AN X S CU S : S ST M H D A ROW PAL 7 9
DESAR OLLO T
NICO
Guido Llallaca hi
SIS Media Number: BI646626 Media Number: SA13-025
August 19, 2013
SIS Media Number: BI646626 Media Number: SA13-025
August 19, 2013
Special Instruction ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________ ________________________________
Adjusting Main Pump Relief Pressure on 7495 and 7495HF HydraCrowd Euipped Ele!tri! Rope "#o$els Ele!tri! Rope "#o$els Model
%dentifi!ation &um'er
E(panded Produ!t )ine "erial &um'er
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
ER801209
141209
ER801325
141325
ER801327
141327
ER801333
141333
ER801424
141424
ER801429
141429
7495!
SIS Media Number: BI646626 Media Number: SA13-025
ER801433
141433
SIS Media Number: BI646626 Media Number: SA13-025
ER801433
141433
ER801483
141483
%ntrodu!tion "#is special instruction pro$i%es t#e in&or'ation to a%(ust t#e 'ain pu'p relie& pressure on )%ra*ro+% euippe% 7495 an% 7495! Electric Rope S#o$els-
%mportant "afety %nformation
"*+RE, E&ER-./ Hydrauli! pressure must 'e relie$ed relie$ed prior to performing t#is t#is pro!edure0 Hydrauli! fluid under pressure pressure may !ause injury or deat# if not released in a !ontrolled manner0
Reuired *ooling *++)"1 2 mm Allen 3ey mm Allen 3ey 9 mm 6ren!# 1- Set t#e %ipper &lat on t#e groun% an% lo+er t#e #oist until until t#e pa%loc.s are %o+n an% t#e #oist ropes are slac.-
SIS Media Number: BI646626 Media Number: SA13-025
SIS Media Number: BI646626 Media Number: SA13-025
%llustration 1 Padlo!s )owered 2- S#ut%o+n t#e 'ac#ine'ac#ine- /oc.out an% tagout tagout controls in co'pliance +it# local regulations3- Install a 08000 psi pressure pressure gauge on t#e pressure outlet outlet test port o& eac# 'ain pu'p- It is i%eal to 'onitor all 4 pu'ps at t#e sa'e ti'e %igital pressure gauge in t#e S127020 co''issioning .it #as t#is capailit)-
Pressure Outlet Test Ports
%llustration 1 Preesure +utlet *est Ports 4- "o a%(ust in%i$i%ual pu'p relie& pressure, re'o$e t#e c)lin%rical relie& $al$e co$er See Illustration 3 &or location mm Allen 3ey
SIS Media Number: BI646626 Media Number: SA13-025
SIS Media Number: BI646626 Media Number: SA13-025
Pump PUV Relief Valves
%llustration 81 Pump P: Relief :al$es
Cylindrical Cover Held in Place by Socket Head Screw
%llustration 41 Cylindri!al Relief :al$e Co$er Retaining "!rew 5- it# t#e c)lin%rical c)lin%rical relie& $al$e co$er re'o$e%, loosen t#e (a' nut securing t#e a%(ust'ent scre+ in place9 mm 6ren!#
Adustment Screw
!am "ut
%llustration 51 Relief ;am &ut and Adjusting "!rew
SIS Media Number: BI646626 Media Number: SA13-025
6- nce t#e relie& relie& $al$es are epose%, re'o$e loc.out tagout tagout &ro' 'ac#ine
SIS Media Number: BI646626 Media Number: SA13-025
6- nce t#e relie& relie& $al$es are epose%, re'o$e loc.out tagout tagout &ro' 'ac#ine controls7- Start t#e 'ac#ine8- Access t#e )%ra*ro+% *o''issioning Screen &ro' t#e operators %ispla) in t#e operator ca see Illustration 59- "urn cro+% control on 10- Energie t#e I* utput utton 11- *#oose t#e $al$e position 14 )ou +oul% li.e to test an% press t#e correspon%ing : utton12- ress t#e Run Ru n *ro+% ;otor at 20< re&erence utton- "#e c#osen c #osen : +ill no+ e &orce% o$er relie&-
%llustration 21 HydraCrowd Commissioning "!reen
SIS Media Number: BI646626 Media Number: SA13-025
IMPORTATNT: I&
t#e &ollo+ing steps %o not a&&ect t#e pu'p outlet pressure, it
SIS Media Number: BI646626 Media Number: SA13-025
IMPORTATNT: I&
t#e &ollo+ing steps %o not a&&ect t#e pu'p outlet pressure, it +ill e i'portant to return t#e relie& to its original setting- =e&ore turning t#e a%(usting scre+, 'ar. t#e scre+ location +it# respect to t#e $al$e o%)- As t#e a%(usting scre+ is turne% count t#e nu'er o& rotations so it coul% e returne% to original13- In t#e 'ac#iner) #ouse, +it# pu'p p u'p pressure going o$er relie&, slo+l) turn t#e a%(ust'ent scre+ +#ile oser$ing t#e pu'p pressure associate% +it# t#e relie& $al$e see Illustrations 6 an% 7 &or pu'p an% correspon%ing relie& locations- "urning t#e scre+ cloc.+ise +ill increase t#e relie& pressure, turning t#e scre+ countercloc.+ise +ill re%uce t#e pressure2 mm Allen 3ey
Pum &
Pum #
Pum %
Pum $
%llustration 71 Pump Referen!e &um'ers
SIS Media Number: BI646626 Media Number: SA13-025
SIS Media Number: BI646626 Media Number: SA13-025
Pump #
Pump $
Pump %
Pump &
%llustration <1 Relief :al$es Asso!iated wit# Ea!# Pump
14- #en t#e gauge pressure rea%s 3700 psi > 50 psi p si tig#ten t#e (a' nut to secure t#e a%(usting scre+- Rec#ec. pressure setting a&ter tig#tening t#e (a' nut to ensure t#e setting #asn?t c#ange%9 mm 6ren!# NOTE: I&
gauge pressure %oes not c#ange +#en t#e a%( ust'ent scre+ is turne%, return t#e a%(ust'ent scre+ to its origional position15- Install t#e c)lin%rical co$er onto t#e relie& an% secure +it# scre+ mm Allen 3ey
16- Re'o$e pressure gauges &ro' t#e t #e pu'p outlet ports an% reinstall test port co$ers17- Ensure c)lin%er spee% is nor'al ) stro.ing t#e c)lin%er c )lin%er se$eral ti'es ti 'es in t#e #oriontal position- eri&) ) oser$ing c)lin%er spee% on t#e operator ;I screen- Eten% spee% is approi'atel) 130 &t- @'in +#ile retract is approi'atel) 120 &t- @'in-
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C -
1
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
GENERAL GENERAL ASSEMBLY INSTRUCTIONS UCTIONS SPRAY ALL M AC HINED AND UNPAINTED/UNPROTECTED SURFACESWITH LPS3 (ITEM 67) PRIOR TO ASSEMBLY. PRIOR TO TORQUING HARDWARE APPLY THREAD LOCKING CO MPOUND (ITEM 46) 1. LIGHTLY CO AT THETWO O-RINGS SUPPLIED ED WITH COUPLING (ITEM 6) AND INSTALL INTO GRO OVES ON EAC H COUPLING SLEEVE.PLACE O NE SLEEVE OVER EAC H SHAFT( MOTOR & PDT) BEFORE INSTALLING NG CO UPLING HUBS. CARE SHOULD BETAKEN NOT TO DAMAG E O-RINGS. MOUNT CO UPLING HUBSTO MO TOR (ITEM 2) A ND PDT( ITEM 3) SHAFTS. REFER TO DETAIL "F"ON SHEET3. 2. SPRAY INSIDE MACHINED MO UNTING SURFACE O F PDTM OUNTS(ITEM 4) WITH LPS3 (ITEM 67). ASSEMBLE PDTMOUNTS(ITEM 4) TO PDT(ITEM 3) USING NG H.H.C.S. C.S. (ITEM 27) AND WASHER(ITEM 38). DO NOTTORQUE H.H.C.S.! 3. SPRAY MAC HINED PDTMO UNTING NG PA DSO N TANK (ITEM 1) WITH LPS3 (ITEM 67). ASSEMBLE PDT/MO UNTSTO TANK (ITEM 1) USING H.H.C.S. (ITEM 25) AND WASHER (ITEM 37), TORQUE H.H.C .S. RETAINING MOUNTSTO TANK (SEE TORQUE CHART).
QTY
ITEM NO.
1 1
55 56
1
C O PYRIG HTED-C USTO MER N I FO RM A TIO N DR DRA WING
2
C O PYRIG HTED-C USTO M ER N I FO RM A TIO N DR DRA WING
REFWGT(#) EACH
PARTNO.
QTY
ITEM NO.
RO DEND,J OI OINT,BA LL,.313 UNF,RH RO D EN END,J OI OINT,BA LL,.313 UN UNF,LH
0.07 0.7
82811285 82811286
0.09
82811287
0.02 0.04 0.01 0.03
03273400 02786345 03273690 02739100 02707150
1 1 1 2 4 1 1
1 2 3 4 5 6 7
1 1
DESCRIPTION
57
RO D,C ON ONN,HEX BO DY,.313 UNF THD
9
58
WA SHER,FLA T,.25
1 2 1 1 3
59 SCR,HEX ,HEX,.25x1.25 1.25,UNC,GR ,UNC,GR5 60 NUT,HEX,LO C K,.25,UNC 61 SC R,HEX,.25x2.25,UNC ,FULL THRD 62 NUT,HEX,J A M ,.312,UNF 63 NUT,HEX,FULL,.25-20 UNC
03951220 2
REFWGT(#) EACH
PARTNO.
TA NK,LO WER,A SSEM ,HYD C RO WD M OT OTO R,700HP,1400/ 700-3-50,4140 PDT,1-1 RA TIO ,4 PA D ISO 30 3019-2 M O UNT,PDT WELD PUM P,BENT A XIS PISTO N,30 C .I. C PLG ,RIG ID,G EA R KEY,SQ ,1x4.19
6195.0 4500.0 2800.0 95.0 342.0 117 1.2
S038951 12482026 S038840 S049563 S038829 4428319 4428317
8
STA ND,C PLG G UA RD,HYD C RO WD
22.5
S049575
9
G UA RD,C OU OUPLING ,FRO NT NT,HYD-C RO WD
13.0
S049577
DESCRIPTION
G N I W A R D N O I T A M R O F N I R E M O T S U C D
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
3
1
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
GENERAL GENERAL ASSEMBLY INSTRUCTIONS UCTIONS SPRAY ALL M AC HINED AND UNPAINTED/UNPROTECTED SURFACESWITH LPS3 (ITEM 67) PRIOR TO ASSEMBLY. PRIOR TO TORQUING HARDWARE APPLY THREAD LOCKING CO MPOUND (ITEM 46)
ITEM NO.
1 1
55 56
1
2
C O PYRIG HTED-C USTO MER N I FO RM A TIO N DR DRA WING
QTY
C O PYRIG HTED-C USTO M ER N I FO RM A TIO N DR DRA WING
REFWGT(#) EACH
PARTNO.
QTY
ITEM NO.
RO DEND,J OI OINT,BA LL,.313 UNF,RH RO D EN END,J OI OINT,BA LL,.313 UN UNF,LH
0.07 0.7
82811285 82811286
0.09
82811287
1 1 1 2
1 2 3 4
TA NK,LO WER,A SSEM ,HYD C RO WD M OT OTO R,700HP,1400/ 700-3-50,4140 PDT,1-1 RA TIO ,4 PA D ISO 30 3019-2 M O UNT,PDT WELD
0.02 0.04 0.01 0.03
03273400 02786345 03273690 02739100 02707150
4 1 1
5 6 7
1 1 1 6 6 1 1 1
DESCRIPTION
57
RO D,C ON ONN,HEX BO DY,.313 UNF THD
9
58
WA SHER,FLA T,.25
3. SPRAY MAC HINED PDTMO UNTING NG PA DSO N TANK (ITEM 1) WITH LPS3 (ITEM 67). ASSEMBLE PDT/MO UNTSTO TANK (ITEM 1) USING H.H.C.S. (ITEM 25) AND WASHER (ITEM 37), TORQUE H.H.C .S. RETAINING MOUNTSTO TANK (SEE TORQUE CHART).
1 2 1 1 3
59 SCR,HEX ,HEX,.25x1.25 1.25,UNC,GR ,UNC,GR5 60 NUT,HEX,LO C K,.25,UNC 61 SC R,HEX,.25x2.25,UNC ,FULL THRD 62 NUT,HEX,J A M ,.312,UNF 63 NUT,HEX,FULL,.25-20 UNC
4. SPRAY MAC HINED MOTOR MOUNTING PA DSO N TANK (ITEM 1) WITH LPS3 (ITEM 67) PRIOR TO M OTOR INSTALLATION. ASSEMBLE MOTOR (ITEM 2) TO TANK (ITEM1) USING H.H.C.S. (ITEM 28), WA SHER (ITEM 39) A ND LOC K NUT(ITEM 33). REFER TO DETAIL "C" ON SHEET3. DO NOT TORQUE HARDWARE!
8 3 2
64 SC R,SET,SQ .HD,.75x5,C P 65 SCR,HEX ,HEX,1x1 ,1x1.25,UNC, 5,UNC,GR 5 66 G REA SE,LO NG TERM
0.5
5. INSTALL JA CK SCREWS(ITEM 29) AND JA M NUTS(ITEM 34) TO PDTMO UNTS(ITEM 4), REFER TO DETAIL "J "O N SHEET2. DO NO TTIGHTEN!
1
67
SEA LA NT,RUST INHIBITO R
0.69
82833893
1
68
LUBRIC A NT 10 O Z. C A N J L-G
0.01
M P390331
1. LIGHTLY CO AT THETWO O-RINGS SUPPLIED ED WITH COUPLING (ITEM 6) AND INSTALL INTO GRO OVES ON EAC H COUPLING SLEEVE.PLACE O NE SLEEVE OVER EAC H SHAFT( MOTOR & PDT) BEFORE INSTALLING NG CO UPLING HUBS. CARE SHOULD BETAKEN NOT TO DAMAG E O-RINGS. MOUNT CO UPLING HUBSTO MO TOR (ITEM 2) A ND PDT( ITEM 3) SHAFTS. REFER TO DETAIL "F"ON SHEET3. 2. SPRAY INSIDE MACHINED MO UNTING SURFACE O F PDTM OUNTS(ITEM 4) WITH LPS3 (ITEM 67). ASSEMBLE PDTMOUNTS(ITEM 4) TO PDT(ITEM 3) USING NG H.H.C.S. C.S. (ITEM 27) AND WASHER(ITEM 38). DO NOTTORQUE H.H.C.S.!
6. POSITION TAP BLOC KS(ITEM 44) TO ENSURE ASMUC H CO NTACT AS POSSIBLE WITH TANK MOTOR SUPPORTS( ITEM 1). WELD TAP BLOC KS (ITEM 44) TO M OTOR SUPPORTSON TANK (ITEM 1), REFERTO SECTION ON "B-B"O N SHEET3. CLEAN, PRIME, AND FINISH PAINTTAP BLOC KS (ITEM 44) WITHORIENT WHITE ENAM EL, B.I.#61037662, AFTER WELDING ISC OM PLETE.
*
03951220 2
03773410 03300560 M P295148
1.0
* SEENO TE 2OF TIGHTENING PROC EDURE
7. INSTALL J AC K SCREWS(ITEM 64) AND J AM N UTS( ITEM 34) TO TAP BLOCKS (ITEM 44) WELDED TO M OTOR SUPPORTSO N TANK (ITEM 1), REFER TO SECTION "D-D" ON SHEET3. G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
8. ALIGN M OTOR (ITEM 2) TO PDT(ITEM 3), SEE DETAIL "F"ON SHEET3 FOR SPAC ING BETWEEN CO UPLING HUBS. REFER TO CO UPLING ALIGNMENT CHART FOR DIMENTIONAL ALLOWA NCES. USING SHIM PACKS (ITEM 43) AND JA CK SCREWS(ITEM 64), MAKE ADJUSTMENTS TO CORRECTANY MIS-ALIGNMENT. 9. LOCK A LL JAC K SCREWS(ITEMS 29 & 64) IN PLACE USING NG J AM N UTS(ITEM 34). TORQUE H.H.C.S.(ITEM 28) RETAINING M OTOR (ITEM 2) TO TANK(ITEM 1) AND H.H.C.S H.C.S. (ITE TEM 27) RETAINING PDT(ITEM 3) TO PDTMOUNTS(ITEM 4), (SEE TORQUE CHART). 10. INSTALL PUMPS; SEETIMING /IN STALLATION PROC EDURE ON SHEET5. 11. THOROUGHLY CO AT CO UPLING HUB AND SLEEVE TEETH WITH GREASE (ITEM 66). SLIDE COUPLING SLEEVESOV ER HUBS, CA REFULLY ENGAG ING TEETH. DO NOTDAMA GE 0-RINGS. PLACE GASKETSUPPLIEDWITH COUPLING NG BETWEEN SLEEVE FLANGES. ALIGN GN BOLTHOLESAND BRING NG FLANGE FAC ESTOGETHER BY HAND. DO NOT USECO UPLING HARDWARE TO REMOV E GAP BETWEEN FLANGES. SECURE SLEEVESBY TIGHTE GHTENING FASTENERSPROVIDED WITH COUPLING NG UNIFORMLY TO A TORQUE VALUE OF 250FT-LBS. ONLY USEHARDWARE SUPPLIED WITH TH CO UPLING. DO NOT SUBSTITUTE OR REUSE HARDWARE. REMOV E ALL G REASE PLUGSAN D FILL WITH GREASE (ITEM 66) UNTIL AN EXCESS APPEARS AT AN O PEN HOLE, THEN PLUG THAT HOLE. REPEATP ROCESSUNTIL ALL PLUGS HAVE BEEN REINSTALLED. WELD IN PLACE MO TOR CHO CK BLOCKS (ITEMS 41 & 42), SEE SECTION "B-B"O N SHEET3. CLEAN, PRIME AND FINISH PAINTM OTOR CHO CK BLOCKS AFTERWELDING ISC OM PLETE. 12. INSTALLATION OF TACHOMETER(ITEM TACHOMETER(ITEM 15), REFERTO DETAIL "E"ON SHEET 3. USETHREAD LOCKING CO MPO UND (ITEM 46) ON ALL FASTENERSUNLESSNO TED. ATTAC H BOTH HALVES O F URETHANE FLEX ELEMENTOF C OUPLING ( ITEM 16) DIRECTLY ONTO PDT (ITEM 3) SHAFT USING NG ( 4) OF THE METRIC H.H.C.S. SUPPLIED WITH COUPLING. INSERT(1) STEEL HUB INTO OPEN END OF FLEX ELEMENTA ND SECURE WITH (4) METRIC H.H.C.S. SUPPLIED ED WITH COUPLING (DISCARD EXTRA HUB). SPRAY TACHO METER SHAFTWITH LPS3 (ITEM 67) PRIOR TO INSTALLATION. ATTAC H TACHO METER(ITEM 15) TO TAC H MO UNT(ITEM 13) USING NG ( ITEM 11) A ND (ITEM 12). ALIGN KEY ON TACHOM ETER SHAFTTO KEY SLOTIN CO UPLING HUB; SLIDE ASSEMBLED TAC HOMETER/MOUNT INTO CO UPLING. ALIGN HO LESIN TACH MO UNTFLANG E (ITEM 13) TO THREADED HOLESIN PDT (ITEM 3) AND SECURE WITH (ITEM 22). ATTAC H TACH C OVER (ITEM 14) TO TACH MO UNTUSING (ITEM 21) AND (ITEM 58). TACHOMETERELECTRICAL CAL FITTING NG SHOULD BELOCATED ON SAME SIDE DE OF TACHOM ETERASTHE TACH COVER GUARD. IF NECESSARY, REMOVE PLUG FROM TACHOM ETER AND REPLACE WITH ELECTRICAL FITTING, NG, REFER TO SECTION "R-R"ON SHEET3.
