Download - ANEXOS CURSO HYDRACROWD.pdf

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August 19, 2013

Special Instruction ________________________________________________________________________________________________________________________________

Adjusting Main Pump Relief Pressure on 7495 and 7495HF HydraCrowd Equipped Electric Rope Shovels Electric Rope Shovels

Model Identification Number Expanded Product Line Serial Number

7495 ER601418 141418

ER601439 141439

ER601452 141452

ER601441 141441

ER601455 141455

ER601462 141462

ER601463 141463

ER601469 141469

ER601470 141470

ER601473 141473

ER601474 141474

ER601477 141477

ER601482 141482

ER601481 141481

ER601494 141494

ER601508 141508

ER601511 141511

7495HF ER801209 141209

ER801325 141325

ER801327 141327

ER801333 141333

ER801424 141424

ER801429 141429

SIS Media Number: BI646626 Media Number: SA13-025

ER801433 141433

ER801483 141483

Introduction This special instruction provides the information to adjust the main pump relief pressure on HydraCrowd equipped 7495 and 7495HF Electric Rope Shovels.

Important Safety Information

STORED ENERGY! Hydraulic pressure must be relieved prior to performing this procedure. Hydraulic fluid under pressure may cause injury or death if not released in a controlled manner.

Required Tooling

TOOLS:

6 mm Allen Key

2 mm Allen Key

19 mm Wrench

1. Set the dipper flat on the ground and lower the hoist until the padlocks are

down and the hoist ropes are slack.

SIS Media Number: BI646626 Media Number: SA13-025

Illustration 1: Padlocks Lowered

2. Shutdown the machine. Lockout and tagout controls in compliance with

local regulations.

3. Install a 0-8000 psi pressure gauge on the pressure outlet test port of each main pump. It is ideal to monitor all 4 pumps at the same time (digital pressure gauge in the S127020 commissioning kit has this capability).

Illustration 2: Preesure Outlet Test Ports

4. To adjust individual pump relief pressure, remove the cylindrical relief

valve cover (See Illustration 3 for location).

2 mm Allen Key

Pressure Outlet

Test Ports

SIS Media Number: BI646626 Media Number: SA13-025

Illustration 3: Pump PUV Relief Valves

Illustration 4: Cylindrical Relief Valve Cover Retaining Screw

5. With the cylindrical relief valve cover removed, loosen the jam nut

securing the adjustment screw in place.

19 mm Wrench

Illustration 5: Relief Jam Nut and Adjusting Screw

Pump PUV

Relief Valves

Cylindrical Cover

Held in Place by

Socket Head Screw

Adjustment

Screw

Jam Nut

SIS Media Number: BI646626 Media Number: SA13-025

6. Once the relief valves are exposed, remove lockout tagout from machine controls.

7. Start the machine.

8. Access the HydraCrowd Commissioning Screen from the operators display in the operator cab (see Illustration 5).

9. Turn crowd control on

10. Energize the PICV Output button

11. Choose the valve position (1-4) you would like to test and press the

corresponding PUV button.

12. Press the Run Crowd Motor at 20% reference button. The chosen PUV will now be forced over relief.

Illustration 6: HydraCrowd Commissioning Screen

SIS Media Number: BI646626 Media Number: SA13-025

IMPORTATNT: If the following steps do not affect the pump outlet pressure, it will be important to return the relief to its original setting. Before turning the adjusting screw, mark the screw location with respect to the valve body. As the adjusting screw is turned count the number of rotations so it could be returned to original.

13. In the machinery house, with pump pressure going over relief, slowly turn the adjustment screw while observing the pump pressure associated with the relief valve (see Illustrations 6 and 7 for pump and corresponding relief locations). Turning the screw clockwise will increase the relief pressure, turning the screw counterclockwise will reduce the pressure.

6 mm Allen Key

Illustration 7: Pump Reference Numbers

Pump 1

Pump 2 Pump 3

Pump 4

SIS Media Number: BI646626 Media Number: SA13-025

Illustration 8: Relief Valves Associated with Each Pump

14. When the gauge pressure reads 3700 psi ± 50 psi tighten the jam nut to secure the adjusting screw. Recheck pressure setting after tightening the jam nut to ensure the setting hasn’t changed.

19 mm Wrench

NOTE: If gauge pressure does not change when the adjustment screw is turned,

return the adjustment screw to its origional position.

15. Install the cylindrical cover onto the relief and secure with screw.

2 mm Allen Key

16. Remove pressure gauges from the pump outlet ports and reinstall test port covers.

17. Ensure cylinder speed is normal by stroking the cylinder several times in the horizontal position. Verify by observing cylinder speed on the operator HMI screen. Extend speed is approximately 130 ft. /min while retract is approximately 120 ft. /min.

Pump 3

Pump 4

Pump 2

Pump 1

SIS Media Number: BI646626 Media Number: SA13-025

*V038979 DOES NOT REPRESENT A PART,IT IS A PLACE HOLDER FOR PLANNING PURPOSES ONLY.

A. CHECK CENTER GAP- MEASURE COUPLING FACE TO COUPLING FACE AT FOUR PLACES 90 APART, APPROXIMATELY 7.00 ON FACES OF RIGID COUPLING HUBS. AVERAGE OF THE FOUR MEASUREMENTS IS TO BE 1.75 +0.02/-0.02

B. CHECK ANGULAR MISALIGNMENT AT APPROXIMATELY 7.00 ON COUPLING FACES. MAX T.I.R =0.002 (@ PARALLEL OFFSET=0.0)

C. CHECK PARALLEL OFFSET - MAX. T.I.R=0.005 (@ ANGULAR OFFSET =0.0)

D. COMBINED ANGULAR + PARALLEL OFFSET MUST BE AT OR BELOW THE LINE IN THE FOLLOWING CHART.

COUPLING ALIGNMENT

GENERAL ASSEMBLY INSTRUCTIONSSPRAY ALL MACHINED AND UNPAINTED/UNPROTECTED SURFACES WITH LPS3 (ITEM 67) PRIOR TO ASSEMBLY.PRIOR TO TORQUING HARDWARE APPLY THREAD LOCKING COMPOUND (ITEM 46)

*INCLUDES 85 FT-LBS FOR NYLON INSERT (LOCK NUT)

1 ITEM 32 SKIPPED IN BILL OF MATERIALTO KEEP CONSISTANCY WITHPREVIOUS DRAWING S038952.

* SEE NOTE 2 OF TIGHTENING PROCEDURE

1. LIGHTLY COAT THE TWO O-RINGS SUPPLIED WITH COUPLING (ITEM 6) AND INSTALL INTO GROOVES ON EACH COUPLING SLEEVE. PLACE ONE SLEEVE OVER EACH SHAFT (MOTOR & PDT) BEFORE INSTALLING COUPLING HUBS. CARE SHOULD BE TAKEN NOT TO DAMAGE O-RINGS.

MOUNT COUPLING HUBS TO MOTOR (ITEM 2) AND PDT (ITEM 3) SHAFTS. REFER TO DETAIL "F" ON SHEET 3.

2. SPRAY INSIDE MACHINED MOUNTING SURFACE OF PDT MOUNTS (ITEM 4) WITH LPS3 (ITEM 67). ASSEMBLE PDT MOUNTS (ITEM 4)TO PDT (ITEM 3) USING H.H.C.S. (ITEM 27) AND WASHER (ITEM 38). DO NOT TORQUE H.H.C.S.!

3. SPRAY MACHINED PDT MOUNTING PADS ON TANK (ITEM 1) WITH LPS3 (ITEM 67). ASSEMBLE PDT/MOUNTS TO TANK (ITEM 1) USING H.H.C.S.(ITEM 25) AND WASHER (ITEM 37), TORQUE H.H.C.S. RETAINING MOUNTS TO TANK (SEE TORQUE CHART).

4. SPRAY MACHINED MOTOR MOUNTING PADS ON TANK (ITEM 1) WITH LPS3 (ITEM 67) PRIOR TO MOTOR INSTALLATION. ASSEMBLE MOTOR(ITEM 2) TO TANK (ITEM1) USING H.H.C.S. (ITEM 28), WASHER (ITEM 39) AND LOCK NUT (ITEM 33). REFER TO DETAIL "C" ON SHEET 3.DO NOT TORQUE HARDWARE!

5. INSTALL JACK SCREWS (ITEM 29) AND JAM NUTS (ITEM 34) TO PDT MOUNTS (ITEM 4), REFER TO DETAIL "J" ON SHEET 2. DO NOT TIGHTEN!

6. POSITION TAP BLOCKS (ITEM 44) TO ENSURE AS MUCH CONTACT AS POSSIBLE WITH TANK MOTOR SUPPORTS (ITEM 1). WELD TAP BLOCKS(ITEM 44) TO MOTOR SUPPORTS ON TANK (ITEM 1), REFER TO SECTION "B-B" ON SHEET 3. CLEAN, PRIME, AND FINISH PAINT TAP BLOCKS(ITEM 44) WITH ORIENT WHITE ENAMEL, B.I. #61037662, AFTER WELDING IS COMPLETE.

7. INSTALL JACK SCREWS (ITEM 64) AND JAM NUTS (ITEM 34) TO TAP BLOCKS (ITEM 44) WELDED TO MOTOR SUPPORTS ON TANK (ITEM 1),REFER TO SECTION "D-D" ON SHEET 3.

8. ALIGN MOTOR (ITEM 2) TO PDT (ITEM 3), SEE DETAIL "F" ON SHEET 3 FOR SPACING BETWEEN COUPLING HUBS. REFER TO COUPLINGALIGNMENT CHART FOR DIMENTIONAL ALLOWANCES. USING SHIM PACKS (ITEM 43) AND JACK SCREWS (ITEM 64), MAKE ADJUSTMENTSTO CORRECT ANY MIS-ALIGNMENT.

9. LOCK ALL JACK SCREWS (ITEMS 29 & 64) IN PLACE USING JAM NUTS (ITEM 34). TORQUE H.H.C.S. (ITEM 28) RETAINING MOTOR (ITEM 2) TOTANK (ITEM 1) AND H.H.C.S. (ITEM 27) RETAINING PDT (ITEM 3) TO PDT MOUNTS (ITEM 4), (SEE TORQUE CHART).

10. INSTALL PUMPS; SEE TIMING/INSTALLATION PROCEDURE ON SHEET 5.

11. THOROUGHLY COAT COUPLING HUB AND SLEEVE TEETH WITH GREASE (ITEM 66). SLIDE COUPLING SLEEVES OVER HUBS, CAREFULLY ENGAGINGTEETH. DO NOT DAMAGE 0-RINGS. PLACE GASKET SUPPLIED WITH COUPLING BETWEEN SLEEVE FLANGES. ALIGN BOLT HOLES AND BRINGFLANGE FACES TOGETHER BY HAND. DO NOT USE COUPLING HARDWARE TO REMOVE GAP BETWEEN FLANGES. SECURE SLEEVES BY TIGHTENING FASTENERS PROVIDED WITH COUPLING UNIFORMLY TO A TORQUE VALUE OF 250 FT-LBS. ONLY USE HARDWARE SUPPLIED WITH COUPLING. DO NOT SUBSTITUTE OR REUSE HARDWARE. REMOVE ALL GREASE PLUGS AND FILL WITH GREASE (ITEM 66) UNTIL AN EXCESSAPPEARS AT AN OPEN HOLE, THEN PLUG THAT HOLE. REPEAT PROCESS UNTIL ALL PLUGS HAVE BEEN REINSTALLED. WELD IN PLACE MOTORCHOCK BLOCKS (ITEMS 41 & 42), SEE SECTION "B-B" ON SHEET 3. CLEAN, PRIME AND FINISH PAINT MOTOR CHOCK BLOCKS AFTER WELDINGIS COMPLETE.

12. INSTALLATION OF TACHOMETER (ITEM 15), REFER TO DETAIL "E" ON SHEET 3. USE THREAD LOCKING COMPOUND (ITEM 46) ON ALL FASTENERS UNLESS NOTED. ATTACH BOTH HALVES OF URETHANE FLEX ELEMENT OF COUPLING (ITEM 16) DIRECTLY ONTO PDT (ITEM 3) SHAFT USING (4) OF THEMETRIC H.H.C.S. SUPPLIED WITH COUPLING. INSERT (1) STEEL HUB INTO OPEN END OF FLEX ELEMENT AND SECURE WITH (4) METRIC H.H.C.S.SUPPLIED WITH COUPLING (DISCARD EXTRA HUB). SPRAY TACHOMETER SHAFT WITH LPS3 (ITEM 67) PRIOR TO INSTALLATION. ATTACH TACHOMETER (ITEM 15) TO TACH MOUNT (ITEM 13) USING (ITEM 11) AND (ITEM 12). ALIGN KEY ON TACHOMETER SHAFT TO KEYSLOT IN COUPLING HUB; SLIDE ASSEMBLED TACHOMETER/MOUNT INTO COUPLING. ALIGN HOLES IN TACH MOUNT FLANGE (ITEM 13) TO THREADED HOLES IN PDT (ITEM 3) AND SECUREWITH (ITEM 22). ATTACH TACH COVER (ITEM 14) TO TACH MOUNT USING (ITEM 21) AND (ITEM 58).TACHOMETER ELECTRICAL FITTING SHOULD BE LOCATED ON SAME SIDE OF TACHOMETER AS THE TACH COVER GUARD.IF NECESSARY, REMOVE PLUG FROM TACHOMETER AND REPLACE WITH ELECTRICAL FITTING, REFER TO SECTION "R-R" ON SHEET 3.

13. QTY (1) OF JACK SCREW (ITEM 64) MUST BE REMOVED PRIOR TO INSTALLATION OF COUPLING GUARD STAND (ITEM 8). ATTACH COUPLINGGUARD STAND (ITEM 8) TO TANK (ITEM 1) USING H.H.C.S. (ITEM 22) & WASHER (ITEM 35). ATTACH COUPLING GUARD FRONT AND REAR(ITEMS 9 & 10) TO COUPLING GUARD STAND (ITEM 8) USING H.H.C.S. AND LOCK NUT (ITEMS 22 & 31), SEE DETAIL "G" ON SHEET 3.REPLACE JACK SCREW (ITEM 64) USING PROCEDURE DESCRIBED ABOVE IN STEP #10.

14. PRIOR TO INSTALLING TACH ADAPTER (ITEM 50) FOR SHIPPING, VERIFY CORRECT FIT ONTO MOTOR SHAFT (ITEM 2). TACH ADAPTER (ITEM 50)SHOULD SCREW ALL THE WAY ONTO MOTOR SHAFT (ITEM 2) WITHOUT BOTTOMING OUT. FACE OF TACH ADAPTER SHOULD SEAT AGAINSTSHOULDER OF MOTOR.

15. INSTALL SHAFT GUARD (ITEM 17) TO REAR OF MOTOR USING H.H.C.S. AND WASHER (ITEMS 26 & 36); INSTALL GUARD COVER (ITEM 53) ANDSECURE TO SHAFT GUARD (ITEM 17) USING H.H.C.S. (ITEM 21). PLUG (3) HOLES ON REAR OF MOTOR USING H.H.C.S. (ITEM 65).

16. SPRAY INTERNAL THREADS OF TACH ADAPTER (ITEM 50) WITH LPS3 (ITEM 67) AND COVER OPEN END OF TACH ADAPTER WITH TAPE PRIORTO SHIPPING.

17. COAT MOUNTING SURFACE OF DUCT (ITEM 19) WITH SILASTIC SEALANT (ITEM 45)AND ATTACH TO MOTOR (ITEM 2) USING S.H.C.S. (ITEM 23),COAT MOUNTING SURFACE OF COVERS (ITEM 18) WITH SILASTIC SEALANT (ITEM 45) AND ATTACH TODUCT (ITEM 19) USING H.H.C.S. (ITEM 22).

18. APPLY SILASTIC SEALANT (ITEM 45) TO MOUNTING SURFACE OF BLOWER (ITEM 20) AND ATTACH TO DUCT (ITEM 19) USING H.H.C.S. AND LOCKNUT (ITEMS 22 & 31).

QTY ITEM NO. DESCRIPTION REF WGT(#)

EACH PART NO.

1 1 TANK,LOWER,ASSEM,HYD CROWD 6195.0 S0389511 2 MOTOR,700HP,1400/700-3-50,4140 4500.0 124820261 3 PDT,1-1 RATIO,4 PAD ISO 3019-2 2800.0 S0388402 4 MOUNT,PDT WELD 95.0 S0495634 5 PUMP,BENT AXIS PISTON,30 C.I. 342.0 S0388291 6 CPLG,RIGID,GEAR 117 44283191 7 KEY,SQ,1x4.19 1.2 44283171 8 STAND,CPLG GUARD,HYD CROWD 22.5 S049575

1 9 GUARD,COUPLING,FRONT,HYD-CROWD 13.0 S049577

1 10 GUARD,COUPLING,REAR,HYD-CROWD 11.0 S0495796 11 SCR,HEX,.25x.75,UNC,GR 5 0.02 032732406 12 WASHER,LOCK,.25,HVY 0.02 039610101 13 MOUNT,TACH,WELD & MACH 10.07 17186511 14 COVER,TACH 5.08 41562401 15 TACH,DIGITAL,FLANGE MOUNT,500 6.83 15571591 16 CPLG,TACH,14MM,E2M 2.4 15571601 17 GUARD,SHAFT,HYD CROWD 43.9 S0490792 18 COVER,BLWR MOTOR DUCT 7.48 S0389711 19 DUCT,HYD CRWD BLWR,WELD & MACH 140.5 S0495691 20 BLOWER,HYD CROWD,VARABLE 210.0 SEE TABLE14 21 SCR,HEX,.25x.625,UNC,GR 5 0327320053 22 SCR,HEX,.375x1.00,UNC,GR5 0.05 0327932028 23 SCR,SOC,.375x.625,UNC,GR8 0.0 034805004 24 SCR,HEX,.375x1.25,UNC,GR5 0.1 0327940014 25 SCR,HEX,.75x2.25,UNC,GR 5 032947203 26 SCR,HEX,1x3.5,UNC,GR 5 033011208 27 SCR,HEX,1x2.75,UNC,GR 5 033008804 28 SCR,HEX,1.25x4.25,UNC,GR5 2.2 43546428 29 SCR,SET,SQ,.75x4,HDP 0.5 0377294032 30 SCR,HEX,M20x60MM,CL10.9 0.5 0355207025 31 NUT,HEX,LOCK,.375,UNC 0.0 027863854 33 SUPERBOLT,TORQUENUT,1.25 0.8 MP26324116 34 NUT,HEX,JAM,.75,UNC 0.1 0271445010 35 WASHER,FLAT,.375 0.1 039514003 36 WASHER,FLAT,1 0395210014 37 WASHER,FLAT,.75,HARDENED 039519508 38 WASHER,FLAT,1,HARDENED 039521504 39 WASHER,FLAT,1.25,HARDENED 0.3 0395235032 40 WASHER,HARDENED,20MM 0.1 MP6007818 41 CHOCK,MOTOR 1.91 S0373528 42 CHOCK,WEDGE 1.39 S0373534 43 SHIM PACK,ELEC MOTOR MTG. 3.48 S0320918 44 BAR,1.25x2.5 2.9 S0291572 45 SEALANT,SILASTIC,10.3 OZ 0.1 828338551 46 COMPOUND,THREAD LOCKING 0.2 828338621 47 LUBE,O-RING,2 OZ. TUBE 0.13 591831274 48 O-RING,-381,VITON,70 DUROMETER 0.1 687664971 50 ADAPTER,MOUNTING,TACH 5.3 S0373321 51 SCR,SET,SOC,.25x.625,NYLON TIP 0.01 038033111 52 PIN,CLEVIS,.31x1.25,W/COTTR PN 0.2 826472241 53 COVER,GUARD,MOTOR SHAFT 1.3 S0373291 54 BRKT,TACH TORQUE ARM 0.32 S037339

QTY ITEM NO. DESCRIPTION REF WGT(#)

EACH PART NO.

