SI

DESARR

ISTE

ROLLO TC

EMA

P

CNICO

ANE

CUR

A HY

PALA

EXO

RSO

YDR

A 74

OS

O:

RAC

495

Gu

CRO

5

ido Llallacac

WD

chi

D

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 hasnt 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

C*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

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).

*

2

QTY ITEM NO. DESCRIPTIONREF 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. DESCRIPTIONREF 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

.12

.19

.19

.25

.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'

DA

TEBY

DES

CRI

PTIO

N

REV

DET

ENGCONTACTNO.

MODEL UNIT

DATE

FIN WGT

DESCRIPTION

REF DWGS

3

4

1 2

4

3

21

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

.06

.12

.09

.19

.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

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

GC

OPY

RIG

HTED

-CUS

TOM

ER IN

FORM

ATIO

N D

RAW

ING

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

GC

OPY

RIG

HTED

-CUS

TOM

ER IN

FORM

ATIO

N D

RAW

ING

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

1

DWGSIZE D

SHEET

REV

25OF

ECN

2V

itas J

.08

-08-

2013

8115

0

ITEM 6 WAS 4280938. CHANGED SUPERBOLT

INSTALLATION INSTRUCTIONS ON SHEET 4.

REVISION DATA

R

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

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

C29 34

24 31 35

30

22

14

153

1

2

20

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

5 47 48

25 37

40

A3A3

H

J20

210

9

3

1

5

4

22 31

19 46

18 46

B3 B3

C3

G3K3

K3

17

44

64

23

29

34

5

1

2

20

23

26 36

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

18 45

D3

D3

L

20

26 36

2231

243135

23

44

64SEE NOTE 6(SHEET 1)

65

DETAIL H

14

21

21 58

58

DETAIL J

29

29

34

34

4

3

27 38SEE NOTE 2(SHEET 1)

2537

P

P

DETAIL L

52

53

21

542150

17

SEE NOTES 14 &16(SHEET 1)

51

SECTION P-P

17

59

55 5858

60

62

57

60

63

58

61

58

56 58

54

REISSUE DATE

NO.

DESCRIPTION

BucyrusInternational, Inc.

3

4

1 2

4

3

21

R

PWR MODULE,HYD CROWD,MECH ASSY

1579888

SOLIDWORKSDRAWING

08-08-2013

2

DWG SIZE DSHEET

OF 5

REV 2

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

GC

OPY

RIG

HTED

-CUS

TOM

ER IN

FORM

ATIO

N D

RAW

ING

CE FR

R

SECTION A3-A3

DETAIL E22

13

314

15

16

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

3

2

6

7

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

44

44

44 43

41

42

QTY (8)

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

41

42

2

44

34

64

283933

SEE NOTE 6(SHEET 1)

1.88(8 PL)

DETAIL C3

28

44

6433

39

DETAIL G3

2738

2537

22 31

8

109

4

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.

2

10

14

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.

3

4

1 2

4

3

21

R

PWR MODULE,HYD CROWD,MECH ASSY

1579888

SOLIDWORKSDRAWING

08-08-2013

3

DWG SIZE DSHEET

OF 5

REV 2

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

GC

OPY

RIG

HTED

-CUS

TOM

ER IN

FORM

ATIO

N D

RAW

ING

C20

2

3

5

1

4

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.

2

REISSUE DATE

NO.

DESCRIPTION

BucyrusInternational, Inc.

3

4

1 2

4

3

21

R

PWR MODULE,HYD CROWD,MECH ASSY

1579888

SOLIDWORKSDRAWING

08-08-2013

4

DWG SIZE DSHEET

OF 5

REV 2

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

GC

OPY

RIG

HTED

-CUS

TOM

ER IN

FORM

ATIO

N D

RAW

ING

C.25

W

W

Y

Y

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)

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.