14. P RIOR TO INSTALLING TACH ADAPTER (ITEM 50) FOR SHIPPING, VERIFY CO RRECT FITONTO M OTOR SHAFT(ITEM 2). TACH A DAPTER (ITEM 50) SHOULD SCREW ALL THE WAY ONTO M OTOR SHAFT(ITEM 2) WITHOUTBOTTOMING OUT. FACE OF TAC H ADA PTERSHOULD SEAT AGA INST SHOULDER OF M OTOR. 15. INSTALL SHAFTGUARD (ITEM 17) TO REAR OF MO TOR USING H.H.C.S. AND WA SHER(ITEMS 26 & 36); INSTALL GUARD C OVER (ITEM 53) AND SECURE TO SHAFT GUARD (ITEM 17) USING H.H.C.S. (ITEM 21). PLUG (3) HOLESO N REAR OF MOTOR USING H.H.C.S. (ITEM 65). 16. SPRAY INTERNAL THREADSO F TACH ADA PTER(ITEM 50) WITH LPS3 (ITEM 67) AND CO VER OPEN END OF TAC H ADAPTER WITH TAPE PRIOR TO SHIPPING. NG.
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
MISALIGNMENT 0.006
13. QTY (1) OF J AC K SCREW (ITEM 64) MUSTBE REMOV ED PRIOR TO INSTALLATION O F COUPLING G UARD STAND (ITEM 8). ATTAC H CO UPLING GUARD STAND (ITEM 8) TO TANK (ITEM 1) USING H.H.C.S. (ITEM 22) & WA SHER(ITEM 35). ATTACH C OUPLING G UARD FRONTA ND REAR (ITEMS 9 & 10) TO CO UPLING GUA RD STAND (ITEM 8) USING H.H.C.S. AND LOC K NUT(ITEMS22 & 31), SEE DETAIL "G" ON SHEET3. REPLACE J AC K SCREW (ITEM 64) USING P ROCEDURE DESCRIBED ABOV E IN STEP #10.
4
COUP CO UPLING ALIGNMENT
0.005
0.004
MISALIGNMENT
0.003
) S E H C N I ( R . I . T L E L L A R A P
0.002
1 0.001
0 0
0. 00 0 5
0 .00 1
0 .0 0 1 5
0 .0 0 2
0 .0 0 25
ANGULAR T. I.R (INCHES)
A. C HECK CENTER GAP- MEASURE COUPLING FAC E TO CO UPLING NG FAC E ATFO URPLACES90 APART, APPROXIMATELY 7.00 ON FACESO F RIGID COUPLING HUBS. AVERAGE OF THEFOUR MEASUREMENTSIS TO BE1.75 +0.02/-0.02 B. CHECK ANGULAR MISALIGNMENTAT APPROXIMATELY 7.00 ON CO UPLING FACES. M AX T.I.R=0.002 (@PARA LLELOFFSET=0.0) C. C HECK PARA LLELOFFSET- MA X. T.I.R=0.005 (@A NGULAR OFFSET=0.0) D. CO MBINED ANGULAR +PARALLEL OFFSETMUSTBE AT OR BELOW THE LINEIN THEFOLLOWING CHART.
17. C OAT MOUNTING SURFACE OF DUC T(ITEM 19) WITH SILASTIC SEALANT (ITEM 45)AND ATTACH TO MO TOR (ITEM 2) USING S.H.C.S. (ITEM 23), CO AT MOUNTING SURFACE OF C OVERS( ITEM 18) WITH SILASTIC SEALANT( ITEM 45) AND A TTAC H TO DUCT( ITEM 19) USING H.H.C.S. (ITEM 22). 18. A PPLY SILASTIC SEALANT (ITEM 45) TO M OUNTING SURFAC E OF BLOWER (ITEM 20) AN D ATTACH TO DUCT (ITEM 19) USING H.H.C.S. AND LOC K NUT(ITEMS22 & 31).
VARIABLE SUBSTITUTION FOR ITEM 20 ASSYP ART NO. 157988 1579889 157989 1579890 157989 1579891 157989 1579892 157989 1579893 157989 1579894
ITEM NO. 20 20 20 20 20 20
PART NO. **V V0389 038979 79 470041 47004197 97 470042 47004227 27 470042 47004228 28 470042 47004229 29 470041 47004198 98
DESCRIPTION BLW BLWR R,H YD C R OWD ,V AR A I BLE BLWR BLWR,5/3H 3 H P,46 P,460V0V-60HZ,380 Z,380V-5 V-50H 0H Z BLWR BLWR ,3H ,3HP,41 P,415V 5V/5 /50H Z,50C ,HC BLWR,3HP,380V/50H 0V/50HZ,520 Z,5200M, 0M,H C BLWR,5HP,460V/60H 0V/60HZ,460 Z,4600M, 0M,H C BLW BLWR R,HYD ,HYD C WD,5H WD,5HP P,5 ,575V 75V,,60H 6 0HZ
N C E
TORQUE CHART B OL T S Z I E M6-1
*
F T/ Lb s 7
.38 GRAD E5
23
.38 GRAD E8
35
.50 GRAD E5
55
. 75 GRA DE 5
2 00
M20 CL CL10.9
2 80
1 .0 0 GR AD E 5
4 80
1 .2 5 GR AD E 5
9 25
E T A D
. J s a t i V Y B
*INCLUDES85FT-LBSFO R NYLON INSERT(LOC K NUT)
2 V E R
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
1
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
T . L 4 O B T R E E E P H U S S N D O E G S N N A O H I C T C . U 8 R 3 T 9 S 0 N 8 I 2 4 N O S I A T N W A O I L T 6 L P I A R M T C E S S E T N I D I
3 1 0 2 8 0 8 0
7
.25 GRADE 5
2
PARTNO.
6195.0 4500.0 2800.0 95.0
S038951 12482026 S038840 S049563
PUM P,BENT A XIS PISTO N,30 C .I. C PLG ,RIG ID,G EA R KEY,SQ ,1x4.19
342.0 117 1.2
S038829 4428319 4428317
8
STA ND,C PLG G UA RD,HYD C RO WD
22.5
S049575
9
G UA RD,C OU OUPLING ,FRO NT NT,HYD-C RO WD
13.0
10
G UA RD,C OU OUPLING ,REA R,HYD-C RO WD
11.0
S049579
11 12
SC R,HEX,.25x.75,UNC ,G R 5 WA SHER,LO C K,.25,HVY
0.02 0.02
03273240 03961010
13 M O UNT,TA C H,WELD &M A C H 14 C O VER,TA C H 15 TA C H,DIG ITA L,FLA NG EM O UNT,500
10.07 5.08 6.83
1718651 4156240 1557159
1 1
16 17
2.4 43.9
1557160 S049079
2
18
C O VER,BLWR M O TO R DUC T
1
19
DUC T,HYD CR CRWD BL BLWR,WELD & MA MA C CH H
140.5
S049569
1
20
BLO WER,HYD C RO WD,V A RA BLE
210.0
SEE TA BLE
14 53 28
21 22 23
SCR,HEX HEX,.25x.625,UNC,GR 5 SC R,HEX,.375x1.00,UNC ,G R5 SC R,SO C ,.375x.625,UNC ,G R8
0.05 0.0
03273200 03279320 03480500
4 14 3
24 25 26
SC R,HEX,.375x1.25,UNC ,G R5 SCR,HEX HEX,.75x2.25,UNC,GR 5 SCR,HEX ,HEX,1x3.5,U .5,UNC,GR 5
8 4 8
27 28 29
SCR,HEX ,HEX,1x2.75, .75,UNC, U NC,GR 5 SC R,HEX,1.25x4.25,UNC ,G R5 SC R,SET,SQ ,.75x4,HDP
2.2 0.5
03300880 4354642 03772940
32 25 4
30 31 33
SC R,HEX,M 20x60M M ,C L10.9 NUT,HEX,LO C K,.375,UNC SUPERBO LT,TO RQ UENUT,1.25
0.5 0.0 0.8
03552070 02786385 M P263241
16 10 3 14 8 4 32 8
34 NUT,HEX,J A M ,.75,UNC 35 WA SHER,FLA T,.375 36 WA W A SHER,FLA T,1 37 WA SHER,FLA T,.75,HA RDENED 38 WA SHER,FLA T,1,HA RDENED 39 WA SHER,FLA T,1.25,HA RDENED 40 WA SHER,HA RDENED,20M M 41 C HO C K,M O TO R
0.1 0.1
0.3 0.1 1.91
02714450 03951400 03952100 03951950 03952150 03952350 M P600781 S037352
8 4 8 2 1 1
42 C HO C K,WEDG E 43 SHIM PA C K,ELEC M O TO R M TG . 44 BA B A R,1.25x2.5 45 SEA LA NT,SILA STIC ,10.3 O Z 46 C O MPO UND,THREA D LO C KING 47 LUBE,O -RING ,2 O Z. TUBE
1.39 3.48 2.9 0.1 0.2 0.13
S037353 S032091 S029157 82833855 82833862 59183127
4
48
O -RING ,-381,V ITO N,70 DU DURO M ETER
0.1
68766497
1
50
A DA PTER,M O UNTING ,TA C H
5.3
S037332
1 1 1
51 52 53
SC R,SET,SO C ,.25x.625,NYLO N TIP PIN,C LEVIS,.31x1.25,W/ C O TTR PN C O VER,G UA RD,M O TO R SHA FT
0.01 0.2 1.3
03803311 82647224 S037329
1
54
BRKT,TA C H TO RQ UE A RM
0.32
S037339
REVISION DATA
0 5 1 1 8
*V038979 DOESN OT REPRESENTA PART, ITIS A PLACE HOLDER FOR PLANNING PURPOSESONLY.
REFWGT(#) EACH
DESCRIPTION
C PLG ,TA C H,14M M ,E2M G UA RD,SHA FT,HYD C RO WD
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
S049577
7.48
3
S038971
0.1
G N I
W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
03279400 03294720 03301120
4
G N I W A R D 1 ITEM 32 SKIPPED IN BILL OF MATERIAL AL N REISSUEDA TE08-08-2013 O I TO KEEP CONSISTANCY WITH T A PREVIOUSDRAWING S038952. SOLIDWORKS M R DRAWING O F N I R THISDOCUMENTISPROTECTEDUNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. E ANY UNA UTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHERUSESHALLBE M SUBJEC TTO LIABILITY. C 2012 BucyrusInternationa l, Inc. ALLRIGHTSRESERVED. O T S ALLDIMENSIONS ININC HES-UNLESSOTHERWISESPECIFIED U C MACHINING TOLERANC ES-UNLESSOTHERWISESPECIFIED D 1. 2PLACEDECIMALDIMENSIONS .01FOREACH12MAX±.09 E 2. 3PLACEDECIMALDIMENSIONS .005UPTO 3 6 6,, .010OVER36 T 3. CONCENTRICIT YOFC YOFC YLINDRICALSURFACES= .010T.I.R. H Bucyrus 4. PARALLELISM,SQUARENESS,ORA NGULARITYBETWEENSURFACES G I AND/ORHOLECENTERLINES 07' (.002INCH/INCH) International, Inc. R FABRICATINGTOLERANCES-UNLESSO THERWISESPECIFIED Y P 1. MAT E RI A L T HC I K NE SS DM I EN SI ON S T OL ER AN C E O A. LESSTHAN.12 0TO 36 .03 C OVER36 .06 R
B. .12 TO 50 5 .0
0TO 36 .06 .12 OVER36 C. .50TO 1.00 0TO 36 .09 OVER36 .19 D. OVER1.00 0TO 36 .19 .25 OVER36 2. BENTANGLES 1 (.0 17IN/IN)FOREACH.37OFMATERIAL 17IN/IN)FOREACH.37OFMATERI THICKNESS(MAX 3)
WELDMENTTOLERANCES-UNLESSOTHERWISESPECIFIED 1 . DM I E NSO I N A. UPTO 36 " B. 36"TO 10' C. 10'TO 30' D. OVER30'
MAT E RI A L T HC I K NE SS UPTO 1" 1"ANDGREATER UPTO 1" 1"ANDGREATER UPTO 1" 1"ANDGREATER ALL
T OL ER A NC E .06 .12 .12 .19 .19 .25 .25
DESCRIPTION
PWR MODULE,HYD CROWD,MECH A SSY REFDWGS M ODEL DET ENG CONTACT
NO.
S038952 7495
GRUBERG. MAREKC.
UNIT
FINWGT 15780.0 (LBS)
DATE (MM-DD-YYYY) DWG SIZE
11-13-2012 REV D
1579888
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
2
SHEET
1 OF 5
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C
1
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
2
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
G N I
2
W A R D N O I T A M R O F N I R E M O T S U C
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
1
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
2
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
2
INSTA LLATION NO N O TES: ES: MA KE SURE SPEC IAL STEEL WASHERSSUPPLIED WITH TORQ UENUTSA RE USED UNDER EAC H TORQUENUT - DO NOT USESTANDARD C OMM ERCIAL WASHERS. AN IM PAC TWRENCH M AY BE USED FOR THE INITIAL RUN UP, BUTA TORQUE WRENCH MUSTBE USED FOR THE FINAL VA LUES.
3
3
INSTA LLATIO LLATION N PROC PRO C EDURE: EDURE: G N I
W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
STEP1: JA EP1: JA CKBOLTTHREADS& END FACESA REPRE-LUBRICATED BY VENDORWITH GRAPHITE TELUBE. ENSURE THAT GRAPHITE LUBE FILM ISPRESENTON THESE SURFACESA ND A PPLY ADDITIONAL G RAPHITE LUBE (MP390331) AS NEEDED.
STEPS 4 & 5
STEPS 6 & 7
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
(INITIAL TORQUE SEQUENCE)
STEP2: CHECK BA SE OF TORQUENUTTO ENSURE THATA LL JA CKBOLTSARE FLUSH WITH BOTTOM. STEP3: LUBRICATE THE THREADS OF THE MA IN STUD WITH ANTI-SEIZE LUBRICA NT. STEP4: SLIDE THE HARDENED WASHER ON TO THE STUD, THEN SPIN THE TENSIONER O NTO THE MA IN THREAD UNTIL ITSEATSAG AINSTTHE WASHER. 2
STEP5: BACK O FF THE TENSIONER TO LEAVE A GA P OF .06-.12 FOR LUBRICATION DURING REMO VAL. STEP6: USING A SUITABLE TABLETORQUING DEVICE, TIGHTEN (4) JA CKBOLTSAT 90 APA RT(SEE FIGURE TO RIGHTFO R SEQUENC E) ON A LL STUDSW ITH A PARTIAL TORQUE (30-70%, 8-19 LB-FT). STEP7: AT 120%TARGETTORQUE (33 LB-FT), TIGHTEN THE SAME (4) JA CKBOLTSON ALL STUDS.
3
STEP8: AT 120%TARGETTORQUE (33 LB-FT), TIGHTEN ALL JA CKBOLTSIN A CIRCULAR PA TTERN. DO THISFOR ALL STUDS(1 ROUND O NLY).
20
STEP9: SWITCH TO A TORQUE WRENCH A ND TIGHTEN ALL J AC KBOLTSTO 100%TARGETTORQUE ( 27 LB-FT) IN A CIRCULAR PA TTERN UNTIL ALL J AC KBOLTSA RE STABILIZED (LESSTHAN 10 ROTATION). THISUSUALLY REQUIRES24 A DDITIONA ONA L PASSES.
5
STEP 8
STEP 9
REMO REMO VA L PROC EDURE EDURE:: PREPARATION: SPRAY J AC KBOLTSWITH PENETRATING O IL OR HYDRAULIC O IL PRIOR TO START.
4
STEP1: LOOSEN EACH J AC KBOLT1/8 TURN FOLLOWING A C IRCULAR PATTERN AROUND THETENSIONER (1 ROUND ONLY). AS YOU MO VE AROUND AND GETBAC K TO THE FIRSTJ AC KBOLT, ITWILLBE TIGHTAG AIN. DO THISFOR ALLSTUDSON THE JO INTPRIOR OR TO THE NEXTSTEP.
4
STEP2: REPEATA 2ND ROUND AS ABOVE FOR ALL STUDS,NOW LOO SENING EACH J AC KBOLT1/4 TURN IN A CIRCULAR PATTERN. STEP3: CO NTINUE LOOSENING 1/ 4 TURN FOR 3RD AND SUCC ESSIVE ROUNDSUNTIL ALL JA CKBOLTSARE LOO SE. NO TE: USUALLY AFTER THE 3RD OR 4TH ROUND , AN IM PAC T TOO L CA N BE USED TO CO MPLETELY EXTRAC T THE JAC KBOLTS, ONE BY O NE. FOR LONG BOLTSOR TIE RODS, ADD ITIONAL ROUNDS M AY BE REQUIRED BEFORE REMOVING THE JAC KBOLTS WITH AN IMPAC T TOO L.
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
STEP4: REMOVE, C LEAN AND RELUBRICATE THE JAC KBOLTTHREADS AND TIPSPRIOR TO NEXT USE WITH CO RRECT SUPERBOLTLUBRICAN T(M P390331). CAUTION! JAC KBOLTS MUSTBE UNLOADED GRAD UALLY. IF SOM E JACKBOLTS ARE FULLY UNLOADED
4
PREMATURELY, THE REMAININ G JA CKBO LTSWILL CA RRY THE ENTIRE RE LOA D AN D M AY BE HARD TO TURN. WITH EXTREME ABUSE, A JA CKBOLT TIP CAN DEFORM, MA KING REMOV AL DIFFICULT. C ULT.
STUCK JAC KBOLTREMOVAL: IF A J AC KBOLTWILL NOTTURN, REMO VE, RE-LUBE, AND RETIGHTEN A NEIGHBORING J AC KBOLT. THEN TRY TO TURN THE STUCK J AC KBOLT.
1
REISSUEDA TE 08-08-2013
SOLIDWORKS DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
THISDOCUMENTISPROTE SDOCUMENTISPROTECTEDUNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION O RO THERUSESHALL BE SUBJEC TTO LIABILITY. C 2012 BucyrusInte rnational, Inc. ALLRIGHTSRESERVED. DESCRIPTION
R
Bucyrus International, Inc.