1 55 ROD END,JOINT,BALL,.313 UNF,RH 0.07 828112851 56 ROD END,JOINT,BALL,.313 UNF,LH 0.7 828112861 57 ROD,CONN,HEX BODY,.313 UNF THD 0.09 828112879 58 WASHER,FLAT,.25 039512201 59 SCR,HEX,.25x1.25,UNC,GR 5 032734002 60 NUT,HEX,LOCK,.25,UNC 0.02 027863451 61 SCR,HEX,.25x2.25,UNC,FULL THRD 0.04 032736901 62 NUT,HEX,JAM,.312,UNF 0.01 027391003 63 NUT,HEX,FULL,.25-20 UNC 0.03 027071508 64 SCR,SET,SQ.HD,.75x5,CP 0.5 037734103 65 SCR,HEX,1x1.25,UNC,GR 5 033005602 66 GREASE,LONG TERM 1.0 MP2951481 67 SEALANT,RUST INHIBITOR 0.69 828338931 68 LUBRICANT 10 OZ. CAN JL-G 0.01 MP390331

REISSUE DATE

1. DIMENSION MATERIAL THICKNESS TOLERANCE

FABRICATING TOLERANCES-UNLESS OTHERWISE SPECIFIED

MACHINING TOLERANCES-UNLESS OTHERWISE SPECIFIEDALL DIMENSIONS IN INCHES-UNLESS OTHERWISE SPECIFIED

1. MATERIAL THICKNESS DIMENSIONS TOLERANCE

1. 2 PLACE DECIMAL DIMENSIONS .01 FOR EACH 12 MAX ± .09 2. 3 PLACE DECIMAL DIMENSIONS .005 UP TO 36, .010 OVER 363. CONCENTRICITY OF CYLINDRICAL SURFACES = .010 T.I.R.4. PARALLELISM, SQUARENESS, OR ANGULARITY BETWEEN SURFACES AND/OR HOLE CENTERLINES 0 7' (.002 INCH/INCH)

WELDMENT TOLERANCES-UNLESS OTHERWISE SPECIFIED

.06

.12

.19

.25

UP TO 1"1" AND GREATERUP TO 1"1" AND GREATERUP TO 1"1" AND GREATERALL

A. UP TO 36"

B. 36" TO 10'

C. 10' TO 30'

D. OVER 30'

TEBY

DES

CRI

PTIO

REV

DET

ENGCONTACTNO.

MODEL UNIT

DATE

FIN WGT

DESCRIPTION

REF DWGS

1 2

A. LESS THAN .12

B. .12 TO .50

C. .50 TO 1.00

D. OVER 1.00

0 TO 36OVER 360 TO 36OVER 360 TO 36OVER 360 TO 36OVER 36

.03

.06

.12

.09

.19

.252. BENT ANGLES 1 (.017 IN/IN) FOR EACH .37 OF MATERIAL THICKNESS (MAX 3 )

PWR MODULE,HYD CROWD,MECH ASSY

GRUBER G.MAREK C.

1579888

7495

11-13-2012

15780.0S038952

08-08-2013

THIS DOCUMENT IS PROTECTED UNDER APPLICABLE COPYRIGHT LAWS TO THE EXTENT AVAILABLE.ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BESUBJECT TO LIABILITY. 2012 Bucyrus International, Inc. ALL RIGHTS RESERVED.

COPYRIGHTED-CUSTOMER INFORMATION DRAWING COPYRIGHTED-CUSTOMER INFORMATION DRAWING COPYRIGHTED-CUSTOMER INFORMATION DRAWING COPYRIGHTED-CUSTOMER INFORMATION DRAWING

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-08-

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8115

ITEM 6 WAS 4280938. CHANGED SUPERBOLT

INSTALLATION INSTRUCTIONS ON SHEET 4.

REVISION DATA

BucyrusInternational, Inc.

SOLIDWORKSDRAWING

(LBS)(MM-DD-YYYY)

ASSY PART NO. ITEM NO. PART NO. DESCRIPTION1579889 20 *V038979 BLWR,HYD CROWD,VARIABLE1579890 20 47004197 BLWR,5/3HP,460V-60HZ,380V-50HZ1579891 20 47004227 BLWR,3HP,415V/50HZ,50C,HC1579892 20 47004228 BLWR,3HP,380V/50HZ,5200M,HC1579893 20 47004229 BLWR,5HP,460V/60HZ,4600M,HC1579894 20 47004198 BLWR,HYD CWD,5HP,575V,60HZ

VARIABLE SUBSTITUTION FOR ITEM 20

MISALIGNMENT

0.001

0.002

0.003

0.004

0.005

0.006

0 0.0005 0.001 0.0015 0.002 0.0025

ANGULAR T.I.R (INCHES)

PARALL

EL T

.I.R (I

NCHES

)

MISALIGNMENT

BOLT SIZE FT/LbsM6-1 7

.25 GRADE 5 7

.38 GRADE 5 23

.38 GRADE 8 35

.50 GRADE 5 55

.75 GRADE 5 200M20 CL10.9 2801.00 GRADE 5 4801.25 GRADE 5 925

TORQUE CHART

29 34

24 31 35

153

STENCIL SHAFT DIRECTION ARROW ON PDTIN APPROXIMATE POSITION, AS SHOWN. USE ACONTRASTING COLOR TO MAKE MARK VISIBLE.

5 47 48

25 37

A3A3

J20

210

22 31

19 46

18 46

B3 B3

G3K3

26 36

22DUCT COVER REMOVEDTO SHOW INNER RETENTION SCREWS FOR DUCT (2 PL).

18 45

26 36

2231

243135

64SEE NOTE 6(SHEET 1)

DETAIL H

21 58

DETAIL J

27 38SEE NOTE 2(SHEET 1)

2537

DETAIL L

542150

SEE NOTES 14 &16(SHEET 1)

SECTION P-P

55 5858

56 58

REISSUE DATE

NO.

DESCRIPTION

BucyrusInternational, Inc.

1 2

PWR MODULE,HYD CROWD,MECH ASSY

1579888

SOLIDWORKSDRAWING

08-08-2013

DWG SIZE DSHEET

OF 5

REV 2

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SECTION A3-A3

DETAIL E22

314

M6-1 X 16 MM SOC. HEAD CAP SCREWPROVIDED WITH COUPLING

URETHANE FLEX ELEMENT

STEEL HUB

(4) M6-1 X 12 MM H.H.C.S.PROVIDED WITH COUPLING

(4) M6-1 X 12 MM H.H.C.S.PROVIDED WITH COUPLING.(DO NOT USE THREAD LOCKING COMPOUND)

(DO NOT USE THREAD LOCKING COMPOUND)

1112

QTY (6)

3.63REF

1.75 HUB TO HUBGAP

.25 HUB TOSHAFT GAP

DETAIL F

RETAINING NUT PROVIDED WITH MOTOR.SECURE NUT WITH BLUE RETAINING COMPOUND

HUB/COUPLING TO BE POSITIONEDSUCH THAT COUPLING IS FLUSH WITHPDT SHAFT FACE, AS SHOWN.

INSTALL TAPERED BORE HUB TOMOTOR SHAFT PER SD8204.(SEE PAGE 2 OF SD8204 FOR COUPLINGS)

.001-.0035" INTERFERENCE FIT PDT SHAFT TO STRAIGHT BORE HUB. (SEE GENERAL ASSEMBLY NOTE 1) BEFORE ASSEMBLY, HEAT HUB TO 275 F. (DO NOT EXCEED 400 F).PRESS HUB ON TO PDT SHAFT (AS SHOWN). ALLOW TO COOL BEFORE FINAL ASSEMBLY.(REFER TO INSTRUCTIONS SUPPLIED WITH COUPLING TO COMPLETE ASSEMBLY)

TORQUE TO250 FT-LBS

.38(4 PL)

1.00(4 PL)

2.50REF

(4 PL)

8.00REF

(4 PL)

SECTION B3-B3

44 43

QTY (8)

SEE NOTE 6(SHEET 1)

SEE NOTE 11(SHEET 1)

SEE NOTE 4(SHEET 1)

.25

WELD ITEM 42(3 SIDES)WITH WEDGEITEM 43 INPLACE AT ASSY(8 PL)

.25

.25(8 PL)

SECTION D3-D3

283933

SEE NOTE 6(SHEET 1)

1.88(8 PL)

DETAIL C3

6433

DETAIL G3

2738

2537

22 31

109

2934

SEE NOTE 2(SHEET 1)

22 35

SECTION K3-K3

STENCIL SHAFT DIRECTION ARROW ON MOTORIN APPROXIMATE POSITION, AS SHOWN. USE ACONTRASTING COLOR TO MAKE MARK VISIBLE.

15 21 58

PLUG ELECTRICALFITTING

TACHCOVERGUARD13

(SEE NOTE 12 ON SHEET 1)

VIEW R-R(SEE NOTE 12 ON SHEET 1)

REISSUE DATE

NO.

DESCRIPTION

BucyrusInternational, Inc.

1 2

PWR MODULE,HYD CROWD,MECH ASSY

1579888

SOLIDWORKSDRAWING

08-08-2013

DWG SIZE DSHEET

OF 5

REV 2

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STEPS 4 & 5(INITIAL TORQUE SEQUENCE)STEPS 6 & 7

STEP 9STEP 8

INSTALLATION NOTES: MAKE SURE SPECIAL STEEL WASHERS SUPPLIED WITH TORQUENUTS ARE USED UNDER EACH TORQUENUT - DO NOT USE STANDARD COMMERCIAL WASHERS.

AN IMPACT WRENCH MAY BE USED FOR THE INITIAL RUN UP, BUT A TORQUE WRENCH MUST BE USED FOR THE FINAL VALUES.

INSTALLATION PROCEDURE: STEP 1: JACKBOLT THREADS & END FACES ARE PRE-LUBRICATED BY VENDOR WITH GRAPHITE LUBE. ENSURE THAT GRAPHITE LUBE FILM IS PRESENT ON THESE SURFACES AND APPLY ADDITIONAL GRAPHITE LUBE (MP390331) AS NEEDED.

STEP 2: CHECK BASE OF TORQUENUT TO ENSURE THAT ALL JACKBOLTS ARE FLUSH WITH BOTTOM.

STEP 3: LUBRICATE THE THREADS OF THE MAIN STUD WITH ANTI-SEIZE LUBRICANT.

STEP 4: SLIDE THE HARDENED WASHER ONTO THE STUD, THEN SPIN THE TENSIONER ONTO THE MAIN THREAD UNTIL IT SEATS AGAINST THE WASHER.

STEP 5: BACK OFF THE TENSIONER TO LEAVE A GAP OF .06-.12 FOR LUBRICATION DURING REMOVAL.

STEP 6: USING A SUITABLE TORQUING DEVICE, TIGHTEN (4) JACKBOLTS AT 90 APART (SEE FIGURE TO RIGHT FOR SEQUENCE) ON ALL STUDS WITH A PARTIAL TORQUE (30-70%, 8-19 LB-FT).

STEP 7: AT 120% TARGET TORQUE (33 LB-FT), TIGHTEN THE SAME (4) JACKBOLTS ON ALL STUDS.

STEP 8: AT 120% TARGET TORQUE (33 LB-FT), TIGHTEN ALL JACKBOLTS IN A CIRCULAR PATTERN. DO THIS FOR ALL STUDS (1 ROUND ONLY).

STEP 9: SWITCH TO A TORQUE WRENCH AND TIGHTEN ALL JACKBOLTS TO 100% TARGET TORQUE (27 LB-FT) IN A CIRCULAR PATTERN UNTIL ALL JACKBOLTS ARE STABILIZED (LESS THAN 10 ROTATION). THIS USUALLY REQUIRES 2-4 ADDITIONAL PASSES.

REMOVAL PROCEDURE: PREPARATION: SPRAY JACKBOLTS WITH PENETRATING OIL OR HYDRAULIC OIL PRIOR TO START.

STEP 1: LOOSEN EACH JACKBOLT 1/8 TURN FOLLOWING A CIRCULAR PATTERN AROUND THE TENSIONER (1 ROUND ONLY). AS YOU MOVE AROUND AND GET BACK TO THE FIRST JACKBOLT, IT WILL BE TIGHT AGAIN. DO THIS FOR ALL STUDS ON THE JOINT PRIOR TO THE NEXT STEP.

STEP 2: REPEAT A 2ND ROUND AS ABOVE FOR ALL STUDS, NOW LOOSENING EACH JACKBOLT 1/4 TURN IN A CIRCULAR PATTERN.

STEP 3: CONTINUE LOOSENING 1/4 TURN FOR 3RD AND SUCCESSIVE ROUNDS UNTIL ALL JACKBOLTS ARE LOOSE. NOTE: USUALLY AFTER THE 3RD OR 4TH ROUND, AN IMPACT TOOL CAN BE USED TO COMPLETELY EXTRACT THE JACKBOLTS, ONE BY ONE. FOR LONG BOLTS OR TIE RODS, ADDITIONAL ROUNDS MAY BE REQUIRED BEFORE REMOVING THE JACKBOLTS WITH AN IMPACT TOOL.

STEP 4: REMOVE, CLEAN AND RELUBRICATE THE JACKBOLT THREADS AND TIPS PRIOR TO NEXT USE WITH CORRECT SUPERBOLT LUBRICANT (MP390331).

CAUTION! JACKBOLTS MUST BE UNLOADED GRADUALLY. IF SOME JACKBOLTS ARE FULLY UNLOADED PREMATURELY, THE REMAINING JACKBOLTS WILL CARRY THE ENTIRE LOAD AND MAY BE HARD TO TURN. WITH EXTREME ABUSE, A JACKBOLT TIP CAN DEFORM, MAKING REMOVAL DIFFICULT.

STUCK JACKBOLT REMOVAL: IF A JACKBOLT WILL NOT TURN, REMOVE, RE-LUBE, AND RETIGHTEN A NEIGHBORING JACKBOLT. THEN TRY TO TURN THE STUCK JACKBOLT.

REISSUE DATE

NO.

DESCRIPTION

BucyrusInternational, Inc.

1 2

PWR MODULE,HYD CROWD,MECH ASSY

1579888

SOLIDWORKSDRAWING

08-08-2013

DWG SIZE DSHEET

OF 5

REV 2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

PYRI

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MER

INFO

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WIN

COPYRIGHTED-CUSTOMER INFORMATION DRAWINGCOPYRIGHTED-CUSTOMER INFORMATION DRAWINGCOPYRIGHTED-CUSTOMER INFORMATION DRAWING

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COPYRIGHTED-CUSTOMER INFORMATION DRAWINGCOPYRIGHTED-CUSTOMER INFORMATION DRAWINGCOPYRIGHTED-CUSTOMER INFORMATION DRAWINGCOPYRIGHTED-CUSTOMER INFORMATION DRAWING

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.25

METAL PLUG IN BOTTOMCASE DRAIN PORT

(ALL PUMPS)

PLASTIC PLUG IN TOPCASE DRAIN PORT

(ALL PUMPS)

SECTION W-W

MARK ON PUMP HOUSING(TIMING PROCEDURE - STEP 1)

TDCPUMP #1

15 TEETHPUMP #2

11 TEETHPUMP #4

7 TEETHPUMP #3

UPPERCASE DRAIN

PUMP - MOUNTING SURFACE(TIMING MARKS)

SECTION Y-Y

PUMP #2

PUMP #1PUMP #4

PUMP #3

PDT - PUMP MOUNTING SURFACE(TDC ORIENTATION)

PUNCH MARK OUTPUT GEAR GROOVE TO MATCH MATING "TDC" PUMP SPLINE TOOTH

DETAIL "TDC"

TIMING MARK (NOTCH)(VIEWED THRU UPPER CASE DRAIN PORT)

MARK THIS TOOTH(ALIGNED WITH TIMING MARK)

PUMP PILOT DIAMETERPUMP FLANGE

PUMP TIMING/INSTALLATION PROCEDUREPRIOR TO INSTALLING PUMPS (ITEM 5) INTO PDT (ITEM 3), THE PUMPS MUST BE TIMED.1.

REMOVE UPPER CASE DRAIN PLUG FROM EACH PUMP; (STEEL PLUG NEEDS TO BE INSTALLED INA.BOTTOM CASE DRAIN PORT AND PLASTIC PLUG WILL BE INSTALLED IN THE TOP CASE DRAIN PORT.

