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ANEEXO
OS
CUR
RSO
O:
SIISTEEMAA HYYDR
RACCROWD
D
PALA
P A 744955

 
 

DESARR
ROLLO TÉC
CNICO

Guido Llallacacchi

SIS Media Number: BI646626
Media Number: SA13-025
August 19, 2013

Special Instruction
________________________________________________________________
________________________________________________________________

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

Identification Number

Expanded Product Line
Serial Number

7495

ER601418

141418

ER601439

141439

ER601452

141452

ER601441

141441

ER601455

141455

ER601462

141462

ER601463

141463

ER601469

141469

ER601470

141470

ER601473

141473

ER601474

141474

ER601477

141477

ER601482

141482

ER601481

141481

ER601494

141494

ER601508

141508

ER601511

141511

ER801209

141209

ER801325

141325

ER801327

141327

ER801333

141333

ER801424

141424

ER801429

141429

7495HF

SIS Media Number: BI646626
Media Number: SA13-025
ER801433

141433

ER801483

141483

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

Important Safety Information

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

Required Tooling
TOOLS:
6 mm Allen Key
2 mm Allen Key
19 mm Wrench
1. Set the dipper flat on the ground and lower the hoist until the padlocks are
down and the hoist ropes are slack.

SIS Media Number: BI646626
Media Number: SA13-025

Illustration 1: Padlocks Lowered
2. Shutdown the machine. Lockout and tagout controls in compliance with
local regulations.
3. Install a 0-8000 psi pressure gauge on the pressure outlet test port of
each main pump. It is ideal to monitor all 4 pumps at the same time (digital
pressure gauge in the S127020 commissioning kit has this capability).

Pressure Outlet
Test Ports

Illustration 2: Preesure Outlet Test Ports
4. To adjust individual pump relief pressure, remove the cylindrical relief
valve cover (See Illustration 3 for location).
2 mm Allen Key

SIS Media Number: BI646626
Media Number: SA13-025

Pump PUV
Relief Valves

Illustration 3: Pump PUV Relief Valves

Cylindrical Cover
Held in Place by
Socket Head Screw

Illustration 4: Cylindrical Relief Valve Cover Retaining Screw
5. With the cylindrical relief valve cover removed, loosen the jam nut
securing the adjustment screw in place.
19 mm Wrench

Adjustment
Screw

Jam Nut

Illustration 5: Relief Jam Nut and Adjusting Screw

SIS Media Number: BI646626
Media Number: SA13-025

6. Once the relief valves are exposed, remove lockout tagout from machine
controls.
7. Start the machine.
8. Access the HydraCrowd Commissioning Screen from the operators
display in the operator cab (see Illustration 5).
9. Turn crowd control on
10. Energize the PICV Output button
11. Choose the valve position (1-4) you would like to test and press the
corresponding PUV button.
12. Press the Run Crowd Motor at 20% reference button. The chosen PUV
will now be forced over relief.

Illustration 6: HydraCrowd Commissioning Screen

SIS Media Number: BI646626
Media Number: SA13-025

IMPORTATNT: If the following steps do not affect the pump outlet pressure, it
will be important to return the relief to its original setting. Before turning the
adjusting screw, mark the screw location with respect to the valve body. As the
adjusting screw is turned count the number of rotations so it could be returned to
original.
13. In the machinery house, with pump pressure going over relief, slowly turn
the adjustment screw while observing the pump pressure associated with
the relief valve (see Illustrations 6 and 7 for pump and corresponding relief
locations). Turning the screw clockwise will increase the relief pressure,
turning the screw counterclockwise will reduce the pressure.
6 mm Allen Key

Pump 4

Pump 1

Pump 3

Pump 2

Illustration 7: Pump Reference Numbers

SIS Media Number: BI646626
Media Number: SA13-025

Pump 1
Pump 2

Pump 3

Pump 4
Illustration 8: Relief Valves Associated with Each Pump

14. When the gauge pressure reads 3700 psi ± 50 psi tighten the jam nut to
secure the adjusting screw. Recheck pressure setting after tightening the
jam nut to ensure the setting hasn’t changed.
19 mm Wrench
NOTE: If gauge pressure does not change when the adjustment screw is turned,
return the adjustment screw to its origional position.
15. Install the cylindrical cover onto the relief and secure with screw.
2 mm Allen Key

16. Remove pressure gauges from the pump outlet ports and reinstall test port
covers.
17. Ensure cylinder speed is normal by stroking the cylinder several times in
the horizontal position. Verify by observing cylinder speed on the operator
HMI screen. Extend speed is approximately 130 ft. /min while retract is
approximately 120 ft. /min.

