying.

Subsequently, when the rope is installed there may be an uneven load distribution to the strands.

This will create a condition that will significantly shorten the life of the rope.

There are two widely accepted methods of applying a seizing, which are illustrated. The seizing material itself should be soft, or an annealed wire or strand. Seizing wire diameter, and the length of the seize, will be dependant on the diameter of the wire rope. But the length of the seize should never be less than the diameter of the rope in use. Normally, for a preformed rope, one seize on each side of the cut is sufficient. For ropes that are not preformed, a minimum of two seizings on each side is recommended; and these should be spaced six rope diameters apart.

For larger wire ropes: lay one end of the seizing wire in the groove between two strands; wrap the other end tightly in a close helix over a position of the groove using a seizing iron (a round bar 1/2" to 5/8" dia. x 18" long) as shown. Both ends of the seizing wire should be twisted together tightly, and the completed seize should appear as shown. Seizing widths should not be less than the rope diameter.

The procedure illustrated below is the second of the two accepted methods for placing seizing on wire rope. This method is normally used on smaller ropes.

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End Preparations/Terminations There may arise a need for special end preparations in order to compensate for certain applications such as tight drum openings, or other complicated reeving systems. When these situations are encountered a number of basic designs (and combinations) are available to choose from. Whenever possible end preparations should be removed after final installation.

“Beckets” are what is referred to when we discuss a termination utilized to pull the operating rope into place. The rope end must be fastened to a mechanism so that force and motion are transferred efficiently without distortion of the wire rope. End terminations become items of great importance for transferring these forces. Each basic type of termination has its own individual characteristic.

Hence, one type will usually fit the needs of a given installation better than others. It should be noted that not all end terminations will develop the full strength of the wire rope being utilized. To lessen the possibility of error, the wire rope industry has determined terminal efficiencies for various types of end terminations. Four commonly used beckets are illustrated.

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Wire Rope Clips Wire rope clips are widely used for making end terminations. Clips are available in two basic designs; the U-BOLT and FIST GRIP. The efficiency of both types is approximately the same.

NOTE: When using U-BOLT clips, extreme care must be exercised to make certain that they are positioned correctly. The important factor is that the U-BOLT clip be applied in order that the “U” section is in contact with the dead end of the rope. Also, the tightening and re-tightening of the nuts must be accomplished as required.

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Wire Rope Clip Application The following is the recommended method of applying U-Bolt clips in order to get the maximum holding power from the installation: 1.

Turn back the specified amount of rope from the thimble. Apply the first clip a distance of one base width from the dead end of the wire rope (U-bolt over the dead end - live end rests in the clip saddle). Tighten nuts diametrically and evenly to recommended torque.

2.

Apply the next clip as near the loop as possible. Snug down the nuts, but do not tighten.

3.

Space additional clips (if required) equally between the first two. Turn on nuts evenly to take up rope slack. Continue to tighten all nuts evenly (on all clips) until recommended torque is reached.

NOTE: Apply the initial load to the strand of rope, and then re-tighten nuts to the recommended torque. This is accomplished because the rope will stretch and be reduced in diameter when loads are applied. Inspect periodically and tighten to recommended torque each time.

A termination complying with the above instructions, using the number of clips shown, has approximately an 80% efficiency rating. This rating is based upon the nominal strength of the wire rope. If a pulley is used in place of a thimble where the rope turns back, add one additional clip.

The number of clips shown is based upon using right regular or lang lay wire rope, 6 x 19 class or 6 x 37 class, fiber core or IWRC, IPS or EIP. If Seale construction is to be used for sizes 1 inch and larger, or similar large outer wire type construction in the 6 x 19 class, add one additional clip.

The number of clips shown also applies to right regular lay wire rope, 8 x 19 class, fiber core, IPS,

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sizes 1-1/2 inch and smaller; and right regular lay wire rope, 18 x 7 class, fiber core, IPS or EIP, size 1-3/4 inch and smaller.