ROTATE EACH PUMP SHAFT (USE LARGE CHANNEL LOCK PLIERS WITH A RAG TO PROTECT SHAFT TEETH) B.UNTIL TIMING MARK IS CENTERED IN THE UPPER CASE DRAIN PORT (SEE DETAIL "TDC"), THIS IS TOP DEAD CENTER. USING A (PAINT STICK OR INK MARKER), MARK THE TOOTH ON EACH PUMP SHAFT THAT LINES UP WITH THE TIMING MARK (SEE DETAIL "TDC"). RE-INSTALL PLASTIC PLUG IN UPPER CASE DRAIN PORT.

PUMP #1: WILL BE INSTALLED IN THE "TDC" POSITION.C.PUMP #2: LOOKING TOWARDS THE PUMP SHAFT, COUNT 15 TEETH (IN A CCW DIRECTION) FROM "TDC" AND MARK THE PUMP HOUSING (SEE SECTION W-W).PUMP #3: LOOKING TOWARDS THE PUMP SHAFT, COUNT 7 TEETH (IN A CCW DIRECTION) FROM "TDC" AND MARK THE PUMP HOUSING (SEE SECTION W-W).PUMP #4: LOOKING TOWARDS THE PUMP SHAFT, COUNT 11 TEETH (IN A CCW DIRECTION) FROM "TDC" AND MARK THE PUMP HOUSING (SEE SECTION W-W)

ROTATE (CCW) EACH PUMP SHAFT OF PUMPS 2, 3 & 4 TO ALIGN MARKED TOOTH (FROM 1B) TO D.APPROPRIATE PUMP HOUSING MARK (FROM 1C). VERIFY THE TOOTH COUNT OF EACH PUMP. PUMPS ARE NOW TIMED AND READY FOR INSTALLATION INTO PDT.

PUNCH MARK SPLINE GROOVE OF OUTPUT GEAR TO COINCIDE WITH MATING "TDC" MARKED PUMP SPLINE E.TOOTH.

APPLY O-RING LUBE (ITEM 47) TO EACH O-RING (ITEM 48). INSTALL O-RING OVER EACH PUMP PILOT DIAMETER.2.

INSTALL PUMP #2, SECURE TO PDT WITH H.H.C.S. (ITEM 30) AND WASHER (ITEM 40). WHEN INSTALLING THE A.PUMP, ROTATE THE SHAFT OF THE PDT NOT THE PUMP SHAFT TO MAKE SURE NOT TO CHANGE THE TIMING SEQUENCE OF THE PUMPS. ROTATE PDT SHAFT USING A LARGE STRAP/CHAIN WRENCH.

INSTALL PUMPS #1, 3 & 4 INTO PDT AND SECURE WITH H.H.C.S. (ITEM 30) AND WASHER (ITEM 40). CARE B.MUST BE TAKEN TO LIMIT PUMP SHAFT ROTATION WHEN ALIGNING AND INSERTING PUMP SHAFT INTO SPLINED RECEIVER OF EACH PUMP PAD OF PDT. IF EXCESSIVE SHAFT ROTATION OCCURS, PULL PUMP OUT OF PDT AND VERIFY CORRECT POSITION OF TIMING MARK OF THAT PUMP. RE-INSTALL PUMP.

TORQUE EACH PUMP RETAINING SCREW TO THE VALUE GIVEN IN THE TORQUE CHART ON SHEET 1.3.

REISSUE DATE

NO.

DESCRIPTION

BucyrusInternational, Inc.

1 2

PWR MODULE,HYD CROWD,MECH ASSY

1579888

SOLIDWORKSDRAWING

08-08-2013

DWG SIZE DSHEET

OF 5

REV 2

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BOMBA DE PALETAS

Jose Manuel Arroyo Rosa Página 1

Bombas de Paletas

Bombas de paletas:

Se compone de un rotor que gira dentro de una carcasa y de las paletas que se

encuentran en unas ranuras que tiene el rotor, con posibilidad de desplazarse

radialmente.

Se dividen en dos grupos, bombas de una carrera y bombas de dos carreras.

Oscilan entre 5 y 100 cm³. Pueden ofrecer presiones de servicio de hasta 150

bar.

Son muy sensibles al nivel de limpieza del aceite. Un aceite con partículas en

suspensión podrá originar una avería en la bomba.

Bombas de paletas de una carrera:

El rotor esta descentrado de la carcasa.

Al girar succiona el fluido desde la entrada de la bomba, generando al girar unos

espacios o cámaras entre las paredes del rotor, del estator y las paletas.

Cuando este espacio comienza a comprimirse la bomba deja salir el fluido por el

orificio de salida

Las paletas salen radialmente, apoyándose en la carcasa.

http://blog.enrimusa.com/wp-content/uploads/2013/04/bomba-paletas-una-carrera.jpg

BOMBA DE PALETAS

Jose Manuel Arroyo Rosa Página 2

La forma de salir es debida a la entrada de aceite dentro del rotor, asegurando en todo

momento que la paleta apoya en la carcasa.

Bomba de paletas de dos carreras:

Estas bombas tienen una carcasa o estator ovalado o doble excéntrico.

Con dos entradas y dos salidas, se sitúa un estator de palas en el centro, generando dos

zonas de cámara “amplia”.

El resto del funcionamiento es similar al de la bomba de paletas de una carrera, con la

diferencia de que realiza dos procesos por cada ciclo.

http://blog.enrimusa.com/wp-content/uploads/2013/04/Bomba-paletas-dos-carreras.jpg

http://blog.enrimusa.com/wp-content/uploads/2013/04/Bomba-paletas-dos-carreras-2.jpg

BOMBA DE PALETAS

Jose Manuel Arroyo Rosa Página 3

El volumen de las cámaras en una bomba de paletas lo determinan las dimensiones del

anillo excéntrico y la medida transversal.

Bomba paletas Vickers de doble paleta y dos carreras

Bomba de paletas de caudal variable:

El funcionamiento de esta bomba consiste en desplazar el estator de tal forma que

variamos la excentricidad entre el rotor y el estator.

De esta manera variamos el caudal de la bomba, variando el volumen de las cámaras.

Estas bombas son de una sola carrera y disponen de tres dispositivos de

posicionamiento.

Tornillo de posicionamiento para cilindrada (9).

Tornillo de ajuste de altura (2).

Tornillo de ajuste de máxima presión (7).

Si la fuerza Ff que es la que produce el muelle (6), es mayor que la fuerza Fh, el estator

de la bomba permanece en su posición excéntrica según la figura.

A medida que aumenta la presión en el sistema, aumenta también la fuerza Fh y la

vence el resorte desplazando el estator a una posición concéntrica.

http://blog.enrimusa.com/wp-content/uploads/2013/04/DSCN0185r.jpg

BOMBA DE PALETAS

Jose Manuel Arroyo Rosa Página 4

El volumen de las cámaras de desplazamiento se reduce hasta que el caudal a la salida

de la bomba sea nulo.

La bomba mantiene la presión en el circuito según tengamos ajustados los tornillos de

regulación.

Estas bombas pueden ser de mando directo, como la que hemos explicado, o pilotadas.

Estas últimas no varían mucho de las de mando directo, solo en que el dispositivo de

pilotaje que emplean para variar el estator se mueve mediante pistones de

posicionamiento cargados previamente con presión.

Estos pistones tienen diferente diámetro, siendo el más grande el que se dedica que la

bomba se encuentre en una posición excéntrica.

Datos para el cálculo del caudal de una bomba de paletas:

Q = ∏·D·(D-d)·b·n/1000000

Q : Caudal teórico en l/min.

D : Diámetro de la cámara interior de la carcasa en mm.

d : Diámetro del rotor en mm.

b : Ancho de la paleta o la cámara en mm.

n : velocidad de giro del engranaje en rpm.

El rendimiento volumétrico de este tipo de bombas es de 0,8 aproximadamente, por lo

que el Qreal será:

Qreal = Qteórico · 0,8

temariosformativosprofesionales.wordpress.com

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ContaminationSensor CS1000 Analog Output (ANAOUT)

ISO Code acc. to 4406:1999

The following ISO values can be output via the analog output:

ISO 4 / ISO 6 / ISO 14 Only one value is output.

ISO-Code, 3-digit (>4 µm(c) / >6 µm(c) / >14 µm(c)) All values are sequentially time-coded before output.

ISO+T All values are sequentially time-coded before output.

HDA.ISO All values are sequentially time-coded before output. Primarily this signal was planned for the HDA 5500 (HYDAC digital display Unit), however, this can use in other applications.

The current 4.8 - -19.2 mA or voltage 2.4 - 9.6 V of the output signal is dependent on the ISO Contamination Class 0.0 - 24.28 (Resolution 1 Class) or an error as shown in the table below.

Current I ISO contamination class / error Voltage U

I < 4.0 mA Cable break U< 2.0 V

4.0 mA < I < 4.1 mA Device error, device not ready 2.0 V < U < 2.05 V

4.1 mA < I < 4.3 mA Not defined 2.05 V < U < 2.15 V

4.3 mA < I < 4.5 mA Flow error (flow insufficient) 2.15 V < U < 2.25 V

4.5 mA < I < 4.8 mA Not defined 2.25 V < U < 2.4 V

I = 4.80 mA ISO 0 U = 2.40 V

I = 5.37 mA ISO 1 U = 2.69 V

I = 5.94 mA ISO 2 U = 2.97 V

I = 6.51 mA ISO 3 U = 3.26 V

I = 7.08 mA ISO 4 U = 3.54 V

I = 7.65 mA ISO 5 U = 3.83 V

I = 8.22 mA ISO 6 U = 4.11 V

I = 8.79 mA ISO 7 U = 4.40 V

I = 9.36 mA ISO 8 U = 4.68 V

I = 9.93 mA ISO 9 U = 4.97 V

I = 10.50 mA ISO 10 U = 5.25 V

I = 11.07 mA ISO 11 U = 5.54 V

I = 11.64 mA ISO 12 U = 5.82 V

I = 12.21 mA ISO 13 U = 6.11 V

I = 12.77 mA ISO 14 U = 6.39 V

I = 13.34 mA ISO 15 U = 6.67 V

I = 13.91 mA ISO 16 U = 6.96 V

I = 14.48 mA ISO 17 U = 7.24 V

I = 15.05 mA ISO 18 U = 7.53 V

I = 15.62 mA ISO 19 U = 7.81 V

I = 16.19 mA ISO 20 U = 8.10 V

I = 16.76 mA ISO 21 U = 8.38 V

I = 17.33 mA ISO 22 U = 8.67 V

HYDAC Filtertechnik GmbH en Page 56 / 100

BeWa CS1000 3247149n en.doc 2008-08-20

ISO Code acc. to 4406:1999

ISO 4 / ISO 6 / ISO 14Only one value is output.

ContaminationSensor CS1000 Analog Output (ANAOUT)

Current I ISO contamination class / error Voltage U

I = 17.90 mA ISO 23 U = 8.95 V

I = 18.47 mA ISO 24 U = 9.24 V

I = 19.20 mA ISO 24.28 U = 9.60 V

19.2 mA < I < 19.8 mA Not defined 9.60 V < U < 9.90 V

19.8 mA < I < 20 mA No measured value 9.90 V < U < 10 V

The current (I) or voltage (U) can be calculated for a given ISO contamination class as follows:

I = 4.8 mA + ISO code x (19.2 mA - 4.8 mA) / 24.28

U = 2.4 V + ISO Code x (9.6 V - 2.4 V) / 24.28

The ISO contamination class can be calculated for a given current I or voltage U as follows

ISO code = (I - 4.8 mA) x (24.28 / 14.4 mA)

ISO code = (U - 2.4 V) x (24.28 / 7.2 V)

HYDAC Filtertechnik GmbH en Page 57 / 100

BeWa CS1000 3247149n en.doc 2008-08-20

ContaminationSensor CS1000 Cleanliness classes - brief overview

Cleanliness classes - brief overview

Cleanliness class - ISO 4406:1999

For ISO 4406:1999 particle counts are determined cumulatively, i.e. > 4 µm(c), >6 µm(c) and >14 µm(c) (manually by filtering the fluid through an analysis membrane or automatically using particle counters) and allocated to key figures.

The goal of allocating particle counts to references is to facilitate the assessment of fluid cleanliness.

In 1999 the "old" ISO 4406:1987 was revised and the size ranges of the particle sizes to be analyzed were redefined. The counting method and calibration were also changed.

Important for the user in his everyday work: Even though the size ranges of the particles to be analyzed have changed, the cleanliness code will change only in individual cases. When the "new" ISO 4406:1999 was created, not all the existing cleanliness provisions for systems were changed.

Table - ISO 4406

Allocation of particle counts to cleanliness classes:

Number of particles / 100 ml Number of particles / 100 ml

Class More than Up to (and including)

0 0 1 15 16,000 32,000

1 1 2 16 32,000 64,000

2 2 4 17 64,000 130,000

3 4 8 18 130,000 250,000

4 8 16 19 250,000 500,000

5 16 32 20 500,000 1,000,000

6 32 64 21 1,000,000 2,000,000

7 64 130 22 2,000,000 4,000,000

8 130 250 23 4,000,000 8,000,000

9 250 500 24 8,000,000 16,000,000

10 500 1,000 25 16,000,000 32,000,000

11 1,000 2,000 26 32,000,000 64,000,000

12 2,000 4,000 27 64,000,000 130,000,000

13 4,000 8,000 28 130,000,000

250,000,000

14 8,000 16,000

HYDAC Filtertechnik GmbH en Page 88 / 100

BeWa CS1000 3247149n en.doc 2008-08-20

SP 7

.958

.0/0

7.12

ContaminationSensorSerie CS 1000

DescripciónEl ContaminationSensor serie CS 1000 es un sensor de fluidos en línea que detecta de forma continua la contaminación de sustancias sólidas en fluidos.La indicación de la clase de pureza puede efectuarse conforme a las normas ISO/SAE o ISO/NAS.El usuario dispone de un sensor estacionario pequeño y resistente, fabricado con la tecnología y los materiales más modernos, según la técnica probada.Gracias a su estupenda relación prestación-precio es especialmente interesante para aplicaciones OEM de control de estado (Condition Monitoring).

Campos de aplicación zSistemas hidráulicos y de lubricación industriales zHidráulica móvil

Ventajas zOpcionalmente puede conmutar entre ISO 4406:1999 / SAE AS 4059 y ISO 4406:1987 / NAS 1638 zDetección temprana de estados críticos de la máquina zControl continuo de los estados del aceite zPlan de mantenimiento en función del estado de la maquinaria

Datos técnicosDatos generalesAutodiagnóstico Continuo, con indicación de fallos a través del

LED de estado y el visualizadorVisualizador (solo CS 1x2x) LED, 6 dígitos, cada uno con 17 segmentosMagnitudes de medición ISO 99 (ISO 4406:1999)

SAE (SAE AS 4059 (D)) o ISO 87 (ISO4406:1987) NAS (NAS 1638)

Magnitudes de servicio Flow (ml/min) Out (mA) o (VCC) Drive (%) Temp (°C) y (°F)

Posición de montaje Cualquiera (se recomienda montaje vertical en el sentido del flujo)

Rango de temperatura ambiente -30 °C ... +80 °C / -22 °F ... 176 °FRango de temperatura de almacenamiento

-40 °C ... +80 °C / -40 °F ... 176 °F

Humedad relativa Máx. 95 %, no condensableJunta FPM para CS1xx0 / EPDM para CS1xx1 Clase de protección III (tensión baja de protección)Tipo de protección IP67Peso 1,3 kgDatos hidráulicosMargen de medición Indicación de la clase ISO 9/8/7 (MIN) hasta la

clase ISO 25/24/23 (MAX) Calibrado en el margen ISO 13/11/10...23/21/18

Precisión +/- ½ clase ISO en margen calibradoPresión de servicio 300 bar máx. / 4350 psi máx.Conexión hidráulica Empalme de tubos rígidos y flexibles (A,B): rosca

G1/4, ISO 228 o conexión con brida (C,D): DN 4Caudal de medición admisible 30 ... 300 ml/minMargen de viscosidad admisible 1 ... 1000 mm²/sRango de temperatura del medio 0 ... +85 °C, +32 ... +185 °FDatos eléctricosClavija de conexión M12x1, 8 polos, según DIN VDE 0627 o

IEC61984Tensión de alimentación 9 ... 36 VCC, ondulación residual < 10%Consumo de potencia 3 Watt máx.Salida analógica (tecnología de 4 hilos)

Salida 4 ... 20 mA (activa): carga máx. 330Ω o Salida 0 ... 10 V (activa): resistencia mín. de carga 820 Ω

Salida de conmutación MOSFET pasivo de potencia de canal n: máx. corriente de conmutación 1,5 A, abierta en ausencia de corriente

Interfaz RS485 Bifilar, semidúplex para transferir el protocolo HSI en conexión con un PC

HSI (HYDAC Sensor Interface) Monofilar, semidúplex

gllallacachi

Resaltado

SP 7

.958

.0/0

7.12

Código del modeloCS 1 2 2 0 - A - 0 - 0 - 0 - 0 / - 000

Tipo CS = ContaminationSensorSerie 1 = Serie 1000, 4 canales de tamaño de partículasCodificación de la contaminación 2 = ISO 4406 : 1999 ; SAE AS 4059 (D) / >4 µm(c) >6 µm(c) >14 µm(c)>21 µm(c) 3 = ISO 4406 : 1987 ; NAS 1638 / > 2 µm > 5 µm > 15 µm > 25 µm conmutable ISO 4406 : 1999 ; SAE AS 4059 (D) / >4 µm(c) >6 µm(c) >14 µm(c) >21 µm(c) conmutableOpciones 1 = Sin visualizador 2 = Con visualizador (el visualizador puede girar de forma continua 270°)Medios 0 = A base de aceite mineral 1 = Para éster fosfatadoInterfases analógicas A = 4 ... 20 mA B = 0 ... 10 VSalida de conmutación 0 = Salida de conmutación de valor límiteInterfaz digital 0 = RS485Tipo de conexión eléctrica 0 = conector M12x1 de 8 polos, clavija, conforme a VDE0627 o IEC61984Conexión hidráulica (ver página 3) 0 = Conexión para tubo rígido o flexible 1 = Conexión con bridaNúmero de modificación 000= Estándar

Volumen de suministro – Contamination Sensor – Software FluMoS 1000 e instrucciones de servicio y mantenimiento en CD

– Certificado de calibración – Instrucciones breves – 2 juntas tóricas en la versión con conexión por brida

Opciones – Caja de acoplamiento con 2 m de cable, apantallado, 8 polos, M12x1, Nº art.: 3281220

– Caja de acoplamiento con 5 m de cable, apantallado, 8 polos, M12x1, Nº art.: 3281239

– Cable prolongador 5 m, caja de acoplamiento 8 polos, M12x1 / enchufe de acoplamiento 8 polos, M12x1, Nº art. 3281240

– Caja de acoplamiento con borne roscado, 8 polos, M12x1, Nº art.: 3281243

SP 7

.958

.0/0

7.12

Dimensiones

CS1x1x sin visualizador

CS1x2x con visualizador

Vista por la cara inferior

Conexión de tubo rígido o flexible

Conexión con brida

Tipos de conexiones hidráulicas

Conexión de tubo rígido o flexible

Conexión con brida

Giro del visualizador

Presión - Margen de viscosidad

Junta tórica

Tapón roscado

∆p : presión ν : viscosidad

Junta tórica

SP 7

.958

.0/0

7.12

Tipos de montaje

1 : con 2 M8 (ISO 4762) o 2, 3 : con 4 M6

para conexión de tubo rígido o flexible para conexión con brida

Sujeción de pared a consola Fijación sobre placa abridada, placa de conexión o bloque de mando

ObservacionesLas indicaciones del presente folleto hacen referencia a las condiciones de servicio descritas y a las especificaciones de aplicación.En caso de presentarse diferentes especificaciones de aplicación y/o condiciones de servicio, contacte con el departamento especializado que corresponda. Sujeto a modificaciones técnicas.

