CAT Bucyrus 295-BIII Electric Mining Shovel Mechanical Maintenance Manual BI005510 PDF DOWNLOAD

Description

CAT Bucyrus 295-BIII Electric Mining Shovel Mechanical Maintenance Manual BI005510 PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus 295-BIII Electric Mining Shovel Mechanical Maintenance Manual BI005510 PDF DOWNLOAD

Language : English
Pages : 504
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT Bucyrus 295-BIII Electric Mining Shovel Mechanical Maintenance Manual BI005510 PDF DOWNLOAD

CHAPTER 1 MECHANICAL MAINTENANCE
SECTION 1 – MAINTENANCE PROCEDURE
GENERAL 1-1-1
MAINTENANCE SCHEDULES AND REPORTS 1-1-1
SAFETY 1-1-2
General 1-1-2
In-Operation Maintenance 1-1-2
Precautions Before and During Maintenance Work 1-1-2
SECTION 2 – LOWER WORKS
CRAWLER BELTS 1-2-1
Inspection 1-2-1
Adjustment 1-2-2
Link Replacement 1-2-3
Belt Replacement 1-2-3
TAKE-UP TUMBLER 1-2-4
UPPER ROLLERS 1-2-5
LOWER ROLLERS 1-2-6
DRIVE TUMBLER 1-2-7
TUMBLER DRIVE SHAFT AND GEAR 1-2-7
TRANSVERSE SHAFT 1-2-9
PROPEL CLUTCHES 1-2-11
Inspection 1-2-11
Repair 1-2-11
Rotary Seal 1-2-11
Clutch Discs 1-2-11
Piston Rings 1-2-11
PROPEL BRAKES 1-2-12
PROPEL MOTOR 1-2-15
PROPEL TACH ASSEMBLY 1-2-16
PROPEL MACHINERY 1-2-18
CRAWLER FRAMES AND TRUCK FRAME 1-2-25
SWING RACK 1-2-25
ROLLER CIRCLE 1-2-26
CENTER PINTLE 1-2-27
COLLECTOR RINGS 1-2-29
CABLE REEL (Optional) 1-2-31
Level Wind Drive Adjustment 1-2-31
Hydraulic Adjustments 1-2-34
Unloading Valve Operating Instructions 1-2-34
Lubrication 1-2-34
Hydraulic Maintenance 1-2-36
Repair 1-2-37
SECTION 3 – ROTATING DECK
REVOLVING FRAME 1-3-1
DECK MACHINERY 1-3-1
HOIST MACHINERY 1-3-1
Gear Train 1-3-1
Hoist Gear & Drum 1-3-5
Hoist Brakes 1-3-7
Hoist Limit Switch 1-3-9
Hoist Motor 1-3-9
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BI005510
CROWD MACHINERY 1-3-10
Gear Train 1-3-10
Crowd Motor 1-3-15
Crowd Brake 1-3-16
Crowd Gear and Drum 1-3-18
Crowd and Retract Limit Switch 1-3-18
SWING MACHINERY 1-3-20
Gear Train 1-3-20
Swing Motor 1-3-26
Swing Brake 1-3-26
MACHINERY HOUSE 1-3-28
HOUSE FANS 1-3-29
DYNAVANE AIR CLEANER 1-3-30
WALKWAYS 1-3-30
SEAT 1-3-31
WINDSHIELD WIPERS 1-3-31
WINDSHIELD WASHER 1-3-33
RETRACTABLE BOARDING STAIR 1-3-34
SECTION 4 – FRONT END EQUIPMENT
BOOM 1-4-1
Boom Limit Switch 1-4-1
Boom Point Sheaves 1-4-2
Boom Bumpers 1-4-3
Saddle Block 1-4-3
DIPPER HANDLE 1-4-5
Dipper Handle Removal 1-4-5
Retract Take-up Mechanism Removal 1-4-6
Front Stop & Spreader Removal 1-4-7
Crown Cushion (with Pre-Assembled Cushion Stack) 1-4-7
DIPPER 1-4-10
Dipper Padlock 1-4-10
DIPPER TRIP DISASSEMBLY 1-4-12
A-FRAME 1-4-13
BOOM STRUCTURAL STANDS 1-4-13
WIRE RUNNING ROPES 1-4-14
Inspection 1-4-14
Hoist Rope Reeving 1-4-14
Retract Rope Reeving 1-4-17
Crowd Rope Reeving 1-4-18
Dipper Trip Rope Reeving 1-4-20
CHAPTER 2 AIR SYSTEM
SECTION 1 – GENERAL MAINTENANCE
SAFETY 2-1-1
GENERAL 2-1-1
AIR COMPRESSOR (Compair-Kellogg B462) 2-1-5
AIR COMPRESSOR (Gardner-Denver Eberd) 2-1-5
AIR LINES 2-1-5