For other classes of wire rope not mentioned, it may be necessary to add additional clips to the number shown. If a greater number of clips are used than shown in the table, the amount of rope turn-back should be increased proportionately. THE ABOVE IS BASED ON THE USE OF CLIPS ON A NEW ROPE.

Failure to make a termination in accordance with the aforementioned instructions, or failure to periodically check and re-tighten to recommended torque, will cause a reduction in the efficiency rating.

The correct spacing and number of clips is shown above.

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Wedge Sockets One of the more popular field end attachments for wire rope is the wedge socket. Attachment and the dismantling of this device is both easy and simple.

1.

Inspect the wedge and socket; remove all rough edges/ burrs that might damage the rope.

2.

Welded ends of the rope should be cut off prior to assembly. This will allow the rope strands to distort slightly as they bend sharply around the wedge. If the welded end were not removed the minimal sliding of the strands would be restricted and evidenced further up the rope. This may result in the development of high strands, wavy rope and uneven loading.

3.

Place the socket in an upright position and bring the rope around it in a large, easy to handle loop. Care must be taken to make certain that the live-loaded-side of the rope is in line with the ears.

4.

The dead end of the rope should extend from the socket for a distance of six to nine times the rope diameter. The wedge is now placed in the socket.

5.

Secure the socket and carefully apply a gradually increasing load to the live side of the rope in order to pull the wedge into position. Only tension sufficiently to hold the pieces in place.

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6.

After checking alignment increase the load GRADUALLY until the wedge is properly seated.

Avoid sudden shock loads.

NOTE: This is the recommended procedure. If variations are made to suit special conditions, they should be carefully evaluated beforehand.

Inspection of Sheaves and Drums Machines should receive periodic inspections, and the results concerning their over-all condition recorded. Such inspections usually include the drum, sheaves, and any other parts that may come into contact with the wire rope. These are considered high wear items. As an additional precaution, any rope-related working parts, particularly those in the areas described below, should be re-inspected prior to the installation of a new wire rope.

Examples of Sheave Groove Conditions

These cross-sections are illustrating three sheave-groove contact areas. “A” is correct, “B” is too tight, and “C” is too loose.

The very first item to be checked when examining sheaves and drums is the condition of the grooves. To accurately check the size, contour and amount of wear, a groove gauge is used. As shown in the figure, the gauge should contact the groove for about 150 degrees of arc when in optimal condition.

There are two types of groove gauges in general use. The two differ by their respective percentage over nominal.

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Groove Gauge for New or Re-Worked Sheaves

For new or re-machined grooves, the groove gauge is nominal plus the full oversize percentage.

The gauge carried by most wire rope representatives today is used for worn grooves and is made nominal plus 1/2 the oversize percentage.

This latter gauge is intended to act as a sort of “no-go” gauge. Any sheave with a groove smaller than this must be re-grooved or, in all likelihood, the existing rope will be damaged.

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Inspecting for Worn Sheave

These sheave-groove cross-sections represent three wire rope seating conditions: “A” - a new rope in a new groove; “B” - a new rope in a worn groove; and “C” - a worn rope in a worn groove.

Breaking In A New Wire Rope A new wire rope requires careful installation. Adherence to the previously covered procedures is highly recommended. After the rope has been installed, and the ends secured in the applicable manner, the mechanisms should be started carefully and then permitted to run through a complete cycle of operation at greatly reduced speed. During this trial operation, a very close watch should be kept on all working parts such as sheaves, drums and rollers to ensure the rope runs freely. Be vigilant to ensure there are no obstructions as it makes its way through the system. If no problems are apparent, the next step should include several run-throughs of the normal operational cycle under light load conditions at a reduced speed. This procedure allows the component parts of the new rope to gradually adjust to the actual operating conditions.

Inspection Data It is essential to maintain a well-planned program of periodic inspection. Frequently, there are

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statutory and/or regulatory agencies that incur additional requirements that must be adhered to.

Refer to the suggested procedures that follow.

Abrasion - Bending and crushing represent the ABC’s of wire rope abuse. It is the primary goal of a good inspection practice to uncover such conditions early enough that corrections may be made, or ropes replaced safely with minimum effort. When any sudden degradation indicates a loss of original rope strength, a timely decision is required as to allowing the rope to remain in service.

