CAT Bucyrus 295BII Electric Mining Shovel Mechanical Maintenance Manual BI005483 PDF DOWNLOAD

Description

CAT Bucyrus 295BII Electric Mining Shovel Mechanical Maintenance Manual BI005483 PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus 295BII Electric Mining Shovel Mechanical Maintenance Manual BI005483 PDF DOWNLOAD

Language : English
Pages : 454
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT Bucyrus 295BII Electric Mining Shovel Mechanical Maintenance Manual BI005483 PDF DOWNLOAD

CHAPTER 1 MECHANICAL MAINTENANCE
PAGE
Section 1 – MECHANICAL PROCEDURE
General 1
Maintenance Schedules and Reports 1
Safety 2
General 2
In-Operation Maintenance 2
Precautions Before and During Maintenance Work 2
Section 2 – LOWER WORKS
Crawler Belts 5
Take-up Tumbler 7
Upper Rollers 8
Lower Roller Bogies 9
Lower Rollers 10
Drive Tumbler 10
Tumbler Drive Shaft and Gear 11
Transverse Shaft 12
Propel Clutches 13
Propel Brakes 15
Propel Motor 17
Propel Machinery 18
Crawler Frames and Truck Frame 22
Swing Rack 23
Roller Circle 23
Center Pintle 24
Collector Rings 27
Cable Reel (Optional) 28
Section 3 – ROTATING DECK
Revolving Frame 29
Deck Machinery 31
Hoist Machinery 31
Gear Train 31
Hoist Gear and Drum 33
Hoist Brake 35
Hoist Limit Switch (Optional) 37
Hoist Motor 39
Crowd Machinery 41
Gear Train 41
Crowd Motor 44
Crowd Brake 45
Crowd Gear and Drum 47
Crowd and Retract Limit Switch(Optional) 49
Swing Machinery 51
Gear Train 51
Swing Motor 56
Swing Brake 56
Machinery House 58
House Fans 59
Dynavane Air Cleaner 60
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Walkways fl)
Operator’s Cab 61
Seat 61
Windshield Wipers 61
Windshield Washer 61
Swing Control Unit ‘ 62
Pedal Angle Adjustment 63
Boarding Ladder 65
Section 4 FRONT END EQUIPMENT
Boom 67
Boom Point Sheaves 67
Boom Bumpers ‘ 68
Saddle Block 68
Dipper Handle 70
Dipper Handle Removal 70
Retract Take-up Mechanism Removal 70
Front Stop and Spreader Removal 71
Crowd Cushion (with D naflaat Cushions) 71
Crowd Cushion (with Pre e ssntued CUshion Stack) 72
Dipper 74
Dipper Padlock 76
Dipper Trip Disassembly 77
A-Frame 78
Boom Structural Strands ‘ 79
Wire Running Ropes 79
Inspection 79
Hoist Rope Replacement 79
Crowd Rope Replacement 82
Retract Rope Replacement 83
Dipper Trip Rope Replacement 85
CHAPTER 2 – AIR SYSTEM
Section 1 GENERAL MAINTENANCE
Safety : 87
General 87
Air Compressor 87
Centrifugal Unloader Service 87
Air Lines 89
Air Tank 89
Air Line Lubricator 89
Air Line Filter 89
Air Line Regulator 89
Anti-Freezer 90
Air Swivel Assembly 90
Pressure Switches ‘ 90
Solenoid Valves 90
Section 2· COMPONENT MAINTENANCE
Air Compressor 93
Disassembly 93
Reassembly 94
Lubrication Specifications 95
Troubleshooting 95
Air Swivel Assembly 96
Removal 96
Repair 97
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CHAPTER 3 – LUBRICATION
Section 1 -GENERAL LUBRICATION
Lower Works 100
Rotating Deck · 100
Front End :’ 101
Lubrication Bench Marks 101
Multi-Purpose Type Grease (MPG) ‘ 101
Air Compressor (Piston Type) Lubricant (ACPL) 102
Multi·Purpose Oil (MPO) 103
Open Gear Lubricant (OGL) 104
Regular Type Gear Lubricant (RGL) 105
Roller Circle Rail Lubricant (RCRL) · 110
Running Wire Rope Lubricant (RWRL) 111
Structural Strand and Stationary Wire Rope Lubricant (SWRL) 113
Lubrication Charts 113
Section 2 -AUTOMATIC LUBRICATION SYSTEMS
Inspection 119
Grease System 119
Open Gear System 119
Air Pump Service 119
Lines and Control Service 120
Injectors and Spray Nozzles 120
CHAPTER 4 – TROUBLESHOOTING
Section 1 -LOWER WORKS
Crawler 123
3rd Intermediate Propel Shaft 128
2nd Intermediate Propel Shaft 129
1st Intermediate Propel Shaft 130
Propel Motor Shaft 130
Propel Clutch 133
Propel Brake 134
Propel Motor Blower and Gear Case 135
Swing Rack Teeth – 135
House Roller Rails 136
House Rollers 137
Center Pintle 138
Section 2 – ROTATING DECK
Hoist Machinery 141
Hoist Motor Pinion Shaft ‘ 141
Hoist Intermediate Shaft Assembly 142
Hoist Shaft Assembly 143
Hoist Limit Switch Malfunction 147
Crowd Machinery 147
Crowd Drum Gear and Pinion Lubrication 149
Crowd Rotary Limit Switch 151
Crowd Disc Type Brake 151
A-Frame 152
Swing Machinery 153
BUCYRUS·ERIE COMPANY 1982
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Section 3 – FRONT END EQUIPMENT
Boom 157
Dippers – Pin Connected 160
Dipper Door Snubbers 162
Dipper Handle 163
Air Grease Swivel 164
APPENDICES
Appendix Al -GEAR INSPECTION 1A
Appendix A2 BOLT TORQUING
Torque Wrench Method 3A
‘IUrn-Of-~ Methcd : 4A
Appendix A3 – MAINTENANCE WELDING
Principal Structures Bulletin 8-80-1
General
Maintenance Welding
Structural Materials
Welding Electrodes
Preheat Requirements
Removal of Cracks
Weld Groove Preparation
Butter Welding
Welding Technique
Weld Inspection
Repair of Broken Parts
Dipper Handles Bulletin 11-80-1
Maintenance Welding
Flame Straightening Bent Tube
Welding Tube Without Backing Ring
I D Weld Build-Up
Stress Relieving Welded Tube
Repair Welding of Swing Racks Bulletin 9-81-1
Crawler Frame to Truck Frame Welding 5A
Swing Rack to Truck Frame Welding 7A

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DESCRIPTION:

CAT Bucyrus 295BII Electric Mining Shovel Mechanical Maintenance Manual BI005483 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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