PWR MODULE,HYD CROWD,MECH A SSY DWG SIZE D REV 2 NO.
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C
1
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
1
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
2 2
1579888
SHEET
4 OF 5
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
G N I
PUMP FLANGE PUMP PILOTDIA METER PLASTIC PLUG IN TOP CASE DRAIN PORT (ALL PUMPS)
UPPER CASE DRAIN
MARK ON PUMP HOUSING (TIMING P P 1)
W A R D N O I T A M R O F N I R E M O T S U C
1
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
2
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
2
INSTA LLATION NO N O TES: ES: MA KE SURE SPEC IAL STEEL WASHERSSUPPLIED WITH TORQ UENUTSA RE USED UNDER EAC H TORQUENUT - DO NOT USESTANDARD C OMM ERCIAL WASHERS. AN IM PAC TWRENCH M AY BE USED FOR THE INITIAL RUN UP, BUTA TORQUE WRENCH MUSTBE USED FOR THE FINAL VA LUES.
3
3
INSTA LLATIO LLATION N PROC PRO C EDURE: EDURE: G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
STEP1: JA EP1: JA CKBOLTTHREADS& END FACESA REPRE-LUBRICATED BY VENDORWITH GRAPHITE TELUBE. ENSURE THAT GRAPHITE LUBE FILM ISPRESENTON THESE SURFACESA ND A PPLY ADDITIONAL G RAPHITE LUBE (MP390331) AS NEEDED.
STEPS 4 & 5
STEPS 6 & 7
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
(INITIAL TORQUE SEQUENCE)
STEP2: CHECK BA SE OF TORQUENUTTO ENSURE THATA LL JA CKBOLTSARE FLUSH WITH BOTTOM. STEP3: LUBRICATE THE THREADS OF THE MA IN STUD WITH ANTI-SEIZE LUBRICA NT. STEP4: SLIDE THE HARDENED WASHER ON TO THE STUD, THEN SPIN THE TENSIONER O NTO THE MA IN THREAD UNTIL ITSEATSAG AINSTTHE WASHER. 2
STEP5: BACK O FF THE TENSIONER TO LEAVE A GA P OF .06-.12 FOR LUBRICATION DURING REMO VAL. STEP6: USING A SUITABLE TABLETORQUING DEVICE, TIGHTEN (4) JA CKBOLTSAT 90 APA RT(SEE FIGURE TO RIGHTFO R SEQUENC E) ON A LL STUDSW ITH A PARTIAL TORQUE (30-70%, 8-19 LB-FT). STEP7: AT 120%TARGETTORQUE (33 LB-FT), TIGHTEN THE SAME (4) JA CKBOLTSON ALL STUDS.
3
STEP8: AT 120%TARGETTORQUE (33 LB-FT), TIGHTEN ALL JA CKBOLTSIN A CIRCULAR PA TTERN. DO THISFOR ALL STUDS(1 ROUND O NLY).
20
STEP9: SWITCH TO A TORQUE WRENCH A ND TIGHTEN ALL J AC KBOLTSTO 100%TARGETTORQUE ( 27 LB-FT) IN A CIRCULAR PA TTERN UNTIL ALL J AC KBOLTSA RE STABILIZED (LESSTHAN 10 ROTATION). THISUSUALLY REQUIRES24 A DDITIONA ONA L PASSES.
5
STEP 8
STEP 9
REMO REMO VA L PROC EDURE EDURE:: PREPARATION: SPRAY J AC KBOLTSWITH PENETRATING O IL OR HYDRAULIC O IL PRIOR TO START.
4
STEP1: LOOSEN EACH J AC KBOLT1/8 TURN FOLLOWING A C IRCULAR PATTERN AROUND THETENSIONER (1 ROUND ONLY). AS YOU MO VE AROUND AND GETBAC K TO THE FIRSTJ AC KBOLT, ITWILLBE TIGHTAG AIN. DO THISFOR ALLSTUDSON THE JO INTPRIOR OR TO THE NEXTSTEP.
4
STEP2: REPEATA 2ND ROUND AS ABOVE FOR ALL STUDS,NOW LOO SENING EACH J AC KBOLT1/4 TURN IN A CIRCULAR PATTERN. STEP3: CO NTINUE LOOSENING 1/ 4 TURN FOR 3RD AND SUCC ESSIVE ROUNDSUNTIL ALL JA CKBOLTSARE LOO SE. NO TE: USUALLY AFTER THE 3RD OR 4TH ROUND , AN IM PAC T TOO L CA N BE USED TO CO MPLETELY EXTRAC T THE JAC KBOLTS, ONE BY O NE. FOR LONG BOLTSOR TIE RODS, ADD ITIONAL ROUNDS M AY BE REQUIRED BEFORE REMOVING THE JAC KBOLTS WITH AN IMPAC T TOO L.
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
STEP4: REMOVE, C LEAN AND RELUBRICATE THE JAC KBOLTTHREADS AND TIPSPRIOR TO NEXT USE WITH CO RRECT SUPERBOLTLUBRICAN T(M P390331).
G N I
CAUTION! JAC KBOLTS MUSTBE UNLOADED GRAD UALLY. IF SOM E JACKBOLTS ARE FULLY UNLOADED
4
PREMATURELY, THE REMAININ G JA CKBO LTSWILL CA RRY THE ENTIRE RE LOA D AN D M AY BE HARD TO TURN. WITH EXTREME ABUSE, A JA CKBOLT TIP CAN DEFORM, MA KING REMOV AL DIFFICULT. C ULT.
STUCK JAC KBOLTREMOVAL: IF A J AC KBOLTWILL NOTTURN, REMO VE, RE-LUBE, AND RETIGHTEN A NEIGHBORING J AC KBOLT. THEN TRY TO TURN THE STUCK J AC KBOLT.
1
REISSUEDA TE 08-08-2013
SOLIDWORKS DRAWING
W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
THISDOCUMENTISPROTE SDOCUMENTISPROTECTEDUNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION O RO THERUSESHALL BE SUBJEC TTO LIABILITY. C 2012 BucyrusInte rnational, Inc. ALLRIGHTSRESERVED. DESCRIPTION
R
Bucyrus International, Inc.
PWR MODULE,HYD CROWD,MECH A SSY DWG SIZE D REV 2 NO.
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
1
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
1
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
2
SHEET
1579888
4 OF 5
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
2
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
PUMP FLANGE PUMP PILOTDIA METER PLASTIC PLUG IN TOP CASE DRAIN PORT (ALL PUMPS)
UPPER CASE DRAIN
MARK ON PUMP HOUSING (TIMING P ROC EDURE- STEP 1)
MARK THISTOOTH (ALIGNED WITH TIMING MING MARK)
TDC PUMP #1
7 TEETH PUMP #3
3
15TEETH PUMP #2
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
3
11TEETH PUMP #4 G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
MARK ON PUMP HOUSING (TIMING P ROC EDURE -STEP 1)
SECTIO ECTIO N W-W PUMP - MOUNTING SURFACE (TIMING MA RKS)
TIMING MING MARK (NOTCH) (VIEWED THRU UPPER CASE DRAIN PO RT)
DETA DETA IL "T "TDC " PUMP TIMING/ INST INSTALLATION PROC EDURE EDURE 1. PRIOR TO INSTALLING P UMPS(ITEM 5) INTO PDT(ITEM 3), THE PUMPS MUSTBE TIMED.
PUNCH MARK OUTPUTGEAR GROO VE TO MATCH MATING "TDC" PUMP SPLINE TOOTH
A. REMOVE UPPER CA SE DRAIN PLUG FROM EACH PUMP; (STEEL PLUG NEEDSTO BE INSTALLED IN BOTTOM CASE DRAIN PORTA ND PLASTIC PLUG WILL BE INSTALLED IN THE TOP CA SE DRAIN PORT.
Y PUMP #1
B. ROTATE EAC H PUMP SHAFT(USE LARGE CHA NNEL LOCK PLIERSWITH A RAG TO PROTECTSHAFTTEETH) UNTIL TIMING MA RK ISC ENTEREDIN THEUPPER CA SE DRAIN PORT (SEE DETAIL "TDC"), THISIS TOP DEAD CENTER. USING A (PA INTSTICK OR INK MARKER), MARK THE TOO TH ON EACH PUMP SHAFTTHATLINESUP WITH THE TIMING MA RK (SEEDETAIL "TDC"). RE-INSTALL PLASTIC PLUG IN UPP ER CASE DRAIN P ORT.
.25
PUMP #4
W
C. PUMP #1: WILL BE INSTALLED IN THE "TDC" PO SITION. PUMP #2: LOOKING TOWARDS THEPUMP SHAFT, COUNT15 TEETH (IN A CC W DIRECTION) FROM "TDC" AND MA RK THE PUMP HOUSING ( SEESECTION W-W). PUMP #3: LOOKING TOWARDS THEPUMP SHAFT, COUNT7 TEETH (IN A C CW DIRECTION) FROM "TDC"AN D MA RK THE PUMP HOUSING ( SEESECTION W-W). PUMP #4: LOOKING TOWARDS THEPUMP SHAFT, COUNT11 TEETH (IN A CC W DIRECTION) FROM "TDC" AND MA RK THE PUMP HOUSING ( SEESECTION W-W)
4
PUMP #2
PUMP #3
METAL PLUG IN BOTTOM CASE DRAIN PORT (ALL PUMPS)
4
D. ROTATE(CC W) EACH PUMP SHAFTO F PUMPS2, 3 & 4 TO ALIGN MARKED TOOTH (FROM 1B) TO APPROPRIATE PUMP HOUSING MARK (FROM 1C). VERIFY THE TOOTH CO UNTOF EAC H PUMP. PUMPSA RE NOW TIMED AN D READY FO R INSTALLATION INTO PDT. E. PUNCH MA RK SPLINE GROOV E OF OUTPUTGEAR TO C OINCIDE WITH MATING "TDC" MARKED PUMP SPLINE TOOTH. 2. APPLY O -RING LUBE (ITEM 47) TO EAC H O-RING (ITEM 48). INSTALL O-RING OVER EAC H PUMP PILOT DIAMETER.
W
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
A. INSTALL PUMP #2, SECURE TO PDT WITH H.H.C.S. (ITEM 30) AND WA SHER (ITEM 40). WHEN INSTALLING THE PUMP, ROTATE THE SHAFTOF THE PDTNOT THE PUMP SHAFTTO MAKE SURE NOTTO C HANGE THE TIMING SEQUENCE O F THE PUMPS. ROTATE PDTSHAFTUSING A LA RGE STRAP/C HAIN WRENCH. B. INSTALL PUMPS #1, 3& 4 INTO PDTA ND SECURE WITH H.H.C.S. (ITEM 30) AND WASHER (ITEM 40). CARE MUSTBE TAKEN TO LIMITPUMP SHAFTROTATION WHEN ALIGNING AND INSERTING PUMP SHAFTINTO SPLINED NED RECEIVER OF EACH PUMP PAD O F PDT. IF EXCESSIVE SHAFTROTATION O CC URS, PULL PUMP OUT OF PDTA ND VERIFY CORRECTPOSITION OF TIMING MARK OF THATPUMP . RE-INSTALL PUMP. 3. TORQUE EACH PUMP RETAINING SCREWTO THE VALUEGIVEN IN THE TORQUE CHARTON SHEET1.
REISSUEDA TE 08-08-2013
Y
SOLIDWORKS DRAWING
SECTIO ECTIO N Y-Y
THISDOCUMENTISPROTE SDOCUMENTISPROTECTEDUNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION O RO THERUSESHALL BE SUBJEC TTO LIABILITY. C 2012 BucyrusInte rnational, Inc. ALLRIGHTSRESERVED.
PDT- PUMP MOUNTING SURFACE (TDCO RIENTATION)
DESCRIPTION
R
Bucyrus International, Inc.
PWR MODULE,HYD CROWD,MECH A SSY DWG SIZE D REV 2 NO.
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
1
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
2
1579888
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
SHEET
5 OF 5
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
1
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
2
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
PUMP FLANGE PUMP PILOTDIA METER PLASTIC PLUG IN TOP CASE DRAIN PORT (ALL PUMPS)
UPPER CASE DRAIN
MARK ON PUMP HOUSING (TIMING P ROC EDURE- STEP 1)
MARK THISTOOTH (ALIGNED WITH TIMING MING MARK)
TDC PUMP #1
7 TEETH PUMP #3
3
15TEETH PUMP #2
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
3
11TEETH PUMP #4 G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
MARK ON PUMP HOUSING (TIMING P ROC EDURE -STEP 1)
SECTIO ECTIO N W-W PUMP - MOUNTING SURFACE (TIMING MA RKS)
TIMING MING MARK (NOTCH) (VIEWED THRU UPPER CASE DRAIN PO RT)
DETA DETA IL "T "TDC " PUMP TIMING/ INST INSTALLATION PROC EDURE EDURE 1. PRIOR TO INSTALLING P UMPS(ITEM 5) INTO PDT(ITEM 3), THE PUMPS MUSTBE TIMED.
PUNCH MARK OUTPUTGEAR GROO VE TO MATCH MATING "TDC" PUMP SPLINE TOOTH
A. REMOVE UPPER CA SE DRAIN PLUG FROM EACH PUMP; (STEEL PLUG NEEDSTO BE INSTALLED IN BOTTOM CASE DRAIN PORTA ND PLASTIC PLUG WILL BE INSTALLED IN THE TOP CA SE DRAIN PORT.
Y PUMP #1
B. ROTATE EAC H PUMP SHAFT(USE LARGE CHA NNEL LOCK PLIERSWITH A RAG TO PROTECTSHAFTTEETH) UNTIL TIMING MA RK ISC ENTEREDIN THEUPPER CA SE DRAIN PORT (SEE DETAIL "TDC"), THISIS TOP DEAD CENTER. USING A (PA INTSTICK OR INK MARKER), MARK THE TOO TH ON EACH PUMP SHAFTTHATLINESUP WITH THE TIMING MA RK (SEEDETAIL "TDC"). RE-INSTALL PLASTIC PLUG IN UPP ER CASE DRAIN P ORT.
.25
PUMP #4
W
C. PUMP #1: WILL BE INSTALLED IN THE "TDC" PO SITION. PUMP #2: LOOKING TOWARDS THEPUMP SHAFT, COUNT15 TEETH (IN A CC W DIRECTION) FROM "TDC" AND MA RK THE PUMP HOUSING ( SEESECTION W-W). PUMP #3: LOOKING TOWARDS THEPUMP SHAFT, COUNT7 TEETH (IN A C CW DIRECTION) FROM "TDC"AN D MA RK THE PUMP HOUSING ( SEESECTION W-W). PUMP #4: LOOKING TOWARDS THEPUMP SHAFT, COUNT11 TEETH (IN A CC W DIRECTION) FROM "TDC" AND MA RK THE PUMP HOUSING ( SEESECTION W-W)
4
PUMP #2
PUMP #3
METAL PLUG IN BOTTOM CASE DRAIN PORT (ALL PUMPS)
4
D. ROTATE(CC W) EACH PUMP SHAFTO F PUMPS2, 3 & 4 TO ALIGN MARKED TOOTH (FROM 1B) TO APPROPRIATE PUMP HOUSING MARK (FROM 1C). VERIFY THE TOOTH CO UNTOF EAC H PUMP. PUMPSA RE NOW TIMED AN D READY FO R INSTALLATION INTO PDT. E. PUNCH MA RK SPLINE GROOV E OF OUTPUTGEAR TO C OINCIDE WITH MATING "TDC" MARKED PUMP SPLINE TOOTH. 2. APPLY O -RING LUBE (ITEM 47) TO EAC H O-RING (ITEM 48). INSTALL O-RING OVER EAC H PUMP PILOT DIAMETER.
W
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
A. INSTALL PUMP #2, SECURE TO PDT WITH H.H.C.S. (ITEM 30) AND WA SHER (ITEM 40). WHEN INSTALLING THE PUMP, ROTATE THE SHAFTOF THE PDTNOT THE PUMP SHAFTTO MAKE SURE NOTTO C HANGE THE TIMING SEQUENCE O F THE PUMPS. ROTATE PDTSHAFTUSING A LA RGE STRAP/C HAIN WRENCH. B. INSTALL PUMPS #1, 3& 4 INTO PDTA ND SECURE WITH H.H.C.S. (ITEM 30) AND WASHER (ITEM 40). CARE MUSTBE TAKEN TO LIMITPUMP SHAFTROTATION WHEN ALIGNING AND INSERTING PUMP SHAFTINTO SPLINED NED RECEIVER OF EACH PUMP PAD O F PDT. IF EXCESSIVE SHAFTROTATION O CC URS, PULL PUMP OUT OF PDTA ND VERIFY CORRECTPOSITION OF TIMING MARK OF THATPUMP . RE-INSTALL PUMP. 3. TORQUE EACH PUMP RETAINING SCREWTO THE VALUEGIVEN IN THE TORQUE CHARTON SHEET1.
REISSUEDA TE 08-08-2013
Y
SOLIDWORKS DRAWING
SECTIO ECTIO N Y-Y
THISDOCUMENTISPROTE SDOCUMENTISPROTECTEDUNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION O RO THERUSESHALL BE SUBJEC TTO LIABILITY. C 2012 BucyrusInte rnational, Inc. ALLRIGHTSRESERVED.
PDT- PUMP MOUNTING SURFACE (TDCO RIENTATION)
DESCRIPTION
R
Bucyrus International, Inc.
PWR MODULE,HYD CROWD,MECH A SSY DWG SIZE D REV 2 NO.
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
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CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
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1579888
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
SHEET
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G N I
W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
××××π
BOMBA DE PALETAS
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 un a carr er a:
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.
Jose Manuel Arroyo Rosa
Página 1
BOMBA DE PALETAS 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. B omba de pale pal etas de dos carr car r er as: as:
Estas bombas tienen una carcasa o estator est ator 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.
.