Such a decision can only be made by an experienced inspector. His/her determination should be based on: 1.

Details of the equipment’s operation.

2.

Frequency of inspection.

3.

Maintenance history.

4.

Consequences of failure.

5.

Historical records of similar equipment.

To ensure sufficient information can be obtained, the following pages contain guidelines that should be adhered to.

Guideline to Inspections and Reports (Equipment, Wire Rope and Wire Rope Slings) 1.

Maintain all inspection records and reports for the length of time deemed appropriate.

2.

Prior to daily use, the following procedure should be followed. a.

Check all equipment functions.

b.

Lower load blocks and check hooks for deformation or cracks.

c. During lowering procedure and the following raising cycle, observe the rope and the reeving. Particular notice should be paid to kinking, twisting or other deformities. Drum winding conditions should also be noted. d. Check wire rope and slings for visual signs of any unsafe condition, including broken wires, excessive wear, kinking or twisting, and severe corrosion. Particular attention should be given to any new damage during operation.

3.

Periodic inspections consistent with applicable standards are recommended with a signed report by an authorized and competent inspector. These Periodic Reports should include inspection of the following: a.

All functional operating mechanisms for excessive wear of components, brake system parts and lubrication.

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b.

Limit switches.

c.

Crane hooks for excessive throat opening or twisting, along with a visual for cracks.

d.

Wire rope and reeving for conditions causing possible removal.

e. Wire rope slings for excessive wear, broken wires, kinking, twisting and mechanical abuse. f.

All end connections such as hooks, shackles, turnbuckles, plate clamps, sockets, etc. for excessive wear, and distortion.

4.

At least one annual inspection with signed report must be made for the following: a.

Crane hook for cracks.

b.

Hoist drum for wear or cracks.

c.

Structural members for cracks, corrosion and distortion.

d.

For loose structural connections such as bolts, rivets, and weldments.

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Wire Rope Inspection Criteria The following is a fairly comprehensive listing of critical inspection factors. It is not, however, presented as a substitute for an experienced inspector. It is rather a user’s guide to the accepted standards by which ropes must be judged.

Abrasion Rope abrades when it moves through an abrasive medium or over drums and sheaves. Most standards require that rope is to be removed if the outer wire wear exceeds 1/3 of the original outer wire diameter. This is not easy to determine and discovery relies upon the experience gained by the inspector in measuring wire diameters of discarded ropes.

Reduction in Rope Diameter: Any marked reduction in rope diameter indicates degradation. Such reduction may be attributed to: •

Excessive external abrasion.

•

Internal or external corrosion.

•

Loosening or tightening of rope lay.

•

Inner wire breakage.

•

Ironing or milking of strands.

In the past, the determination on the continued service of a rope was largely dependent on the rope’s diameter at the time of inspection. Recently this practice has undergone significant modification.

Previously, a decrease in the rope’s diameter was compared with published standards of minimum diameters. The amount of change in diameter is, of course, useful in assessing a rope’s condition.

But, comparing this figure with a fixed set of values can be misleading. These long-accepted minimums are not, in themselves, of any serious significance since they do not take into account such factors as: •

Variations in compressibility between IWRC and Fiber Core.

• Differences in the amount of reduction in diameter from abrasive wear, or from core compression, or a combination of both.

•

The actual original diameter of the rope rather than its nominal value.

As a matter of fact, all ropes will show a significant reduction in diameter when a load is applied.

Therefore, a rope manufactured close to its nominal size may, when it is subjected to loading, be reduced to a smaller diameter that stipulated in the minimum diameter table. Yet, under these circumstances, the rope would be declared unsafe although it may, in actuality, be safe.

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As an example of the possible error at the other extreme, we can take the case of a rope manufactured near the upper limits of allowable size. If the diameter has reached a reduction to nominal or slightly below that, the tables would show this rope to be safe. But it should, perhaps, be removed.

Evaluations of the rope diameter are first predicated on a comparison of the original diameter when NEW and subjected to a KNOWN load with the current reading under comparable circumstances.