HYDAC FIlTer SYSTeMS GMbHIndustriegebiet D-66280 Sulzbach / Saar Tel.:+49 (0) 6897/509-01 Fax:+49 (0) 6897/509-846 Internet: www.hydac.com E-mail: [email protected]

1 ISO 9001: 2000 Registered Firm

SERVICE ADVISORY Caterpillar Global Mining LLC 6744 S. Howell Ave Oak Creek, WI 53154, USA 414.768.4000 / Fax: 414.768.4570

Date: November 19, 2012

Advisory No.: 12-006 Revision No.: 1

MANDATORY Compliance with this advisory is mandatory. Failure to do so may result in machine failure.

SUBJECT: HYDRAULIC CROWD ACCUMULATOR INSPECTION & PRESSURE TEST

NOTE: IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS THOSE SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

MODELS AFFECTED: 7495, 7495HF (HydraCrowd equipped machines only) MACHINES AFFECTED S/N’s: 141209, 141325, 141327, 141333, 141418, 141424, 141429, 141433, 141439, 141441, 141452, 141455, 141463, 141469, 141470, 141473, 141474, 141477, 141481, 141482 Problem: Correct accumulator charge is critical to maintain proper operation of the hydraulic crowd system. Acceptable pressure is 900 psi (+15 psi / -0 psi) at 20 °C. Action: It is recommended that the proper gas pre-charge is checked at the next available maintenance opportunity. After that, it should be checked according to the following intervals: If accumulator pressure monitoring system is installed The proper gas pre-charge pressure should be verified after each new installation or repair. The proper gas pre-charge pressure should be checked using the operators display every 500 hours or monthly which ever occurs first. The system should be verified to be functioning correctly every 6 months by comparing the actual accumulator charge pressure on the operator's display to the pressure reading on the charging/gauging unit. If accumulator pressure monitoring system is not installed The proper gas pre-charge pressure should be set after each new installation or repair. It should be rechecked at least once during the first week of operation. It should be rechecked again every 500 hours or monthly, which ever occurs first. See Accumulator Inspection section and Accumulator Pressure Test & Charge section in Service Manual

SIS Media Number: BI646664

2 ISO 9001: 2000 Registered Firm

The acceptable pre-charge pressure is dependant on the ambient air temperature. At 20 °C, the correct pressure is 900 psi (+15 psi / -0 psi). When charging an accumulator, ensure it is filled to the correct pressure based on the ambient air temperature. See table below for correct charge pressure.

Accumulator Pre-charge Pressure/Temperature Relationship for a Typical 900 psi (+15psi / -0psi)

HydraCrowd Accumulator Temperature Pressure

C F bar psi

-40 -40 49.35 716

-35 -31 50.41 731

-30 -22 51.47 746

-25 -13 52.53 762

-20 -4 53.59 777

-15 5 54.64 793

-10 14 55.70 808

-5 23 56.76 823

0 32 57.82 839

5 41 58.88 854

10 50 59.94 869

15 59 60.99 885

20 68 62.05 900

25 77 63.11 915

30 86 64.17 931

35 95 65.23 946

40 104 66.29 961

45 113 67.34 977

50 122 68.40 992

SIS Media Number: BI646664

3 ISO 9001: 2000 Registered Firm

Charging/Gauging Unit (P/N: S134578) was provided with each new machine. The charging unit will allow the accumulator to be connected directly to a nitrogen bottle.

For regulator use, the parts listed below will also be required. The traditional Caterpillar part numbers for these items are listed (legacy part numbers for these items are not available). Additional parts required for regulator use: Caterpillar P/N: 338-0500 Regulator Assembly Caterpillar P/N: 334-1071 Adapter

Charging and Gauging Unit

Charging Hose

Adapters from Nitrogen Bottle to Charging Hose

Items included in Kit S134578

If the charging and gauging unit comes as shown on the left, remove the ferrule nut and ferrule so the charging hose can be attached.

Remove the ferrule nut and ferrule

SIS Media Number: BI646664

4 ISO 9001: 2000 Registered Firm

CRGV Accumulator

RECV Accumulator

SIS Media Number: BI646664

5 ISO 9001: 2000 Registered Firm

Additional Information In order to check the pressure, only the gauging unit is required. There is a check valve at the connection for the charging hose, so the accumulator will not lose its charge if a nitrogen bottle isn’t connected. Ensure the bleed valve is closed when checking the charge pressure.

Gauging unit connected to accumulator. Accumulator shown has an added block for accumulator charge pressure transducer. The connection type is the same with or without the block.

Check Valve Location

Bleed Valve

Check Valve

T-Handle

SIS Media Number: BI646664

6 ISO 9001: 2000 Registered Firm

There should not be any interference issues connecting the gauging unit to the CRGV accumulator. RECV Accumulator Mounting (Lot 183 and Newer) The accumulator mounting bracket is tilted so the charging/gauging unit will not interfere with the RECV module located above the accumulator when attached.

SIS Media Number: BI646664

7 ISO 9001: 2000 Registered Firm

Previous RECV Accumulator Mounting (Lot 181 and Older) The accumulator mounting bracket is straight, so the gauging unit will interfere with the RECV module when trying to check the pressure. In order to check the pressure, the lower bolt holding the accumulator to the bar will need to be loosened and the upper bolt will need to be removed. Then, the accumulator can be tilted away from the RECV module so the gauging unit can be installed. Ensure the upper bolt is re-installed and both bolts are tightened after accumulator charge is checked.

Fastener Information

Item Qty Part Number Description

2.6 2 03951850 WASHER,FLAT,.625,HARDENED

2.7 2 03485281 SCR,SOC,.925X2.5,UNC,GR8

2.8 2 02786465 NUT,HEX,LOCK,.625,UNC

SIS Media Number: BI646664

8 ISO 9001: 2000 Registered Firm

If you have any questions on the above, please contact:

Caterpillar Global Mining LLC Product Health 6744 S. Howell Ave Oak Creek, WI 53154, USA 414.768.4000

SIS Media Number: BI646664

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9.5.9 Accumulator Inspection

The condition of the accumulator is primarily determined by periodic checking of the pre-chargepressure. To check the gas precharge pressure in an accumulator, it must first be isolated fromthe system, using the shut off and bleed valve. The most accurate pre-charge readings are takenwhen the hydraulic oil pressure is at 0.

9.5.9.1 Intervals Between Checking Gas Pre-charge Pressure

If accumulator pressure monitoring system is installed:

The proper gas precharge pressure should be verified after each new installation or repair. Theproper gas precharge pressure should be checked, using the operator’s display, every 500 hoursor monthly, whichever comes first. The system should be verified to be functioning correctlyevery 6 months by comparing the actual accumulator charge pressure on the operator's displayto the pressure reading on the charging/gauging unit.

If accumulator pressure monitoring system is not installed:

The proper gas precharge pressure should be set after each new installation or repair. It shouldbe rechecked at least once during the first week of operation. It should be rechecked again every500 hours or monthly, which ever occurs first.

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9.5.10 Accumulator Pressure Test & Charge

STORED ENERGY! Hydraulic accumulators are pressure vessels and only qualified personnel should perform repairs or maintenance. NEVER use oxygen (or compressed air) to precharge the accumulator! Use dry nitrogen only.

NOTE: This procedure can be performed with the dipper handle in either the horizontal position (Option A) or the vertical position (Option B). If performing this procedure with the bucket in the air (Option A), manually engage the optional hoist maintenance locking bar (if equipped) as a secondary safety device. With the dipper handle positioned horizontally, the cylinder and sleeve assembly can be reached from the machinery house. With the dipper handle positioned vertically, a man-lift will be required to reach the cylinder and sleeve assembly. Regardless of which option the machine is positioned, ensure that service personnel have proper PPE and fall protection required to do their job safely.

NOTE: Both hydraulic crowd accumulators (RECV and CRGV) should be set to the same parameters.

TOOLS:Charging/Gauging Unit PN: S134578Bottled Nitrogen

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To pressure test and/or charge the accumulator:

1. Position the machine for service using option A or B.

Option A

• Position the handle so the accumulators can be accessed from the house roof.

• Use the crowd motion to position the hoist ropes as close to vertical as possible in order tominimize the force (pulling out or pushing in) the hoist ropes exert on the cylinder. The rodend pressure can be monitored from the operator cab screen to ensure the hoist rope forceon the cylinder is minimized.

Option B

• Place the dipper on the ground.

2. Shutdown the machine. Lockout and tagout controls in compliance with local regulations.3. Verify that the rod end of the cylinder is void of pressure by bleeding excess oil pressure

from the rod end test port on the cylinder manifold. This can be achieved by attaching amicro bore hose from the hydraulic test kit and emptying the oil into a bucket or otherstorage vessel. This may take several minutes. Once pressure is relieved, remove themicro bore hose from the test port and install a pressure gauge to verify no pressure ispresent.

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4. On the CRGV accumulator, close the shutoff valve located on the safety/shutoff block.5. On the CRGV accumulator, locate the manual bleed valve on the safety/shut-off block.

Relieve the oil pressure by turning the manual bleed valve spindle counter-clockwise. Drainall fluid from the accumulator before connecting the pressure testing equipment.

6. If equipped with accumulator pressure monitoring system check accumulator pressure onoperators display otherwise continue to Step 7 check accumulator charge pressure withcharging/gauging unit. The nominal pressure is 900 psi (+15 psi / -0 psi) at 20°C. Ifaccumulator charge pressure shown on the operators display is low, continue to Step 7 tocharge accumulator.

NOTE: The actual pressure in the accumulator will be dependant on ambient air temperature.

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Figure 9-28

7. Remove the valve protection and the valve seal cap from the top of the accumulator. Cleanany dirt, debris or paint from the charging valve area and ensure that the threads andsealing surface are in good condition.

8. Using an allen wrench, break loose the charging cap screw located at the top of theaccumulator. Do not rotate this screw more than 1/8 turn. Ensure that the charging gasdoes not leak from the accumulator.

9. Attach the adapter and the charging/gauging unit to the accumulator.10. Tighten the adapter to the top of the accumulator to ensure that a gas tight seal is formed.11. With the charging unit connected to the regulator and nitrogen bottle as shown in the Figure

above, slowly turn the T-handle in a counter clockwise direction while pushing down slightly.After the handle engages the screw, turn the screw out until the pressure reading can beseen on the charging unit. If the pressure is acceptable skip to step 16. The nominalpressure is 900 psi (+15 psi / -0 psi) at 20°C, but the actual pressure in the accumulator willbe dependant on the ambient air temperature.

Charging/Gauging Unit PN: S134578

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To determine correct charge pressure with varying ambient air temperatures use the chart below.

12. If the gas pressure is low, charge the accumulator until the correct pressure is reached. Thecharging process should be done very slowly to ensure that the accumulator is notdamaged. With accumulator pressure monitoring system installed, charge to 900 psi (+15psi / -0 psi) as shown on the operators display as the Temperature Corrected Value.Without accumulator pressure monitoring system installed, charge to the pressure shown inthe chart above based on the current outside ambient temperature.

If the accumulator is new or has fallen below 100 psi, the accumulator must be charged at a very slow rate. It should take 2-3 minutes for every 20-30 psi. Charge at this rate until the accumulator pressure reaches 100 psi. Above 100 psi, the rate of charging can increase to 100 psi per 2-3 minutes until the system is fully charged to the correct pressure.

13. Allow 10 minutes for the gas temperature and pressure to stabilize. Recheck and adjust asnecessary.

14. If the gas precharge is still low, continue charging. If the gas pressure is high, bleed gas offthrough the charging system. Allow 10 minutes for the gas temperature and pressure tostabilize.

15. If accumulator is unable to maintain charge, replace accumulator.16. Once the proper gas precharge pressure is reached, close the shut-off valve on the nitrogen

bottle and tighten the charging cap screw on the accumulator by rotating the T-handle. Thiswill seal the gas in the accumulator. Loosen the adapter and disconnect the charging/gaugeunit from the accumulator.

17. Using an allen wrench, tighten the charging cap screw to 15 Ft-Lbs and check the areaaround the screw for leaks using a soapy solution. If any leaks are found, repair or replacethe sealing ring and recharge the accumulator.

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18. Replace the protective cap on the top of the accumulator.19. On CRGV accumulator, return the shutoff valve to the open position and install a bolt and

lock nut to lock this valve into this position.20. On CRGV accumulator, tighten manual bleed valve spindle to close manual bleed valve.

Locate the spindle against the relief when complete.

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9.10 Hydraulic Crowd Service Schedule

Interval (Hours)

Task Daily 100 500 1,250 2,500 5,000 10,000 15,000 30,000

Visually Inspect1) Hydraulic tanks (Upper & Lower) and PDT for oil leaks2) Hose and tube connections for leaks3) Inspect isolators & plumbing on top of house

Verify System Hydraulic Oil Level (Upper tank sight gauge) - See SYSTEM TOP OFF in HYDRAULIC CROWD SERVICE PROCEDURES section

Verify Pump Drive Transmission (PDT) Oil Level (Dipstick) - See PDT OIL LEVEL CHECK in HYDRAULIC CROWD SERVICE PROCEDURES section

Verify Correct Accumulator Pressure: - See ACCUMULATOR PRESSURE TEST AND CHARGE in HYDRAULIC CROWD SERVICE PROCEDURES section

Inspect Crowd Position Sensor (CPS)

Inspect Aux Unit Filters (2) and Prefill Filter - (Replace as required)

Inspect and clean Coolers as required (Externally) - See HYDRAULIC CROWD COOLER CLEANING in HYDRAULIC CROWD SERVICE PROCEDURES section

Trend Hydraulic Oil - Main System - Send oil sample to approved lab.

Inspect and Replace Electrical Wiring as required (Cylinder Manifold, Circulation Manifold and Pump Control Manifold)

Change Circulation Filter (Power Module) - See CIRCULATION FILTER REPLACEMENT in HYDRAULIC CROWD SERVICE PROCEDURES section

Test Cylinder Leakage flow rate

Inspect and replace Dipper Handle Guide Bushings as required - See DIPPER HANDLE GUIDE BUSHING REPLACEMENT in SERVICE PROCEDURES section

Inspect Return Filters (Inspect for debris - clean and replace as required) - See UPPER TANK RETURN FILTER REPLACEMENT in HYDRAULIC CROWD SERVICE PROCEDURES section

Inspect Power Module (Loose bolts, chock blocks and leaks)

Lube Crowd Motor Bearing - See GREASING MAIN A.C. DRIVE MOTORS in LUBRICATION section

Lubricate Cooler and Circulation Motor Bearings

Inspect Power Module Blower (Hardware, ductwork, clean and replace as required)

Replace Crowd Position Sensor (CPS) - (if required) See CROWD POSITION SENSOR REPLACEMENT in HYDRAULIC CROWD SERVICE PROCEDURES section

** After initial start up only

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Pressure Test Accumulators (RECV and CRGV) - See ACCUMULATOR PRESSURE TEST AND CHARGE in HYDRAULIC CROWD SERVICE PROCEDURES section

Perform System Health Monitoring - See HYDRACROWD HEALTH MONITORING CHECKS in PREVENTIVE MAINTENANCE section

Change Pump Drive Transmission (PDT) Fluid - See PDT OIL DRAIN in HYDRAULIC CROWD SERVICE PROCEDURES section

Verify Torque Values - (Cylinder sleeve cap and pin retaining plate hardware) See SPLIT FLANGE ASSEMBLY in ENGINEERING DATA section

Verify Torque Values (Cylinder sleeve to saddle block connection hardware) - See SPLIT FLANGE ASSEMBLY in ENGINEERING DATA section

Replace Aux Unit Filters (2) and Prefill Filter - See AUXILIARY POWER UNIT FILL AND FILTER REPLACEMENT in HYDRAULIC CROWD SERVICE PROCEDURES section

Replace select hoses - See HYDRAULIC HOSE REPLACEMENT in HYDRAULIC CROWD SERVICE PROCEDURES section

Lubricate Power Module Motor Coupling- Refer to BRAKES & COUPLINGS section

Replace Circulation Pump and Coupling - See OIL CIRCULATION PUMP REMOVAL AND REPLACEMENT in SERVICE PROCEDURES section

Replace Hydraulic Oil for the entire Hydraulic System - See COMPLETE SYSTEM FLUSHING AND FILTRATION, See SYSTEM OIL DRAIN - COMPLETE, See INITIAL SYSTEM OIL FILL, See SYSTEM TOP OFF in HYDRAULIC CROWD SERVICE PROCEDURES section

Replace Main Pumps - See MAIN PUMP REMOVAL, See PUMP TIMING AND INSTALLATION in SERVICE PROCEDURES section

Replace Main Pump Hoses - See MAIN PUMP PRESSURE HOSE REPLACEMENT in HYDRAULIC CROWD SERVICE PROCEDURES section

Replace Hydraulic Cylinder - See SLEEVE AND CYLINDER REMOVAL, See HYDRAULIC CROWD CYLINDER REMOVAL in SERVICE PROCEDURES section

Replace Flushing/PDT Lubrication Pump and Coupling - See FLUSHING/PDT LUBE MOTOR DISASSEMBLY AND REPLACEMENT in SERVICE PROCEDURES section

Replace Pump Drive Transmission (PDT) - See PDT REMOVAL in SERVICE PROCEDURES section

** After initial start up only

Interval (Hours)

Task Daily 100 500 1,250 2,500 5,000 10,000 15,000 30,000

SM141494-EN Electric Rope Shovel 9 – 185November 2012

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Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 1

February 8, 2012 HydraCrowd Initial Start-up Procedure

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 2

HydraCrowd Initial Start-up Procedure

This procedure is to be used when the system is started for the first time, when the oil has been drained and re-filled, or after a major repair procedure has been completed. An electrical engineer may be required to “force” the PLC to advance or remain in the heating mode. The S127020 HydraCrowd Commissioning Tool Kit contains the pressure gauges required to take the required measurements listed below. Section 9 of the Maintenance Manual contains additional information related to HydraCrowd Servicing. NOTE: IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY M EASURES SUCH

AS THOSE SET FORTH IN THE APPLICABLE MACHINE MAINTE NANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

Procedure

1. Fill the main hydraulic system with clean hydraulic oil. a. Begin by filling the auxiliary tank (approximately 120 gallons)

as described in Section 9.6.9 (Auxiliary Power Unit Fill & Filter Replacement) of the Maintenance Manual.

b. Circulate the oil through the auxiliary unit filters until the contamination monitor reads 16/14/12 or lower.

c. Transfer the hydraulic oil into the upper tank as described in Section 9.6.6 (System Top Off) of the Maintenance Manual

d. Repeat steps a, b and c until the hydraulic system is full (approximately 1000 gallons)

Note: Replace the Pressure, Return and Pre-fill filters as required during the system fill process by monitoring the filter indicators. As the filters become contaminated, the gauge will move from green to red.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 3

2. Fill the PDT with clean gear oil. The transmission holds 5.75 gallons and the cooler core, circulating pump and lines will hold an additional 3.25 gallons. Refer to Section 9.6.10 “PDT – Initial Oil Fill” in the Maintenance Manual.