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

1. LIGHTLY COAT THE TWO O-RINGS SUPPLIED WITH COUPLING (ITEM 6) AND INSTALL INTO GROOVES ON EACH COUPLING SLEEVE. PLACE ONE
SLEEVE OVER EACH SHAFT (MOTOR & PDT) BEFORE INSTALLING COUPLING HUBS. CARE SHOULD BE TAKEN NOT TO DAMAGE O-RINGS.
MOUNT COUPLING HUBS TO MOTOR (ITEM 2) AND PDT (ITEM 3) SHAFTS. REFER TO DETAIL "F" ON SHEET 3.
2. SPRAY INSIDE MACHINED MOUNTING SURFACE OF PDT MOUNTS (ITEM 4) WITH LPS3 (ITEM 67). ASSEMBLE PDT MOUNTS (ITEM 4)
TO PDT (ITEM 3) USING H.H.C.S. (ITEM 27) AND WASHER (ITEM 38). DO NOT TORQUE H.H.C.S.!
3. SPRAY MACHINED PDT MOUNTING PADS ON TANK (ITEM 1) WITH LPS3 (ITEM 67). ASSEMBLE PDT/MOUNTS TO TANK (ITEM 1) USING H.H.C.S.
(ITEM 25) AND WASHER (ITEM 37), TORQUE H.H.C.S. RETAINING MOUNTS TO TANK (SEE TORQUE CHART).
4. SPRAY MACHINED MOTOR MOUNTING PADS ON TANK (ITEM 1) WITH LPS3 (ITEM 67) PRIOR TO MOTOR INSTALLATION. ASSEMBLE MOTOR
(ITEM 2) TO TANK (ITEM1) USING H.H.C.S. (ITEM 28), WASHER (ITEM 39) AND LOCK NUT (ITEM 33). REFER TO DETAIL "C" ON SHEET 3.
DO NOT TORQUE HARDWARE!
5. INSTALL JACK SCREWS (ITEM 29) AND JAM NUTS (ITEM 34) TO PDT MOUNTS (ITEM 4), REFER TO DETAIL "J" ON SHEET 2. DO NOT TIGHTEN!
6. POSITION TAP BLOCKS (ITEM 44) TO ENSURE AS MUCH CONTACT AS POSSIBLE WITH TANK MOTOR SUPPORTS (ITEM 1). WELD TAP BLOCKS
(ITEM 44) TO MOTOR SUPPORTS ON TANK (ITEM 1), REFER TO SECTION "B-B" ON SHEET 3. CLEAN, PRIME, AND FINISH PAINT TAP BLOCKS
(ITEM 44) WITH ORIENT WHITE ENAMEL, B.I. #61037662, AFTER WELDING IS COMPLETE.

*

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

REF WGT(#)
EACH

PART NO.

QTY

ITEM
NO.

ROD END,JOINT,BALL,.313 UNF,RH
ROD END,JOINT,BALL,.313 UNF,LH

0.07
0.7

82811285
82811286

57

ROD,CONN,HEX BODY,.313 UNF THD

0.09

82811287

9
1
2
1
1
3
8
3
2
1

58
59
60
61
62
63
64
65
66
67

WASHER,FLAT,.25
SCR,HEX,.25x1.25,UNC,GR 5
NUT,HEX,LOCK,.25,UNC
SCR,HEX,.25x2.25,UNC,FULL THRD
NUT,HEX,JAM,.312,UNF
NUT,HEX,FULL,.25-20 UNC
SCR,SET,SQ.HD,.75x5,CP
SCR,HEX,1x1.25,UNC,GR 5
GREASE,LONG TERM
SEALANT,RUST INHIBITOR

1
1
1
2
4
1
1

1
2
3
4
5
6
7

1

1

68

LUBRICANT 10 OZ. CAN JL-G

QTY

ITEM
NO.