AIR TANK 2-1-5
AIR LINE LUBRICATOR 2-1-5
AIR LINE FILTER 2-1-5
AIR LINE REGULATOR 2-1-5
TANNER DE-ICER (Optional) 2-1-6
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BI005510
AIR LINE ANTI-FREEZER (Optional) 2-1-6
AIR/LUBE SWIVEL ASSEMBLY 2-1-7
PRESSURE SWITCHES 2-1-7
SOLENOID VALVES 2-1-7
SECTION 2 – COMPONENT MAINTENANCE
AIR COMPRESSOR (Gardner-Denver Eberd) 2-2-1
AIR COMPRESSOR (Compair-Kellogg B462) 2-2-1
Piston Ring Service 2-2-1
Overhaul Procedure 2-2-3
Re-assembly 2-2-7
AirILube Swival Assembly Removal 2-2-8
Repair 2-2-9
CHAPTER 3 LUBRICATION
SECTION 1 – GENERAL LUBRICATION
LOWER WORKS 3-1-2
ROTATING DECK 3-1-2
FRONT END 3-1-3
LUBRICATION BENCHMARKS 3-1-3
MPO – Multipurpose Oil 3-1-4
OGL – Open Gear Lubricant 3-1-5
RGL – Regular Type Gear Lubricant 3-1-6
RCRL – Roller Circle Rail Lubricant 3-1-8
RWRL – Running Wire Rope Lubricant 3-1-10
SWRL – Structural Strand and Stationary Wire Rope Lubricant 3-1-11
LUBRICATION CHARTS 3-1-11
SECTION 2 – AUTOMATIC LUBRICATION SYSTEMS
INSPECTION 3-2-1
LUBE SYSTEM 3-2-1
AIR PUMP SERVICE 3-2-2
LINES AND CONTROL SERVICE 3-2-2
INJECTORS AND SPRAY NOZZLES 3-2-2
STARTUP OF AUTOMATIC LUBRICATION SYSTEMS 3-2-3
All Systems 3-2-3
Multi-Purpose Grease Lubrication System 3-2-4
Open Gear Lubrication System 3-2-5
CHAPTER 4 TROUBLESHOOTING
SECTION 1 – LOWER WORKS
CRAWLER 4-1-1
THIRD INTERMEDIATE PROPEL SHAFT .4-1-5
SECOND INTERMEDIATE PROPEL SHAFT .4-1-6
FIRST INTERMEDIATE PROPEL SHAFT .4-1-7
PROPEL MOTOR SHAFT 4-1-7
PROPEL CLUTCH 4-1-9
PROPEL BRAKE 4-1-10
PROPEL MOTOR, BLOWER AND GEARCASE .4-1-11
SWING RACK TEETH 4-1-11
HOUSE ROLLER RAILS 4-1-12
HOUSE ROLLERS 4-1-13
CENTER PINTLE 4-1-14
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BI005510
SECTION 2 – ROTATING DECK
HOIST MOTOR PINION SHAFT 4-2-1
HOIST BRAKE 4-2-1
HOIST INTERMEDIATE SHAFT ASSEMBLY .4-2-2
HOIST DRUM ASSEMBLY 4-2-3
HOIST LIMIT SWITCH 4-2-5
CROWD MACHINERY 4-2-5
CROWD DRUM GEAR AND PINION LUBRICATION 4-2-7
CROWD BRAKE 4-2-9
A-FRAME 4-2-9
SWING MACHINERY 4-2-10
SWING BRAKE 4-2-12
SECTION 3 – FRONT END EQUIPMENT
BOOM 4-3-1
DIPPER – PIN CONNECTED 4-3-4
DIPPER DOOR SNUBBERS 4-3-5
DIPPER HANDLE 4-3-6
AIR/LUBE SWIVEL 4-3-7
SECTION 4 – AIR SYSTEM
AIR COMPRESSOR (Compair-Kellogg B462) 4-4-1
APPENDICIES
APPENDIX Al – GEAR INSPECTION
APPENDIX A2 – BOLT TORQUING
APPENDIX A3 – MAINTENANCE WELDING
APPENDIX A4 – PINION, BRAKE DRUM AND COUPLING INSTALLATION
APPENDIX A5 – PREVENTIVE MAINTENANCE CHECKLIST
APPENDIX A6 – ROLLER REPLACEMENT
APPENDIX A7 – BRAKE OR CLUTCH MAINTENANCE CHECKLIST
APPENDIX AS – ROLLER CIRCLE REPAIR MODIFICATION
APPENDIX A9 – SHIMMING INSTRUCTIONS
APPENDIX AI0 – DRIVE TUMBLER REBUILD PROCEDURE
APPENDIX All – ELECTRIC MINING SHOVEL “BREAK-IN” INSTRUCTIONS
APPENDIX A12 – MOTOR COUPLING ALIGNMENT
APPENDIX A13 – PROPEL MOTOR SHAFT/PINION SLEEVE CHANGEOUT USING A SUBASSEMBLY
APPENDIX A14 – SPECIAL FITS
APPENDIX A15 – PIN LOCKING ASSEMBLIES
APPENDIX A16 – TORQUING PROCEDURE FOR SUPERBOLT® TORQUE NUTS