3. Purge the 4 main pumps to insure that the 4 pump cases are full of oil. Loosen the hose connection on top of each pump and allow the air to bleed out (Figure 1). When oil is flowing from the fitting, tighten the hose fitting. (See Section 9.9.1 “Purging The Main Pumps” in the Maintenance Manual)

Figure 1

4. Verify correct rotation of the main crowd motor and couple the motor

to the PDT. (See Figure 2) Note: Turning the pumps in the wrong direction may cause damage to the pumps.

5. Verify correct rotation of the flushing pump. (See Figure 2)

Note: Turning the pumps in the wrong direction may cause damage to the pumps.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 4

6. Verify correct rotation of the circulation pump. (See Figure 2) Note: Turning the pumps in the wrong direction may cause damage to the pumps.

Figure 2

7. Start warm-up mode to heat the oil. State 1A will turn the immersion

heaters on.

8. With the warm-up mode in state 1B, the immersion heaters and the circulation pump will be on. Oil will be flowing over the relief valve in the circulation manifold (HOCCV). This will heat the oil. (No oil will be flowing through the crowd cooler.)

Alternate Method: If the oil in the tank is above 25 degrees C (77 degrees F) force the circulation pump on in the heating mode. The pump should start in low speed and then go to full speed. (This is not always noticeable if the oil temperature in the upper tank is above -7degrees C [20 degrees F].)

Check the hydraulic oil pressure in the circulation manifold.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 5

Install a 0- 600 psi pressure gauge on outlet pressure port GCP (Figure 3). Expected pressure reading is 400 psi.

Record the pressure reading __________________ (Spec. is 400 psi.)

Figure 3

9. When the oil is warm, the HOCCV will energize and oil will flow

through the hydraulic oil cooler and return to the lower tank through the flow meter and circulation filter. (State 2A) This will clean the oil. Check the oil cooler circuit for leaks.

Alternate method: Force the circulation manifold to go into the cooling mode.

Observe the flow meter on the right side of the power module. In the cooling mode, the expected pump flow is 90 gpm. Record the flow meter reading ______________

Check the hydraulic oil pressure in the circulation manifold.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 6

Install a 0- 600 psi pressure gauge on outlet pressure port GCP. Expected pressure reading is approximately 120 psi.

Record the pressure reading __________________ (Spec. is 120 psi if there are 2 crowd oil coolers in series) (Spec. is 150 psi if there are 3 crowd oil coolers in series) (Spec. is 70 psi if there is only one crowd oil cooler)

Note: Pressures are preset and cannot be adjusted in the field.

10. Bleed the circulation return oil filter using a Stauff test hose on the

test port (Figure 4) on top of the filter housing and run the other end of the test hose into an empty 5 gallon pail. There will be very little flow and very low pressure. Wait until there is a continuous stream of oil and then disconnect the test hose.

Figure 4

11. Bleed the crowd cooler core. Air can be trapped in the cooler core.

(Optional)

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 7

12. Energize the flushing pump. This will turn the contamination monitor (HOCM) on. Check the flushing circuit for leaks. This can be “forced on” by the electrical engineer, or the crowd control can be turned on.

Warning: if the crowd control is on, the handle can move if the crowd joystick is moved.

13. When the flushing pump is running, check the screens on the four

flow meters (Figure 5) located on the power module. Insure that they are reading. Expected reading is approximately 2 gpm. There is no need to record the readings at this time.

Figure 5

14. Filter the oil in the main system until the cleanliness is 16-14-12

before proceeding. The circulation pump filters the oil when the system is the cooling mode. The flushing pump sends oil through the contamination monitor (Figure 6) and shows the oil cleanliness reading.

Record the cleanliness reading ________________

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 8

Figure 6

15. When the flushing pump is turned on, the PDT oil pump will move

PDT oil through the PDT oil cooler. The PDT oil level may need to be topped off several times until the system is full. Check the PDT oil circuit for leaks. If the oil level is too low, the crowd system will shut down. The operator’s screen will show a low PDT pressure fault (CDA 218-2).

Verify the PDT oil level _________

16. Install a 0- 8000 psi pressure gauge on the outlet pressure port of

each main hydraulic pump (Figure 7). It is important to be able to monitor all four pumps at the same time. The Parker digital pressure gauge in the S127020 Commissioning Tool Kit has this capability.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 9

Figure 7

17. When the oil meets the cleanliness requirement of 16-14-12, run the

crowd motor in the “Pump Unloaded” mode. (State 1C) The crowd motor will turn at 250 RPM. This causes oil to flow from the pumps, through the pump manifold, and back to the upper tank. Check for hydraulic oil leaks. Allow the flushing to continue for at least 15 minutes to insure complete flushing of the pump, hoses and pump manifold.

18. After step 17, the contamination monitor values may increase,

indicating that the system is cleaning the oil. Before proceeding to the next step, continue to circulate the oil until the cleanliness value returns to below 16-14-12.

Verify that the cleanliness reading on the power module contamination monitor is 16-14-12 or lower and record it here. ______________

19. Advance the heating mode to State 2B. The main pump heating

mode is active. All four PICV solenoids will be turned on. The crowd motor will turn at 250 RPM. Hydraulic oil will be flowing past two PUV valves, back to tank, causing the oil to heat. The PUV valves are turned on and off in pairs to prevent the valves from overheating.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 10

Each PUV pressure relief valve limits the maximum pressure in its corresponding pump to 3700 psi.

Alternate method: Force the crowd motor to run at 200 RPM with the 4 PICV valves forced “on” and PUV 1 and 3 forced on. Check the pressures and adjust if necessary. Then stop the crowd motor and force PUV 2 and 4 on. Run the crowd motor at 200 RPM and check the pressures and adjust if necessary. Record the pressure readings on the chart shown above.

PUV 1 and PUV 3 are turned on together. Read the pressure on the pump 1 and pump 3 pressure gauges. Expected pressure is 3700 psi.

Record the Pump 1 pressure reading __________________ (Spec. is 3700 psi.)

Record the Pump 3 pressure reading __________________ (Spec. is 3700 psi.)

PUV 2 and PUV 4 are turned on together. Read the pressure on the pump 1 and pump 3 pressure gauges. Expected pressure is 3700 psi.

Record the Pump 2 pressure reading __________________ (Spec. is 3700 psi.)

Record the Pump 4 pressure reading __________________ (Spec. is 3700 psi.)

Note: The individual pressure relief valves (Figure 8) on the pump manifold can be adjusted if required. The pressure relief valve should be replaced if it does not respond when adjusted.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 11

Figure 8

20. Advance the heating mode to state 2C, manifold heating. Note: this

is the same as “hose flushing” and will clean the hydraulic hoses and manifold. Allow the hose flushing to continue for at least 15 minutes.

Alternate method: Activate the Hose Flushing Mode using the button on the operators screen. Hose Flushing runs for approximately 15 minutes.

Record the reading on the 4 pump case drain flow meters (PCDM) at this time.

PCDM1 ___________ PCDM2 ___________ PCDM3 ___________ PCDM4 ___________

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 12

Observe the pressure readings of the 4 main pumps on the digital pressure gauge. The expected reading on each pump should be approximately 500 psi. It is not necessary to record the readings.

21. Record the reading of the contamination monitor at the conclusion of

hose flushing. ____________

22. After step 21, the contamination monitor values may increase indicating that the system is cleaning the oil. Before proceeding to the next step, continue to circulate the oil until the cleanliness value returns to below 16-14-12.

Verify that the cleanliness reading on the power module contamination monitor is 16-14-12 or lower and record it here. ______________

23. When the contamination monitor indicates the oil is clean, continue

the heating mode until cylinder motion in allowed.

Alternate method: If the system is not in heating mode, turn on the crowd control and operate the crowd from the operator’s seat.

24. Raise the cylinder to the horizontal position. 25. Bleed the cylinder using Step 4 of the “HydraCrowd Cylinder

Bleeding Process”. (See Section 9.6.1 in the Maintenance Manual)

26. Operate the cylinder in mid-stroke (between 8’ and 15’ of crowd extension) until the operational temperature is reached.

Warning: Do not fully extend or retract the cylinde r when the hydraulic oil is below operating temperature. Damage to the cylinder snubbers could occur.

27. When the hydraulic oil has reached operating temperature, set the

crowd limits. (See Section 4.4.17 “Hoist and Crowd Limit Systems” in the Maintenance Manual)

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 13

28. When full crowd motion is permitted, check the speeds in extend and retract. These numbers are viewable on the operator’s display on the “HydraCrowd Status” screen (Figure 9).

Full speed extend ________________ feet per minute (Spec. is 140 fpm)

Full speed retract ________________ feet per minute (Spec. is 120 fpm)

Figure 9

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING. 14

29. Take WinDaq recordings. (See Section 3.7 “HydraCrowd Health Monitoring Checks” in the Maintenance Manual) Send the WinDaq recordings to South Milwaukee Service Department for interpretation.

30. Remove the two auxiliary quick disconnect couplings (Figure 10)

from the cylinder manifold and install two “Zero Leak” plugs.

Figure 10

Commissioning Engineer Date

Media Number: BI643125

Special Instruction ________________________________________________________________________________________________________________________________

Inspection Procedure for Saddle Block Liner and Handle Guide Bushing Wear on HydraCrowd™ Equipped 7495 and 7495HF Electric Rope Shovels Electric Rope Shovel 7495 (ER6) HydraCrowd™ 7495HF (ER8) HydraCrowd™

Introduction This special instruction provides the information to monitor the wear on the saddle block liners and the handle guide bushings during operation. It also provides a measurement method for determining wear on removed saddle block liners. Important Safety Information

While working on the front end of the saddle block, people will be working at heights. Proper procedures must be followed while operating the man lift.

Required Parts and/or Tools

Man lift Feeler Gauges – 12 inch length Ruler Camera Calipers

Media Number: BI643125

Publication Date: 2/11/2014

Media Number: BI643125

Component Replacement

The saddle block liners should be replaced when the 0.38 inch chamfer has been worn off the end of the liner bushings. Note: The subsequent measurements can be used for monitoring and trending purposes, but the

determination for liner replacement should be made based on the condition of the wear chamfer. The Handle Guide bushings should be replaced when the 0.37 inch wear chamfer is no longer visible upon inspection.

Illustration 1 – Saddle Block Liner and Handle Guide Bushing

Procedure – Saddle Block Liner Installed on Machine 1) Position machine for inspection. 2) Go into the man lift and position yourself so you are facing the front end of the saddle block. 3) Using the 12 inch length feeler gauge, measure the gap, shown in green, between the front liner and handle at these 8 locations. Record the numbers in the first table below.

1 2 3 4 5 6 7 8

Liner

Handle

Media Number: BI643125

The nominal diametrical clearance between the saddle block liner and the handle is 0.25 inches.

Illustration 2 – Position Reference

Media Number: BI643125

4) With the feeler gauge inserted at each interval, use a ruler and measure to the OD of the flange, as shown in Illustration 3, and record in the table below.

Illustration 3 - Measuring of OD Flange

1 2 3 4 5 6 7 8

The nominal distance from the ID of the saddle block liner to the OD of the flange as shown above is 5.315 inches. 5) Measure the distance from the end of the chamfer to the OD of the saddle block liner as shown in Illustration 4. Measurement Step 5 _____

Media Number: BI643125

Illustration 4 - Measuring of Chamfer to OD

The table below can be used to help determine remaining saddle block liner life.

Current hours on liners

Measurement from Step 5

Position 1 2 3 4 5 6 7 8

Measurement from Step 4

Remaining Chamfer = Step 4 - Step 5

% Remaining Chamfer (0.38/Remaining

Chamfer)*100

Units are Inches for Formula above

Media Number: BI643125

6) Inspect the guide bushing from the manhole shown in Illustration 4. Going onto the access platforms may be required for cleaning, but the bushing chamfer is visible from the boom walkways.

Illustration 5 - Manhole Inspection Port

7) Inspect that the wear chamfer is still visible. If not visible record hours here: ________

Illustration 6 - Guide Bushings

Wear Chamfer

Media Number: BI643125

8) Additional Information Requested

• Inspect dipper handle for adequate OGL coverage and any signs of pitting or other damage. Refer to Illustration 6 for handle pitting example.

• Inspect the top of the handle end retainer and the top surface of the sleeve for any signs of wear. Refer to Illustration 7 and 8

Illustration 7 – Example Dipper Handle Pitting

Dipper Handle Adequate OGL Coverage Yes No

Signs of Pitting On Handle Yes No

Top of Handle End Retainer Wear Yes No

Top of Sleeve Wear Yes No

OGL Type

Injector Type SL1 or SLV

Guide Bushing Change Out Frequency Hours

Media Number: BI643125

Illustration 8 – Handle End Retainer. Photo taken from the viewing window at the end of the sleeve

Illustration 9– Handle End Retainer Metal Flow

Inspect the top of the handle end retainer and the top surface of the sleeve for any signs of wear

Media Number: BI643125

Procedure – Saddle Block Liner Removed From Machine

1) Mark the top of each saddle block liner so its position as it was installed on the saddle block is recorded. 2) Measure the grease groove depth at the following locations for the front and rear saddle block liners (Refer to Illustration 9):

• Front and Rear of each grease groove

• Both sides of each grease groove

• Repeat for all 8 grease grooves Ensure each grease groove position relative to its position on an installed machine is recorded. If the grease groove is completely worn away, measure the flange width as shown in Illustration 10.

Illustration 9 – Saddle Block Liner Measurement Locations

Measure grease groove depth at locations shown. Repeat for all 8 grease grooves

A Side

B Side

Media Number: BI643125

Illustration 10 – Alternative Measurement Location if Grease Groove is Gone

Illustration 11 – Example Measurement Method

Media Number: BI643125

Illustration 12 – Grease Groove Position Reference

Media Number: BI643125

Front Liner Rear Liner

Groove

Location Position

Flange

End

Inboard

End

Flange

End

Inboard

End

1 A

2 A

3 A

4 A

5 A

6 A

7 A

8 A

Grease Groove Measurement Table

Front Liner Rear Liner

Location Flange End Flange End

Flange Width Measurement Table

Media Number: BI643125

3) Additional Information Requested

Dipper Handle Adequate OGL Coverage Yes No

Signs of Pitting On Handle Yes No

Top of Handle End Retainer Wear Yes No

Top of Sleeve Wear Yes No

OGL Type

Injector Type SL1 or SLV

Guide Bushing Change Out Frequency Hours

Saddle Block Liner Component Hours When Removed

Hours

Information Reporting

Please report all information obtained on the DSN so it can be used for tracking purposes and aid in saddle block liner improvements.

©2012 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks

of Caterpillar and may not be used without permission.

New Band Clamps Available for 7495 and 7495HF HydraCrowd™-Equipped Electric Rope Shovels Electric Rope Shovel Model Identification Number Expanded Product Line

Serial Number 7495 ER601418 141418

ER601439 141439

ER601452 141452

ER601441 141441

ER601455 141455

ER601462 141462

ER601463 141463

ER601469 141469

ER601470 141470

ER601473 141473

ER601474 141474

ER601477 141477

ER601482 141482

ER601481 141481

ER601494 141494

ER601516 141516

ER601509 141509

ER601508 141508

ER601514 141514

ER601511 141511 7495HF ER801325 141325

ER801327 141327

ER801333 141333

ER801424 141424

ER801429 141429

Service Magazine

Media Number: BI643161 Publication Date: 27 June 2014

Media Number: BI643161

ER801517 141517

ER801518 141518

ER801433 141433

ER801209 141209

ER801483 141483 Description of Change: Redesigned band clamps that secure the feed tube guard covers to the HydraCrowd™ cylinder on 7495 and 7495HF Electric Rope Shovels are now available. This more robust design of band clamp is wider and thicker, and has over 5 times the torque value of the previous clamp.