3

4

1 2

4

3

21

R

PWR MODULE,HYD CROWD,MECH ASSY

1579888

SOLIDWORKSDRAWING

08-08-2013

5

DWG SIZE DSHEET

OF 5

REV 2

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

G

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

CO

PYRI

GHT

ED-C

USTO

MER

INFO

RMA

TION

DRA

WIN

GC

OPY

RIG

HTED

-CUS

TOM

ER IN

FORM

ATIO

N D

RAW

ING

"2%1((-((12,, (HI%F)

8 !@J

8 ,2.%7I%

3%-."%9)$$

$ $ $

( 2 %1 %"%-2 3%-."%:).

! " #

$ % & ' ( ) *

+ ( ,

' & - . & ( % & /

& ) ' ) % ) '

( % & ' ( ) *

( 0 ' , ( , 1 & * 2 , 3 & % , *

, 3 , ( - & , 4 , *

" , 4 . , 3 $ . , 3 1 &

5 + & 6 ' , 4 )

2 . * % ) ( & *

& * 7 3 , 8 , 9 & . ( % )

. 1 )

7 & ' , 4 , *

4 . ' & - % , 9 & ( % &

7 & ' , 4 , *

7 ) ' 7 . 3 ) % )

2 , 3 & % , *

2 . * % ) ( & *

" , 4 . , 3

2 . * % ) ( & *

$ . , 3

1 &

5 + & 6 ' , 4 )

2 . * % ) ( & *

& * 7 3 , 8 , 9 . & ( % )

: , ' . , 6 3 &

) 9 6 , * ; . 4 ' < + 3 . - , *

4 & 4 & * 7 3 , 8 , 9 . & ( % ) 7 ) * . % . = )

.'

> ? ? @ @ A

$ . .

. &

> .

8 (,,2.%7I%

B C @ ?

80 &2-%(1

. ..! &% -."% 0

' $...A' : . $ . . ).

>'

$

# . 6. $ . : $> > . .>! / $ $ # )! #.)84 &2%"2

)

$ (6>' . $ !

85 %((12%(1

&. .) /.

:. $ . ) .

'$...) : ) . ) $) $' .>$ . )* . ) ! / . $

.. : $ . . '/ . 6 .$

88 "(

I . !'$

:$> $ ! !.. &

:(-."%0$!? 6 .

! ). .

0 ).

A# 5$).

D ? G

& $ .

). / . !$

! $ : $

89 ,(F2%C"(

! & -."%00$ $ . > > $ ) $ )

BOMBA DE PALETAS

Jose Manuel Arroyo Rosa Pgina 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 cm. Pueden ofrecer presiones de servicio de hasta 150

bar.

Son muy sensibles al nivel de limpieza del aceite. Un aceite con partculas en suspensin podr originar una avera 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 cmaras 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, apoyndose en la carcasa.

BOMBA DE PALETAS

Jose Manuel Arroyo Rosa Pgina 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 excntrico.

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

zonas de cmara 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.

.

BOMBA DE PALETAS

Jose Manuel Arroyo Rosa Pgina 3

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

anillo excntrico 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 cmaras.

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 mxima presin (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 posicin excntrica segn la figura.

A medida que aumenta la presin en el sistema, aumenta tambin la fuerza Fh y la

vence el resorte desplazando el estator a una posicin concntrica.

BOMBA DE PALETAS

Jose Manuel Arroyo Rosa Pgina 4

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

de la bomba sea nulo.

La bomba mantiene la presin en el circuito segn tengamos ajustados los tornillos de

regulacin.

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

Estas ltimas no varan 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 presin.

Estos pistones tienen diferente dimetro, siendo el ms grande el que se dedica que la

bomba se encuentre en una posicin excntrica.

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

Q = D(D-d)bn/1000000

Q : Caudal terico en l/min.

D : Dimetro de la cmara interior de la carcasa en mm.

d : Dimetro del rotor en mm.

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

n : velocidad de giro del engranaje en rpm.

