CAT Bucyrus 395-BIII Electric Mining Shovel Mechanical Maintenance Manual BI005528 PDF DOWNLOAD

Description

CAT Bucyrus 395-BIII Electric Mining Shovel Mechanical Maintenance Manual BI005528 PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus 395-BIII Electric Mining Shovel Mechanical Maintenance Manual BI005528 PDF DOWNLOAD

Language : English
Pages : 251
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT Bucyrus 395-BIII Electric Mining Shovel Mechanical Maintenance Manual BI005528 PDF DOWNLOAD

CHAPTER I 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 Manintenance 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
Optional Link Bushing Replacement 1-2-4
TAKE-UP TUMBLER 1-2-4
UPPER ROLLERS 1-2-6
LOWER ROLLERS 1-2-6
DRIVE TUMBLER 1-2-7
TUMBLER DRIVE SHAFT 1-2-9
PROPEL BRAKE 1-2-10
PROPEL MACHINERY 1-2-14
PLANETARY GEARCASE 1-2-15
PROPEL MOTOR BLOWER AND DUCTS 1-2-18
CRAWLER FRAMES AND TRUCK FRAME 1-2-18
SWING RACK 1-2-18
ROLLER CIRCLE 1-2-20
CENTER PINTLE 1-2-21
COLLECTOR RINGS 1-2-24
CABLE REEL (OPTIONAL) 1-2-26
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 and Drum 1-3-4
Hoist Brake 1-3-6
Hoist Limit Switch 1-3-9
Hoist Motor 1-3-9
CROWD MACHINERy 1-3-10
Gear Train 1-3-10
Crowd Motor 1-3-14
Crowd Brake 1-3-16
Crowd Gear and Drum 1-3-19
Crowd and Retract Limit Switch 1-3-21
SWING MACHINERY 1-3-21
Gear Train 1-3-21
Swing Motor 1-3-27
Swing Brake 1-3-27
MACHINERY HOUSE 1-3-31
HOUSE FANS 1-3-32
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DYNAVANE AIR CLEANER 1-3-32
WALKWAYS 1-3-33
OPERATOR’S CAB 1-3-33
Seat 1-3-33
Windshield Wipers 1-3-34
Windshield Washer 1-3-35
TYPICAL RETRACTABLE BOARDING LADDER (Optional) 1-3-36
TYPICAL RETRACTABLE BOARDING STAIR 1-3-37
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 1-4-6
Crowd Cushion (with Preassembled Cushion Stack) 1-4-7
DIPPER 1-4-9
Dipper Padlock 1-4-9
DIPPER TRIP DISASSEMBLY 1-4-12
A-FRAME 1-4-12
AUXILIARY WINCH 1-4-13
BOOM STRUCTURAL STRANDS 1-4-13
WIRE RUNNING ROPES 1-4-14
Inspection 1-4-14
Hoist Rope Reeving Procedure 1-4-14
Retract Rope Reeving Procedure 1-4-17
Crowd Rope Reeving Procedure 1-4-19
Dipper Trip Rope Reeving Procedure 1-4-21
CHAPTER 2 AIR SYSTEM
SECTION 1 – GENERAL MAINTENANCE
SAFETY 2-1-1
GENERAL 2-1-3
AIR COMPRESSOR (Sullair 6E-10) 2-1-3
AIR DRYER (Deltech HB51-N6) 2-1-4
AIR LINES 2-1-5
AIR TANK 2-1-5
AIR LINE FILTER 2-1-5
AIR LINE REGULATOR 2-1-5
AIR LINE LUBRICATOR 2-1-5
AIR/LUBE SWIVEL ASSEMBLY 2-1-5
PRESSURE SWITCHES 2-1-5
SOLENOID VALVES 2-1-6
SECTION 2 – COMPONENT MAINTENANCE
AIR COMPRESSOR (Sullair 6E-10) 2-2-1
Encapsulated Compressor System 2-2-1
Fluid Management System 2-2-2
Motor/Drive Section 2-2-2
Compressor Cooling System 2-2-3
Air Inlet System 2-2-3
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Compressor Control System 2-2-3
Instrumentation 2-2-4
Indicators and Controls 2-2-5
COMPRESSOR OPERATION 2-2-5
Before Starting 2-2-5
Initial Starting of the Compressor 2-2-6
Subsequent Starting of the Compressor 2-2-6
Stopping the Compressor 2-2-6
PREPARING FOR MAINTENANCE OR SERVICE 2-2-6
SERVICING 2-2-7
Safety 2-2-7
Lubrication 2-2-7
Fluid Filter Maintenance 2-2-8
Cooler Maintenance 2-2-9
Air Filter Maintenance 2-2-9
Separator Element Replacement 2-2-10
Minimum Pressure/Check Valve Maintenance 2-2-10