Illustration 1 – Band clamp (P/N 4419574) location and position on the HydraCrowd™ cylinder.

Adaptable To: The redesigned band clamps (P/N 4419574) are effective in HydraCrowd™ cylinders assembled after June 25, 2014. Clamp torque is 28 ±7 Nm (Illustration 2). Clamps should be positioned just off-center from the feed tube (Illustration 2). A quantity of 23 clamps should be used (Illustration 3). The clamps should be spaced according to the Illustration 3.

Media Number: BI643161

Illustration 2 – Torque and position of the clamp on the cylinder.

Media Number: BI643161

Illustration 3 – Quantity and spacing of the band clamps (P/N 4419574) on the HydraCrowd™ cylinder.

MR Flow Transmitter

Installation & Maintenance

Instructions DIVISION OF RACINE FEDERATED INC.

FORM #HLIT 306 8635 Washington Avenue • Racine • Wisconsin 53406-3738TEL 1-800-HEDLAND • FAX 1-800 CHK-FLOW

Page 1

I. INTRODUCTION

The MR Flow Transmitter is a state-of-the-art,

microprocessor based variable area " ow meter.

It combines the rugged proven technology of a

piston-type, variable area " ow meter with solid state

circuitry including:

• Non-contact sensor electronics

• Electronic signal conditioning circuit

• Digital " ow rate and total indication

• Proportional analog output

The product is sealed against industrial contamination

by a NEMA 12 and 13 (IP 52/54) rated enclosure and is

available for either liquid or gas service.

The MR Flow Transmitter is capable of calculating

and displaying both " ow rate and total accumulated

" ow. The " ow rate and total " ow can be displayed in

any of the user selectable measurement units. The

monitor’s large 8 digit numeric liquid crystal display

makes extended range viewing practical. The second

8 character alphanumeric display provides for

selectable units viewing in RUN mode and prompts

for variables in PROGRAM mode.

All MR Flow Transmitters come pre-calibrated from

the factory. However, the unit may be adjusted

by the user to meet speci# c system requirements.

Calibration parameters are included for:

• Speci# c gravity compensation (all " uids)

• Viscosity compensation (petroleum-based " uids)

• Pressure and temperature compensation

(pneumatic applications)

US Patent 7,130,750

Figure 1 - MR Flow Transmitter

All meters include an analog output that can be

con# gured for 0-5 Vdc, 0-10 Vdc, or 4-20 mA current

loop.

Applications for the MR Flow Transmitter include:

• Bearing lubrication

• Case drain veri# cation

• Gun drill and machine cooling

• Pump " ow outputs

Page 2 Form #HLIT 306 10/10

MR Flow Transmitter

Installation & Maintenance Instructions

II. SPECIFICATIONSEnclosure Rating

• NEMA 12 & 13 (IP 52 & 54)

Operating Temperature

• Fluid: -20 °F to +240 °F (-29 °C to +116 °C)

• Ambient: -20 °F to +158 °F (-29 °C to +70 °C)

Environmental

• Humidity: 0-90% non-condensing

Pressure Rating Aluminum/Brass

• Liquids (¼” to 1-½”): 3500 psi (241 bar)

maximum with a 3:1 safety factor

• Gases (¼” to 1-½”): 1000 psi (69 bar)

maximum with a 10:1 safety factor

Pressure Rating Stainless Steel

• Liquids (¼” to ½”): 6000 psi (414 bar)

maximum with a 3:1 safety factor

• Liquids (¾” to 1-½”): 5000 psi (345 bar)

maximum with a 3:1 safety factor

• Gases (¼” to 1-½”): 1500 psi (103 bar)

maximum with a 10:1 safety factor

Accuracy

• ±2% of full scale

Repeatability

• ±0.5%

Pressure Drop

• See Appendix for speci# c meter information

Electrical

Power Requirement:

• 0-5 Vdc Output 10-30 Vdc @ 0.75W maximum

• 0-10 Vdc Output 12-30 Vdc @ 0.75W maximum

• 4-20 mA Output loop-powered, 30 Vdc maximum

Power Consumption:

• 25 mA maximum

Analog Outputs:

• 0-5 Vdc and 0-10 Vdc into 10,000 Ohms minimum

• 4-20 mA into 1000 Ohms maximum (see Figure 2)

Circuit Protection:

• Reverse polarity and current limiting

Transmission Distance:

• 4-20 mA limited by cable resistance

• 0-5 Vdc 1000 feet (300 m) maximum

• 0-10 Vdc 1000 feet (300 m) maximum

Isolation:

• Inherently isolated from the piping system

Rate and Totalization Display

• Fixed or toggle modes of operation for rate and

totalizer display

• 8 digit, .70” high numeric display for rate and total

• 8 digit, .34” high alphanumeric display for units

and setup

Temperature Drift

• 50 ppm / °C (maximum)

Analog Output

• Resolution - 1:4000

Compliance

• Meets the requirements of EN61000-6-4 for a

Class A product for emissions and EN61000-6-2

for immunity tests of an ISM product.

Dimensions

• See Appendix

Figure 2 - Load Limitations (4-20 mA only)

QTY ITEM NO. DESCRIPTION PART NO.1 1 KIT,HOSE,PUMP TO CONTROL MAN S089090

1 2 KIT,HOSE,PWR MODULE DRAIN S046545

1 3 HOSE ASSY,-64 CD61,STR-STR 650422-165

1 4 PIPE ASSY,10.0 TANK CONNECTION S038915

1 5 SUPPORT,CLAMP,10 PIPE 171125761 6 BRACKET,10 PIPE S0465461 7 U-BOLT,.75UNC,10 PIPE,RUB.COAT 490325272 8 BAR,3x3 S0465471 9 SHIM PACK,0.38 THK S0465484 10 SUPPORT,HOSE,WELDED S0496594 11 BAR,.25x4 S0496604 12 BAR,.25x4 S0496612 13 PL,.5 S0465491 14 THERMOWELL,1/2 NPT,4.00,304SS 1546777

1 15 TRANSMITTER,TEMP,-40 TO 240F 128441694 16 FLANGE,HALF,4 5330364116 17 FLANGE,HALF,1.5,6000 PSI 20325237

1 18 FTG,EL,90 D,1.0MP#12MORB 20287452

1 19 COCK,IRON,SQ.HD,1,125# 79091440

1 20 PLUG,PIPE,SQ HD,1,150# 207678001 21 CONN,#6 ORS-#16 ORB 785543602 22 CONN,#16 ORS-#16 ORB 785542311 23 CONN,#8 ORS-#12 ORB 785542328 24 O-RING,-225,VITON,90 DUROMETER 68136132

2 25 O-RING,-245,VITON,70 DUROMETER 687608011 26 LABEL,HOTSL S052002

16 27 SCR,HEX,M16x2.0x50mm,CL8.8 035521184 28 SCR,HEX,.5x2,UNC,GR5 0328564016 29 SCR,HEX,.625x1.25,UNC,GR 5 03291400

24 30 SCR,HEX,.625x2.25,UNC,GR 5 03291720

16 31 SCR,HEX,.875x4.5,UNC,GR5,PLTD 03552119

40 33 WASHER,BELLEVILLE,.625 039550044 34 WASHER,FLAT,.562 0395170016 35 WASHER,FLAT,.875,HARDENED,PLTD 0355212116 36 WASHER,BELLVILLE,.875 0395501116 37 NUT,HEX,FULL,.625,UNC 0271305032 38 NUT,HEX,FULL,.875,UNC 027151002 39 STRAP,HOSE BUNDLE,VELCRO 17431970

2 40 STRAP,VELCRO BUNDLE,20 DIA MAX 17431971

2 41 STRAP,VELCRO BUNDLE,24 DIA MAX 17431972

1 42 COMPOUND,THREAD LOCKING 828338628 46 WIRE,LOCK,#16(.0625) 842800001 47 CONN,STR,-12 MORB - .5FNPT 78553919

1 48 XDCR,PRESSURE,0-10000PSI 12858367

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

OPY

RIG

HTED

-CUS

TOM

ER IN

FORM

ATIO

N D

RAW

ING

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

COPYRIGHTED-CUSTOMER INFORMATION DRAWINGCOPYRIGHTED-CUSTOMER INFORMATION DRAWINGCOPYRIGHTED-CUSTOMER INFORMATION DRAWINGCOPYRIGHTED-CUSTOMER INFORMATION DRAWING

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

OPY

RIG

HTED

-CUS

TOM

ER IN

FORM

ATIO

N D

RAW

ING

PYRI

GHT

ED-C

USTO

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INFO

RMA

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DRA

WIN

COPYRIGHTED-CUSTOMER INFORMATION DRAWING COPYRIGHTED-CUSTOMER INFORMATION DRAWING COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1. DIMENSION MATERIAL THICKNESS TOLERANCE

FABRICATING TOLERANCES-UNLESS OTHERWISE SPECIFIED

MACHINING TOLERANCES-UNLESS OTHERWISE SPECIFIEDALL DIMENSIONS IN INCHES-UNLESS OTHERWISE SPECIFIED

1. MATERIAL THICKNESS DIMENSIONS TOLERANCE

WELDMENT TOLERANCES-UNLESS OTHERWISE SPECIFIED

.06

.12

.19

.25

UP TO 1"1" AND GREATERUP TO 1"1" AND GREATERUP TO 1"1" AND GREATERALL

A. UP TO 36"

B. 36" TO 10'

C. 10' TO 30'

D. OVER 30'

TEBY

DES

CRI

PTIO

REV

DET

ENGCONTACTNO.

MODEL UNIT

DATE

FIN WGT

DESCRIPTION

REF DWGS

THIS DOCUMENT IS PROTECTED UNDER APPLICABLE COPYRIGHT LAWS TO THE EXTENT AVAILABLE.ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BESUBJECT TO LIABILITY. C 2006 Bucyrus International, Inc. ALL RIGHTS RESERVED.

1 2 3

321

A. LESS THAN .12

B. .12 TO .50

C. .50 TO 1.00

D. OVER 1.00

0 TO 36OVER 360 TO 36OVER 360 TO 36OVER 360 TO 36OVER 36

.03

.06

.12

.09

.19

.252. BENT ANGLES 1 (.017 IN/IN) FOR EACH .37 OF MATERIAL THICKNESS (MAX 3 )

PLUMBING,HYD CROWD HOUSE,FLD

ALBRECHT K.FUERST J.

S089091

495 160012-12-2008

S038972

41013.6

DWGSIZE E

SHEET

REV

OF 7

REVISION DATA

ECN

Que

lla P

.04

-17-

2012

DELETED ITEM 32, QTY 8 OF 03552120; ITEM

35, QTY 16 WAS 24; ITEM 36, QTY 16 WAS 24;

ITEM 38, QTY 32 WAS 48; UPDATED REF

5357

GEOMETRY IN ALL VIEWS; SHT 1, DIM 22.50 WAS

REF, DELETED DIM 16.00; SHT 3, DIM 1.43 WAS

0.60, NOTE - PMOPT IN PORT GSP2 WAS IN PORT

SP; SHT 6, NOTES 1,2,5, AND 18 REVISED; SHT

7, DIM 0.25 WAS 0.25 REF, 14.63 TO 15.38

REF WAS 15.13

BucyrusInternational, Inc.

04-17-2012

SOLIDWORKSDRAWING

REISSUE DATE

20.003 PLCS22.50

B4 B4

L4 L4

S5S5

NOTE: = COMPONENTS FROM KIT (ITEM 1), SEE DRAWING S089090.1. = COMPONENTS FROM KIT (ITEM 2), SEE DRAWING S046545.2.SEE DWG S038986 FOR SPLIT FLANGE INSTALLATION INSTRUCTIONS.3.APPLY LOCTITE 7471 PRIMER T (P/N 1561393) AND LOCTITE 545 4.THREAD SEALANT (P/N 1561392) TO ALL NPT THREADS UNLESS STATED OTHERWISE.SEE SHEETS 6 & 7 FOR INSTALLATION OF PIPE (ITEM 4) AND5.

TORQUE PROCEDURE FOR EXPANSION JOINTS.

4 PLCS

USE AS NEEDED TO SUPPORT-24 HOSE FROM KIT S089090

3 2

SEE NOTE 3

18 19SEE NOTE 4

363531

36 35 31

11 10 12

4 PLCS

* QTY MEASURE IN FEET

2417

39 40 41

REISSUE DATE

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SOLIDWORKSDRAWING

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THIS DOCUMENT IS PROTECTED UNDER APPLICABLE COPYRIGHT LAWS TO THE EXTENT AVAILABLE.ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BESUBJECT TO LIABILITY. C 2006 Bucyrus International, Inc. ALL RIGHTS RESERVED.

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DETAIL C2

BALL VALVE IN BOTTOMOF UPPER TANK

SEE NOTE 3

28 343330

363531

422516

DETAIL D5 13

31 35 36 38

.133 SIDESWHEREACCESSIBLE

.13

WELD ITEM 13 TOLUBE ROOM FLOOR4 SIDES WHERE ACCESSIBLECENTER ITEM 13 UNDERITEM 5

SECTION A2-A2

LUBE ROOMBULKHEAD

REISSUE DATE

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WALL TO 10" PIPE

42.50INSIDE OF FRONT

1.43

SECTION E3-E3

LABEL "HOTSL"LOCATE AS SHOWN

1526

SEENOTE 4

31 35 36 3814 47 HOTSL

ORIENT ITEMS 18, 19 AND 20TOWARDS FRONT OF MACHINE

18 19

SEE NOTE 4

SECTION G3-G3

SECTION T3-T3

48 PMOPTIN PORT "GSP2"4

REISSUE DATE

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THIS DOCUMENT IS PROTECTED UNDER APPLICABLE COPYRIGHT LAWS TO THE EXTENT AVAILABLE.ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BESUBJECT TO LIABILITY. C 2006 Bucyrus International, Inc. ALL RIGHTS RESERVED.

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K K

SECTION B4-B4

233 2

USE AS NEEDED TO SUPPORT -24HOSE FROM KIT S089090(ITEM 1)

38363531

39 40 41

DETAIL J

SEE NOTE 3

333025

33302417

VIEW K-K

5.25TRIMMEDLENGTH

SECTION L4-L4

REISSUE DATE

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1.16

SECTION F5-F5

29 37

1211

ADJUST HEIGHT OF SUPPORTSBY MOVING ITEM 10 UP OR DOWN TO DESIRED BOLT HOLE LOCATION. LOCATE AS REQUIRED 4PLCS

(USE ITEM 10 ASLOCATION FIXTURE)

.13

.138 PLCS

SECTION S5-S5

LUBEROOM

SIDE

11 1011 10 11 10 11

12121012101210

37 29 16 PLCS

ITEMS 11 & 12 TO BE ALIGNED WITH ROOFPANEL CROSS MEMBERS PRIOR TO WELDING

ROOF PANELCROSS MEMBERS

NO BARS (ITEMS 11 & 12)ALIGNED WITH OR WELDEDTO THIS CROSS MEMBER.

FRONT OFPANEL/MACHINE

ITEM 4 INSTALLATION PROCEDURE:

1) REMOVE SHIPPING CAPS & HARDWARE FROM TANKS & TRANSFER TUBE. RETAIN HARDWARE (BOLT, WASHERS, AND NUTS) FROM BOLTED CONNECTIONS USED TO FASTEN CONTROL ROD RETAINER PLATES (4 BOLTED CONNECTIONS ON UPPER TANK AND 4 BOLTED CONNECTIONS ON LOWER TANK).

2) ATTACH TRANSFER TUBE (ITEM 4) ONTO LOWER TANK EXPANSION JOINT USING SUPPLIED HARDWARE, ITEMS 35, 36, 38, 31. INSTALL HARDWARE LOOSELY. RE-ATTACH CONTROL ROD RETAINER PLATES USING HARDWARE RETAINED FROM STEP 1, LESS 5 FLAT WASHERS ON NUT SIDE (SEE DETAIL P7).

3) PLACE PANCAKE JACK UNDER TRANSFER TUBE IN SPECIFIED LOCATION, AS SHOWN.

4) RAISE PANCAKE JACK UNTIL THE TOP FLANGE OF THE TRANSFER TUBE CONTACTS THE LOWER FLANGE OF THE EXPANSION JOINT THAT IS ATTACHED TO THE UPPER TANK.

5) ADJUST UPPER TANK AND TRANSFER TUBE POSITIONS UNTIL THE SUPPLIED HARDWARE CAN BE INSTALLED, ITEMS 35, 36, 38, 31. INSTALL HARDWARE LOOSELY. RE-ATTACH CONTROL ROD RETAINER PLATES USING HARDWARE RETAINED FROM STEP 1, LESS 5 FLAT WASHERS ON NUT SIDE (SEE DETAIL P7).

6) ADJUST TUBE SUPPORT CLAMP (ITEM 5) TO THE MID-POINT OF ITS ADJUSTMENT RANGE. INSTALL UNDER TRANSFER TUBE AT SPECIFIED LOCATION AS SHOWN. USE SHIMS (ITEM 13) TO MAKE UP THE REMAINING HEIGHT DIFFERENCE. ADJUST SUPPORT CLAMP UNTIL A SNUG FIT BETWEEN THE SUPPORT AND TRANSFER TUBE IS MAINTAINED.

7) LOWER AND REMOVE PANCAKE JACK.

8) POSITION UPPER TUBE SUPPORT CLAMP (ITEM 6) AND BASE (ITEM 8) ONTO TRANSFER TUBE. LOCATE ITEMS AGAINST LUBE ROOM WALL TO SPECIFIED DIMENSIONS, AS SHOWN, USING SUPPLIED HARDWARE (ITEM 28 & 34). USE SHIMS (ITEM 9) AS REQUIRED. WELD ITEM 8 IN PLACE AS SHOWN.