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

que el Qreal ser:

Qreal = Qterico 0,8

temariosformativosprofesionales.wordpress.com

temariosformativos.foroactivo.com

89 ,2I276",%2

!.>>!$$

gllallacachiResaltado

gllallacachiResaltado

89 "( ! . $ .. . . $ : . $>-."%:;. $ ) $ $ $

$ $ 3% -."% ;)$$$$

-."% ;' . . . !. $ $ 1

890 %-%(12%6"%1>!.$..

! . . . $ . . -."% ;# ( . (! $ . .

" #

-."%;#$ $. $

$ (.. $ .

89# 7%(222"((1 ! . .!) . $)> !))) ) $!. )&-."%;4$

! 6

> $

$ # %

$$ $ !. ) > !. #).0P$

47,, . ) & $ .

. ! )-."%;5. $ $ ) .>@..> $

& # % ' ' %

#> $) $ $ $:.>

$R#H

( # ) ' ' %

* #

+

894 %.F2%C"(2(>.$ )

: > )$

> . $ ( $ .> .

895 K2&C&"22%,"(1-A%(

$ ! $ .

/> $.(

)& $ $

)$'

ContaminationSensor CS1000 Analog Output (ANAOUT)

ISO Code acc. to 4406:1999

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

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

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

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

x 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 m(c), >6 m(c) and >14 m(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)

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

11

SP 7

.958

.0/0

7.12

ContaminationSensorSerie CS 1000

DescripcinEl ContaminationSensor serie CS 1000 es un sensor de fluidos en lnea que detecta de forma continua la contaminacin de sustancias slidas en fluidos.La indicacin de la clase de pureza puede efectuarse conforme a las normas ISO/SAE o ISO/NAS.El usuario dispone de un sensor estacionario pequeo y resistente, fabricado con la tecnologa y los materiales ms modernos, segn la tcnica probada.Gracias a su estupenda relacin prestacin-precio es especialmente interesante para aplicaciones OEM de control de estado (Condition Monitoring).

Campos de aplicacin zSistemas hidrulicos y de lubricacin industriales zHidrulica mvil

Ventajas zOpcionalmente puede conmutar entre ISO 4406:1999 / SAE AS 4059 y ISO 4406:1987 / NAS 1638 zDeteccin temprana de estados crticos de la mquina zControl continuo de los estados del aceite zPlan de mantenimiento en funcin del estado de la maquinaria

Datos tcnicosDatos generalesAutodiagnstico Continuo, con indicacin de fallos a travs del

LED de estado y el visualizadorVisualizador (solo CS 1x2x) LED, 6 dgitos, cada uno con 17 segmentosMagnitudes de medicin 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)

Posicin 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 Mx. 95 %, no condensableJunta FPM para CS1xx0 / EPDM para CS1xx1 Clase de proteccin III (tensin baja de proteccin)Tipo de proteccin IP67Peso 1,3 kgDatos hidrulicosMargen de medicin Indicacin 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

Precisin +/- clase ISO en margen calibradoPresin de servicio 300 bar mx. / 4350 psi mx.Conexin hidrulica Empalme de tubos rgidos y flexibles (A,B): rosca

G1/4, ISO 228 o conexin con brida (C,D): DN 4Caudal de medicin admisible 30 ... 300 ml/minMargen de viscosidad admisible 1 ... 1000 mm/sRango de temperatura del medio 0 ... +85 C, +32 ... +185 FDatos elctricosClavija de conexin M12x1, 8 polos, segn DIN VDE 0627 o

IEC61984Tensin de alimentacin 9 ... 36 VCC, ondulacin residual < 10%Consumo de potencia 3 Watt mx.Salida analgica (tecnologa de 4 hilos)

Salida 4 ... 20 mA (activa): carga mx. 330 o Salida 0 ... 10 V (activa): resistencia mn. de carga 820

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

Interfaz RS485 Bifilar, semidplex para transferir el protocolo HSI en conexin con un PC

HSI (HYDAC Sensor Interface) Monofilar, semidplex

gllallacachiResaltado

12

SP 7

.958

.0/0

7.12

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

Tipo CS = ContaminationSensorSerie 1 = Serie 1000, 4 canales de tamao de partculas