1
1

55
56

1

DESCRIPTION

1.0
0.69

03951220
03273400
02786345
03273690
02739100
02707150
03773410
03300560
MP295148
82833893

0.01

MP390331

0.02
0.04
0.01
0.03
0.5

2

* SEE NOTE 2 OF TIGHTENING PROCEDURE

8. ALIGN MOTOR (ITEM 2) TO PDT (ITEM 3), SEE DETAIL "F" ON SHEET 3 FOR SPACING BETWEEN COUPLING HUBS. REFER TO COUPLING
ALIGNMENT CHART FOR DIMENTIONAL ALLOWANCES. USING SHIM PACKS (ITEM 43) AND JACK SCREWS (ITEM 64), MAKE ADJUSTMENTS
TO CORRECT ANY MIS-ALIGNMENT.
9. LOCK ALL JACK SCREWS (ITEMS 29 & 64) IN PLACE USING JAM NUTS (ITEM 34). TORQUE H.H.C.S. (ITEM 28) RETAINING MOTOR (ITEM 2) TO
TANK (ITEM 1) AND H.H.C.S. (ITEM 27) RETAINING PDT (ITEM 3) TO PDT MOUNTS (ITEM 4), (SEE TORQUE CHART).
0.006

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

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

0.004

MISALIGNMENT

0.003

0.002

1
0.001

0
0

0.0005

0.001

0.0015

0.002

0.0025

ANGULAR T.I.R (INCHES)

A. CHECK CENTER GAP- MEASURE COUPLING FACE TO COUPLING FACE
AT FOUR PLACES 90 APART, APPROXIMATELY
7.00 ON FACES OF RIGID COUPLING HUBS. AVERAGE OF
THE FOUR MEASUREMENTS IS TO BE 1.75 +0.02/-0.02
B. CHECK ANGULAR MISALIGNMENT AT APPROXIMATELY 7.00
ON COUPLING FACES. MAX T.I.R =0.002 (@ PARALLEL OFFSET=0.0)
C. CHECK PARALLEL OFFSET - MAX. T.I.R=0.005 (@ ANGULAR OFFSET =0.0)
D. COMBINED ANGULAR + PARALLEL OFFSET MUST BE AT OR BELOW
THE LINE IN THE FOLLOWING CHART.

17. COAT MOUNTING SURFACE OF DUCT (ITEM 19) WITH SILASTIC SEALANT (ITEM 45)AND ATTACH TO MOTOR (ITEM 2) USING S.H.C.S. (ITEM 23),
COAT MOUNTING SURFACE OF COVERS (ITEM 18) WITH SILASTIC SEALANT (ITEM 45) AND ATTACH TO
DUCT (ITEM 19) USING H.H.C.S. (ITEM 22).
18. APPLY SILASTIC SEALANT (ITEM 45) TO MOUNTING SURFACE OF BLOWER (ITEM 20) AND ATTACH TO DUCT (ITEM 19) USING H.H.C.S. AND LOCK
NUT (ITEMS 22 & 31).

VARIABLE SUBSTITUTION FOR ITEM 20

ASSY PART NO.
1579889
1579890
1579891
1579892
1579893
1579894

ITEM NO.
20
20
20
20
20
20

PART NO.
*V038979
47004197
47004227
47004228
47004229
47004198

DESCRIPTION
BLWR,HYD CROWD,VARIABLE
BLWR,5/3HP,460V-60HZ,380V-50HZ
BLWR,3HP,415V/50HZ,50C,HC
BLWR,3HP,380V/50HZ,5200M,HC
BLWR,5HP,460V/60HZ,4600M,HC
BLWR,HYD CWD,5HP,575V,60HZ
81150

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

*

BOLT SIZE
M6-1
.25 GRADE 5
.38 GRADE 5
.38 GRADE 8
.50 GRADE 5
.75 GRADE 5
M20 CL10.9
1.00 GRADE 5
1.25 GRADE 5

Vitas J. DATE 08-08-2013 ECN

TORQUE CHART
FT/Lbs
7
7
23
35
55
200
280
480
925

REV

2

BY

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

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

PART NO.

