CAT Bucyrus 395-BI Electric Mining Shovel Mechanical Maintenance Manual BI005525 PDF DOWNLOAD

Description

CAT Bucyrus 395-BI Electric Mining Shovel Mechanical Maintenance Manual BI005525 PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus 395-BI Electric Mining Shovel Mechanical Maintenance Manual BI005525 PDF DOWNLOAD

Language : English
Pages : 245
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

CAT Bucyrus 395-BI Electric Mining Shovel Mechanical Maintenance Manual BI005525 PDF DOWNLOAD

CHAPTER 1 MECHANICAL MAINTENANCE
Section 1 – MECHANICAL 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
Take-up Tumbler 1-2-4
Upper Rollers 1-2-5
Lower Roller Bogies 1-2-6
Lower Rollers 1-2-6
Drive Tumbler 1-2-8
Tumbler Drive Shaft and Gear 1-2-9
Transverse Shaft 1-2-10
Propel Clutches 1-2-11
Propel Brakes 1-2-13
Propel Motor 1-2-15
Propel Tach Assembly 1-2-17
Propel Machinery 1-2-18
Crawler Frames and Truck Frame 1-2-24
Swing Rack 1-2-24
Roller Circle 1-2-24
Center Pintle 1-2-26
Collector Rings 1-2-28
Section 3 – ROTATING DECK
Revolving Frame 1-3-1
Deck Machinery 1-3-2
Hoist Machinery 1-3-2
Gear Train 1-3-2
Hoist Gear & Drum 1-3-4
Hoist Brakes 1-3-5
Hoist Limit Switch 1-3-7
Hoist Motor 1-3-7
Crowd Machinery 1-3-8
Gear Train 1-3-8
Crowd Motor 1-3-12
Crowd Brake 1-3-13
Crowd Gear and Drum 1-3-15
Crowd and Retract Limit Switch 1-3-15
Swing Machinery 1-3-15
Gear Train 1-3-15
Swing Motor 1-3-22
Swing Brake 1-3-22
Machinery House 1-3-24
House Fans 1-3-25
Dynavane Air Cleaner 1-3-25
Walkways 1-3-26
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Operator’s Cab 1-3-26
Seat 1-3-26
Windshield Wipers 1-3-26
Windshield Washer 1-3-27
Retractable Boarding Stair 1-3-27
Section 4 – FRONT END EQUIPMENT
Boom 1-4-1
Boom Point Sheaves 1-4-1
Boom Bumpers 1-4-2
Saddle Block 1-4-2
Dipper Handle 1-4-4
Dipper Handle Removal 1-4-4
Retract Take-up Mechanism Removal 1-4-4
Front Stop & Spreader Removal 1-4-4
Crown Cushion (with Pre-Assembled Cushion Stack) 1-4-6
Disassembly 1-4-7
Dipper 1-4-9
Dipper Padlock 1-4-9
Dipper Trip Disassembly 1-4-11
A-Frame 1-4-11
Boom Structural Strands 1-4-12
Wire Running Ropes 1-4-13
Inspection 1-4-13
Hoist Rope Reeving 1-4-13
Retract Rope Reeving 1-4-16
Crowd Rope Reeving 1-4-17
Dipper Trip Rope Reeving 1-4-19
CHAPTER 2 AIR SYSTEM
Section 1- GENERAL MAINTENANCE
Safety 2-1-1
General 2-1-1
Air Compressor Compair-Kellogg B462 (106 CFM) 2-1-4
Air Lines 2-1-4
Air Tank 2-1-4
Air Line Lubricator 2-1-4
Air Line Filter 2-1-4
Air Line Regulator 2-1-4
Compressor Air Intake Anti-Freezer 2-1-5
Air Line Anti-Freezer 2-1-5
Air/Lube Swivel Assembly 2-1-6
Pressure Switches 2-1-6
Solenoid Valves 2-1-6
Section 2 – COMPONENT MAINTENANCE
Air Compressor Compair-Kellogg B462 (l06 CFM) 2-2-1
Belt Adjustment 2-2-1
Head Valve Service 2-2-1
Piston Ring Service 2-2-1
Overhaul Procedure 2-2-3
Reassembly 2-2-7
Air/Lube Swivel Assembly 2-2-8
Removal 2-2-8
Repair 2-2-9
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CHAPTER 3 LUBRICATION
Section 1 – GENERAL LUBRICATION
Lower Works 3-1-2