Jose Manuel Arroyo Rosa
Página 2
BOMBA DE PALETAS 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 dos carreras B omba de paletas pal etas de caudal vari var i able abl e:
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 cámar as. 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. Jose Manuel Arroyo Rosa
Página 3
BOMBA DE PALETAS 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
temariosformativos.foroactivo.com
Jose Manuel Arroyo Rosa
Página 4
ContaminationSensor Contaminatio nSensor CS1000
Analog Output (ANAOUT)
ISO Code o e acc. acc. to to 4406:1999 : The following ISO values can be output via the analog output:
ISO 4 / ISO 6 / ISO I SO 14 Only one value is output. ISO-Code, 3-digit (>4 µm(c) / >6 µm(c) / >14 µm(c)) All values are sequentially sequentially time-coded time-coded before output. ISO+T All values are sequentially sequentially time-coded time-coded before output. HDA.ISO All values are sequentially sequentially time-coded 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 I < 4.0 mA
ISO contamination class / error Cable break
Voltage U 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 4.3 mA < I < 4.5 mA
Not defined Flow error (flow insufficient)
2.05 V < U < 2.15 V 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 I = 5.37 mA
ISO 0 ISO 1
U = 2.40 V U = 2.69 V
I = 5.94 mA
ISO 2
U = 2.97 V
I = 6.51 mA I = 7.08 mA
ISO 3 ISO 4
U = 3.26 V U = 3.54 V
I = 7.65 mA I = 8.22 mA
ISO 5 ISO 6
U = 3.83 V U = 4.11 V
I = 8.79 mA
ISO 7
U = 4.40 V
I = 9.36 mA I = 9.93 mA
ISO 8 ISO 9
U = 4.68 V U = 4.97 V
I = 10.50 mA
ISO 10
U = 5.25 V
I = 11.07 mA I = 11.64 mA
ISO 11 ISO 12
U = 5.54 V U = 5.82 V
I = 12.21 mA I = 12.77 mA
ISO 13 ISO 14
U = 6.11 V U = 6.39 V
I = 13.34 mA
ISO 15
U = 6.67 V
I = 13.91 mA I = 14.48 mA
ISO 16 ISO 17
U = 6.96 V U = 7.24 V
I = 15.05 mA I = 15.62 mA
ISO 18 ISO 19
U = 7.53 V U = 7.81 V
I = 16.19 mA
ISO 20
U = 8.10 V
I = 16.76 mA I = 17.33 mA
ISO 21 ISO 22
U = 8.38 V U = 8.67 V
HYDAC Filtertechnik GmbH BeWa CS1000 3247149n en.doc
en
Page 56 / 100 2008-08-20
ContaminationSensor Contaminatio nSensor CS1000
Analog Output (ANAOUT)
Current I I = 17.90 mA
ISO contamination class / error ISO 23
Voltage U U = 8.95 V
I = 18.47 mA I = 19.20 mA
ISO 24 ISO 24.28
U = 9.24 V 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 BeWa CS1000 3247149n en.doc
en
Page 57 / 100 2008-08-20
ContaminationSensor Contaminati onSensor 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 cleanlines cleanliness. s. 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 particle counts to cleanliness cleanliness classes: classes: Number of particles / 100 ml Class
More than
Up to (and including)
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
250,000,000 130,000,000
14
8,000
HYDAC Filtertechnik GmbH BeWa CS1000 3247149n en.doc
16,000
en
Page 88 / 100 2008-08-20
ContaminationSensor Serie CS 1000
Descripción
Datos técnicos
El ContaminationSensor serie CS 1000 es un sensor de uidos en línea que detecta de forma continua la contaminación de sustancias sólidas en uidos. 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).
Datos generales Autodiagnóstico
Campos de aplicación Sistemas hidráulicos y de lubricación industriales z Hidráulica móvil z
Visualizador (solo CS 1x2x) Magnitudes de medición
Magnitudes de servicio
Posición de montaje Rango de temperatura ambiente Rango de temperatura de almacenamiento Humedad relativa Junta Clase de protección Tipo de protección Peso Datos hidráulicos Margen de medición
Ventajas Opcionalmente puede conmutar entre ISO 4406:1999 / SAE AS 4059 y ISO 4406:1987 / NAS 1638 z Detección temprana de estados críticos de la máquina z Control continuo de los estados del aceite z Plan de mantenimiento en función del estado de la maquinaria z
Precisión Presión de servicio Conexión hidráulica Caudal de medición admisible Margen de viscosidad admisible Rango de temperatura del medio Datos eléctricos Clavija de conexión Tensión de alimentación Consumo de potencia Salida analógica (tecnología de 4 hilos)
Salida de conmutación
Interfaz RS485 HSI (HYDAC Sensor Interface)
Continuo, con indicación de fallos a través través del LED de estado y el visualizador LED, 6 dígitos, cada uno con 17 segmentos ISO 99 (ISO 4406:1999) SAE (SAE AS 4059 (D)) o ISO 87 (ISO4406:1987) NAS (NAS 1638) Flow (ml/min) Out (mA) o (VCC) Drive (%) Temp (°C) y (°F) Cualquiera (se recomienda montaje vertical en el sentido del ujo) -30 °C ... +80 °C / -22 °F ... 176 °F -40 °C ... +80 °C / -40 °F ... 176 °F Máx. 95 %, no condensable FPM para CS1xx0 / EPDM para CS1xx1 III (tensión baja de protección) IP67 1,3 kg 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 +/- ½ clase ISO en margen calibrado 300 bar máx. / 4350 psi máx. Empalme de tubos rígidos y exibles (A,B): rosca G1/4, ISO 228 o conexión con brida (C,D): DN 4 30 ... 300 ml/min 1 ... 1000 mm²/s 0 ... +85 °C, +32 ... +185 °F M12x1, 8 polos, según DIN VDE 0627 o IEC61984 9 ... 36 VCC, ondulación residual < 10% 3 Watt máx. Salida 4 ... 20 mA (activa): carga máx. 330Ω o Salida 0 ... 10 V (activa): resistencia mín. de carga 820 Ω MOSFET pasivo de potencia de canal n: máx. corriente de conmutación 1,5 A, abierta en ausencia de corriente Bilar, semidúplex para transferir el protocolo HSI en conexión con un PC Monolar, semidúplex
2 1 . 7 0 / 0 . 8 5 9 . 7 P S
11
Código del modelo
Volumen de suministro CS 1 2 2 0 - A - 0 - 0 - 0 - 0 / - 000
Tipo CS = Serie 1 =
ContaminationSensor Serie 1000, 4 canales de tamaño de partículas
Codifcación 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) conmutable Opciones 1 = Sin visualizador 2 = Con visualizador (el visualizador puede girar de forma continua 270°) Medios 0 = A base de aceite mineral 1 = Para éster fosfatado Interfases analógicas A = 4 ... 20 mA B = 0 ... 10 V Salida de conmutación 0 = Salida de conmutación de valor límite Interfaz digital 0 = RS485 Tipo de conexión eléctrica 0 = conector M12x1 de 8 polos, clavija, conforme a VDE0627 o IEC61984 Conexión hidráulica (ver página 3) 0 = Conexión para tubo rígido o exible 1 = Conexión con brida Número de modifcación 000= Estándar
2 1 . 7 0 / 0 . 8 5 9 . 7 P S
12
– Contamination Sensor – Software FluMoS 1000 e instrucciones de servicio y mantenimiento en CD – Certicado 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
Dimensiones
Tipos de conexiones hidráulicas
CS1x1x sin visualizador
Conexión de tubo rígido o exible
Conexión con brida
Junta tórica
CS1x2x con visualizador
Tapón roscado
Giro del visualizador
Vista por la cara inferior Presión - Margen de viscosidad
Conexión de tubo rígido o exible
∆p ν
: presión : viscosidad
Conexión con brida Junta tórica
2 1 . 7 0 / 0 . 8 5 9 . 7 P S
13
Tipos de montaje
Sujeción de pared a consola
Fijación sobre placa abridada, placa de conexión o bloque de mando
para conexión de tubo rígido o exible
para conexión con brida
1 : con 2 M8 (ISO 4762) o 2, 3 : con 4 M6
Observaciones Las indicaciones del presente folleto hacen referencia a las condiciones de servicio descritas y a las especicaciones de aplicación. En caso de presentarse diferentes especicaciones de aplicación y/o condiciones de servicio, contacte con el departamento especializado que corresponda. Sujeto a modicaciones técnicas.
HYDAC FILTER SYSTEMS GMBH 2 1 . 7 0 / 0 . 8 5 9 . 7 P S
14
Industriegebiet D-66280 Sulzbach / Saar Tel.:+49 (0) 6897/509-01 Fax:+49 (0) 6897/509-846 Internet: www.hyda www.hydac.com c.com E-mail: ltersystems@h
[email protected] ydac.com
SIS Media Number: BI646664
SERVICE ADVISORY Date: November 19, 2012 Caterpillar Global Mining LLC 6744 S. Howell Ave Oak Creek, WI 53154, USA 414.768.4000 / Fax: 414.768.4570
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 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 press ure is 900 9 00 psi (+15 psi ps i / -0 psi) ps i) at 20 °C. Action: It is recommended that the proper p roper gas pre-charge is checked at a t 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
1
ISO 9001: 2000 Registered Firm
SIS Media Number: BI646664
SIS Media Number: BI646664
The acceptable accepta ble pre-charge pressure is dependant on the ambient air temperature. At 20 °C, the correct c orrect 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 Accumulator Pre-charge Pressure/Temperature Pressure/Temperature Relationship for a Typical 900 psi (+15psi / -0psi) HydraCrowd Accumulator 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 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
2
ISO 9001: 2000 Registered Firm
SIS Media Number: BI646664
SIS Media Number: BI646664
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.
Items included in Kit S134578
Adapters from Nitrogen Bottle to Charging Hose Charging Hose
Charging and Gauging Unit
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
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
3
ISO 9001: 2000 Registered Firm
SIS Media Number: BI646664
SIS Media Number: BI646664
CRGV Accumulator
RECV Accumulator
4
ISO 9001: 2000 Registered Firm
SIS Media Number: BI646664
SIS Media Number: BI646664
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.
Check Valve Location
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.
T-Handle
Check Valve Bleed Valve
5
ISO 9001: 2000 Registered Firm
SIS Media Number: BI646664
SIS Media Number: BI646664
There should not be any interference issues connecting the gauging unit to the CRGV accumulator. accum ulator.
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.
6
ISO 9001: 2000 Registered Firm
SIS Media Number: BI646664
SIS Media Number: BI646664
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 accum ulator can be tilted away from the RECV module so the gauging unit can be installed. Ensure the upper bolt is re-installed r e-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
7
ISO 9001: 2000 Registered Firm
SIS Media Number: BI646664
SIS Media Number: BI646664
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
8
ISO 9001: 2000 Registered Firm
SIS Media Number: BI646664
Hydraulic Crowd Service Procedures
SIS Media Number: BI646664
Hydraulic Crowd Service Procedures Inspection
BI010733
9.5.9 Accumulator Inspection The condition of the accumulator is primarily determined by periodic checking of the pre-charge pressure. To check the gas precharge pressure in an accumulator, it must first be isolated from the system, using the shut off and bleed valve. The most accurate pre-charge readings are taken , when the hydraulic oil pressure is at 0. 0
2 r e b m e v If accumulator pressure monitoring system is installed: o N Y The proper gas precharge pressure should be verified after each new installation or repair. The L proper gas precharge pressure should be checked, using the operator’s display, every 500 hours N O or monthly, whichever comes first. The system should be verified to be functioning correctly E every 6 months by comparing the actual accumulator charge pressure on the operator's display C N to the pressure reading on the charging/gauging unit. E R E F E R R O F E S U E L P M A S Y R A N I M I L E R P
9.5.9.1 Intervals Between Checking Gas Pre-charge Pressure
If accumulator pressure monitoring system is not installed: The proper gas precharge 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.
9 – 50 November 2012
Electric Rope Shovel
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SIS Media Number: BI646664
Hydraulic Crowd Service Procedures
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Hydraulic Crowd Service Procedures Inspection
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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. TOOLS: Char Ch argi ging ng/G /Gau augi ging ng Un Unit it Bottled Nitrogen
PN: PN: S134 S13457 578 8
NOTE:
This procedure can be performed with the dipper handle in either the horizontal posit ion (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.
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Electric Rope Shovel
P R E L I M I N A R Y S A M P L E U S E F O R R E F E R E N C E O N L Y N o v e m b e r 2 0 ,
9 – 51 November 2012
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Hydraulic Crowd Service Procedures
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Hydraulic Crowd Service Procedures Inspection
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To pressure test and/or charge the accumulator: 1.
Posit Positio ion n the the mach machine ine for for servi service ce usi using ng opt optio ion n A or or B.
Option A Positio Position n the handl handle e so the the accumul accumulator ators s can be be accessed accessed from the the house house roof roof.. , • 0 2 • Use the the crowd crowd motion motion to positi position on the hoist hoist rope ropes s as close close to vertica verticall as possibl possible e in order order to r e minimize the force (pulling out or pushing in) the hoist ropes exert on the cylinder. The rod b end pressure can be monitored from the operator cab screen to ensure the hoist rope force m e on the cylinder is minimized. v o N Y L N O E C N E R E F E R R O F E S U E L P M A S Y R A N I M I L E R P Option B • 2. 3.
Plac Place e the the dipp dipper er on the the gro groun und. d. Shutdow Shutdown n the machin machine. e. Lockout Lockout and and tagout tagout contr controls ols in comp complia liance nce with with local local regula regulation tions. s. Verify Verify that that the rod rod end end of the cylin cylinder der is is void of of pressur pressure e by bleedi bleeding ng excess excess oil oil pressu pressure re from the rod end test port on the cylinder manifold. This can be achieved by attaching a micro bore hose from the hydraulic test kit and emptying the oil into a bucket or other storage vessel. This may take several minutes. Once pressure is relieved, remove the micro bore hose from the test port and install a pressure gauge to verify no pressure is present.
9 – 52 November 2012
Electric Rope Shovel
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SIS Media Number: BI646664
Hydraulic Crowd Service Procedures
SIS Media Number: BI646664
Hydraulic Crowd Service Procedures Inspection
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4. 5.
6.
On the CRGV accum accumula ulator, tor, close close the shuto shutoff ff valve valve locate located d on the the safety/ safety/shu shutoff toff block block.. On the CRGV CRGV accum accumula ulator tor,, locate locate the manual manual bleed bleed valve valve on the the safety/s safety/shuthut-off off block. block. Relieve the oil pressure by turning the manual bleed valve spindle counter-clockwise. Drain all fluid from the accumulator before connecting the pressure testing equipment. If equipp equipped ed with with accumula accumulator tor pressu pressure re monito monitorin ring g system system check check accumul accumulato atorr pressur pressure e on operators display otherwise continue to Step 7 check accumulator charge pressure with charging/gauging unit. The nominal pressure is 900 psi (+15 psi / -0 psi) at 20°C. If accumulator charge pressure shown on the operators display is low, continue to Step 7 to charge accumulator.
NOTE:
The actual pressure in the accumulator will be dependant on ambient air temperature.
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Electric Rope Shovel
P R E L I M I N A R Y S A M P L E U S E F O R R E F E R E N C E O N L Y N o v e m b e r 2 0 ,
9 – 53 November 2012
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Hydraulic Crowd Service Procedures
SIS Media Number: BI646664
Hydraulic Crowd Service Procedures Inspection Char Ch argi ging ng/G /Gau augi ging ng Un Unit it
, 0 2 r e b m e v o N Y L N O E C N E R E F E R R O F E S U 7. E L P M A 8. S Y R A N I 9. M I 10. L E 11. R P
BI010733
PN: PN: S134 S13457 578 8
Figure 9-28
Remove Remove the valve valve prot protecti ection on and the the valve valve seal seal cap from from the top top of the the accumul accumulator ator.. Clean Clean any dirt, debris or paint from the charging valve area and ensure that the threads and sealing surface are in good condition. Using Using an alle allen n wrench wrench,, break break loose loose the the charg charging ing cap cap screw screw locat located ed at the the top top of the the accumulator. Do not rotate this screw more than 1/8 turn. Ensure that the charging gas does not leak from the accumulator. Attach Attach the the adapte adapterr and and the the chargi charging/ ng/gau gaugin ging g unit unit to to the the accumu accumulat lator. or. Tighten the adapter adapter to the top of the accumula accumulator tor to ensure ensure that that a gas gas tight seal seal is formed. formed. With the charging charging unit unit connected connected to the regulat regulator or and nitrogen nitrogen bottle bottle as shown shown in the Figure 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 be seen on the charging unit. If the pressure is acceptable skip to step 16. The nominal pressure is 900 psi (+15 psi / -0 psi) at 20°C, but the actual pressure in the accumulator will be dependant on the ambient air temperature.
9 – 54 November 2012
Electric Rope Shovel
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Hydraulic Crowd Service Procedures
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Hydraulic Crowd Service Procedures Inspection
To determine correct charge pressure with varying ambient air temperatures use the chart below.
P R E L I M I N A R Y S A M P L E U S E F O R 12. If the gas pressure pressure is is low, charge charge the accumulato accumulatorr until the the correct pressure pressure is reached. reached. The R E charging process should be done very slowly to ensure that the accumulator is not F E damaged. With accumulator pressure monitoring system installed, charge to 900 psi (+15 R psi / -0 psi) as shown on the operators display as the Temperature Corrected Value. E N Without accumulator pressure monitoring system installed, charge to the pressure shown in C E the chart above based on the current outside ambient temperature. O N L Y N o If the accumulator is new or has fallen below 100 psi, the accumulator must be charged at v e a very slow rate. It should take 2-3 minutes for every 20-30 psi. Charge at this rate until m b the accumulator pressure reaches 100 psi. Above 100 psi, the rate of charging can e r increase to 100 psi per 2-3 minutes until the system is fully charged to the correct 2 pressure. 0 ,
13. Allow 10 minutes for for the gas temperature temperature and pressure pressure to stabilize. stabilize. Recheck Recheck and adjust as as necessary. 14. If the gas precharg precharge e is still low, low, continue continue charging. charging. If the the gas pressure pressure is high, high, bleed bleed gas off off through the charging system. Allow 10 minutes for the gas temperature and pressure to stabilize. 15. If accumulator accumulator is unable unable to maintain maintain charge, replace replace accumulator accumulator.. 16. Once the proper proper gas gas precharge precharge pressure pressure is reached reached,, close the shut-off valve valve on the the nitrogen nitrogen bottle and tighten the charging cap screw on the accumulator by rotating the T-handle. This will seal the gas in the accumulator. Loosen the adapter and disconnect the charging/gauge unit from the accumulator. 17. Using an an allen wrench, wrench, tighten tighten the the charging charging cap screw screw to 15 Ft-Lbs Ft-Lbs and check the area area around the screw for leaks using a soapy solution. If any leaks are found, repair or replace the sealing ring and recharge the accumulator.