TANK,LOWER,ASSEM,HYD CROWD
MOTOR,700HP,1400/700-3-50,4140
PDT,1-1 RATIO,4 PAD ISO 3019-2
MOUNT,PDT WELD
PUMP,BENT AXIS PISTON,30 C.I.
CPLG,RIGID,GEAR
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

STAND,CPLG GUARD,HYD CROWD

22.5

S049575

1

9

GUARD,COUPLING,FRONT,HYD-CROWD

13.0

S049577

1

10

GUARD,COUPLING,REAR,HYD-CROWD

11.0

S049579

6
6
1
1
1
1
1
2

11
12
13
14
15
16
17
18

SCR,HEX,.25x.75,UNC,GR 5
WASHER,LOCK,.25,HVY
MOUNT,TACH,WELD & MACH
COVER,TACH
TACH,DIGITAL,FLANGE MOUNT,500
CPLG,TACH,14MM,E2M
GUARD,SHAFT,HYD CROWD
COVER,BLWR MOTOR DUCT

0.02
0.02
10.07
5.08
6.83
2.4
43.9
7.48

03273240
03961010
1718651
4156240
1557159
1557160
S049079
S038971

1

19

DUCT,HYD CRWD BLWR,WELD & MACH

140.5

S049569

1
14
53
28
4
14
3
8
4
8
32
25
4
16
10
3
14
8
4
32
8
8
4
8
2
1
1

20
21
22
23
24
25
26
27
28
29
30
31
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47

BLOWER,HYD CROWD,VARABLE
SCR,HEX,.25x.625,UNC,GR 5
SCR,HEX,.375x1.00,UNC,GR5
SCR,SOC,.375x.625,UNC,GR8
SCR,HEX,.375x1.25,UNC,GR5
SCR,HEX,.75x2.25,UNC,GR 5
SCR,HEX,1x3.5,UNC,GR 5
SCR,HEX,1x2.75,UNC,GR 5
SCR,HEX,1.25x4.25,UNC,GR5
SCR,SET,SQ,.75x4,HDP
SCR,HEX,M20x60MM,CL10.9
NUT,HEX,LOCK,.375,UNC
SUPERBOLT,TORQUENUT,1.25
NUT,HEX,JAM,.75,UNC
WASHER,FLAT,.375
WASHER,FLAT,1
WASHER,FLAT,.75,HARDENED
WASHER,FLAT,1,HARDENED
WASHER,FLAT,1.25,HARDENED
WASHER,HARDENED,20MM
CHOCK,MOTOR
CHOCK,WEDGE
SHIM PACK,ELEC MOTOR MTG.
BAR,1.25x2.5
SEALANT,SILASTIC,10.3 OZ
COMPOUND,THREAD LOCKING
LUBE,O-RING,2 OZ. TUBE

210.0

0.3
0.1
1.91
1.39
3.48
2.9
0.1
0.2
0.13

SEE TABLE
03273200
03279320
03480500
03279400
03294720
03301120
03300880
4354642
03772940
03552070
02786385
MP263241
02714450
03951400
03952100
03951950
03952150
03952350
MP600781
S037352
S037353
S032091
S029157
82833855
82833862
59183127

4

48

O-RING,-381,VITON,70 DUROMETER

0.1

68766497

1
1
1
1
1

50
51
52
53
54

ADAPTER,MOUNTING,TACH
SCR,SET,SOC,.25x.625,NYLON TIP
PIN,CLEVIS,.31x1.25,W/COTTR PN
COVER,GUARD,MOTOR SHAFT
BRKT,TACH TORQUE ARM

5.3
0.01
0.2
1.3
0.32

S037332
03803311
82647224
S037329
S037339

0.05
0.0
0.1

2.2
0.5
0.5
0.0
0.8
0.1
0.1

1 ITEM 32 SKIPPED IN BILL OF MATERIAL
TO KEEP CONSISTANCY WITH
PREVIOUS DRAWING S038952.

REVISION DATA

ITEM 6 WAS 4280938. CHANGED SUPERBOLT
INSTALLATION INSTRUCTIONS ON SHEET 4.