Codificacin de la contaminacin 2 = ISO 4406 : 1999 ; SAE AS 4059 (D) / >4 m(c) >6 m(c) >14 m(c)>21 m(c) 3 = ISO 4406 : 1987 ; NAS 1638 / > 2 m > 5 m > 15 m > 25 m conmutable ISO 4406 : 1999 ; SAE AS 4059 (D) / >4 m(c) >6 m(c) >14 m(c) >21 m(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 ster fosfatadoInterfases analgicas A = 4 ... 20 mA B = 0 ... 10 V

Salida de conmutacin 0 = Salida de conmutacin de valor lmite

Interfaz digital 0 = RS485Tipo de conexin elctrica 0 = conector M12x1 de 8 polos, clavija, conforme a VDE0627 o IEC61984Conexin hidrulica (ver pgina 3) 0 = Conexin para tubo rgido o flexible 1 = Conexin con bridaNmero de modificacin 000= Estndar

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

Certificado de calibracin Instrucciones breves 2 juntas tricas en la versin con conexin por brida

Opciones Caja de acoplamiento con 2 m de cable, apantallado, 8 polos, M12x1, N art.: 3281220

Caja de acoplamiento con 5 m de cable, apantallado, 8 polos, M12x1, N art.: 3281239

Cable prolongador 5 m, caja de acoplamiento 8 polos, M12x1 / enchufe de acoplamiento 8 polos, M12x1, N art. 3281240

Caja de acoplamiento con borne roscado, 8 polos, M12x1, N art.: 3281243

13

SP 7

.958

.0/0

7.12

Dimensiones

CS1x1x sin visualizador

CS1x2x con visualizador

Vista por la cara inferior

Conexin de tubo rgido o flexible

Conexin con brida

Tipos de conexiones hidrulicas

Conexin de tubo rgido o flexible

Conexin con brida

Giro del visualizador

Presin - Margen de viscosidad

Junta trica

Tapn roscado

p : presin : viscosidad

Junta trica

14

SP 7

.958

.0/0

7.12

Tipos de montaje

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

para conexin de tubo rgido o flexible para conexin con brida

Sujecin de pared a consola Fijacin sobre placa abridada, placa de conexin o bloque de mando

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

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: filtersystems@hydac.com

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/Ns: 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 isnt 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

PREL

IMIN

AR

Y SA

MPL

E U

SE F

OR

REF

EREN

CE

ON

LY N

ovem

ber 2

0,SIS Media Number: BI646664Hydraulic Crowd Service ProceduresInspection BI010733

9.5.9 Accumulator InspectionThe 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 PressureIf 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 operators 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.9 50 Electric Rope Shovel SM141494-ENNovember 2012

PRELIM

INA

RY SA

MPLE U

SE FOR

REFER

ENC

E ON

LY N

ovember 20,

SIS Media Number: BI646664Hydraulic Crowd Service ProceduresBI010733 Inspection

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 NitrogenSM141494-EN Electric Rope Shovel 9 51November 2012

PREL

IMIN

AR

Y SA

MPL

E U

SE F

OR

REF

EREN

CE

ON

LY N

ovem

ber 2

0,SIS Media Number: BI646664Hydraulic Crowd Service ProceduresInspection BI010733 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 to

minimize 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.9 52 Electric Rope Shovel SM141494-ENNovember 2012

PRELIM

INA

RY SA

MPLE U

SE FOR

REFER

ENC

E ON

LY N

ovember 20,

SIS Media Number: BI646664Hydraulic Crowd Service ProceduresBI010733 Inspection

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 20C. 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.SM141494-EN Electric Rope Shovel 9 53November 2012

PREL

IMIN

AR

Y SA

MPL

E U

SE F

OR

REF

EREN

CE

ON

LY N

ovem

ber 2

0,SIS Media Number: BI646664Hydraulic Crowd Service ProceduresInspection BI010733

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 20C, but the actual pressure in the accumulator willbe dependant on the ambient air temperature.