9) MAKE ADJUSTMENTS TO THE TUBE BY MOVING TUBE SUPPORT CLAMP (ITEM 5) [IN 4 DIRECTIONS] AND/OR MOVING UPPER TANK [IN 4 DIRECTIONS] IN ROOF RAIN GUTTERS AND/OR ADJUSTING SHIMMING OF UPPER TRANSFER TUBE CLAMP. POSITION TRANSFER TUBE SO THAT IT IS APPROXIMATELY PERPENDICULAR TO THE LOWER AND UPPER TANK.

10) TIGHTEN FLANGE HARDWARE (ITEMS 35, 36, 38, 31) ON LOWER EXPANSION JOINT, NO MORE THAN 10FT.LBS. SEE TIGHTENING SEQUENCE BELOW.

11) TIGHTEN FLANGE HARDWARE (ITEMS 35, 36, 38, 31) ON UPPER EXPANSION JOINT, NO MORE THAN 10FT.LBS. SEE TIGHTENING SEQUENCE BELOW.

12) INSPECT EXPANSION JOINT DIMENSIONS AT POINTS A, B, C & D TO ENSURE THEY ARE WITHIN TOLERANCES AS EXPLAINED IN TABLE "X-X", SECTION N7-N7 AND DETAIL P7. IF REQUIRED, ADJUST TRANSFER TUBE AND/OR UPPER TANK TO BRING EXPANSION JOINT DIMENSIONS INTO SPECIFICATION. ENSURE DIMENSIONS OF BOTH EXPANSION JOINTS ARE AS CLOSE A POSSIBLE TO THE MIDDLE OF THE ACCEPTABLE RANGE AS INDICATED BY TABLE "X-X".

13) INSPECT LOWER AND UPPER EXPANSION JOINTS FOR ANY DEFORMATION OR "DIMPLING" CAUSED FROM TORSIONAL LOADING. IF PRESENT, THE TORSIONAL STRESS MUST BE RELIEVED BY REMOVING ALL HARDWARE ON THE TRANSFER TUBE FLANGE CONNECTION AND PULLING BACK THE EXPANSION JOINT STEEL FLANGE RETAINING PLATE, SEE DETAIL P7. ALLOW THE RUBBER TO ROTATE/MOVE FREELY TO RELIEVE ANY TORSIONAL STRESS (DIMPLING) THAT MAY HAVE BEEN CAUSED DURING TRANSFER TUBE INSTALLATION AND ADJUSTMENT.

14) TORQUE DRILLED HEAD EXPANSION JOINT BOLTS PER THE FOLLOWING TORQUE SEQUENCE DIAGRAM, FOLLOWING THE TORQUE STEPS BELOW. SECURE BOLTS WITH LOCKWIRE (ITEM 46) FOLLOWING THE PROCEDURE LISTED IN THE ENGINEERING DATA SECTION OF THE MAINTENANCE & OPERATION MANUAL.

STEP 1. TORQUE TO 30 FT-LBS, THEN REST FOR 30 MINUTES. STEP 2. TORQUE TO 50 FT-LBS, THEN REST FOR 60 MINUTES. STEP 3. TORQUE TO 75-85 FT-LBS. 15) HAND TIGHTEN VALVE FLANGE H.H.C.S. THEN FOLLOW THE TORQUE SEQUENCE DIAGRAM, FOLLOWING THE TORQUE STEPS BELOW: STEP 1. TORQUE TO 30 FT-LBS, THEN REST FOR 30 MINUTES. STEP 2. TORQUE TO 50 FT-LBS, THEN REST FOR 60 MINUTES. STEP 3. TORQUE TO 75-85 FT-LBS. STEP 4. AFTER TORQUING SCREWS (ITEM 31) INSTALL SECOND NUT (ITEM 38) AS SHOWN.

16) WELD UPPER TANK SHIMS IN PLACE INTO RAIN GUTTERS AS SPECIFIED ON UPPER TANK INSTALLATION DRAWING.

17) VERIFY EXPANSION JOINT DIMENSIONS AS EXPLAINED IN TABLE "X-X", SECTION N7-N7 AND DETAIL P7. ADJUST AS NECESSARY.

18) INSTALL CONTROL ROD ASSEMBLIES TO SPECIFIED DIMENSIONS AS SHOWN IN DETAIL P7. A) TIGHTEN THE TWO OUTSIDE NUTS AGAINST EACH OTHER SO THAT THE FACE OF THE WASHER MEASURES 0.25" FROM THE FACE OF THE CONTROL ROD RETAINING PLATE, AS SHOWN IN DETAIL P7. B) TIGHTEN THE TWO INSIDE NUTS AGAINST EACH OTHER SO THE FACE OF THE WASHER NEAREST TO THE TWO OUTSIDE NUTS IS 1.38" FROM THE NEAREST FACE OF THE WASHER, AS SHOWN IN DETAIL P7.

19) WELD TRANSFER TUBE SUPPORT CLAMP BASE & SHIMS (ITEM 5 & 13) IN PLACE AS INDICATED IN DETAIL D.

20) COMPLETE HOUSE PLUMBING INSTALLATION AS INDICATED ON THIS DRAWING.

SEE NOTE 14

.13WELD ITEM 8 TOLUBE ROOM WALL2 PLCS

REISSUE DATE

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THIS DOCUMENT IS PROTECTED UNDER APPLICABLE COPYRIGHT LAWS TO THE EXTENT AVAILABLE.ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BESUBJECT TO LIABILITY. C 2007 Bucyrus International, Inc. ALL RIGHTS RESERVED.

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COPYRIGHTED-CUSTOMER INFORMATION DRAWING COPYRIGHTED-CUSTOMER INFORMATION DRAWING COPYRIGHTED-CUSTOMER INFORMATION DRAWING COPYRIGHTED-CUSTOMER INFORMATION DRAWING

8.60±1.0

P74

PANCAKE JACKLOCATION

31353638

FOR TORQUING SCREWSSEE NOTE 15 THIS SHEET

28 34

363531

TORQUESEQUENCE

FOR 12 BOLTFLANGE

910

7 1

TABLE X-X

REISSUE DATE

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SECTION N7-N7

MEASUREMENT POINTS AROUNDEXPANSION JOINTS

.25.37REF

(WASHER TO WASHER)14.63 TO 15.38 REF

1.38 (SPACING BETWEEN WASHERS)

AROUND CIRCUMFERENCE

DIMENSIONAL REFERENCEFOR POINTS A, B, C, D

.50±.25OFFSET

MIS-ALIGNMENTALLOWED

DETAIL P7

CONTROL RODRETAINING PLATE CONTROL ROD

RETAINING PLATE

TYPICAL EXPANSION JOINT INSTALLATIONUPPER AND LOWER TANK

SEE NOTE 14 (SHEET 6)

ENGINEERING REF: CECV Modificationfor Cylinder Manifold S134500 ONLY.

Accumulator is "PED/CRN/AS1210" Certified.

Notes:

= Denotes item numbers from assembly S134553

QTY ITEM NO. DESCRIPTION REF WGT(#) EACH PART NO.

1 1 MODULE,CECV,HYD ASSY 37.61 S1345461 2 CLAMP,HOSE,ASSY 5.8 15613221 2.1 BASE,CLAMP,HOSE 3.3 15613132 2.2 ROD,THD,.5,UNCx5.5 0.3 15613192 2.3 NUT,HEX,LOCK,.5,UNC 0.1 027864251 2.4 PL,COVER,SINGLE CLAMP,6S,HEAVY 0.93 15613211 2.5 BODY,CLAMP,54.4mm,PAH,6S,HVY 0.6 15613241 2.6 SCR,SOC,M16x2.0x35,CL12.9 0.02 15613281 3 ACCUMULATOR,CYL MANIFOLD ASSY 73.41 S1345891 4 MODULE,D05 DIVERSION,HYD ASSY 5.59 S1345714 5 SCR,SOC,M6x1.0x75,CL12.9 0.1 S1345772 6 SCR,HEX,M16x2.0x35mm,CL12.9 0.2 S1345792 7 HOSE ASSY,-6,STR-90,ORS 1.2 650474-3510 8 O-RING,-014,VITON,70 DUROMETER 0.01 687870271 9 ELBOW,90D,#6 ORS-#8 ORB 0.7 571411212 10 WASHER,BELLEVILLE,.625 0.1 039550041 11 COMPOUND,RETAINING 0.2 828338591 12 ORING,-219,VITON,70 0.019 S134950

REISSUE DATE

1. DIMENSION MATERIAL THICKNESS TOLERANCE

FABRICATING TOLERANCES-UNLESS OTHERWISE SPECIFIED

MACHINING TOLERANCES-UNLESS OTHERWISE SPECIFIEDALL DIMENSIONS IN INCHES-UNLESS OTHERWISE SPECIFIED

1. MATERIAL THICKNESS DIMENSIONS TOLERANCE

WELDMENT TOLERANCES-UNLESS OTHERWISE SPECIFIED

.06

.12

.19

.25

UP TO 1"1" AND GREATERUP TO 1"1" AND GREATERUP TO 1"1" AND GREATERALL

A. UP TO 36"

B. 36" TO 10'

C. 10' TO 30'

D. OVER 30'

TEBY

DES

CRI

PTIO

REV

DET

ENGCONTACTNO.

MODEL UNIT

DATE

FIN WGT

DESCRIPTION

REF DWGS

1 2

A. LESS THAN .12

B. .12 TO .50

C. .50 TO 1.00

D. OVER 1.00

0 TO 36OVER 360 TO 36OVER 360 TO 36OVER 360 TO 36OVER 36

.03

.06

.12

.09

.19

.252. BENT ANGLES 1 (.017 IN/IN) FOR EACH .37 OF MATERIAL THICKNESS (MAX 3 )

MOD,CECV,CYLINDER MANIFOLD

SZPEK F.FUERST J.

S134590

495HF/HR 5600

01-08-2011

121.0S134500,S134569

03-17-2011

THIS DOCUMENT IS PROTECTED UNDER APPLICABLE COPYRIGHT LAWS TO THE EXTENT AVAILABLE.ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BESUBJECT TO LIABILITY. C 2011 Bucyrus International, Inc. ALL RIGHTS RESERVED.

COPYRIGHTED-CUSTOMER INFORMATION DRAWING COPYRIGHTED-CUSTOMER INFORMATION DRAWING COPYRIGHTED-CUSTOMER INFORMATION DRAWING COPYRIGHTED-CUSTOMER INFORMATION DRAWING

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SHEET

REV

22OF

ECN

2Sz

pek

F.03

-17-

2011

3301

ITEM NO. 2 HOSE CLAMP KIT WAS P/N S134553.

REVISION DATA

BucyrusInternational, Inc.

SOLIDWORKSDRAWING

(LBS)(MM-DD-YYYY)ISOMETRIC VIEW

From Pressure Port atAccumulator SafetyRelief Valve (Item #3)

From Tank Port atAccumulator SafetyRelief Valve (Item #3)

Relief Valve (RV3)By-Pass Hose Ref.

See Assembly Note 6

See Assembly Note 3 & 4

C4-CRGV Module

C5-CECV Module

C8-CDB Module

DO5 Valve

See Assembly Note 1

See Assembly Note 2

See Assembly Note 5

Remove Lifting Eye.See Assembly Note 6.

X.X

Note orientation of machined relief groove in block to face down towardsCRGV module.

B Tank connection

A Pressure connection

Ref Manual Bleed Valve.Turn clockwise to close.See Section E-E

Ref Main Shut-Off Valve.Handle position shown is open.

2.3

2.6

2.4

2.5

2.1

2.2

2.3

2.2

2 CLAMP ASSEMBLY

C4-CRGVModule

DO5 Valve C8-CDBModule

Assembly Notes Cylinder Manifold Modifications:CRGV Module Part Removal:1.

Remove/Scrape paint along base of D05 valve.•Remove D05 valve from CRGV Module.•Cover open module ports to prevent contamination. •Clean any residual paint or contaminates from valve•mounting area. DO NOT DAMAGE O-RING SEAL AREA!Retain D05 solenoid valve.•Discard the (5) o-rings under the D05 valve and (4) socket head screws •used to retain the D05 valve.

D05 Diversion Module Installation:2.Lubricate and install supplied o-rings (Item No. 8) into•grooves on bottom of Diversion Module (Item No. 4).Install Diversion Module (Item No. 4) in correct orientation,•with o-ring grooves facings down.Lubricate and install o-rings (Item No. 8) into grooves on D05 valve.•Position D05 valve onto Diversion Module (Item No. 8).•Using (4) socket head screws (Item No. 5) fasten the D05•and Diversion Module to block. No Loctite required.Torque screws using sequence shown in Detail B to 5 lb-ft (7 N-m),•repeat torque sequence and torque per torque specification chart.

CECV Module Removal:3.Remove/Scrape paint (see Section D-D) along base of CECV Module•on the CECV Cover as shown with cross-hatching. Paint removercan be used instead of scraping.Remove and Discard existing CECV Module.•Cover open block ports to prevent contamination.•Clean any residual paint or contaminates from Module mounting area.•DO NOT DAMAGE O-RING SEAL AREA!

CECV Module Installation:4.Lubricate and install o-rings, supplied with CECV Module•(Item No. 1), into grooves on bottom of the module.Using (4) M10 socket head screws, supplied with the CECV•Module, fasten new CECV Module (Item No.1) to CECV Cover.No Loctite required.Torque screws using sequence shown in Detail C to 13 lb-ft (18 N-m),•repeat torque sequence and torque using torque specification chart.

CDB Module Modification:5.Remove CDB Module.•Cover open Cylinder Manifold ports to prevent contamination.•Clean any residual paint or contaminates from Module mounting area.•DO NOT DAMAGE O-RING SEAL AREA!Clean and remove any existing retaining compound in threads and•seal area of port.Remove existing #8 plug from CDB Module. See Section A-A.•Install elbow fitting (Item No. 9). Note fitting installed orientation.•Torque fitting per torque specification chart.Lubricate and install supplied o-ring (Item No. 12) into groove on•bottom of CDB Module.Use existing M10 screws and fasten the CDB Module back onto the•block. No Loctite required.Using torque sequence similar to Detail C, torque bolts per torque•specification chart.

Accumulator Assembly Installation:6.Remove (1) lifting eye from top of manifold block (see isometric view).•Install accumulator assembly (Item No 3) in location shown.•Apply Loctite (Item No. 11) to fasteners and fasten assembly to the manifold •assembly using (2) washers (Item No. 10) and (2) screws (Item No. 6). Torque (Item No. 6) per torque specification chart.•Connect pressure hose (Item No. 7A) from accumulator to D05 Diversion•Module and connect tank return hose (Item No. 7B) from accumulator toCDB Module.Torque hose fittings per torque specification chart.•

By-Pass Hose Support Bracket Installation:7.Apply, Loctite (Item No. 11) to end of rod (Item No. 2.2) with 0.75 inches•of thread. Install into Base (Item No. 2.1) tighten until threads are fully engaged, 0.75 inch. Apply Loctite (Item No. 11) to Socket Head Screw (Item No. 2.6) and fasten •hose support base to manifold assembly using supplied M16 screw. Note hose orientation shown and verify clearance in location indicated with "X". Tighten per torque specification chart. Do not apply Loctite to locknuts(Item No. 2.3). Fasten hose to bracket with Stauff clamp.•

Manual Bleed Valve Handle Positioning:8.Verify that the Manual Bleed Valve is completely closed by turning •clockwise. After closing valve, pull out handle to disengage it from needle valve. Without re-opening valve, rotate handle to position shown in Section E-E to prevent accidental opening of valve.

REISSUE DATE

NO.

DESCRIPTION

BucyrusInternational, Inc.

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MOD,CECV,CYLINDER MANIFOLD

S134590

SOLIDWORKSDRAWING

03-17-2011

DWG SIZE DSHEET

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THIS DOCUMENT IS PROTECTED UNDER APPLICABLE COPYRIGHT LAWS TO THE EXTENT AVAILABLE.ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BESUBJECT TO LIABILITY. C 2011 Bucyrus International, Inc. ALL RIGHTS RESERVED.

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Pressureconnection

Tankconnection

B Tankconnection

A Pressureconnection

Ref - Main Shut-OffValve Handle. Shownin open position.

Ref - Manual Bleed Valve.Turn clockwise to close.See Note 8.

2.2

2.3

2.4

2.6

2.1

C5-CECVModule

D D

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Remove #8 plug.See Assembly Note 5.

See Assembly Note 5

Pressureconnection

Tankconnection

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SECTION D-D

C5-CECV Module Cover

Remove paint fromcross-hatched area.See Assembly Note 3

Pre-Mod CECV Modulebefore removal.

54x

A PressureConnection

B Tank Connection

A PressureConnection

85x

B Tankconnection

Pressureconnection

C5-CECVModule

BTankconnection

Pressureconnection

SECTION E-E Ref Manual Bleed Valve.Turn clockwise to close.See Note 8.

Handle store positionSee Note 8.

(See Note 8)

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8 5x B

APressureConnection

TankConnection

2.3 2.4

2.5

2.1

2.6

2 4

Refer to: Assembly Note 2for Torque Procedure.

DETAIL B

Refer to: Assembly Note 4for Torque Procedure.

DETAIL C

DETAIL F

Insure handle is positioned as shown and "locked" with nut and bolt to prevent handle movement during operation.

SAE Size

Straight Thread

Nut Hex Size

Torque (Lubricated)(N-m)

Torque (Lubricated)(Ft-Lbs)

#6 .69-16 0.75 26 +/- 1 19 +/- 1.0

SAE Size

Straight Thread

Nut Hex Size

Torque (Lubricated)(N-m.)

Torque (Lubricated)(Ft.-Lbs.)

#8 .75-16 0.88 75 +/- 7 55 +/- 5

Style ThreadSocket Hex Key Size

Torque (Lubricated)(N-m) 12.9 Class

Torque (Lubricated)(Ft-Lbs)

Metric M6 x 1 6 mm 18 +/- 0.6 13 +/- 0.5Metric M10 x 1.5 8 mm 55 +/- 2.7 41 +/- 2Metric M16 x 2 14 mm 273 +/- 27.3 201 +/- 20

ORS Fittings

Socket Head Cap Screws

ORB Fittings

1 ISO 9001: 2000 Registered Firm

SERVICE ADVISORY Caterpillar Global Mining LLC 6744 S. Howell Ave Oak Creek, WI 53154, USA 414.768.4000 / Fax: 414.768.4570

Date: July 2, 2012

Advisory No.: 12-005 Revision No.: 0

MANDATORY Compliance with this advisory is mandatory. Failure to do so may result in machine failure.