Thermostat Actuator Maintenance 2-2-11
Inlet Control Valve Maintenance 2-2-11
Motor Shaft Seal Replacement 2-2-12
Pressure Regulator Replacement 2-2-12
AIR DRYER (DELTECH HB51-N6) 2-2-13
Description 2-2-13
Operation 2-2-13
Initial Starting of the Air Dryer 2-2-15
Maintenance Shutdown 2-2-15
Maintenance – General 2-2-15
Desiccant Replacement 2-2-15
Desiccant Dusting Muffler Core Replacement.. 2-2-16
Dew Point Verification 2-2-16
Coalescing Prefilter Replacement 2-2-16
Particulate Afterfilter Replacement 2-2-17
Automatic Drain Valve (ADV) 2-2-18
Air Dryer System Environment Space Heater 2-2-20
AIR/LUBE SWIVEL ASSEMBLY 2-2-20
Removal 2-2-20
Repair 2-2-20
CHAPTER 3 LUBRICATION
SECTION 1 – GENERAL LUBRICATION
SAFETY 3-1-1
LOWER WORKS 3-1-2
ROTATING DECK 3-1-2
LUBRICATION BENCHMARKS 3-1-3
FRONT END 3-1-3
LUBRICATION BENCHMARKS 3-1-3
LUBRICATION CHARTS 3-1-13
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
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CHAPTER 4 TROUBLESHOOTING
SECTION 1 – LOWER WORKS
CRAWLER 4-1-1
PROPEL MOTOR COUPLING 4-1-5
PROPEL BRAKE 4-1-6
PROPEL MOTOR AND BLOWER 4-1-6
SWING RACK TEETH 4-1-7
HOUSE ROLLER RAILS 4-1-7
HOUSE ROLLERS 4-1-8
CENTER PINTLE 4-1-9
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
HOIST BRAKE 4-2-5
CROWD MACHINERY 4-2-6
CROWD DRUM GEAR AND PINION LUBRICATION 4-2-8
CROWD BRAKE 4-2-9
SWING MACHINERY 4-2-10
SWING BRAKE 4-2-12
A-FRAME 4-2-13
SECTION 3 – FRONT END EQUIPMENT
BOOM 4-3-1
DIPPER 4-3-4
DIPPER HANDLE 4-3-5
DIPPER PADLOCK 4-3-6
SECTION 4 – AIR SYSTEM
SULLAIR 6E-I0 SCREW COMPRESSOR 4-4-1
DELTECH HB51-N6 AIR DRyER 4-4-6
AIR DRYER AUTO-DRAIN VALVE 4-4-7
AIR/LUBE SWIVEL 4-4-8
APPENDICES
APPENDIX Al – GEAR INSPECTION Al-l
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
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DIPPER HANDLES A3-8
Maintenance Welding A3-8
Flame Straightening Bent Tube A3-8
Welding Tube Without Backing Ring A3-l0
Welding Tube Using Backing Ring A3-l3
Handle End Casting Replacement.. A3-l4
Tube Replacement A3-l5
Stress Relieving Welded Tube A3-l5
REPAIR WELDING OF SWING RACKS A3-l5
Crack Repair Welding A3-l5
Broken Tooth Repair Welding A3-l7
Swing Rack to Truck Frame Welding A3-l8
APPENDIX A4 – PINION, BRAKE DRUM AND COUPLING INSTALLATION A4-l
APPENDIX A5 – PREVENTIVE MAINTENANCE CHECKLISTS
VISUAL WEEKLY CHECKLIST A5-l
VISUAL MONTHLY CHECKLIST A5-5
VISUAL SEMI-ANNUAL CHECKLIST A5-7
VISUAL ANNUAL CHECKLIST A5-9
APPENDIX A6 – ROLLER REPLACEMENT A6-l
APPENDIX A7′- BRAKE OR CLUTCH MAINTENANCE CHECKLIST A7-l
APPENDIX A8 – ROLLER CIRCLE REPAIR MODIFICATION A8-l
APPENDIX A9 – SHIMMING INSTRUCTIONS A9-l
APPENDIX AlO – DRIVE TUMBLER REBUILD PROCEDURE AlO-l
APPENDIX All – ELECTRIC MINING SHOVEL “BREAK-IN” INSTRUCTIONS All-l
APPENDIX Al2 – MOTOR COUPLING ALIGNMENT Al2-l
APPENDIX Al3 – INSTALLATION GUIDELINES FOR DUO-CONE SEALS Al3-l
APPENDIX Al4 – TORQUING PROCEDURE FOR SUPERBOLT@ TORQUE NUTS Al4-l
APPENDIX Al5 – PIN LOCKING ASSEMBLIES Al5-l
APPENDIX Al6 – TYPICAL GEARCASE FLANGE SEALING INSTRUCTIONS Al6-l

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CAT Bucyrus 395-BIII Electric Mining Shovel Mechanical Maintenance Manual BI005528 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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