Cat Electric Rope Shovel 7295 Preventive Maintenance Manual (Service Manual) - PDF DOWNLOAD

Preventive Maintenance BI010514

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 BI010514 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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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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•

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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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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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.

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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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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.

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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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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.

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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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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.

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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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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.

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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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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.

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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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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.

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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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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.

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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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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.

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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.

SM141402-EN

7295 Electric Rope Shovel

3 - 23 July 2012

Preventive Maintenance BI010514

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 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

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.

SM141402-EN

7295 Electric Rope Shovel

3 - 25 July 2012

Preventive Maintenance BI010514

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 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

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.

SM141402-EN

7295 Electric Rope Shovel

3 - 27 July 2012

Preventive Maintenance BI010514

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 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

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.

SM141402-EN

7295 Electric Rope Shovel

3 - 29 July 2012

Preventive Maintenance BI010514

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 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

Major Component Locations

Boom Point Sheaves

Crowd Half Sheave

Suspension Strands Electrical Control Room Filter

Machinery House

House Filter

Equalizers

Crowd Rope

Air Conditioner 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 141402_nm

Machine Nomenclature

SM141402-EN

7295 Electric Rope Shovel

3 - 31 July 2012

Preventive Maintenance BI010514

Lower Works and Crawlers

3 - 32 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

Crawler Assembly

SM141402-EN

7295 Electric Rope Shovel

3 - 33 July 2012

Preventive Maintenance BI010514

Crawler Link Assembly

3 - 34 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

Propel Machinery

SM141402-EN

7295 Electric Rope Shovel

3 - 35 July 2012

Preventive Maintenance BI010514

Roller Circle Section View

3 - 36 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

Roller Frame Assembly

SM141402-EN

7295 Electric Rope Shovel

3 - 37 July 2012

Preventive Maintenance BI010514

Collector Rings Propel and Low Voltage (Rear Section View)

3 - 38 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

SM141402-EN

7295 Electric Rope Shovel

3 - 39 July 2012

Preventive Maintenance BI010514

Center Pintle Assembly

3 - 40 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

Revolving Frame Deck Extensions

SM141402-EN

7295 Electric Rope Shovel

3 - 41 July 2012

Preventive Maintenance BI010514

Hoist Machinery

3 - 42 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

Swing Machinery

SM141402-EN

7295 Electric Rope Shovel

3 - 43 July 2012

Preventive Maintenance BI010514

Crowd Machinery

3 - 44 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

Lubrication Reservoirs

SM141402-EN

7295 Electric Rope Shovel

3 - 45 July 2012

Preventive Maintenance BI010514

Operators Cab

3 - 46 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

Boarding Stairway

SM141402-EN

7295 Electric Rope Shovel

3 - 47 July 2012

Preventive Maintenance BI010514

Machinery House Walkways and Platforms

3 - 48 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

Front End Equipment

SM141402-EN

7295 Electric Rope Shovel

3 - 49 July 2012

Preventive Maintenance BI010514

Boom Support Ropes

3 - 50 July 2012

7295 Electric Rope Shovel

SM141402-EN

Preventive Maintenance BI010514

Boom Bumpers

SM141402-EN

7295 Electric Rope Shovel

3 - 51 July 2012

Preventive Maintenance BI010514

Dipper Assembly

3 - 52 July 2012

7295 Electric Rope Shovel

SM141402-EN