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

0.005

DESCRIPTION

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

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

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

MISALIGNMENT

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

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

4

COUPLING ALIGNMENT

PARALLELT.I.R(INCHES)

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

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

REF WGT(#)
EACH

DESCRIPTION

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

1

4

REISSUE DATE 08-08-2013

SOLIDWORKS
DRAWING

THIS DOCUMENT IS PROTECTED UNDER APPLICABLE COPYRIGHT LAWS TO THE EXTENT AVAILABLE.
ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BE
SUBJECT TO LIABILITY. C 2012 Bucyrus International, Inc. ALL RIGHTS RESERVED.
ALL DIMENSIONS IN INCHES-UNLESS OTHERWISE SPECIFIED
MACHINING TOLERANCES-UNLESS OTHERWISE SPECIFIED
1.
2.
3.
4.

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

R

FABRICATING TOLERANCES-UNLESS OTHERWISE SPECIFIED
1.

2.

DIMENSIONS
TOLERANCE
0 TO 36
.03
.06
OVER 36
B. .12 TO .50
0 TO 36
.06
.12
OVER 36
C. .50 TO 1.00
0 TO 36
.09
.19
OVER 36
D. OVER 1.00
0 TO 36
.19
.25
OVER 36
BENT ANGLES
1 (.017 IN/IN) FOR EACH .37 OF MATERIAL
THICKNESS (MAX 3 )

Bucyrus
International, Inc.

MATERIAL THICKNESS
A. LESS THAN .12

WELDMENT TOLERANCES-UNLESS OTHERWISE SPECIFIED
1. DIMENSION
A. UP TO 36"
B. 36" TO 10'
C. 10' TO 30'
D. OVER 30'

MATERIAL THICKNESS
UP TO 1"
1" AND GREATER
UP TO 1"
1" AND GREATER
UP TO 1"
1" AND GREATER
ALL

TOLERANCE
.06
.12
.12
.19
.19
.25
.25

DESCRIPTION

PWR MODULE,HYD CROWD,MECH ASSY

REF DWGS
MODEL
DET
ENG
CONTACT

NO.

S038952
7495

GRUBER G.
MAREK C.

FIN WGT

UNIT
DATE
DWG
SIZE

(LBS)

(MM-DD-YYYY)

11-13-2012
D

1579888

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

15780.0

REV

2

SHEET

1 OF 5

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

58

55

2

54

58

9

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

10

5

59

60

H
A3

SEE NOTES 14 &16
(SHEET 1)

A3

51

62

54

21

50

17

14
17

P
19

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

34
18

29
1

4

29

J

22

27

3

21

P

31

56

DETAIL L

58

58

SECTION P-P

DETAIL J

25

15

58

38

STENCIL SHAFT DIRECTION ARROW ON PDT
IN APPROXIMATE POSITION, AS SHOWN. USE A
CONTRASTING COLOR TO MAKE MARK VISIBLE.
2

61

20

4

60

53

34

37

46

46

3

63

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

SEE NOTE 2
(SHEET 1)

57

52

58

DETAIL H

3

5

47

23

22

K3

48
30

G3

40

18 45
2

23

DUCT COVER REMOVED
TO SHOW INNER RETENTION
SCREWS FOR DUCT (2 PL).

31 22
20

L

65

34

26

36

23

20

26 36

14
22

20

24

29

25

44
31

34

4

17

5

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

58
3

21

4

2

SEE NOTE 6
(SHEET 1)

64

64

35

35

B3

31

D3

24

B3

K3

D3

44

C3

37

1
REISSUE DATE 08-08-2013

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29

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

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COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

Bucyrus
International, Inc.

PWR MODULE,HYD CROWD,MECH ASSY
DWG SIZE

NO.

1579888

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

D

REV
SHEET

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13
3

14

7

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1.75 HUB TO HUB
GAP

.25 HUB TO
SHAFT GAP

2
3

URETHANE FLEX ELEMENT
QTY (6)
12

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

16

11
(4) M6-1 X 12 MM H.H.C.S.
PROVIDED WITH COUPLING.
(DO NOT USE THREAD LOCKING COMPOUND)

3.63
REF

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

15

3

RETAINING NUT PROVIDED WITH MOTOR.
SECURE NUT WITH BLUE RETAINING COMPOUND
HUB/COUPLING TO BE POSITIONED
SUCH THAT COUPLING IS FLUSH WITH
PDT SHAFT FACE, AS SHOWN.