Charging/Gauging Unit PN: S1345789 54 Electric Rope Shovel SM141494-ENNovember 2012

PRELIM

INA

RY SA

MPLE U

SE FOR

REFER

ENC

E ON

LY N

ovember 20,

SIS Media Number: BI646664Hydraulic Crowd Service ProceduresBI010733 Inspection

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 replaceSM141494-EN Electric Rope Shovel 9 55November 2012

the sealing ring and recharge the accumulator.

PREL

IMIN

AR

Y SA

MPL

E U

SE F

OR

REF

EREN

CE

ON

LY N

ovem

ber 2

0,SIS Media Number: BI646664Hydraulic Crowd Service ProceduresInspection BI010733 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.9 56 Electric Rope Shovel SM141494-ENNovember 2012

PREL

IMIN

AR

Y SA

MPL

E U

SE F

OR

REF

EREN

CE

ON

LY N

ovem

ber 2

0,SIS Media Number: BI646664Hydraulic Crowd Service ProceduresHydraulic Crowd Service Schedule BI010733

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 section9 184 Electric Rope Shovel SM141494-ENNovember 2012

** After initial start up only

PRELIM

INA

RY SA

MPLE U

SE FOR

REFER

ENC

E ON

LY N

ovember 20,

SIS Media Number: BI646664Hydraulic Crowd Service ProceduresBI010733 Hydraulic Crowd Service Schedule

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 30,000SM141494-EN Electric Rope Shovel 9 185November 2012

!

!"#

$

"##!

"$%&'$%

!(!

)*#$+),

!!-!#

#.!

% &

(#/0#'($)

*

11111111111111111

*

*2!311111111111111111

(+

4!5-!..+,-./ *0/ 1

23415 -,-.6"! / "6!"#*+& -"16!!! &(1!!7!!! *898:- -*8

6;/ ---8

$#

*306 6

) (!!7

$ !#!7

, *2!8

#**" >/**************************************************************************7#** ****************************************************************************2#**# 0*************************************************************************************************4#**#*" = ***************************************************************************************4#**#* 0*********************************************************************************************"!#**#*# *******************************************************************************************"!#**#*3 0 *****************************************************************************************""

#*3*"

$3

) (

,-.5 2341-(5 2* (6*

- /5

3&"!*

+ ;/;"16!!!- (1!!7!!!

0 *

+

;

+ ,-.-

+

-

898:$9$:

$ *9

< 16+2341,-.5

/"! ,-. /* +

6 *+/"/-

- - 6 6

*8/

*

$ >"72-

$1

.!: 0 ; #

"2 "3"#1 #@!!

$ "7! "3"311 121!

"23 "3"37# "1!!

"@# "3"33" "!!!

$ "@# "3"33" "!!

"72 "3"31 1!!!

"2@ "3"322 1!!

"72 "3"31 "!!

"72 "3"31 !!

"77 "3"3"@ 7!!!

+/" >,-.

9A 6A6$A$ :B

, **0

$7

0 ";

-,-.-

,$ #!##+ -C-*0 - 8@"*

,$)!50/*##0 - * >/ 9 >/: -

883"3!11,=

+ 0 - (-*;

/ (- ( - -, +(

+

$2

0 +

0 #

,$$.5!!.!0 3- -F@!&3!"&4"7&!!7*+ / 8@"*G - (- -& 5 (- *0 1-

/(-!*77H !*1H*+*

$@

0 38@";

0 1 (- *

+II-JH$

5!5+IA,C

Caterpillar Confidential: YELLOW / WHEREVER THERES MINING. 1

February 8, 2012

HydraCrowd Initial Start-up Procedure

Caterpillar Confidential: YELLOW / WHEREVER THERES 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 MEASURES SUCH AS THOSE SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE 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 THERES 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 THERES 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 THERES 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 THERES 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 THERES 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 THERES 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 operators 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 THERES 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 THERES 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 THERES 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 THERES 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 operators 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 retr