Periodically, throughout the life of the rope, the actual diameter should be recorded while the rope is under equivalent loading and in the same operation section. This procedure, if followed carefully, reveals a common rope characteristic: after an initial reduction, the diameter soon stabilizes. Later, there will be a continuous, albeit small, decrease in diameter throughout its life.

Core deterioration, when it occurs, is revealed by a more rapid reduction in diameter and is time for removal.

Deciding whether or not a rope is safe is not always a simple matter. A number of different but interrelated conditions must be evaluated. It would be dangerously unwise for an inspector to declare a rope safe for continued service simply because its diameter had not reached the minimum arbitrarily established in a table, while at the same time, other observations lead to an opposite conclusion.

Because criteria for removal are varied, and because diameter in itself, is a vague criterion, the table of minimum diameters has been deliberately omitted from this publication.

Rope Stretch All ropes will stretch when loads are initially applied.

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Engineering Data BI010945

Wire Rope Stretch vs. Rope Life

As a rope degrades from wear, fatigue, etc., (excluding accidental damage), continued application of a load of constant magnitude will produce varying amounts of rope stretch. A “stretch” curve plotted for stretch vs. time displays three distinct phases: PHASE 1. - Initial stretch, during the early (beginning) period of rope service, caused by the rope adjustments to operating conditions (constructional stretch).

PHASE 2. - Following break-in, there is a long period-the greatest part of the rope’s service lifeduring which a slight increase in stretch will take place over an extended time. This results from normal wear, fatigue, etc. On the plotted curve stretch vs. time-this portion would almost be a horizontal straight line inclined slightly upward from its initial level.

PHASE 3. - Thereafter, the stretch occurs at a quicker rate. This means that the rope has reached the point of rapid degradation, a result of prolonged subjection to abrasive wear, fatigue, etc. This second upturn of the curve is a warning indicating that the rope should soon be removed.

Corrosion Corrosion, while difficult to evaluate, is a more serious cause of degradation than abrasion. Usually, it signifies a lack of lubrication. Corrosion will often occur internally before there is any visible external evidence on the rope surface. Pitting of wires is a cause for immediate rope removal. Not only does it attack the metal wires, but also prevents the rope’s component parts from moving smoothly as it is flexed. Usually, a slight discoloration because of rust merely indicates a need for lubrication.

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Severe rusting, on the other hand, leads to premature fatigue failures in the wires necessitating the rope’s immediate removal from service. When a rope shows more than one wire failure adjacent to a terminal fitting, it should be removed immediately. To retard corrosive deterioration, the rope should be kept well lubricated. In situations where extreme corrosive action can occur, it may be necessary to use galvanized wire rope.

Kinks Kinks are permanent distortions caused by loops drawn too tightly. Ropes with kinks must be removed from service.

Bird Caging Bird caging results from torsional imbalance that comes about due to mistreatment such as sudden stops, rope being pulled through excessively tight sheaves, or wound on too small a drum for a given rope diameter. This is cause for rope replacement unless the affected section can be removed.

Localized Conditions Careful attention must be paid to wear at the equalizing sheaves. During normal operation this wear is not visible. Excessive vibration, or whip can cause abrasion and/or fatigue. Drum crossover and flange point areas must be carefully evaluated. All end fittings, to include splices, should be examined for worn or broken wires, loose or damaged strands, cracked fittings and worn or distorted thimbles and tucks of strands.

Heat Damage After a fire, or exposure to elevated temperatures, there may be discoloration, or an apparent loss of internal lubrication. Fiber core ropes are particularly vulnerable. Under these circumstances the rope should be replaced.

Protruding Core If, for any cause, the rope core protrudes from an opening between the strands, the rope is unfit for service and should be removed.

Damaged End Attachments Cracked, bent, or broken end fittings must be eliminated. The cause should be sought out and corrected. In the case of bent hooks, the throat openings must be measured at the narrowest point and should not exceed 15% over normal. Twisting to be no greater than 10 degrees.