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Hydraulic Crowd Service Procedures
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Hydraulic Crowd Service Procedures Inspection
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18. Replace Replace the the protect protective ive cap cap on the top top of the accum accumula ulator tor.. 19. On CRGV accumulato accumulator, r, return return the shutoff shutoff valve to the open open position position and install install a bolt bolt and lock nut to lock this valve into this position. 20. On CRGV accumulator, accumulator, tighten tighten manual manual bleed bleed valve valve spindle spindle to close manual manual bleed valve. Locate the spindle against the relief when complete. , 0 2 r e b m e v o N Y L N O E C N E R E F E R R O F E S U E L P M A S Y R A N I M I L E R P
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Electric Rope Shovel
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Hydraulic Crowd Service Procedures
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Hydraulic Crowd Service Procedures Hydraulic Crowd Service Schedule
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9.10 Hydraulic Crowd Service Schedule Interval (Hours)
, 0 2 r e b m e v o N Y L N O E C N E R E F E R R O F E S U E L P M A S Y R A N I M I L E R P
Task
Daily
100
500
1,250
2,500
5,000
10,000
15,000
30,000
Visually Inspect 1) Hydraulic tanks (Upper & Lower) and PDT for oil leaks 2) Hose and tube connections for leaks 3) Inspect isolators & plumbing on top of house Verify System Hydraulic Oil Level (Upper Level (Upper tank sight gauge) See SYSTEM TOP OFF in HYDRAULIC CROWD SERVICE PROCEDURES section Verify Pump Drive Transmission (PDT) Oil Level (Dipstick) Level (Dipstick) HYDRAULIC CROWD SERVICE See PDT OIL LEVEL CHECK in 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 FilterFilter - (Replace as required) Inspect and clean Coolers as required (Externally) 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 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 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 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) 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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Electric Rope Shovel
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Hydraulic Crowd Service Procedures
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Hydraulic Crowd Service Procedures Hydraulic Crowd Service Schedule
BI010733
Interval (Hours) Task
Daily
100
500
1,250
2,500
5,000
10,000
15,000
30,000
Pressure Test Accumulators (RECV and CRGV) - See ACCUMULATOR PRESSURE TEST AND AND CHARGE in CHARGE in HYDRAULIC CROWD SERVICE PROCEDURES section Perform System Health Monitoring Monitoring - See HYDRACROWD HEALTH MONITORING CHECKS in PREVENTIVE MAINTENANCE section 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 POWER UNIT FILL AND FILTER REPLACEMENT REPLACEMENT in HYDRAULIC CROWD SERVICE PROCEDURES section
**
P R E L I M I N A R Y S A M P L E U S E F O R R E F E R E N C E O N L Y N o v e m b e r 2 0 ,
Replace select hoses 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 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 CouplingCoupling - 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
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Electric Rope Shovel
9 – 185 November 2012
February 8, 2012
HydraCrowd Initial Start-up Procedure
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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 auxiliary tank (approximately 120 120 gallons) as described in Section 9.6.9 (Auxiliary Power Unit Fill & Filter Replacement) of the Maintenance Manual. b. Circulate the oil through the the auxiliary unit filters until until the contamination monitor reads 16/14/12 or lower. c. Transfer the hydraulic oil into into the upper tank as described described in Section 9.6.6 (System Top Off) of the Maintenance Manual d. Repeat steps a, b and c until until the hydraulic system is full (approximately 1000 gallons) Note: Replace the Pressure, Return and and Pre-fill filters as required during the system system fill process by by monitoring the filter indicators. As the filters become contaminated, the gauge will move from green to red.
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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 Section 9.6.10 “PDT – Initial Oil Fill” in the the Maintenance Manual. 3. Purge the 4 main pumps to insure that that the 4 pump cases are are full of of oil. Loosen the hose connection on top of each pump and allow the air to bleed out out (Figure 1). When oil is flowing flowing from the fitting, fitting, tighten the hose fitting. fitting. (See Section 9.9.1 9.9.1 “Purging The Main Main Pumps” in the Maintenance Manual)
Figure 1 4. Verify correct correct rotation rotation of the main crowd crowd motor and couple couple the the motor to th the e PDT. PDT. (See Figure Figure 2) Note: Turning the pumps pumps in the wrong direction may cause cause damage to the pumps. 5. Verify correct rotation of the flushing pump. (See Figure 2) Note: Turning the pumps pumps in the wrong direction may cause cause damage to the pumps.
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6. Verify correct rotation of the circulation pump. (See Figure 2) Note: Turning the pumps pumps in the wrong direction may cause 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 the warm-up mode in state 1B, 1B, the immersion heaters heaters and the the circulation pump will be on. Oil will be flowing flowing over the relief valve in the circulation circulation manifold manifold (HOCCV). This will heat the the oil. (No oil oil will be flowing through the crowd cooler.) Alternate Method: If 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 should start in low speed and then then go to full full speed. (This is not always always noticeable noticeable if the oil temperature temperature in the upper tank is above -7degrees C [20 degrees F].) Check the hydraulic oil pressure in the circulation manifold.
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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, warm, the HOCCV will energize 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 the oil. Check the oil cooler circuit for leaks. Alternate method: Force method: Force the circulation manifold to go into the cooling mode. Observe the flow meter on the right r ight 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.
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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 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 hose into an empty empty 5 gallon pail. pail. There will be very little little flow and very low low pressure. Wait until there there is a continuous continuous stream of oil and then disconnect the test hose.
Figure 4 11. Bleed the crowd cooler cooler core. Air can be trapped in the cooler core. (Optional)
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12. Energize the flushing pump. pump. This will turn turn the contamination contamination monitor monitor (HOCM) on. on. Check the fflushing lushing circuit for leaks. This can 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 screens on the four flow meters (Figure 5) located on the the power module. module. Insure that they are are reading. reading. Expected reading is approximately approximately 2 gpm. gpm. There is no need to record the readings at this time.
Figure 5 14. Filter the oil in the main system until until the cleanliness is 16-14-12 16-14-12 before proceeding. proceeding. The circulation pump filters the oil when the system is the cooling cooling mode. The flushing pump pump sends oil through through the contamination monitor (Figure 6) and shows the oil cleanliness reading. Record the cleanliness reading ________________
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Figure 6 15. When the flushing pump pump is turned on, the PDT oil pump will will move PDT oil through the the PDT oil cooler. The PDT oil level may need to be topped off off several times until the system is full. Check the PDT PDT oil circuit for leaks. leaks. If the oil level is is too low, the crowd system will shut down. The operator’s screen will show a low PDT pressure 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.
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Figure 7 17. When the oil meets the cleanliness requirement requirement of 16-14-12, run the crowd motor motor in the “Pump “Pump Unloaded” Unloaded” mode. mode. (State 1C) 1C) The crowd motor will turn at 250 250 RPM. This causes oil to to flow from the pumps, pumps, through the pump pump manifold, and and back to the the upper tank. Check for hydraulic oil leaks. leaks. Allow the flushing flushing to continue continue for at least 15 15 minutes to insure complete flushing of the pump, hoses and pump manifold. 18. After step 17, the contamination monitor monitor values may increase, indicating that that the system is cleaning the oil. Before proceeding 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 the heating mode to State 2B. The main pump heating heating mode is active. All four PICV solenoids solenoids will will be turned turned on. The crowd motor will turn at 250 250 RPM. Hydraulic oil will be be flowing past two PUV valves, back back to tank, causing causing the oil to heat. The PUV valves are turned on and off in pairs to prevent the valves from overheating.
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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 pressures and adjust 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 pressure on the pump 1 and pump pump 3 pressure gauges. gauges. Expected pressure 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 pressure on the pump 1 and pump pump 3 pressure gauges. gauges. Expected pressure 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 Note: The individual pressure relief valves (Figure 8) on the pump manifold can be adjusted if required. required. The pressure relief relief valve should be replaced if it does not respond when adjusted.
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Figure 8 20. Advance the the heating mode to state 2C, manifold heating. heating. Note: this is the same as “hose flushing” and will clean the hydraulic hoses and manifold. Allow the hose flushing to continue continue for at least least 15 minutes. minutes. Alternate method: Activate method: Activate the Hose Flushing Mode using the button on the operators operators screen. Hose Flushing 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 ___________ ___________
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Observe the pressure readings of the 4 main pumps on the digital pressure gauge. The expected reading on each each pump should should be approximately 500 500 psi. It is not necessary necessary to record the the readings. 21. Record the reading of the contamination contamination monitor at the conclusion of hose flushing. ____________ 22. After step 21, the contamination monitor monitor values may increase indicating that that the system is cleaning the oil. Before proceeding 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 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 horizontal position. position. 25. Bleed the cylinder using Step Step 4 of the “HydraCrowd Cylinder Cylinder Bleeding Process”. (See Section 9.6.1 in the Maintenance Manual) 26. Operate the cylinder cylinder in mid-stroke (between 8’ and 15’ 15’ of crowd extension) until the operational temperature is reached. Warning: Do not fully extend or retract the cylinder when the hydraulic oil is below operating temperature. Damage to the cylinder snubbers could occur. 27. When the hydraulic oil has reached operating operating temperature, set the crowd limits. (See Section 4.4.17 4.4.17 “Hoist and Crowd Limit Systems” Systems” in the Maintenance Manual)
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28. When full crowd motion is permitted, check the speeds in extend and and retract. These numbers numbers are viewable on on the operator’s 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
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29. Take WinDaq recordings. (See Section 3.7 “HydraCrowd “HydraCrowd Health Monitoring Checks” Checks” in the Maintenance Maintenance Manual) Manual) Send the WinDaq WinDaq recordings to South Milwaukee Service Department for interpretation. 30. Remove the two auxiliary quick disconnect disconnect couplings (Figure 10) from the cylinder manifold and install two “Zero Leak” plugs.
Figure 10
Commissioning Engineer
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Date
14
Media Number: BI643125 Number: BI643125 Media Number: BI643125 Number: BI643125 Publication /ate: 211214 /ate: 211214
Media Number: BI643125 Number: BI643125 Media Number: BI643125 Number: BI643125 Publication /ate: 211214 /ate: 211214
Special Instruction ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ______________________________ __________________________________
Inspection Procedure for Saddle Block Liner and Handle Guide Bushing Wear on Hdra!ro"d# $%uipped &'() and &'()H* $lectric +ope Sho,els
$lectric +ope Sho,el 7495 (ER6) Hyra!ro"# 7495H$ (ER%) Hyra!ro"#
Introduction &'is special instruction proies t'e inor*ation to *onitor t'e "ear on t'e sale +loc, liners an t'e 'anle -uie +us'in-s urin- operation. It also proies a *easure*ent *et'o or eter*inin- "ear on re*oe sale +loc, liners.
Important Safet Information
/'ile "or,in- on t'e ront en o t'e sale +loc,0 people "ill +e "or,in- at 'ei-'ts. roper proceures *ust +e ollo"e "'ile operatin- t'e *an lit.
+e%uired Parts and-or .ools an lit $eeler au-es 12 inc' len-t' Ruler !a*era !alipers
Media Number: BI643125 Number: BI643125
!omponent +eplacement
Media Number: BI643125 Number: BI643125
!omponent +eplacement &'e sale +loc, liners s'oul +e replace "'en t'e .3% inc' c'a*er 'as +een "orn o t'e en o t'e liner +us'in-s. Note Note &'e su+se8uent *easure*ents can +e use or *onitorin- an trenin- purposes0 +ut t'e eter*ination or liner replace*ent s'oul +e *ae +ase on t'e conition o t'e "ear c'a*er. &'e Hanle uie +us'in-s s'oul +e replace "'en t'e .37 inc' "ear c'a*er is no lon-er isi+le upon inspection.
Illustration 0 1 Saddle Block Liner and Handle Guide Bushing
Procedure 1 Saddle Block Liner Installed on Machine 1) osition *ac'ine or inspection. 2) o into t'e *an lit an position yoursel so you are acin- t'e ront en o t'e sale +loc,. 3) sin- t'e 12 inc' len-t' eeler -au-e0 *easure t'e -ap0 s 'o"n in -reen0 +et"een t'e ront liner an 'anle at t'ese % locations. Recor t'e nu*+ers in t'e irst ta+le +elo".
:iner 1
8
2
7
Hanle
3
6
4 5
1
2
3
4
5
6
7
%
Media Number: BI643125 Number: BI643125
&'e no*inal ia*etrical clearance +et"een t'e sale +loc, liner an t'e 'anle is .25 inc'es.
Media Number: BI643125 Number: BI643125
&'e no*inal ia*etrical clearance +et"een t'e sale +loc, liner an t'e 'anle is .25 inc'es.
1 %
2
7
3
6
4 5
Illustration 2 1 Position +eference
Media Number: BI643125 Number: BI643125
4) /it' t'e eeler -au-e inserte at eac' interal0 use a ruler an *easure to t 'e ;< o t'e
Media Number: BI643125 Number: BI643125
4) /it' t'e eeler -au-e inserte at eac' interal0 use a ruler an *easure to t 'e ;< o t'e lan-e0 as s'o"n in Illustration 30 an recor in t'e ta+le +elo".
Illustration 3 4 Measuring of 5/ *lange
1
2
3
4
5
6
7
%
&'e no*inal istance ro* t'e I< o t'e sale +loc, liner t o t'e ;< o t'e lan-e as s'o"n a+oe is 5.315 inc'es.
5) easure t'e istance ro* t'e en o t'e c'a*er to t'e ;< o t 'e sale +loc, liner as s'o"n in Illustration 4. easure*ent Step 5 _____
Media Number: BI643125 Number: BI643125
Media Number: BI643125 Number: BI643125
Illustration ' 4 Measuring of !hamfer to 5/
&'e ta+le +elo" can +e use to 'elp eter*ine re*ainin- sale +loc, liner lie.
!urrent 'ours on liners easure*ent ro* Step 5 osition
1
2
3
4
5
6
7
8
easure*ent ro* Step 4
Re*ainin- !'a*er = Step 4 > Step 5
? Re*ainin- !'a*er (.3%Re*ainin!'a*er)@1
Units are Inches for Formula above
Media Number: BI643125 Number: BI643125
6) Inspect t'e -uie +us'in- ro* t'e *an'ole s'o"n in Illustration 4. oin- onto t'e access
Media Number: BI643125 Number: BI643125
6) Inspect t'e -uie +us'in- ro* t'e *an'ole s'o"n in Illustration 4. oin- onto t'e access plator*s *ay +e re8uire or cleanin-0 +ut t'e +us'in- c'a*er is isi+le ro* t'e +oo* "al,"ays.
/ear !'a*er
Illustration ) 4 Manhole Inspection Port
________ 7) Inspect t'at t'e "ear c'a*er is still isi+le. I not isi+le recor 'ours 'ere ________
Illustration 6 4 Guide Bushings
Media Number: BI643125 Number: BI643125
%) Aitional Inor*ation Re8ueste
Media Number: BI643125 Number: BI643125
%) Aitional Inor*ation Re8ueste Inspect ipper ipper 'anle or ae8uate ae8uate ;: coera-e an an any si-ns o pittin- or ot'er a*a-e. Reer to Illustration 6 or 'anle pittin- ea*ple. Inspect t'e top o t'e 'anle en retainer an t'e top surace o t'e sleee or any si-ns o "ear. Reer to Illustration 7 an % •
•
Illustration & 1 $7ample /ipper Handle Pitting
Ces
Do
Si-ns o ittin- ;n Hanle
Ces
Do
&op o Hanle En Retainer /ear
Ces
Do
&op o Sleee /ear
Ces
Do
;: &ype Inector &ype uie Bus'in- !'an-e ;ut $re8uency
S:1 or S:F Hours
Media Number: BI643125 Number: BI643125
Media Number: BI643125 Number: BI643125
Inspect t'e top o t'e 'anle en retainer an t'e top surace o t'e sleee or any si-ns o "ear
Illustration 8 1 Handle $nd +etainer9 Photo taken from the ,ie"ing "indo" at the end of the slee,e
Illustration (1 Handle $nd +etainer Metal *lo"
Media Number: BI643125 Number: BI643125
Procedure 1 Saddle Block Liner L iner +emo,ed *rom Machine
Media Number: BI643125 Number: BI643125
Procedure 1 Saddle Block Liner L iner +emo,ed *rom Machine 1) ar, t'e top o eac' sale +loc, liner so its position as it "as installe on t'e sale +loc, is recore. 2) easure t'e -rease -rooe ept' at t'e ollo"in- locations or t'e ront an rear sale +loc, liners (Reer to Illustration 9) $ront an Rear o eac' -rease -rooe Bot' sies o eac' -rease -rooe Repeat or all % -rease -rooes • • •
Ensure eac' -rease -rooe position relatie to its position on an installe *ac'ine is recore. I t'e -rease -rooe is co*pletely "orn a"ay0 *easure t'e lan-e "it' as s'o"n in Illustration 1.
B Sie
A Sie
easure -rease -rooe ept' at locations s'o"n. Repeat or all % -rease -rooes
Illustration ( 1 Saddle Block Liner Measurement Locations
Media Number: BI643125 Number: BI643125
Media Number: BI643125 Number: BI643125
Illustration 0 1 ;lternati,e Measurement Measurement Location if Grease Groo,e is Gone
Illustration 00 1 $7ample Measurement Method
Media Number: BI643125 Number: BI643125
Media Number: BI643125 Number: BI643125
%
1
7
2
6
3 5
4
Illustration 02 1 Grease Groo,e Position +eference
Media Number: BI643125 Number: BI643125
Media Number: BI643125 Number: BI643125
Front Liner Groove Location 1 2 ! " # $ %
Position
Flange End
Inboard End
Rear Liner Flange End
Inboard End
A B A B A B A B A B A B A B A B Grease Groo,e Measurement .able
Location
Front Liner
Rear Liner
Flange End
Flange End
1 2 ! " # $ % *lange Width Measurement .able
Media Number: BI643125 Number: BI643125
3) Aitional Inor*ation Re8ueste
Media Number: BI643125 Number: BI643125
3) Aitional Inor*ation Re8ueste
Ces
Do
Si-ns o ittin- ;n Hanle
Ces
Do
&op o Hanle En Retainer /ear
Ces
Do
&op o Sleee /ear
Ces
Do
;: &ype Inector &ype
S:1 or S:F
uie Bus'in- !'an-e ;ut $re8uency
Hours
Sale Bloc, :iner !o*ponent Hours /'en Re*oe
Hours
Information +eporting lease report all inor*ation o+taine on t'e
G212 !aterpillar All Ri-'ts Resere
!at0 !aterpillar0 t'eir respectie lo-os0 !aterpillar Cello" an t'e o"er e-e trae ress0 as "ell as corporate corporate an prouct ientity use 'erein0 are are trae*ar,s o !aterpillar an *ay not +e use "it'out per*ission.
Media Number: BI643161 Publication Date: Date: 27 June 2014
Media Number: BI643161 Publication Date: Date: 27 June 2014
Service Magazine New Band Clamps Available for 7495 and 7495HF HydraCrowd™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
ER801325
141325
ER801327
141327
ER801333
141333
ER801424
141424
ER801429
141429
7495HF
Media Number: BI643161
ER801517
141517
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. 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 – 1 – Band clamp (P/N 4419574) location and position on the HydraCrowd™ cylinder.
Adaptable To: The redesigned band clamps (P/N 4419574) 4419574) are effective in HydraCrowd™ cylinders assembled after June 25, 2014. 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.
©2012 Caterpillar All Rights Reserved Reserved
Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge trade dress, as well as corporate corporate and product identity used herein, are trademarks trademarks of Caterpillar and may not be used without permission.
Media Number: BI643161
Media Number: BI643161
Illustration 2 – 2 – Torque Torque and position of the clamp on the cylinder.
Media Number: BI643161
Media Number: BI643161
Illustration 3 – 3 – Quantity and spacing of the band clamps (P/N 4419574) on the HydraCrowd™ cylinder.
MR Flow Transmitter Transmitter Installation & Maintenance Instructions FORM #HLIT 306
DIVISION OF RACINE FEDERATED INC.