Rotating Deck 3-1-2
Front End 3-1-3
Lubrication Bench Marks 3-1-3
MPG – Multipurpose Type Grease 3-1-3
ACPL – Air Compressor (Piston Type) Lubricant.. 3-1-4
MPO – Multipurpose Oil 3-1-6
OGL – Open Gear Lubricant 3-1-6
RGL – Regular Type Gear Lubricant.. 3-1-7
Mining Shovels 3-1-9
RCRL – Roller Circle Rail Lubricant 3-1-9
RWRL – Running Wire Rope Lubricant 3-1-10
SWRL – Structural Strand and Stationary Wire Rope Lubricant 3-1-12
Lubrication Charts 3-1-12
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 3-2-3
Startup of Automatic Lubrication Systems 3-2-4
All Systems 3-2-4
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
3rd Intermediate Propel Shaft 4-1-5
2nd Intermediate Propel Shaft 4-1-6
1st 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 Gear Case .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
Section 2 – ROTATING DECK
Hoist Machinery 4-2-1
Hoist Motor Pinion Shaft 4-2-1
Hoist Intermediate Shaft Assembly 4-2-2
Hoist Drum Assembly 4-2-3
Crowd Machinery 4-2-5
Crowd Drum Gear and Pinion Lubrication .4-2-6
Crowd Disc Type Brake 4-2-8
A-Frame 4-2-8
Swing Machinery 4-2-9
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Section 3 – FRONT END EQUIPMENT
Boom 4-3-1
Dippers – Pin Connected 4-3-4
Dipper Door Snubbers 4-3-5
Dipper Handle 4-3-5
Air/Lube Swivel 4-3-7
Air Compressor 4-4-1
Section 4 – AIR SYSTEM
APPENDICES
Appendix A1- GEAR INSPECTION A1-1
Appendix A2 – BOLT TORQUING
Torque Wrench Method A2-1
Turn-Of-The-Nut Method A2-2
Appendix A3 – MAINTENANCE WELDING
Principal Structures A3-1
General A3-1
Maintenance Welding A3-1
Structural Material A3-2
Welding Electrodes A3-2
Preheat Requirements A3-5
Removal of Cracks A3-6
Weld Groove Preparation A3-6
Butter Welding A3-6
Welding Technique A3-6
Weld Inspection A3-6
Repair of Broken Parts A3-8
Dipper Handles A3-8
Maintenance Welding A3-8
Flame Straightening Bent Tube A3-8
Welding Tube Without Backing Ring A3-10
Welding Tube Using Backing Ring A3-13
Handle End Casting Replacement A3-14
Tube Replacement A3-15
Stress Relieving Welded Tube A3-15
Repair Welding of Swing Racks A3-15
Crack Repair Welding A3-15
Broken Tooth Repair Welding A3-17
Appendix A4 – PINION, BRAKE DRUM AND COUPLING INSTALLATION REMOVAL FROM
SHAFT A4-1
Appendix A5 – PREVENTIVE MAINTENANCE CHECKLISTS
Visual Weekly Checklist A5-1
Visual Monthly Checklist A5-7
Visual Semi-Annual Checklist A5-11
Appendix A6 – ROLLER REPLACEMENT A6-1
Appendix A7 – BRAKE OR CLUTCH MAINTENANCE CHECKLIST A7-1
Appendix A8 – ROLLER CIRCLE REPAIR MODIFICATION A8-1
Appendix A9 – SHIMMING INSTRUCTIONS A9-1
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Appendix AIO – DRIVE TUMBLER REBUILD PROCEDURE AIO-l
Appendix All – ELECTRIC MINING SHOVEL “BREAK-IN” INSTRUCTIONS All-l
Appendix A12 – MOTOR COUPLING ALIGNMENT A12-1

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CAT Bucyrus 395-BI Electric Mining Shovel Mechanical Maintenance Manual BI005525 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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