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

DETAIL E

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

(SEE NOTE 12 ON SHEET 1)

TORQUE TO
250 FT-LBS

E
15

21

F

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

DETAIL F

STENCIL SHAFT DIRECTION ARROW ON MOTOR
IN APPROXIMATE POSITION, AS SHOWN. USE A
CONTRASTING COLOR TO MAKE MARK VISIBLE.

R

58

6

.25

2

WELD ITEM 42
(3 SIDES)
WITH WEDGE
ITEM 43 IN
PLACE AT ASSY
(8 PL)

44
2.50
REF
(4 PL)

14

R

10

.38
(4 PL)

SEE NOTE 4
(SHEET 1)

1.00
(4 PL)

TACH
COVER
GUARD

13

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

22 (DO NOT USE THREAD LOCKING COMPOUND)

SEE NOTE 6 44
(SHEET 1)

4

43

44

4

SECTION K3-K3
PLUG

VIEW R-R

ELECTRICAL
FITTING

(SEE NOTE 12 ON SHEET 1)

9

41 QTY (8)

10

34 29
COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

SECTION A3-A3

22
38

8.00
REF
(4 PL)

31

SEE NOTE 11
(SHEET 1)

44

42 QTY (8)

27

.25

2
33 39

.25

28

(8 PL)

41
28
42

39

8
4

SECTION B3-B3

SEE NOTE 2
(SHEET 1)

SEE NOTE 6
(SHEET 1)

64

44

REISSUE DATE 08-08-2013

SOLIDWORKS
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1.88
(8 PL)

33

22

64

34

SECTION D3-D3
COPYRIGHTED-CUSTOMER INFORMATION DRAWING

44

DETAIL C3
1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

37

35

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

25

DESCRIPTION

DETAIL G3
COPYRIGHTED-CUSTOMER INFORMATION DRAWING

R

2

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PWR MODULE,HYD CROWD,MECH ASSY
DWG SIZE

NO.

1579888

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STEEL HUB

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

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COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

INSTALLATION NOTES:
MAKE SURE SPECIAL STEEL WASHERS SUPPLIED WITH TORQUENUTS ARE USED UNDER EACH TORQUENUT - DO
NOT USE STANDARD COMMERCIAL WASHERS.
AN IMPACT WRENCH MAY BE USED FOR THE INITIAL RUN UP, BUT A TORQUE WRENCH MUST BE USED FOR THE
FINAL VALUES.

3

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

STEPS 4 & 5

STEPS 6 & 7

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

INSTALLATION PROCEDURE:
(INITIAL TORQUE SEQUENCE)

STEP 2: CHECK BASE OF TORQUENUT TO ENSURE THAT ALL JACKBOLTS ARE FLUSH WITH BOTTOM.
STEP 3: LUBRICATE THE THREADS OF THE MAIN STUD WITH ANTI-SEIZE LUBRICANT.
STEP 4: SLIDE THE HARDENED WASHER ONTO THE STUD, THEN SPIN THE TENSIONER ONTO THE MAIN THREAD UNTIL
IT SEATS AGAINST THE WASHER.
2

STEP 5: BACK OFF THE TENSIONER TO LEAVE A GAP OF .06-.12 FOR LUBRICATION DURING REMOVAL.
STEP 6: USING A SUITABLE TORQUING DEVICE, TIGHTEN (4) JACKBOLTS AT 90 APART (SEE FIGURE TO RIGHT FOR
SEQUENCE) ON ALL STUDS WITH A PARTIAL TORQUE (30-70%, 8-19 LB-FT).
STEP 7: AT 120% TARGET TORQUE (33 LB-FT), TIGHTEN THE SAME (4) JACKBOLTS ON ALL STUDS.