8635 Washington Washington Avenue • Racine • Wisconsin 53406-3738 TEL 1-800-HEDLAND • FAX FAX 1-800 CHK-FLOW CHK-FLOW
I. INTRODUCTION The MR Flow Trans Transmitter mitter is a state-of-the-art, microprocessor based variable area flow meter. It combines the rugged proven technology of a piston-type,, variable area flow meter with solid state piston-type circuitry including: • • • •
Non-contact sensor electronics Electronic signal conditioning circuit Digital flow flow rate 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. ser vice. The MR Flow Trans Transmitter mitter is capable of calculating and displaying both flow rate and total accumulated flow. The flow rate and total flow 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. prac tical. 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 specific system requirements. Calibration parameters are included for: • Specific gravity compensation (all fluids) fluids) • Viscosity compensation (petroleum-base (petroleum-based d fluids) • Pressur Pressure e and temperature compensation (pneumatic applications)
US Patent 7,130,750
Figure 1 - MR Flow Transmitter
All meters include an analog output that can be configured for 0-5 Vdc, 0-10 Vdc, or 4-20 mA current loop. Applications for the MR Flow Transmitter Transmitter include: • • • •
Bearing lubrication Case drain verification Gun drill and machine cooling Pump flow outputs
Page 1
MR Flow Transmitter Installation & Maintenance Instructions
II. SPECIFICATIONS Enclosure Rating • NEMA 12 & 13 (IP 52 & 54) Operating Temperature • Fluid: -20 °F to +240 +240 °F (-29 °C to +116 °C) • Ambient: -20 °F to +158 +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 fac tor • Gases (¼” (¼” to 1-½”): 1000 psi psi (69 (69 bar) maximum with a 10:1 safety factor fac tor Pressure Rating Stainless Steel • Liquids (¼” to ½”): 6000 psi (414 bar) maximum with a 3:1 safety factor fac tor • Liquids (¾” to 1-½”): 5000 psi (345 bar) maximum with a 3:1 safety factor fac tor • Gases (¼” (¼” to 1-½”): 1500 psi psi (103 (103 bar) maximum with a 10:1 safety factor Accuracy • ±2% of full scale Repeatability • ±0.5% Pressure Drop • See Appendix for specific specific meter meter information information
Electrical Power Requirement: • 0-5 Vdc Vdc Output 10-30 Vdc Vdc @ 0.75W maximum maximum • 0-10 Vdc Vdc Output 12-30 Vdc @ 0.75W maximum • 4-20 mA Output Output loop-powered, loop-powered, 30 Vdc Vdc maximum Power Consumption: • 25 mA maximum Analog Outputs: • 0-5 Vdc Vdc and 0-10 Vdc into into 10,000 Ohms minimum • 4-20 mA into 1000 Ohms Ohms maximum maximum (see (see Figure 2) Circuit Protection: • Reverse polarity and current limiting Transmission Trans mission Distance: • 4-20 mA limited by cable resistance resistance • 0-5 Vdc 1000 feet (300 m) maximum • 0-10 Vdc 1000 feet (300 m) maximum Isolation: • Inherently isolated from the piping system system Rate and Totalization Display • Fixed or or toggle modes of of operation for rate and and totalizer display • 8 digit, .70” high numeric display display for rate and total • 8 digit, .34” high alphanumeric display for 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)
Page 2
Form #HLIT 306 10/10
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
1
2
C O PYRIG HTED-C USTO MER INFORM ATIO N DRA WING
3
C O PYRIG HTED-C USTO M ER INFO RMA TIO N DRA WING
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
11 10 12
A2
4
4
4 PLCS 20.00 3 PLCS
22.50
1
F5
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
C2 S5 S5 T3 T3
B4 2
1
31 35 36 38
B4
F5
4
5
T3 T3
1
SEE NOTE 3
3 39 40 41
4 PLCS
KIT,HO SE,PUM P TO CO CO N TRO L MA MA N
2
KIT,HO SE,PWR M O DULE DRA IN
DESC RIPTIO N
PA RT NO .
1
3
HO SE AS ASSY,-64 CD CD61,STR-STR
1
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PIPE AS ASSY,10.0 TA NK C ON ONN EC TIO N
1
5
SUPPO RT,C LA M P,10 PIPE
17112576
1
6
BRA C KET,10 PIPE
S046546
1
7
U-BO LT,.75UNC ,10 PIPE,RUB.C OA OA T
49032527
2
8
BA R,3x3
S046547
S089090 S046545
650422-165 S038915
4
1
9
SHIM PA C K,0.38 THK
4
10
SUPPO RT,HO SE,WELDED
S049659
4
11
BA R,.25x4
S049660
S046548
4
12
BA R,.25x4
2
13
P L,.5
S046549
1
14
THERM OW OWELL,1/ 2N PT,4.00,304SS
1546777
1
15
TRA NSM ITTER,TEM P,-40 TO 24 240F
12844169
4
16
FLA NG E,HA LF,4
53303641
16
17
FLA NG E,HA LF,1.5,6000 PSI
20325237
1
18
FTG ,EL,90 D, D,1.0M P#12M O RB
20287452
1
19
C O C K,IRO N ,SQ .HD,1,125#
79091440
1
20
PLUG ,PIPE,SQ HD H D,1,150#
20767800
1
21
C O NN,#6 O RS-#16 O RB
78554360
2
S049661
22
C O NN,#16 O RS-#16 O RB
1
23
C O NN,#8 O RS-#12 O RB
78554232
8
24
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6 81 36 13 2
78554231
2
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68760801
1
26
LA BEL,HO TSL SC R,HEX,M 16x2.0x50mm ,C L8.8
03552118
SC R,HEX,.5x2,UNC ,G R5
03285640
16
29
SC R, R, HE X, .6 25 x1 .2 5, UN C ,G R 5
0 32 91 40 0
24
30
SC R, R, HE X, .6 25 x2 .2 5, UN C ,G R 5
0 32 91 72 0
16
31
SC R,HEX,.875x4.5,UNC ,G R5,PLTD
03552119
40
33
WA SHER,BELLEVILLE,.625
03955004
4
34
WA SHER,FLA T,.562
03951700
4
16
35
W AS ASHER,FLA T,.875,HA RDEN ED,P LTD
03552121
4
16
36
WA SHER,BELLVILLE,.875
03955011
16
37
NUT,HEX,FULL,.625,UNC
32
38
NUT,HEX,FULL,.875,UNC
02715100
2
39
STRA P,HO SE BUNDLE,VELC RO
17431970
2
40
STRA P,VELC RO B BU UN DLE,20 DIA MA MA X
17431971
2
41
STRA P,VELC RO B BU UN DLE,24 DIA MA MA X
17431972
1
42
C O M PO UND,THREA D LO L O C KING
8
46
WIRE,LO C K,#16(.0625)
84280000
1
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C O NN,STR,-12 M O RB - .5FNPT
78553919
1
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XDC R,PRESSURE,0-10000PSI
12858367
*
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02713050
82833862
* QTY MEA SURE IN FEET
2
5 4
E3 NO TE: 1. X =C OM PONENTS FROM KIT(ITEM 1), SEE DRAWING S089090. 2. X =C OM PONENTS FROM KIT(ITEM 2), SEE DRAWING S046545. 3. SEE DWG S038986 FOR SPLITFLA NG E INSTALLA TION INSTRUCTIONS. 4. AP PLY LOC TITE 7471 PRIMER T(P/ N 1561393) AND LO C TITE 545 THR THREAD EAD SEALANT(P/N 1561392) 392) TO ALL NPTTHREADS HREADS UNLESS STATED OTHERWISE. 5. SEE SHEETS 6 & 7 FOR INSTALLATION OF P IPE (ITEM 4) A ND TORQUE PROC EDURE FOR EXPANSION JO INTS.
E3
6
L4
L4
G3
A2
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
18 19 20
38 36 35 31 REVISION DATA
SEE NOTE 4
T S S T ; A R A H 4 W O W S 2 P 8 M E 0 3 ; 3 S 5 N T 4 . D A . I I . 5 E W 2 1 S 1 2 S ; F I 6 E M A 0 O V 1 R M W I T E N 2 1 I D R C 2 Y D D 2 3 E 5 T E , P 8 6 , S Q T 2 5 3 . 1 1 3 A 1 G 4 0 0 , D T D 1 2 6 T T P H N 3 U H R 7 F S , A 1 S O F - O M ; ; P , E 4 8 ; E 8 0 5 R 0 S T 4 0 N , E Y I W . I 5 2 T E T S 6 , 2 A Q I ; A 1 T . 1 D V 4 W P 0 . 2 M O P , S L 2 I M E S a 2 S L l 3 3 D P T A l A A 3 O W e M W Y D N 1 u E N T E 5 . Q T I 5 6 Q T E , 2 1 I 1 E . T 6 Y Y , L B N O 0 R D Y 8 E N T S O I 3 T A E T D H M T 4 P W Q E , S I I T E M M , R 0 D L , E O F 6 ; F C S E 5 E E . P , E T V E E D 3 I G R 0 S 7 R
4 7 5 3 5
1
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
2
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
3
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
1
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
2
C OPYRIGHTED-C USTO MER N I FORM A TIO N DRAWING
3
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
6
G N I W A R D N REISS UEDATE 04-17-2012 O I T A SOLIDWORKS M R DRAWING O F N I THISDOCUMENTISPROTECT SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. R E ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION OROTHERUSESHALL BE M SUBJECTTO LIABILITY. C 2006 BucyrusInternational,Inc. usInternational,Inc. ALLRIGHTSRESERVED. O T S ALLDIMENSIONS ININCHES-UNLESSOTHERWISESPECIFIED U MACHINING TOLERANCES-UNLESSOTHERWISESPECIFIED C 1. 2PLACEDECIMALDIMENSIONS .01FOREACH12MAX±.09 D 2. 3PLACEDECIMALDIMENSIONS .005UPTO 3 6, .010OVER36 E T 3. CONCENTRICITYOFCYLINDRICALSURFACES=.010T.I.R . Bucyrus H 4. PARALLE LISM,SQUARE NESS,ORANGULARIT Y BETW EENSURFACES G AND/ORHOLECENTERLINES 07'(.002INCH/INCH) International, Inc. I R FABRICATING TOLERANCES-UNLESSOTHERWISESPECIFIED Y 1. MAE T RI A L H TC I K NE SS D I ME NS O I NS T OL ER AN C E P A. LESSTH AN.12 0TO 36 .03 O OVER36 .06 C 0TO 36 .06 B..12 TO .5 0 R
OVER36 .12 0TO 36 .09 OVER36 .19 D.OVER 1.0 0 0TO 36 .19 OVER36 .25 2. BENTANGLES 1 (.017IN/IN)FOREACH.37OFMATERIAL THICKNE SS(MAX 3 ) C. .50TO 1.0 0
WELDMENTTOLERANCES-UNLESSOTHERWISESPECIFIED 1 . DM I E NS O I N A. UPTO 36"
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B. 36"TO 10 ' C. 10'TO 30 '
R D
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
S052002
27 28
USE ASNEEDED TO SUPPORT 4 -24 HOSE FROM KITS089090
3
1
1
4
G3
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
ITEM NO.
1
16
4
17 24 27 33
QTY
D.OVER30'
T OL ER AN C E .06 .12 .12 .19 .19 .25 .25
DESCRIPTION
PLUMBING,HYD CROW D HOUSE,FLD REFDWGS MODEL DET ENG CONTACT
NO.
S038972 495
ALBRECHTK. FUERSTJ .
UNIT DATE DWG SIZE
1600 12-12-2008
FINWGT
1013.6
REV
4
E SHEET
S089091
1 OF 7
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
C OPYRIG HTED-C USTO MER N I FO RMA TIO N DRAWING
4
4
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
BALLVA LVE IN BOTTOM OF UPPER TANK
6
21
8
1
22
5
5 2
2 28 34 42
16 25 30 33
9
SEE NOTE 3 31 35 36 38
7
DETAIL C 2 31 35
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
36 38
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
LUBE ROOM BULKHEAD
D 6
6
.13
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
.13
SECTION A2-A 2
5
13
DETAIL D
3 SIDES WHERE ACC ESSIBLE BLE
G N I W A R D N O I T A M R O WELD ITEM 13 TO F N LUBEROOM FLOO R I R 4 SIDESWHERE AC CESSIBLE E M CENTER ITEM 13 UNDER O T ITEM 5 S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2006 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED. DESCRIPTION
R
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
1
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
2
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
3
Bucyrus International, Inc.
PLUMBING,HYD CRO WD HOUSE,FLD REV DWG SIZE 4 E NO.
S089091
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
SHEET
2 OF 7
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2
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3
C OPYRIG HTED-C USTO MER N I FO RMA TIO N DRAWING
4
4
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
BALLVA LVE IN BOTTOM OF UPPER TANK
6
21
8
1
22
5
5 2
2 28 34 42
16 25 30 33
9
SEE NOTE 3 31 35 36 38
7
DETAIL C 2 31 35
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
36 38
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
LUBE ROOM BULKHEAD
D 6
6
.13
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
.13
SECTION A2-A 2
5
13
DETAIL D
3 SIDES WHERE ACC ESSIBLE BLE
G N I W A R D N O I T A M R O WELD ITEM 13 TO F N LUBEROOM FLOO R I R 4 SIDESWHERE AC CESSIBLE E M CENTER ITEM 13 UNDER O T ITEM 5 S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2006 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED. DESCRIPTION
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COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
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COPYRIGHTED-CUSTOMERINFORMATION DRAWING
2
1
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2
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3
3
Bucyrus International, Inc.
PLUMBING,HYD CRO WD HOUSE,FLD REV DWG SIZE 4 E NO.
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4
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
42.50 INSIDE OF FRONT WALLTO 10"PIPE
5
5
4 1.43 14 G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
47
15 HOTSL
26
31
35 36 38 G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
SEE NOTE 4
LABEL"HOTSL" LOCATE ASSHOWN
SEC SEC TION IO N E3-E3 E3-E3
6
6
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
4
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
PMOPT 48 IN PORT"GSP2"
SECT SEC TION IO N T3-T3 18 19 20 SEE NOTE 4
SECTION ECTION G 3-G3
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2006 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED.
ORIENTITEMS18, 19 AND 20 TOWARDSFRONTOF MACHINE
DESCRIPTION
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COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
1
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
2
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
3
Bucyrus International, Inc.
PLUMBING,HYD CRO WD HOUSE,FLD REV DWG SIZE 4 E NO.
S089091
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
SHEET
3 OF 7
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C OPYRIG HTED-C USTO MER N I FO RMA TIO N DRAWING
4
4
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
42.50 INSIDE OF FRONT WALLTO 10"PIPE
5
5
4 1.43 14 G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
15 HOTSL
26
47
31
35 36 38 G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
SEE NOTE 4
LABEL"HOTSL" LOCATE ASSHOWN
SEC SEC TION IO N E3-E3 E3-E3
6
6
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
4
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
PMOPT 48 IN PORT"GSP2"
SECT SEC TION IO N T3-T3 18 19 20 SEE NOTE 4
SECTION ECTION G 3-G3
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2006 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED.
ORIENTITEMS18, 19 AND 20 TOWARDSFRONTOF MACHINE
DESCRIPTION
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COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
1
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
2
1
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
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3
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
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23
K
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C OPYRIG HTED-C USTO MER N I FO RMA TIO N DRAWING
3
2
J
4
4
2
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
1
5
5
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
39 40 41 31 35 36 38
USE ASNEEDED TO SUPPORT-24 HOSE FROM KITS089090(ITEM 1)
SEC SEC TION IO N B4-B B4-B4 4 2
3 SEE NOTE 3
4 2
25 30 33
2
3
6
6
22
3
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
2 5 5.25 TRIMMED LENGTH
17 24 30 33 SEE NOTE 3
SEC SEC TION IO N L4-L4
1
DETAIL J
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2006 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED. DESCRIPTION
VIEW K-K COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
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COPYRIGHTED-CUSTOMERINFORMATION DRAWING
2
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
3
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Bucyrus International, Inc.
PLUMBING,HYD CRO WD HOUSE,FLD REV DWG SIZE 4 E NO.
S089091
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3
23
K
K
C OPYRIG HTED-C USTO MER N I FO RMA TIO N DRAWING
3
2
J
4
4
2
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
1
5
5
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
39 40 41 USE ASNEEDED TO SUPPORT-24 HOSE FROM KITS089090(ITEM 1)
SEC SEC TION IO N B4-B B4-B4 4
31 35 36 38
2 3 4
SEE NOTE 3
2
25 30 33
2
3
6
6
22
3
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
2 5 5.25 TRIMMED LENGTH
17 24 30 33 SEE NOTE 3 1
SEC SEC TION IO N L4-L4
DETAIL J
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2006 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED. DESCRIPTION
VIEW K-K COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
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2
1
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
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4
4 37 29 16 PLCS
11
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
10
LUBE ROOM SIDE
11
10
11
10
ROOF PANEL CROSS MEMBERS
11
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
ROOF PANEL CROSSMEMBERS
FRO FRO NT O F PANEL/MACHINE
5
10
12
10
12
10
12
5
12 NO BARS(ITEMS 11 & 12) ALIGNED WITH OR WELDED TO THISCROSSMEMBER.
SEC SEC TION IO N S5-S5 S5-S5 ITEMS 11 & 12 TO BE ALIGNED WITH ROOF PANELCROSSMEMBERSPRIORTO WELDING NG G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
ADJ USTHEIGHTOF SUPPORTS BY MOVING ITEM 10 UP OR DOWN TO DESIRED BOLTHOLE LOCATION. ON. LOCA TE AS REQUIRED 4PLCS 3
6
.13 .13
6 8 PLCS
(USE ITEM 10 AS LOCA TIONFIXTURE) 1.16
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
29 37
11 12
10
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2007 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED.
2
DESCRIPTION
SEC SEC TION IO N F5-F5 R
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
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COPYRIGHTED-CUSTOMERINFORMATION DRAWING
2
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
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Bucyrus International, Inc.
PLUMBING,HYD CRO WD HOUSE,FLD REV DWG SIZE 4 E NO.
S089091
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
SHEET
5 OF 7
1
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3
C OPYRIGHTED-C USTO MER N I FORM A TIO N DRAWING
C OPYRIG HTED-C USTO MER N I FO RMA TIO N DRAWING
4
4 37 29 16 PLCS
11
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
10
LUBE ROOM SIDE
11
10
11
10
ROOF PANEL CROSS MEMBERS
11
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
ROOF PANEL CROSSMEMBERS
FRO FRO NT O F PANEL/MACHINE
5
10
12
10
12
10
12
5
12 NO BARS(ITEMS 11 & 12) ALIGNED WITH OR WELDED TO THISCROSSMEMBER.
SEC SEC TION IO N S5-S5 S5-S5 ITEMS 11 & 12 TO BE ALIGNED WITH ROOF PANELCROSSMEMBERSPRIORTO WELDING NG G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
ADJ USTHEIGHTOF SUPPORTS BY MOVING ITEM 10 UP OR DOWN TO DESIRED BOLTHOLE LOCATION. ON. LOCA TE AS REQUIRED 4PLCS 3
6
6
.13
8 PLCS
.13
(USE ITEM 10 AS LOCA TIONFIXTURE) 1.16
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
29 37
11 12
10
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2007 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED.