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Engineering Data BI010945

Peening Continuous pounding is one of the causing of peening. The rope can strike against an object, such as some structural part of the machine, or it beats against a roller, or itself. Often this can be avoided by placing protectors between the rope and the object it is striking. Another common cause of peening is continuous working under high loads over a sheave or drum. Where peening action cannot be controlled it is necessary to have more frequent inspections and be prepared for premature rope replacement.

Scrubbing Scrubbing refers to the displacement of wires and strands as a result of rubbing against itself or another object. This, in turn, causes wear and displacement of wires and strands along one side of the rope. Corrective measures should be taken as soon as this condition is observed.

Fatigue Fracture Wires that break with square ends and show little surface wear have usually failed as a result of fatigue. Such fractures can occur on the crown of the strands, or in the valleys between the strands where adjacent strand contact exists. In almost all cases, these failures are related to bending stresses or vibration.

If diameter of the sheaves, rollers or drum cannot be increased, a more flexible rope should be used. But, if the rope in use is already of maximum flexibility, the only remaining course that will help prolong its service life is to move the rope through the system by cutting off the dead end. By moving the rope through the system, the fatigued sections are moved to less fatiguing areas of the reeving.

Broken Wires The number of broken wires on the outside of a wire rope are an index of 1) its general condition, and 2) whether or not it must be considered for replacement. Frequent inspection will help determine the elapsed time between breaks.

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On occasion, a single wire will break shortly after installation. However, if no other wires break at that time, there is no need for concern. On the other hand, should more wires break, the cause should be immediately investigated.

On any application, valley breaks (where the wire fractures between strands) should be given serious attention. When two or more such fractures are found, the rope should be replaced immediately.

NOTE: No valley breaks are permitted in elevator ropes.

Once broken wires appear within a rope operating under normal conditions many more will show up within a relatively short period. Attempting to squeeze the last measure of service from a rope that is beyond the allowable number of broken wires will create an intolerably hazardous situation.

Examples of Broken Wires

A wire broken under a tensile load that has exceeded its strength is recognized by the “cup and cone” configuration at the fracture point (Rope A). The necking down of the wire at this point shows that failure occurred while the wire retained its ductility. Shear-tensile fracture (Rope B) occurs in wire subjected to a combination of transverse and axial loads. Fatigue breaks are usually characterized by squared-off ends perpendicular to the wire either straight across or Z-shaped (Ropes C and D).

Electric Arc Rope that has either been in contact with a live power line or been used as “ground” in an electric welding circuit, will have wires that are fused, discolored and/or annealed, and must be removed.

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Engineering Data BI010945

Seals Oil and grease seals are critical to machine availability. Careless storage, handling, removal and installation can contribute to reduced service life of machine components and higher cost of operation.

Seals come in all sizes, shapes and materials. Wherever possible, the manufacturer has specified the use of the most common solid molded element type seals for use on electric rope shovels.

All types of oil and grease seals have a limited shelf life. Store seals in a cool, dry location protected from direct sunlight. Keep in sealed containers or packaging until ready to use. Seals keep lubricant clean and contained in their respective housings, bearings or passageways. Always handle seals carefully to prevent exposure to nicks, bends or pinching. Do not wash them in solvents as some solvents may destroy properties of the seal.

Seal Installation Solid molded seals are installed at time of manufacture with interference fit between seal and bore.

This method of installation creates an oil tight fit. When partial disassembly of a machine component involves removal of solid molded seal before reassembly inspect it carefully for cuts, nicks or cracking. Replace with a split seal if complete disassembly is inconvenient or with a new solid molded seal. Split seals, especially those made with interference fit at butt, also install with compression at the joint. Split seals used as substitutes for solid molded seals should be replaced at next major component overhaul.

Do not cut a solid seal and reuse for a split seal.

Check shaft for scratches, burrs or surface roughness that may cut or score the lip of seal. Be aware of sharp threads keyways or splines over which the seal must travel. Protect seal lip by covering these interferences with tape.

Inspect the bore area for surface roughness, dirt or burrs. Remove and clean as required. The bore and shaft need .0625 in. (1.588 mm) chamfer to accommodate a leak free installation. If shaft or bore do not have chamfer, carefully provide one by trimming inside flange of seal.