SUBJECT: CYLINDER MANIFOLD MOUNTING PLATE

NOTE: IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH AS THOSE SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS WORK.

MODELS AFFECTED: 7495, 7495HF (HydraCrowd equipped machines only) MACHINES AFFECTED S/N’s: 141325, 141327, 141333, 141418, 141424, 141429, 141433, 141439, 141441, 141452, 141455, 141463, 141469, 141470, 141473, 141477, 141482 (and spare cylinders) Problem: The manifold mounting plate can become loose from the cylinder manifold.

Mounting Plate

pvaliente

Resaltado

2 ISO 9001: 2000 Registered Firm

Action: Install shims as required to ensure no gap between mounting plate and cylinder manifold. Parts will be provided at no charge to customer. Labor will not be included. The following items will be provided per machine:

- SHIM PACK,HYD CROWD CYL ASSY (P/N 1577755) – Quantity 1 - SCR,SOC,M12X1.75X55,CL 12.9 (P/N 1573785) – Quantity 7 - WASHER,BELEVILLE,M12 (P/N 1573597) – Quantity 7

Shimming Procedure:

- Fit mounting plate to cylinder manifold. - Install all bolts each side to 20% of final torque value (20 N-m) per torque sequence and procedure. Do not

use Loctite on the bolts at this time. - Ensure there is no gap between mounting plate and cylinder before taking measurements. - Measure the gap between the mounting plate and cylinder manifold at Location A and B. Measurements

should be taken at inboard sides of mounting plate as shown below. - Shim amount should be the average of the two measurements = (A measurement + B measurement)/2 - Install equal amount of shims on both sides. - Install all bolts with Loctite 243 (Blue). - Torque bolts to 100 N-m per torque sequence and procedure. - Ensure no gap between mounting plate and cylinder manifold. - Ensure no gap between mounting plate and cylinder.

Cylinder

Ensure there is no gap between mounting plate and cylinder.

Mounting Plate

Measurement Location A

Measurement Location B

3 ISO 9001: 2000 Registered Firm

Shims installed in these locations to ensure no gap between mounting plate and cylinder manifold.

4 ISO 9001: 2000 Registered Firm

Torque Sequence

5 ISO 9001: 2000 Registered Firm

Torque Procedure

If you have any questions on the above, please contact:

Caterpillar Global Mining LLC Product Health 6744 S. Howell Ave Oak Creek, WI 53154, USA 414.768.4000

Tensionadores SuperboltInstrucciones de instalación

SPA

NIS

H •

ESP

AÑ

Al apretar los tornillos de presión (jackbolts), se genera una gran fuerza de empuje dirigida contra la arandela endurecida. Los tornillos de presión tienen un pequeño diámetro de fricción y crean una gran fuerza de empuje con un par relativamente pequeño.

Las cargas se transfieren a través del cuerpo de la tuerca, que se coloca a mano a mano sobre la rosca principal.

La arandela endurecida se usa para transferir la fuerza a la vez que protege la cara de la brida y el cuerpo de la tuerca.

La fuerza de empuje (axial) de múltiples tornillos y la fuerza de reacción opuesta de la cabeza del tornillo principal crean una gran fuerza de apriete sobre la brida.

La fuerza de empuje (axial) del tornillo de presión crea una fuerza de reacción igualmente fuerte en el perno principal.

Cómo funcionan los tensionadores Superbolt:

Con los tensionadores SuperboltTM usted ha elegido un un producto tecnológicamente superior.Se trata de un producto puramente mecánico y, por tanto, muy seguro.

Los siguientes pasos sencillos le ayudarán con su aplicación. Al seguir éstas instrucciones podrá incrementar la seguridad, reducir el tiempo de parada y ampliar la vida en servicio.

Contenido page/s

1. Procedimiento de apriete 4/5 2. Procedimiento de aflojado 6/7 3. Lubricante y herramientas 8/9 4. Mantenimiento 10 5. Indicaciones generales 11 6. Contacto 12

Estas instrucciones son válidas para la gama estándar de tensionadores Superbolt, conformes a las fichas técnicas de Nord-Lock AG:

Tuercas tensoras: – MT / MTT / MTL / MTA – MR / MRA – CY – SJ / SJL / SJX – GR2 – SM – H650 / H650T – H850 / H850T – SH / SHT – PV350C / PV450C

Tornillos tensores: – SB8 – SB12 – SBU – SSJ

Instrucciones

1.1 Comprobar:Cuál es el par de apriete del tornillo de presión? Para el par M recomendado, véase: – Sus instrucciones internas– Certificado de Nord-Lock AG– Fichas técnicas de Nord-Lock AG

Atención: EI par de apriete gravado es normalmente el valor admisible máximo, pero podría ser inapropiado para su aplicacion!

Si no está seguro, póngase en contacto con su oficina Nord-Lock más cercana.

1.2 ¿Qué herramientas se deben utilizar?– Llave dinamométrica apropiada – Llave de vaso apropiada, serie gruesa– Lubricante

1.3 Preparación:– Limpie Ia rosca principal y las superficies de

contacto, engrase bien el producto con el lubricante apropiado (A) y coloque la arandela (B).

– Asegúrese de que los tornillos de presión en el lado de carga no sobresalen del tensionador Superbolt y que están bien engrasados. Si resulta necesario, reengrase con el lubricante Superbolt recomendado (véase el certificado).

– Apriete a mano firmemente el cuerpo de la tuerca (D).

– A continuación afloje aprox. ¼ de vuelta. Dependiendo del tamaño, el espacio de separación (E) será de 1 a 3 mm aprox.

1. Procedimiento de apriete

1–3 mm

1.4 Apriete:Paso 1: Apriete 4 tornillos a mano o usando una pequeña llave para centrar la rosca principal y para eliminar holguras. Apriete los tornillos en cruz.

Paso 2: Apriete los mismos 4 tornillos en cruz con el 50% del par recomendado para los tornillos de presión.

Paso 3: Apriete los mismos 4 tornillos de presión al 100% del par.

Paso 4: Ahora cambie y apriete de forma circular todos los tornillos al 100% del par recomendado.

Paso 5: Repita el paso 4 hasta que todos los tornillos estén apretados uniformemente (menos de 10º de movimiento) . Normalmente son suficientes de 2 a 4 pasadas, sin embargo con los pernos mayores pueden necesitarse más.

Los atornilladores de impacto pueden ahorrar tiempo, véase el punto 3.3. 5

50%

100%

Atención! El aflojado requiere un procedimiento exacto. Los tornillos de presión se deben aflojar gradualmente! En ningún caso descargue completamente los tornillos. Los restantes tornillos de presión soportarían entonces toda la carga y por lo tanto el aflojado sería muy difícil. En casos extremos los tornillos se podrían deformar e imposibilitar el aflojado.

2.1 Empleo a temperaturas normales (< 100 °C)Preparación: antes del aflojado, emplear aceite penetrante, especialmente si se ha formado alguna capa de óxido.

Paso 1: Comenzando con el tornillo Nº 1 (elegido arbitrariamente) y en sucesión circular afloje cada tornillo ¼ de vuelta (basta iniciar el aflojado). Tras la primera vuelta apriete el tornillo Nº 1, aunque a un nivel de carga inferior.

Nota: En caso de que se deban aflojar varios elementos de tensado como, por ejemplo bridas, realice el paso 1 en todos los elementos, antes de proceder al paso 2.

Paso 2: Repita el paso 1, de nuevo en todos los tensionadores.

Paso 3: Repita el paso 1 en una 3ª vuelta.

Paso 4: Destense por completo los tornillos de presión. A continuación afloje el tensionador a mano.

Nota: los tornillos largos se expanden más y, por lo tanto, pueden necesitar 2 o más pasadas.

Atención: Antes de proceder con la reutilización, consulte las instrucciones de mantenimiento!

2. Procedimiento de aflojado

1/4

2.2 Empleo a altas temperaturas (> 100 °C)Preparación:A temperaturas elevadas la base de petróleo del lubricante se evapora, y por lo tanto el esfuerzo de aflojado se incrementa.

Paso 1: Aplique de ser posible el aceite penetrante durante el enfriamiento de la instalación (a unos 150º C). A temperaturas superiores, emplear aceite sintético.

Paso 2: Comenzando con el tornillo Nº 1 (elegido arbitrariamente) y en sucesión circular afloje ¼ de vuelta cada uno de los tornillos del tensionador (basta iniciar el aflojado). Nota: No gire ningún tornillo de presión más allá del inicio del aflojado. Si se usan varios tensiona- dores en la unión, aplique este procedimiento a todos ellos antes de seguir con el siguiente paso.

Paso 3: Complete el procedimiento de aflojado según lo descrito en el Punto 2.1 (caso normal), comenzando con el Paso 1.

Nota: Para las aplicaciones a alta temperatura se utilizan frecuentemente tornillos con agujeros. Mediante el uso de varillas de calentamiento se puede acelerar el proceso de aflojado. Cinco minutos de calentamiento serán suficientes para acelerar el proceso.

1/4

3.1 LubricanteTornillos de presión: Los tornillos de presión se suministran engrasados, listos para ser usados. Consulte el certificado en lo referente al lubricante. Para los tornillos de presión se recomienda utilizar exclusivamente el lubricante Superbolt o recomendado por Nord-Lock AG.

Arandelas de presión: Utilice el lubricante Superbolt adecuado en Ia cara superior (en contacto con los tornillos de presión). En la cara inferior se puede utilizar cualquier tipo de lubricante.

Rosca principal: Se puede utilizar cualquier tipo de lubricante además del lubricante Superbolt. Aplíquelo con pincel o pulverizador.

3.2 Llaves de vaso Para el apriete de los tornillos de presión se deben utilizar únicamente herramientas de calidad en buen estado. Lo más apropiado es usar Llaves de vaso hexagonales. Las bocas gastadas son peligrosas y no deberían utilizarse.

3.3 Atornilladores de fuerza Los atornilladores de impacto de aire comprimido son los más apropiados aunque con los tornillos de presión Superbolt alcanzan solamente entre un 30 y 50% de su potencia (recor ridos cortos). Por ello, es preferible utilizar grandes secciones de manguera y acoplamientos. Debido a las elevadas fuerzas y usos continuados, utilice exclusivamente productos industriales. El par de apriete se puede comprobar fácilmente con el tornillador de impacto de aire comprimido: Apriete hasta que se detenga, a conti nuación mida el par con una llave dinamométrica (mejor con visualización electrónica).

3. Lubricante y herramientas

3.3 Atornilladores de fuerza (continuación)El par de apriete se puede regular fácilmente: instale una unidad de mantenimiento (filtro, regulador, engrasador) directamente delante del atornillador. Ajuste en el regulador Ia presión, y con ello Ia potencia del atornillador. Apriete un tornillo de presión Superbolt con Ia llave dinamométrica al par de apriete deseado, a continuación aplique el atornillador y aumente Ia presión hasta que el tornillo de presión comience a girarse de nuevo.

En cuanto el atornillador gire, compruebe que Ia presión en el regulador no disminuye, de lo contrario se produciría una caída de presión en Ia red de conducción. Para ello sería conveniente aprovisionarse de secciones de manguera de grandes dimensiones! Si utiliza con regularidad atornilladores de impacto de aire comprimido, es recomendable utilizar un mando de control (disponible bajo pedido).

Para el apriete, el paso 2 al paso 5 es especialemente apropiado para este tipo de herramientas y se deben ajustar del 90 al 100% del par de apriete M.

Nota: debido a la baja precisión de los atomilladores de impacto de aire comprimido es recomendable realizar Ia última vuelta de apriete a mano con una llave dinamométrica apropiada.

Nota: Durante el aflojado se ruega precaución: utilice los atornilladores normales de aire comprimido únicamente para el paso 4 (aflojamiento completo), nunca para los pasos 1 a 3.

Información útil para la utilización del atornillador de impacto de aire comprimido:

Presión mín. 6,5 bar:

– hasta 70 Nm atornillador de impacto de 3/8“ o trinquete por aire – 70-130 Nm atornillador de impacto de 1/2“, estrangulado (Atención: No rebasar Ia capacidad!) – 130-200 Nm atornillador de impacto de 1/2“ – 200-270 Nm atornillador de impacto de 1/2“ (manual) o de 3/4“ – más de 270 Nm atornillador de impacto de 3/4“ – más de 400 Nm atornillador de impacto de 3/4“ 9

M [Nm]

4.1 Inspecciones habituales Las uniones atornilladas diseñadas adecuadamente y que usan tensionadores Superbolt mantienen su precarga con la condición de que estén correctamente apretadas. Las precargas se pueden controlar durante las inspecciones. Usen una llave dinamométrica ajustada al 100% del par de apriete permitido según el certificado del procemiento de su instalación. Si en contra de lo esperado los tornillos de presión se han aflojado, se recomienda realizar el siguiente procedimiento: - Aflojar y sacar un tornillo de presión. Limpiar y lubricar con el producto antiagarrotamiento especificado en el certificado de Nord-Lock. Posteriormente recolocar el tornillo de presión y volver a apretarlo al 100%. Repitan el proceso para cada tornillo de presión. - Ahora tensar de nuevo según el procedimiento de apriete- Paso 5, es decir, apretar de forma circular todos los tornillos al 100% del par recomendado, hasta que todos estén apretados.

4.2 Mantenimiento preventivo P. ej.desinstalación para realizar tareas de mantenimiento:

– Desafloje siguiendo el procedimiento de aflojado.

– Limpie la rosca y los extremos de los tornillos de presión Superbolt y trate con el lubricante indicado en el certificado. No use disulfuro de Molibdeno (MoS2) si no está expresamente indicado en el certificado.

– Las arandelas endurecidas se pueden reutilizar a pesar de las marcas de contacto simplemente dándolas la vuelta. Son normales las huellas de algunas centésimas de mm.

– Apriete de nuevo según el procedimiento de apriete.

4.3 ¿Qué hacer en caso de problemas? Problema: Los tornillos no pueden aflojarse:

– Intente retirar al menos un tornillo de presión. – Rengrase adecuadamente y apriete al 110 % del par de apriete recomendado. – Los 2 tornillos de presión contiguos se deberían aflojar.– Retírelos también, engrase y apriete de nuevo al 110 % del par de apriete recomendado. – Los dos tornillos de presión siguientes se deberían de aflojar.– Realice el mismo paso. – A continuación, suelte todos los tornillos de presión según el procedimiento de aflojado.

Problema: Las arandelas endurecidas están dañadas tras un largo tiempo en servicio: – Sustitúyalas por arandelas endurecidas Superbolt originales.

Problema: Los tornillos de presión están dañados o se han perdido: – Sustitúyalas por tornillos de presión originales Superbolt. No utilice tornillos comerciales ya

que no son apropiados para cargas tan altas. Otros problemas: Para más información, por favor diríjase a su oficina Nord-Lock más cercana.

4. Mantenimiento

5.1 Apriete de elementos de tensado con solo 4 o 6 tornillos de presión Paso 1: Apriete en cruz ligeramente con Ia mano todos los tornillos de presion. Paso 2: Apriete 2 tornillos de presión situados opuestamente al 50% del par de apriete M. Paso 3: Apriete los otros 2 tornillos de presión situados opuestos al 100 % del par de apriete M. Paso 4: Apriete todos los tornillos de presión de forma circular aplicando el 100% del par hasta que estén bien atornillados.

5.2 Apriete de anclajes largosPara acelerar el tensado de anclajes largos recomendamos realizar el paso 4 durante algunas vueltas con un par de apriete aumentado (aprox. 110-125 %).Atención: en las últimas pasadas comprueben que el par de apriete de los tornillos de presión está al 100% para evitar sobrecargas.

5.3 Juntas con largos recorridos de alargamientoEs normal que algunos tornillos de presión (o algún tensionador en una aplicación con múltiples tensionadores) se afloje durante el apriete de la brida. Sólo soportarán la carga los tornillos apre-tados. No reajustar los tensionadores sueltos ya que si no habrá problemas posteriormente.

5.4 Tensado de grandes bridas o de juntas de división Es preferible que se realice con 2 personas desplazadas cada una 180°, o con 4 personas desp lazadas 90°.

5.5 Uso de distanciadoresLos tensionadores deberían posicionarse en en la parte más externa del perno para proteger la rosca principal. Coloquen distanciadores o arandelas gruesas adecuadas debajo de la arandela endurecida. Así se pueden puentear las zonas roscadas dañadas.

5.6 Herramientas de instalación Además de las diversas herramientas estandar existentes para la instalación de los tensionadores Superbolt, también existen herramientas especiales sencillas, las cuales simplifi can el montaje de tuercas o tornillos grandes.

5.7 Capuchones protectores De PVC, acero o acero inoxidable están disponibles para proteger al tensionador según sea el empleo. Rellenos de grasa, ofrecen una buena protección contra la oxidación a temperaturas normales.

5. Indicaciones generales

Para más información sobre posibles usos, aplicaciones y mantenimiento de los sistemas de tensionado Superbolt. Por favor contacten con su distribuidor local de Nord-Lock o directamente a www.nord-lock.com/contact

Exclusión de responsabilidadDebido al esfuerzo hecho para asegurar la corrección del manual de instrucciones, el Grupo Nord-Lock declina toda responsabilidad por la selección inapropiada del producto para una aplicación específica, por el empleo inadecuado, asi como por los daños que se originen por no observar nuestras instrucciones y directrices.

El Grupo Nord-Lock se reserva los cambios debidos debidos a los progresos técnicos.

© Copyright 2014 Nord-Lock Group. NORD-LOCK and SUPERBOLT are trademarks owned by different companies within the Nord-Lock Group. All other logos, trademarks, registered trademarks or service marks used herein are the property of the Nord-Lock Group. All rights reserved.

6. Contacto

Nord-Lock AGRietwiesstrasse 2, CH-8735 St. Gallenkappel, SwitzerlandTel: +41 (0)55 284 64 64, Fax: +41 (0)55 284 64 69Email: [email protected]

Nord-Lock GroupTel: +46 (0)31 7192 300, Fax: +46 (0)40 240 851Email: [email protected]

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