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CAT Bucyrus 295-BIII Electric Mining Shovel Mechanical Maintenance Manual BI005510 PDF DOWNLOAD

• It also contains an air filtration system to minimize heat and dirt build-up in the machinery house. An elevated cab mounted on the house provides the machinery operator’s station. The cab contains all machine operating controls.
• The front end equipment is comprised ofthe A-frame, dipper, dipper handle, boom, running ropes, and boom structural strands. This manual consists offour chapters, each divided into sections. A table ofcontents is located in the front of the manual. Throughout this manual the words CAUTION, WARNING and NOTE appear in bold face type.
• CAUTION is preceeded by the safety alert symbol A and indicates that injury to personnel could occur if the proper procedures are not followed during operation or maintenance. Always read the CAUTION note carefully and use extreme care while performing that particular function.
• WARNING indicates a possible hazard to the machine or its components if the proper procedures are not followed. Whenever the word WARNING appears, special attention should be given to prevent possible equipment damage.
• NOTE is used to stress a point or to give additional information concerning the procedure being discussed. These
• CAUTION’s and WARNING’s are not all-inclusive. It is impossible for Bucyrus-Erie Company to know, evaluate, and advise maintenance and service personnel in every conceivable way a service operation might be performed and of the resulting possible hazardous consequences of each method.
• It is therefore extremely important that anyone who uses a service procedure or tool which is not recommended by Bucyrus-Erie Company to first satisfy himself that the service procedure or tool he chooses will not jeopardize his own safety, the safety of others, or cause machine or component damage.
• Every effort has been made to make this manual as complete and accurate as possible at the time of publication. Bucyrus-Erie Company, however, reserves the right to continually improve its products. For this reason changes may have been made to the machine or its equipment that are not detailed in this manual.

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