Determine the correct direction for lip installation and start the seal into the cavity by finger pressure, then tap evenly all around until seated or flush with the housing face. (Tap only on outer edge of seal with hammer on wood block.)

A double seal, installed back to back can be used to retain grease or oil plus be more effective in preventing egress of contaminants.

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Engineering Data BI010945

Split Seal Installation

Follow this installation procedure for split seals: •

Remove garter spring and separate at the hook and eye.

•

Open the seal, ends sideways, for installation on shaft as shown by moving the butt ends along the axis of the seal.

•

Lubricate spring and install around shaft. Connect ends and insert spring in lip groove with spring ends 90o away from butt joint.

Do not trim or cut ends of split seals or pull ends apart. This will destroy seal.

Gearcase seals used for all oil tight gearcase assemblies require surface preparation on one side of case flanges with a 1/100 inch thick Form-a-Gasket #3 (Permatex Co.) coating. If using a manila paper gasket always replace with a new one, never reuse. Apply Form-a-Gasket #3 to both sides of the paper gasket. Tighten gearcase cover bolts until seal material “squeezes out” at joint.

When surface finishes range up to 250 micro-inches, a compression type gasket seal is recommended. This material (VELLUMOID) available in standard thickness inches (mm) 1/64 (.397), 1/32 (.794), 1/16 (.063), and 1/8 (.125) should also be installed with Permatex applied to both sides.

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Engineering Data BI010945

Gearcase Sealing Use the information in the following image to properly seal gearcase halves and /or covers.

NOTE:

Before applying any sealants or gaskets, clean all mating surfaces of all dirt, rust and scale.

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BI010946

Boom Point Sheaves

Crowd Half Sheave

Suspension Strands Electrical Control Room Filter

House Filter

Equalizers Crowd Rope

Air Conditioner Machinery House

A-Frame

Operator’s Cab

Boom Shipper Shaft Saddle Block Retract Rope

Swing Machinery Boarding Stair Crawler Assembly

Dipper Handle Dipper Trip Rope Boom Pitch Bumper Brace

Swing Rack

Dipper Door Snubbers

Retract Rope Take-Up Mechanism

Hoist Ropes Padlocks

Dipper

Dipper Door SN: 141403 141403_n

SIDE VIEW

BI010947 Lube Room Jib Crane C L Rotation APT Auxiliary Resistor Power Transformer

Vertical Ladder Mine Signal

Air Tank Drive Power Transformer

Remote I/O Hoist Rack

Air Compressor

Lubrication Room Auto Lube Pumps and Reservoirs

Fire Protection Junction Box

Swing Machinery, Left

DPT Blower IGBT Skid

Lube/Air Control Panel Hoist Planetary Gearcase

Boom Foot Lugs

Hoist Machinery

Hoist Coupling Shaft

Front of Machine Hoist Motor

Center Pintle

Crowd Motor

Crowd Machinery

C L Machine

Hoist Blower

Crowd Drum

Hoist Drum

A-Frame Lugs, Rear

A-Frame Lugs, Front Thermostats Hoist Brake

PLC Cabinet

Fire Suppression (Opt)

Constant Voltage Transformer

High Voltage Cabinet

Dipper Trip Transformer

Remote I/O Crowd Rack

Lighting Load Center

Lighting Transfomer Unit Mine Signal Remote I/O Accuload Rack

Swing Machinery, Right

Operator’s Cab Outline

Motor Control Center Emergency Stop Thermostat

Boarding Stairs, Right

Aux Seat Machine Start Console Operator’s Seat

SN: 141403 DECK PLAN

BI010948

BI010949

BI010950

BI010598

®

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No part of this publication may be reproduced or transferred in any way or form without the prior written approval of Caterpillar Global Mining LLC. Caterpillar Global Mining LLC declines any liability for direct or indirect consequences of printing errors. © 2012 Caterpillar Global Mining LLC. LatchFree™ and HydraCrowd™ © 2012 Bucyrus International, Inc.