CAT Bucyrus Electric 395-B Mining Shovel Mechanical Maintenance Manual BI005519 PDF DOWNLOAD

Description

CAT Bucyrus Electric 395-B Mining Shovel Mechanical Maintenance Manual BI005519 PDF DOWNLOAD

FILE DETAILS:

CAT Bucyrus Electric 395-B Mining Shovel Mechanical Maintenance Manual BI005519 PDF DOWNLOAD

Language : English
Pages : 446
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

CAT Bucyrus Electric 395-B Mining Shovel Mechanical Maintenance Manual BI005519 PDF DOWNLOAD

CHAPTER 1 – MECHANICAL MAINTENANCE
PAGE PAG
S~on1·NUUNTENANCEPROCEDURE
General 1
Maintenance Schedul and Report 1
Safety 1
General 1
In Qperation Maintenance 2
Precautions Before and During
Maintenance 2
Section 2 LOWER WORKS
Crawler Belts 3
Take-up Tumbler 5
Upper Rollen 6
Lower Roller Bogies 7
Lower Rollen 8
Drive Tumbler 8
Tumbler Drive Shaft and Gear 9
Transvene Shaft 10
Propel Clutches 11
Propel Brakes 13
Propel Motor 15
Propel Machinery 16
Crawler Frame and Truck Frame 20
Swing Rack 21
Roller Circle 21
Center Pintle 22
Collector Rings 24
Section 3· ROTATING DECK
Revolving Frame 27
Deck Machinery 27
Hoist Machinery 27
Gear Train 27
Hoist Gear and Drum 30
Hoist Brake 31
Hoist Limit Switch (Optional) 33
Hoist Motor 35
Crowd Machinery 36
Gear Train 36
Crowd Motor 38
Crowd Brake 39
Crowd Gear and Drum 41
Crowd Limit Switch (Optional) 42
Swing Machinery 44
Gear Train 44
Swing Motor ~ 46
Swing Brake 47
Machinery Houe 4
HoueFau 4
Dynavane Air Cleaner 5
Walkways • 5
Operator’s Cab 5
Seat 5
Windshield Wipen 5
Windshield Washer 5
Swing Control Unit :: 5
Pedal Angle Adjustment 5
Retractable Boord:i ng Stair 5
Section 4 • FRONT END EQUIPMENT
Boom 5
Boom Point Sheave 5
Boom Bumpen 5
Saddle Block 5
Dippel’ Handle 5
Retract Take-up ‘ 5
Front Stop and Spreader e
Crowd Cushion e
Dipper e
Dipper Padlock e
Dipper Trip e
A·Frame e
Boom Structural Strands e
Wire Running Ropes e
Hoist Ropes e
Retract Rope 6
Crowd Rope 6
Dipper Trip Rope 6
‘BUCYRUS·ERIE COMPANY 19111
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CHAPTER 2 – AIR SYSTEM
PAGE
Section 1 -GENERAL MAINTENANCE
Safety 73
General 73
Air Compressor 74
Centrifugal Unloader 74
Air Lines 75
Air Tank 75
Air Line Lubricator 75
Air Line Filters 75
Air Line Regulator 75
Anti-Freezer 75
Air Swivel Assembly 75
Pressure Switches 76
Solenoid Valves 76
PAGE
Section 2 -COMPONENT MAINTENANCE
Air Compressor 77
Disassembly 77
Reassembly 78
Lubrication Specification 79
Troubleshooting 79
Air Swivel Assembly 80
Removal 80
Repair 81
CHAPTER3 – ELECTRICAL CABINET COOLINGSYSTEM
CHAPTER 4 – LUBRICATION
PAGE PAGE
Section 1 -GENERAL LUBRICATION 87
Lower Works 88
Rotating Deck 88
Front End 88
Lubrication Bench Marks 89
Multi-Purpose Type-Grease
(MPG) 89
Air Compressor (Piston Type)
Lubricant (ACPL) 90
Multi-Purpose Oil (MPO) 91
Open Gear Lubricant (OGL) 92
Regular Type Gear Lubricant
(RGL) 93
Roller Circle Rail Lubricant
(RCRL) 98
Running Wire Rope Lubricant
(RWRL) 99
Stationary Wire Rope Lubricant
(SWRL) 101
Lubrication Charts 102
ii
Section 2 – AUTOMATIC LUBRICATION
SYSTEMS
Inspection 105
Grease System 105
Open Gear System 105
Air Pump Service 105
Lines and Control Service 106
Injectors and Spray Nozzles 106
Startup of AutOOBtiC Lube Systems _ 100
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CHAPTER 5 – TROUBLESHOOTING
PAGE PAG:
Section 1 – LOWER WORKS
Crawler 113
3rd Intermediate Propel Shaft 118
2nd Intermediate Propel Shaft 119
1st Intermediate Propel Shaft 120
Propel Motor Shaft 120
Propel Clutch 123
Propel Brake 124
Propel Motor Blower and
Gear Case 125
Swing Rack Teeth 125
House Roller Rails ‘ 126
House Rollers 127
Center Pintle 128
Section 2 – ROTATING DECK
Hoist Machinery 131
Hoist Motor Pinion Shaft 131
Hoist Intermediate Shaft
Assembly 132
Hoist Shaft Assembly 133
Hoist Limit Switch Malfunction 137
Crowd Machinery 137
Crowd Drum Gear and
Pinion Lubrication 139
Crowd Rotary Limit Switch 141
Crowd Disc Type Brake 141
A-Frame 142
Swing Machinery 143
Section 3 – FRONT END EQUIPMENT
Boom 14
Dipper 1t
Dipper Door Snubbers It
Dipper Handle It
Air-Grease Spindle It
‘BUCYRUS-ERIE COMPANY 1981 iii
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APPENDICES
PAGE
Appendix Al GEAR INSPECTION 1A
Appendix A2 – BOLT TORQUING
Bolt Torque Valun for Static Joint 3A
Special Bolt Torquing Requirement 4A
Appendix A3 – MAINTENANCE WELDING
Principal Structure• Bulletin 8-80-1
General
Maintenance Welding
Structural Materia
Welding Electrodes
Preheat Requirements
Removal of Cracks
Weld Groove Preparation
Butter Welding
Weldinl Technique
Weld Inspection
Repair of Broken Parts
Dipper Handles Bulletin 11-80-1
Maintenance Welding
Flame Straightenil1g 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
Truck Frame Swing Rack and Crawler Frame Welding 5A
Swing Rack to Truck Frame Welding 7A
Appendix A4· PINION AND COUPLING INSTALLATION 9A
Appendix AS PREVENTIVE MAINTENANCE CHECKLISTS
Weekly 13A
Monthly 19A
Semi·Annually 21A
Appendix A6 SPECIAL FITS
Propel Shafts 23A
Hoist Shafts 24A
Crowd Shafts 25A
Swing Shafts 26A
Appendix A7· PROPEL MOTOR SHAFT/PINION SLEEVE ASSEMBLy 27A
Appendix AS ROLLER REPLACEMENT 29A
Appendix A9 BRAKE OR CLUTCH MAINTENANCE CHECKLIST 31A
Appendix A10· ROLLER CIRCLE REPAIR MODIFICATION 33A
Appendix All -SHIMMING INSTRUCTIONS 35A
AppendiX A12 – DRIVE TUMBLER REBUILD PROCEDURE Bulletin 88-017
Appendix A13 – ELECTRIC MINING SHOVEL BREAK-IN INSTRUCTION 37A

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CAT Bucyrus Electric 395-B Mining Shovel Mechanical Maintenance Manual BI005519 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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