2
DESCRIPTION
SEC SEC TION IO N F5-F5 R
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
1
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
2
1
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C OPYRIG HTED-C USTO MER N I FO RMA TIO N DRAWING
ITEM 4 INSTALLATION PROC EDURE: 4
4
4
1) REMOVE SHIPPING C APS & HARDWARE FROM TANKS & TRANSFERTUBE. RETAIN HARDWA RE (BOLT, WASHERS, AND NUTS) FROM BOLTED CO NNECTIONS USED TO FASTEN CONTROL ROD RETAINER PLATES(4 BOLTED CONNEC TIONSO N UPPER TANK AND 4BOLTED CONNEC TIONS ONS ON LOWER TANK).
4
2) ATTACH TRANSFERTUBE (ITEM 4) ONTO LOWER TANK EXPANSION J OINT USING SUPPLIED HARDWARE, ITEMS35, 36, 38, 31. INSTALL HARDWARE LOOSELY. RE-ATTACH C ONTROL ROD RETAINER PLATESUSING HARDWARE RETAINED FROM STEP 1, LESS5 FLATWASHERS ON NUTSIDE (SEE DETAIL P7). 3) PLAC E PANCA KE JAC K UNDER TRANSFER TUBE N I SPECIFIED LOCATION, AS SHOWN. 4) RAISE PANCA KE JA CK UNTIL THE TOP FLANGE O F THE TRANSFER TUBE CONTAC TSTHE LOWER FLANGE OF THE EXPANSION JO INTTHATISATTACHED TO THEUPPERTANK.
46
4
SEE NOTE 14 G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
5) ADJ USTUPPER TANK AND TRANSFER TUBE POSITIONS UNTIL THE SUPPLIED HARDWARE CA N BE INSTALLED, ITEMS35, 36, 38, 31. INSTALLHARDWARE LOOSELY. RE-ATTACH C ONTROL ROD RETAINERPLATESUSING HARDWARE RETAINED FROM STEP 1, LESS5 FLAT WASHERSO N NUTSIDE (SEE DETAIL P7). G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
6) ADJ USTTUBE SUPPORTCLA MP (ITEM 5) TO THE MID-POINT OF ITSADJ USTMENTRAN GE. INSTALLUNDER TRANSFER TUBE AT SPECIFIED LOC ATION ASSHOWN. USE SHIMS (ITEM 13) TO MAKE UP THE REMAINING HEIGHTDIFFERENCE. AD JUST SUPPORTC LAMP UNTILA SNUG FITBETWEEN THE SUPPORT AND TRANSFERTUBE ISMAINTAINED.
6
7) LOWERAND REMOVE PANCAKE JACK. 8) POSITION UPPER TUBE SUPPORTC LAMP (ITEM 6) AND BASE (ITEM 8) ONTO TRANSFER TUBE. LO CATE ITEMSAG AINSTLUBE ROOM WALL TO SPECIFIED DIMENSIONS, ASSHO WN, USING SUPPLIED HARDWARE (ITEM 28 & 34). USE SHIMS( ITEM 9) AS REQUIRED. WELD ITEM 8 N I PLACE AS SHOWN. 8.60±1.0
9) MAKE ADJ USTMENTSTO THE TUBE BY MOVING TUBE SUPPORTCLAM P (ITEM 5) [IN 4DIRECTIONS] AND/ OR MO VING UPPER TANK [IN 4 DIRECTIONS] IN ROOF RAIN GUTTERSAN D/O R ADJ USTING SHIMMING O F UPPER TRANSFER TUBE CLAMP. POSITION TRANSFER TUBE SO THATITIS APPROXIMA TELY PERPENDICULAR TO THE LOWER A ND UPPER TANK.
FOR TORQUING SCREWS SEE NOTE 15 THISSHEET 31 35 36 38
10) TIGHTEN FLANGE HA RDWARE (ITEMS35, 36, 38, 31) ON LOWER EXPANSION J OINT, NO M ORE THAN 10FT.LBS. SEE TIGHTENING SEQUENC E BELOW.
8
11) TIGHTEN FLANGE HA RDWARE (ITEMS35, 36, 38, 31) ON UPPER EXPANSION J OINT, NO M ORE THAN 10FT.LBS. SEE TIGHTENING SEQUENC E BELOW.
WELD ITEM 8 TO LUBE ROO M WALL 2 PLCS
.13
9
12) INSPECTEXPANSION J OINT DIMENSIONS ATPO INTSA, B, C & D TO ENSURE THEY ARE WITHIN TOLERANCESA SEXPLAINED IN TABLE"X-X", SECTION N7-N7 AND DETAILP7. IF REQUIRED, ADJUSTTRANSFER TUBE AND/ OR UPPER TANK TO BRING EXPANSION JO INTDIMENSIO NS INTO SPECIFICATION. ENSUREDIMENSIONS OF BOTH EXPANSION JO INTSARE ASC LOSE A POSSIBLE BLE TO THE MIDDLE OF THE AC CEPTABLE RANGE A SIND ICATED BY TABLE "X-X".
28 34
13) INSPECTLOWER AND UPPER EXPANSION ON JO INTSFOR A NY DEFORMATION OR "DIMPLING"CAUSED FROM TORSIONAL LOADING. IF PRESENT, THE TORSIONAL ONAL STRESSMUSTBE RELIEVED BY REMOVING ALL HARDWARE O N THE TRANSFER TUBE FLANGE C ONNEC TION AND PULLING BAC K THEEXPANSION J OINT STEEL FLANGE RETAINING PLATE, SEE DETAIL P7. A LLOW THE RUBBERTO ROTATE/MOVE FREELY TO RELIEVE EVE ANY TORSIONAL STRESS(DIMPLING ) THATMAY HAVE BEEN CAUSED DURING TRANSFERTUBE INSTALLATION AND ADJ USTMENT.
5
5
14) TORQUE DRILLED HEAD EXPANSION J OINT BOLTSPER THEFOLLOWING TORQ UE SEQUENCE DIAGRAM , FOLLOWING THE TORQUE STEPS BELOW. SECURE BOLTSWITH LOCKW IRE (ITEM 46) FOLLOWING THE PROC EDURE LISTED IN THE ENGINEERING DATA SECTION OF THE MAINTENANCE & OPERATION MANUAL. STEP 1. TORQ UE TO 30 FT-LBS, THEN RESTFO R 30MINUTES. STEP 2. TORQ UE TO 50 FT-LBS, THEN RESTFO R 60MINUTES. STEP 3. TORQUE TO 75-85 FT-LBS. 15) HAND TIGHTEN VALVE FLANGE H.H.C.S. THEN FOLLOW THE TORQUE SEQUENC E DIAGRAM , FOLLOWING THE TORQUE STEPSBELOW: STEP 1. TORQ UE TO 30 FT-LBS, THEN RESTFO R 30 MINUTES. STEP 2. TORQ UE TO 50 FT-LBS, THEN RESTFO R 60MINUTES. STEP 3. TORQUE TO 75-85 FT-LBS. STEP 4. AFTERTORQUING SCREWS( ITEM 31) INSTALL SECO ND NUT(ITEM 38) ASSHOWN . 16) WELD UPPER TANK SHIMSIN PLAC E INTO RAIN GUTTERSAS SPECIFIED ON UPPER TANK INSTALLATION DRAWING. G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
17) VERIFY EXPANSION JO INTDIMENSION SA SEXPLAINED IN TABLE "X-X", SECTION N7-N7 AND DETAIL P7. AD JUSTA SN ECESSARY. ESTO SPECIFIED DIMENSIONS AS SHOWN IN DETAIL P7. 4 18) INSTALL CON TROL ROD ASSEMBLIESTO A) TIGHTEN THE TWO OUTSIDE NUTSAG AINSTEAC H OTHER SO THATTHE FACE OF THE WASHER MEASURES0.25" FROM THE FACE OF THE CONTROL ROD RETAINING PLATE, ASSHOWN IN DETAIL P7. B) TIGHTEN THE TWO INSIDE NUTSA GAINST EACH OTHER SO THE FACE OF THE WASHER NEARESTTO THE TWO OUTSIDE NUTSIS 1.38" FROM THE NEARESTFAC E OF THE WASHER, AS SHOWN IN DETAIL P7. 19) WELD TRANSFER TUBE SUPPORT CLAM P BASE & SHIMS(ITEM 5 & 13) IN PLACE A SINDIC ATED IN DETAIL D. FOR TORQUING SCREWS 38 36 35 31 SEE NOTE 15 THISSHEET
20) COM PLETEHOUSE PLUMBING INSTALLATION ASIND ICATED ON THISDRAWING .
N7
4
P7 11
6
1
7
6
5 5
3 13
TORQUE TORQUE SEQUENC E FOR 12 BOLT FLANGE
10
N7
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
9
4
6
8
2 PANCAKE JACK LOCATION
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
12
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2007 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED. DESCRIPTION
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Bucyrus International, Inc.
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C OPYRIG HTED-C USTO MER N I FO RMA TIO N DRAWING
ITEM 4 INSTALLATION PROC EDURE: 4
4
4
1) REMOVE SHIPPING C APS & HARDWARE FROM TANKS & TRANSFERTUBE. RETAIN HARDWA RE (BOLT, WASHERS, AND NUTS) FROM BOLTED CO NNECTIONS USED TO FASTEN CONTROL ROD RETAINER PLATES(4 BOLTED CONNEC TIONSO N UPPER TANK AND 4BOLTED CONNEC TIONS ONS ON LOWER TANK).
4
2) ATTACH TRANSFERTUBE (ITEM 4) ONTO LOWER TANK EXPANSION J OINT USING SUPPLIED HARDWARE, ITEMS35, 36, 38, 31. INSTALL HARDWARE LOOSELY. RE-ATTACH C ONTROL ROD RETAINER PLATESUSING HARDWARE RETAINED FROM STEP 1, LESS5 FLATWASHERS ON NUTSIDE (SEE DETAIL P7). 3) PLAC E PANCA KE JAC K UNDER TRANSFER TUBE N I SPECIFIED LOCATION, AS SHOWN. 4) RAISE PANCA KE JA CK UNTIL THE TOP FLANGE O F THE TRANSFER TUBE CONTAC TSTHE LOWER FLANGE OF THE EXPANSION JO INTTHATISATTACHED TO THEUPPERTANK.
46
4
SEE NOTE 14 G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
5) ADJ USTUPPER TANK AND TRANSFER TUBE POSITIONS UNTIL THE SUPPLIED HARDWARE CA N BE INSTALLED, ITEMS35, 36, 38, 31. INSTALLHARDWARE LOOSELY. RE-ATTACH C ONTROL ROD RETAINERPLATESUSING HARDWARE RETAINED FROM STEP 1, LESS5 FLAT WASHERSO N NUTSIDE (SEE DETAIL P7). G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
6) ADJ USTTUBE SUPPORTCLA MP (ITEM 5) TO THE MID-POINT OF ITSADJ USTMENTRAN GE. INSTALLUNDER TRANSFER TUBE AT SPECIFIED LOC ATION ASSHOWN. USE SHIMS (ITEM 13) TO MAKE UP THE REMAINING HEIGHTDIFFERENCE. AD JUST SUPPORTC LAMP UNTILA SNUG FITBETWEEN THE SUPPORT AND TRANSFERTUBE ISMAINTAINED.
6
7) LOWERAND REMOVE PANCAKE JACK. 8) POSITION UPPER TUBE SUPPORTC LAMP (ITEM 6) AND BASE (ITEM 8) ONTO TRANSFER TUBE. LO CATE ITEMSAG AINSTLUBE ROOM WALL TO SPECIFIED DIMENSIONS, ASSHO WN, USING SUPPLIED HARDWARE (ITEM 28 & 34). USE SHIMS( ITEM 9) AS REQUIRED. WELD ITEM 8 N I PLACE AS SHOWN. 8.60±1.0
9) MAKE ADJ USTMENTSTO THE TUBE BY MOVING TUBE SUPPORTCLAM P (ITEM 5) [IN 4DIRECTIONS] AND/ OR MO VING UPPER TANK [IN 4 DIRECTIONS] IN ROOF RAIN GUTTERSAN D/O R ADJ USTING SHIMMING O F UPPER TRANSFER TUBE CLAMP. POSITION TRANSFER TUBE SO THATITIS APPROXIMA TELY PERPENDICULAR TO THE LOWER A ND UPPER TANK.
FOR TORQUING SCREWS 31 35 36 38 SEE NOTE 15 THISSHEET
10) TIGHTEN FLANGE HA RDWARE (ITEMS35, 36, 38, 31) ON LOWER EXPANSION J OINT, NO M ORE THAN 10FT.LBS. SEE TIGHTENING SEQUENC E BELOW.
8
11) TIGHTEN FLANGE HA RDWARE (ITEMS35, 36, 38, 31) ON UPPER EXPANSION J OINT, NO M ORE THAN 10FT.LBS. SEE TIGHTENING SEQUENC E BELOW.
WELD ITEM 8 TO LUBE ROO M WALL 2 PLCS
.13
9
12) INSPECTEXPANSION J OINT DIMENSIONS ATPO INTSA, B, C & D TO ENSURE THEY ARE WITHIN TOLERANCESA SEXPLAINED IN TABLE"X-X", SECTION N7-N7 AND DETAILP7. IF REQUIRED, ADJUSTTRANSFER TUBE AND/ OR UPPER TANK TO BRING EXPANSION JO INTDIMENSIO NS INTO SPECIFICATION. ENSUREDIMENSIONS OF BOTH EXPANSION JO INTSARE ASC LOSE A POSSIBLE BLE TO THE MIDDLE OF THE AC CEPTABLE RANGE A SIND ICATED BY TABLE "X-X".
28 34
13) INSPECTLOWER AND UPPER EXPANSION ON JO INTSFOR A NY DEFORMATION OR "DIMPLING"CAUSED FROM TORSIONAL LOADING. IF PRESENT, THE TORSIONAL ONAL STRESSMUSTBE RELIEVED BY REMOVING ALL HARDWARE O N THE TRANSFER TUBE FLANGE C ONNEC TION AND PULLING BAC K THEEXPANSION J OINT STEEL FLANGE RETAINING PLATE, SEE DETAIL P7. A LLOW THE RUBBERTO ROTATE/MOVE FREELY TO RELIEVE EVE ANY TORSIONAL STRESS(DIMPLING ) THATMAY HAVE BEEN CAUSED DURING TRANSFERTUBE INSTALLATION AND ADJ USTMENT.
5
5
14) TORQUE DRILLED HEAD EXPANSION J OINT BOLTSPER THEFOLLOWING TORQ UE SEQUENCE DIAGRAM , FOLLOWING THE TORQUE STEPS BELOW. SECURE BOLTSWITH LOCKW IRE (ITEM 46) FOLLOWING THE PROC EDURE LISTED IN THE ENGINEERING DATA SECTION OF THE MAINTENANCE & OPERATION MANUAL. STEP 1. TORQ UE TO 30 FT-LBS, THEN RESTFO R 30MINUTES. STEP 2. TORQ UE TO 50 FT-LBS, THEN RESTFO R 60MINUTES. STEP 3. TORQUE TO 75-85 FT-LBS. 15) HAND TIGHTEN VALVE FLANGE H.H.C.S. THEN FOLLOW THE TORQUE SEQUENC E DIAGRAM , FOLLOWING THE TORQUE STEPSBELOW: STEP 1. TORQ UE TO 30 FT-LBS, THEN RESTFO R 30 MINUTES. STEP 2. TORQ UE TO 50 FT-LBS, THEN RESTFO R 60MINUTES. STEP 3. TORQUE TO 75-85 FT-LBS. STEP 4. AFTERTORQUING SCREWS( ITEM 31) INSTALL SECO ND NUT(ITEM 38) ASSHOWN . 16) WELD UPPER TANK SHIMSIN PLAC E INTO RAIN GUTTERSAS SPECIFIED ON UPPER TANK INSTALLATION DRAWING. G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
17) VERIFY EXPANSION JO INTDIMENSION SA SEXPLAINED IN TABLE "X-X", SECTION N7-N7 AND DETAIL P7. AD JUSTA SN ECESSARY. ESTO SPECIFIED DIMENSIONS AS SHOWN IN DETAIL P7. 4 18) INSTALL CON TROL ROD ASSEMBLIESTO A) TIGHTEN THE TWO OUTSIDE NUTSAG AINSTEAC H OTHER SO THATTHE FACE OF THE WASHER MEASURES0.25" FROM THE FACE OF THE CONTROL ROD RETAINING PLATE, ASSHOWN IN DETAIL P7. B) TIGHTEN THE TWO INSIDE NUTSA GAINST EACH OTHER SO THE FACE OF THE WASHER NEARESTTO THE TWO OUTSIDE NUTSIS 1.38" FROM THE NEARESTFAC E OF THE WASHER, AS SHOWN IN DETAIL P7. 19) WELD TRANSFER TUBE SUPPORT CLAM P BASE & SHIMS(ITEM 5 & 13) IN PLACE A SINDIC ATED IN DETAIL D. FOR TORQUING SCREWS 38 36 35 31 SEE NOTE 15 THISSHEET
20) COM PLETEHOUSE PLUMBING INSTALLATION ASIND ICATED ON THISDRAWING .
N7
4
P7 11
6
1
7
6
5 5
3 13
TORQUE TORQUE SEQUENC E FOR 12 BOLT FLANGE
10
N7
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
9
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
4
6
8
2 PANCAKE JACK LOCATION
12
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2007 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED. DESCRIPTION
R
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
1
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
2
1
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
2
3
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
PLUMBING,HYD CRO WD HOUSE,FLD REV DWG SIZE 4 E NO.
S089091
SHEET
6 OF 7
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
3
C OPYRIGHTED-C USTO MER N I FORM A TIO N DRAWING
Bucyrus International, Inc.
C OPYRIG HTED-C USTO MER N I FO RMA TIO N DRAWING
4
4
A B
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
D
5
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
C
TABL TABLE E X-X X-X
DIMENSIONAL REFERENCE FOR POINTSA, B, C, D AROUND CIRCUMFERENCE
.50±.25 OFFSET MIS-ALIGNMENT ALLOWED
A
D
5
46 SEE NOTE 14 (SHEET6)
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
B
6
6
CONTROLROD RETA INING PLA TE
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
C O NTRO L RO D RETAINING PLATE
.25
C
4
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
.37 REF 1.38 (SPACING BETWEEN WASHERS)
SEC SEC TION N7-N7
14.63 TO 15.38 REF (WASHER TO WASHER)
MEASUREMENTPOINTS AROUND EXPANSION JOINTS
4
DETA IL P7 TYPICALEXPANSION JOINTINSTALLATION UPPER AND LOWER TANK
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2007 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED. DESCRIPTION
R
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
1
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
2
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
3
Bucyrus International, Inc.
PLUMBING,HYD CRO WD HOUSE,FLD REV DWG SIZE 4 E NO.
S089091
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
SHEET
7 OF 7
1
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
2
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
3
C OPYRIGHTED-C USTO MER N I FORM A TIO N DRAWING
C OPYRIG HTED-C USTO MER N I FO RMA TIO N DRAWING
4
4
A B
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
D
5
C
TABL TABLE E X-X X-X
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
DIMENSIONAL REFERENCE FOR POINTSA, B, C, D AROUND CIRCUMFERENCE
.50±.25 OFFSET MIS-ALIGNMENT ALLOWED
A
D
5
46 SEE NOTE 14 (SHEET6)
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
B
6
6
CONTROLROD RETA INING PLA TE
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
C O NTRO L RO D RETAINING PLATE
.25
C
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I REISS UEDATE 04-17-2012 R Y P O SOLIDWORKS C DRAWING
.37 REF
4
1.38 (SPACING BETWEEN WASHERS)
SEC SEC TION N7-N7
14.63 TO 15.38 REF (WASHER TO WASHER)
MEASUREMENTPOINTS AROUND EXPANSION JOINTS
4
DETA IL P7 TYPICALEXPANSION JOINTINSTALLATION UPPER AND LOWER TANK
THISDOCUMENTISPROTECTE SDOCUMENTISPROTECTED UNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. ANY UNAUTHORIZED AND UNLAWFULREPRODUCTION, DISTRIBUTION BUTION OROTHERUSESHALL BE SUBJECTTO LIABILITY. C 2007 BucyrusInternatio nal, Inc. ALLRIGHTSRESERVED. DESCRIPTION
R
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
1
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
1
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
2
3
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
2
See Assembly Note 5
C L A M P A S SE M BL Y 2
X.X 2.1 2
From Tank Port at AccumulatorSafety 7 Relief Valve (Item #3)
B
2.5
9
2 2.3 2 2.2
Remove Lifting Eye. See Assembly Note 6. 2.4
3
2.6 2 2.3
From Pressure Port at 7 Accumulator Safety Relief Valve (Item #3)
QTY
ITEM NO .
1
1
7 OF 7
DESCRIPTION M OD ODULE,C EC V, V,HYD A SSY
REFWGT(#) EACH
PARTNO. 1561322 1561313
S134546
1
2
C LA M P,HO SE,A SSY
37.61 5.8
1
2.1
BA SE,C LA M P,HO SE
3.3
2
2.2
RO D,THD,.5,UNC x5.5
0.3
1561319
2
2.3
NUT,HEX,LO C K,.5,UNC
0.1
02786425
1 1
2.4 2.5
PL,C OV OV ER,SING LE C LA M MP P,6S,HEA V VY Y BO DY,C LA MP MP,54.4mm,PA H,6S,HVY
0.93 0.6
1561321 1561324
1
2.6
SC R,SO C ,M 16x2.0x35,C L12.9
0.02
1
3
AC CC C UMULA TO R,C YL YL M AN ANIFO LD A SSY
73.41
S134589
1
4
M OD OD ULE,D 05 DI DIV ERSIO N, N, HY D AS ASSY
5.59
S134571
4
5
2
6
SC R, R, HEX ,M 16 16 x2 .0x35 mm ,C L1 L1 2. 9
0.2
S134579
2
7
HO SE AS ASSY,-6,STR-90,O RS
1.2
650474-35
0.01
68787027
10
2
DO5 Valve See Assembly Note 2
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
SHEET
S089091
C O PYRIG HTED-C USTO M ER N I FO RM A TIO N DR DRA WING
2
C8-CDB Module
PLUMBING,HYD CRO WD HOUSE,FLD REV DWG SIZE 4 E NO.
COPYRIGHTED-CUSTOMERINFORMA TION DRAWING
2
C O PYRIG HTED-C USTO MER N I FO RM A TIO N DR DRA WING
Bucyrus International, Inc.
SC R, R,SO C ,M 6x1.0x75, CL CL12. 9
1561328
S134577
0.1
8
O -RING ,-014,V ITO N, N,70 DURO ME METER
1
9
ELBO W, W,90D,#6 O RS-#8 O RB
0.7
57141121
2
10
WA SHER,BELLEV ILLE,.625
0.1
03955004
1
11
C OM OMPO UND,RETA INING
0.2
82833859
1
12
O RIN G, G,-219,V ITO N, N,70
0.019
S134950
Notes: 2.2
X.X
3
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
2
A
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
=Deno tes item numbers from assembly S134553
2 Note orientation of machined relief groove in blockto face down 4 towardsCRGV module.
C4-CRGV Module See Assembly Note 1
4
4
ENGINEER ENGINEERING REF: CECV C ECV Modification Modific ation for Cylinde Cylinder r Manifold Manifold S134500 ONLY. Ac c umulator is "PED/C D/ C RN/AS1 N/ AS1210 210" Cert Certified.
Relief Valve (RV3) By-PassHose Ref.
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
REVISION DATA Ref Main Shut-Off Valve. Handle position shown isope n.
1 1 0 3 3
A Pressure connection
N C E
3 See Assembly Note 6
1 1 0 2 7 1 3 0
B Tankconnection
C5-CECV Module
Ref ManualBleed Valve. Turn clockwise to close.
1
E T A D
See Section E-E
See Assembly Note 3& 4
. F k e p z S
ISO ISO M ETRIC RIC VIEW CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
1
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
. 3 5 5 4 3 1 S N / P S A W T I K P M A L C E S O H
2 Y B N . O I O T 2 P I N R M C E S V E T E I R D
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
2
G N I W A R D N O REISSUEDA TE03-17-2011 I T A SOLIDWORKS M R DRAWING O F N I R THISDOCUMENTISPROTECTEDUNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. E ANY UNA UTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHERUSESHALLBE M SUBJEC TTO LIABILITY. C 2011 BucyrusInternationa l, Inc. ALLRIGHTSRESERVED. O T S ALLDIMENSIONS ININC HES-UNLESSOTHERWISESPECIFIED U C MACHINING TOLERANC ES-UNLESSOTHERWISESPECIFIED D 1. 2PLACEDECIMALDIMENSIONS .01FOREACH12MAX±.09 E 2. 3PLACEDECIMALDIMENSIONS .005UPTO 3 6, .010OVER36 T 3. CONCENTRICIT YOFC YOFC YLINDRICALSURFACES= .010T.I.R. H Bucyrus 4. PARALLELISM,SQUARENESS,ORA NGULARITYBETWEENSURFACES G I AND/ORHOLECENTERLINES 07' (.002INCH/INCH) R International, Inc. FABRICATINGTOLERANCES-UNLESSO THERWISESPECIFIED Y P 1. MAT E RI A L T HC I K NE SS DM I EN SI ON S T OL ER AN C E O A. LESSTHAN.12 0TO 36 .03 C OVER36 .06 R
B. .12 TO 50 5 .0
0TO 36 .06 .12 OVER36 C. .50TO 1.00 0TO 36 .09 OVER36 .19 D. OVER1.00 0TO 36 .19 .25 OVER36 2. BENTANGLES 1 (.0 17IN/IN)FOREACH.37OFMATERIAL THICKNESS(MAX 3)
WELDMENTTOLERANCES-UNLESSOTHERWISESPECIFIED 1 . DM I E NSO I N A. UPTO 36 " B. 36"TO 10' C. 10'TO 30' D. OVER30'
MAT E RI A L T HC I K NE SS UPTO 1" 1"ANDGREATER UPTO 1" 1"ANDGREATER UPTO 1" 1"ANDGREATER ALL
T OL ER A NC E .06 .12 .12 .19 .19 .25 .25
DESCRIPTION
MOD,C ECV,C YLINDER MANIFOLD REFDWGS M ODEL DET ENG CONTACT
NO.
S134500,S134569 495HF/ HR SZPEKF. FUERSTJ.
UNIT
FINWGT 121.0 5600 (LBS) 01-08-2011 REV D
DATE (MM-DD-YYYY) DWG SIZE
S134590
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
2
SHEET
1 OF 2
1
COPYRIGHTED-CUSTOMERINFORMATION DRAWING
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
2
C O PYRIG HTED-C USTO MER N I FO RM A TIO N DR DRA WING
C O PYRIG HTED-C USTO M ER N I FO RM A TIO N DR DRA WING
2
C8-CDB Module
2
See Assembly Note 5
C L A M P A S SE M BL Y 2
X.X 2.1 2
From Tank Port at AccumulatorSafety 7 Relief Valve (Item #3)
B
2.5
9
2 2.3 2 2.2
Remove Lifting Eye. See Assembly Note 6. 2.4
3
2.6
See Assembly Note 2
2
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
2.3 From Pressure Port at 7 Accumulator Safety Relief Valve (Item #3)
ITEM NO .
1
1
DESCRIPTION M OD ODULE,C EC V, V,HYD A SSY
REFWGT(#) EACH
PARTNO. 1561322 1561313
S134546
1
2
C LA M P,HO SE,A SSY
37.61 5.8
1
2.1
BA SE,C LA M P,HO SE
3.3
2
2.2
RO D,THD,.5,UNC x5.5
0.3
1561319
2
2.3
NUT,HEX,LO C K,.5,UNC
0.1
02786425
1 1
2.4 2.5
PL,C OV OV ER,SING LE C LA M MP P,6S,HEA V VY Y BO DY,C LA MP MP,54.4mm,PA H,6S,HVY
0.93 0.6
1561321 1561324
1
2.6
SC R,SO C ,M 16x2.0x35,C L12.9
0.02
1
3
AC CC C UMULA TO R,C YL YL M AN ANIFO LD A SSY
73.41
S134589
1
4
M OD OD ULE,D 05 DI DIV ERSIO N, N, HY D AS ASSY
5.59
S134571
4
5
2
6
SC R, R, HEX ,M 16 16 x2 .0x35 mm ,C L1 L1 2. 9
0.2
S134579
2
7
HO SE AS ASSY,-6,STR-90,O RS
1.2
650474-35
0.01
68787027
10
2
DO5 Valve
QTY
SC R, R,SO C ,M 6x1.0x75, CL CL12. 9
1561328
S134577
0.1
8
O -RING ,-014,V ITO N, N,70 DURO ME METER
1
9
ELBO W, W,90D,#6 O RS-#8 O RB
0.7
57141121
2
10
WA SHER,BELLEV ILLE,.625
0.1
03955004
1
11
C OM OMPO UND,RETA INING
0.2
82833859
1
12
O RIN G, G,-219,V ITO N, N,70
0.019
S134950
Notes: 2.2
X.X
3
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
2
A
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
=Deno tes item numbers from assembly S134553
2 Note orientation of machined relief groove in blockto face down 4 towardsCRGV module.
C4-CRGV Module See Assembly Note 1
4
4
ENGINEER ENGINEERING REF: CECV C ECV Modification Modific ation for Cylinde Cylinder r Manifold Manifold S134500 ONLY. Ac c umulator is "PED/C D/ C RN/AS1 N/ AS1210 210" Cert Certified.
Relief Valve (RV3) By-PassHose Ref.
G N I W A R D N O I T A M R O F N I R E M O T S U C D E T H G I R Y P O C
REVISION DATA Ref Main Shut-Off Valve. Handle position shown isope n.
1 1 0 3 3
A Pressure connection
N C E
3 See Assembly Note 6
1 1 0 2 7 1 3 0
B Tankconnection
C5-CECV Module
Ref ManualBleed Valve. Turn clockwise to close.
1
E T A D
See Section E-E
See Assembly Note 3& 4
. F k e p z S
ISO ISO M ETRIC RIC VIEW CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
1
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
. 3 5 5 4 3 1 S N / P S A W T I K P M A L C E S O H
2 Y B N . O I O T 2 P I N R M C E S V E T E I R D
CO PYRIGHTED-CUSTOMER INFORMATION DRAWING
2
G N I W A R D N O REISSUEDA TE03-17-2011 I T A SOLIDWORKS M R DRAWING O F N I R THISDOCUMENTISPROTECTEDUNDERAPPLICABLECOPYRIGHTLAWSTO THEEXTENTAVAILABLE. E ANY UNA UTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHERUSESHALLBE M SUBJEC TTO LIABILITY. C 2011 BucyrusInternationa l, Inc. ALLRIGHTSRESERVED. O T S ALLDIMENSIONS ININC HES-UNLESSOTHERWISESPECIFIED U C MACHINING TOLERANC ES-UNLESSOTHERWISESPECIFIED D 1. 2PLACEDECIMALDIMENSIONS .01FOREACH12MAX±.09 E 2. 3PLACEDECIMALDIMENSIONS .005UPTO 3 6, .010OVER36 T 3. CONCENTRICIT YOFC YOFC YLINDRICALSURFACES= .010T.I.R. H Bucyrus 4. PARALLELISM,SQUARENESS,ORA NGULARITYBETWEENSURFACES G I AND/ORHOLECENTERLINES 07' (.002INCH/INCH) R International, Inc. FABRICATINGTOLERANCES-UNLESSO THERWISESPECIFIED Y P 1. MAT E RI A L T HC I K NE SS DM I EN SI ON S T OL ER AN C E O A. LESSTHAN.12 0TO 36 .03 C OVER36 .06 R
B. .12 TO 50 5 .0
0TO 36 .06 .12 OVER36 C. .50TO 1.00 0TO 36 .09 OVER36 .19 D. OVER1.00 0TO 36 .19 .25 OVER36 2. BENTANGLES 1 (.0 17IN/IN)FOREACH.37OFMATERIAL THICKNESS(MAX 3)
WELDMENTTOLERANCES-UNLESSOTHERWISESPECIFIED 1 . DM I E NSO I N A. UPTO 36 " B. 36"TO 10' C. 10'TO 30' D. OVER30'
MAT E RI A L T HC I K NE SS UPTO 1" 1"ANDGREATER UPTO 1" 1"ANDGREATER UPTO 1" 1"ANDGREATER ALL
T OL ER A NC E .06 .12 .12 .19 .19 .25 .25
DESCRIPTION
MOD,C ECV,C YLINDER MANIFOLD REFDWGS M ODEL DET ENG CONTACT
NO.
S134500,S134569 495HF/ HR SZPEKF. FUERSTJ.
UNIT
FINWGT 121.0 5600 (LBS) 01-08-2011 REV D
DATE (MM-DD-YYYY) DWG SIZE
S134590
CO PYRIGHTED-CUSTOMERINFO RMATION DRAWING
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SHEET
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SERVICE ADVISORY Date: July 2, 2012 Caterpillar Global Mining LLC 6744 S. Howell Ave Oak Creek, WI 53154, USA 414.768.4000 / Fax: 414.768.4570
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 FOLLOWED DURING 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)
SERVICE ADVISORY Date: July 2, 2012 Caterpillar Global Mining LLC 6744 S. Howell Ave Oak Creek, WI 53154, USA 414.768.4000 / Fax: 414.768.4570
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 FOLLOWED DURING 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 1
ISO 9001: 2000 Registered Firm
Action: Install shims as required to ensure ens ure 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 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. Do not Install all bolts each side to 20% of final torque value (20 (20 N-m) per torque sequence and procedure. procedure.Do use Loctite on the bolts at this time. Ensure there there is is no gap between mounting plate 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.
Ensure there is no gap between mounting plate and cylinder. C lind linde er
Mounting Plate
Measurement Location B
Measurement Location A
2
ISO 9001: 2000 Registered Firm
Shims installed in these locations to ensure no gap between mounting plate and cylinder manifold.
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ISO 9001: 2000 Registered Firm
Torque Sequence
4
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
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L O Ñ A P S E • H S I N A
ISO 9001: 2000 Registered Firm
L O Ñ A P S E • H S I N A P S
Tensionadores Superbolt Instrucciones de instalación
Cómo funcionan los tensionadores Superbolt:
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.
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Instrucciones Con los tensionadores SuperboltTM usted ha elegido un un un producto tecnológicamente superior. 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
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2. Procedimiento de aflojado
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3. Lubricante y herramientas
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4. Mantenimiento
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5. Indicaciones generales
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6. Contacto
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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
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1. Procedimiento de apriete 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 rosca principal y las superficies superficies de contacto, engrase bien el producto con el lubricante apropiado (A) y coloque la arandela (B). – Asegúrese de que los tornillos de presión 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).
A
B
C
– 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.
D
1–3 mm
E 4
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.
1 4
3 2
Paso 2: Apriete los mismos 4 tornillos en cruz con el 50% del par recomendado para los tornillos de presión.
1
50% Paso 3: Apriete los mismos 4 tornillos de presión al 100% del par.
4
3 100%
2
Paso 4: Ahora cambie y apriete de forma circular todos los tornillos al 100% del par recomendado. 100% 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
2. Procedimiento de aflojado 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!
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2.2 Empleo a altas temperaturas temperaturas (> 100 °C) Preparación:A tempera temperaturas turas 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 tensionadores 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.
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3. Lubricante y herramientas 3.1 Lubricante Tornillos 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 l os tornillos de presión Superbolt alcanzan solamente entre un 30 y 50% de su potencia (recorridos (recorridos 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 continuación mida el par con una llave dinamométrica (mejor con visualización electrónica).
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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.
M [Nm]
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 – 70-130 Nm – – – –
atornillador de impacto de 3/8“ o trinquete por aire 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“
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4. Mantenimiento 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 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 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 nuevo según según el procedimiento procedimiento de apriete. 4.3 ¿Qué hacer en caso caso de de problemas? problemas? Problema: Los tornillos no pueden aflojarse: – Intente retirar al menos un tornillo de presión. – Rengrase adecuadamente adecuadamente y apriete al 110 % del par de apriete recomendado. – Los 2 tornillos tornillos de presión presión contiguos contiguos se deberían aflojar. – Retírelos también, engrase y apriete de nuevo nuevo al 110 % del par de apriete recomendado. – Los dos tornillos de presión siguientes se deberían de aflojar. – Realice el mismo paso. – A continuación, continuación, suelte todos los tornillos de presión según 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. Superbolt. No utilice tornillos comerciales ya que no son apropiados para cargas tan altas. 10
favor diríjase a su oficina Nord-Lock Nord-Lock más cercana. Otros problemas: Para más información, por favor
5. Indicaciones generales 5.1 Apriete de elementos de tensado con 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 largos Para 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 largos recorridos recorridos de alargamiento alargamiento Es 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 apretados. No reajustar los tensionadores sueltos ya que si no habrá problemas posteriormente. 5.4 Tensado de grandes bridas 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 distanciadores Los 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 simplifican 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.
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6. Contacto 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 responsabilidad Debido 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, r egistered trademarks or service marks used herein are the property of the Nord-Lock Group. All rights reserved.
Nord-Lock AG Rietwiesstrasse 2, CH-8735 St. Gallenkappel, Switzerland Tel: +41 (0)55 284 64 64, Fax: +41 (0)55 284 64 69 Email:
[email protected] Nord-Lock Group Tel: +46 (0)31 7192 300, Fax: +46 (0)40 240 851 Email:
[email protected] www.nord-lock.com
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