3

STEP 8: AT 120% TARGET TORQUE (33 LB-FT), TIGHTEN ALL JACKBOLTS IN A CIRCULAR PATTERN. DO THIS FOR ALL
STUDS (1 ROUND ONLY).
STEP 9: SWITCH TO A TORQUE WRENCH AND TIGHTEN ALL JACKBOLTS TO 100% TARGET TORQUE (27 LB-FT) IN A
CIRCULAR PATTERN UNTIL ALL JACKBOLTS ARE STABILIZED (LESS THAN 10 ROTATION). THIS USUALLY REQUIRES 24 ADDITIONAL PASSES.

20

STEP 8

5

STEP 9

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

4

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

4

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

STEP 4: REMOVE, CLEAN AND RELUBRICATE THE JACKBOLT THREADS AND TIPS PRIOR TO NEXT USE WITH
CORRECT SUPERBOLT LUBRICANT (MP390331).
CAUTION! JACKBOLTS MUST BE UNLOADED GRADUALLY. IF SOME JACKBOLTS ARE FULLY UNLOADED
PREMATURELY, THE REMAINING JACKBOLTS WILL CARRY THE ENTIRE LOAD AND MAY BE HARD TO TURN. WITH
EXTREME ABUSE, A JACKBOLT TIP CAN DEFORM, MAKING REMOVAL DIFFICULT.

4

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

1

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ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BE
SUBJECT TO LIABILITY. C 2012 Bucyrus International, Inc. ALL RIGHTS RESERVED.
DESCRIPTION

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COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

Bucyrus
International, Inc.

PWR MODULE,HYD CROWD,MECH ASSY
DWG SIZE

NO.

1579888

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

D

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

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

PUMP FLANGE
PUMP PILOT DIAMETER
PLASTIC PLUG IN TOP
CASE DRAIN PORT
(ALL PUMPS)

UPPER
CASE DRAIN

MARK ON PUMP HOUSING
(TIMING PROCEDURE - STEP 1)

MARK THIS TOOTH
(ALIGNED WITH TIMING MARK)

TDC
PUMP #1

7 TEETH
PUMP #3

3

15 TEETH
PUMP #2

3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

MARK ON PUMP HOUSING
(TIMING PROCEDURE - STEP 1)

SECTION W-W
PUMP - MOUNTING SURFACE
(TIMING MARKS)

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

DETAIL "TDC"
PUMP TIMING/INSTALLATION PROCEDURE
1. PRIOR TO INSTALLING PUMPS (ITEM 5) INTO PDT (ITEM 3), THE PUMPS MUST BE TIMED.

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

Y
PUMP #1

PUMP #4

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

W

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

.25

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

4
METAL PLUG IN BOTTOM
CASE DRAIN PORT
(ALL PUMPS)

PUMP #2

PUMP #3

4

D. ROTATE (CCW) EACH PUMP SHAFT OF PUMPS 2, 3 & 4 TO ALIGN MARKED TOOTH (FROM 1B) TO
APPROPRIATE PUMP HOUSING MARK (FROM 1C). VERIFY THE TOOTH COUNT OF EACH PUMP. PUMPS ARE
NOW TIMED AND READY FOR INSTALLATION INTO PDT.
E. PUNCH MARK SPLINE GROOVE OF OUTPUT GEAR TO COINCIDE WITH MATING "TDC" MARKED PUMP SPLINE
TOOTH.
2. APPLY O-RING LUBE (ITEM 47) TO EACH O-RING (ITEM 48). INSTALL O-RING OVER EACH PUMP PILOT DIAMETER.

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

W

A. INSTALL PUMP #2, SECURE TO PDT WITH H.H.C.S. (ITEM 30) AND WASHER (ITEM 40). WHEN INSTALLING THE
PUMP, ROTATE THE SHAFT OF THE PDT NOT THE PUMP SHAFT TO MAKE SURE NOT TO CHANGE THE TIMING
SEQUENCE OF THE PUMPS. ROTATE PDT SHAFT USING A LARGE STRAP/CHAIN WRENCH.
B. INSTALL PUMPS #1, 3 & 4 INTO PDT AND SECURE WITH H.H.C.S. (ITEM 30) AND WASHER (ITEM 40). CARE
MUST BE TAKEN TO LIMIT PUMP SHAFT ROTATION WHEN ALIGNING AND INSERTING PUMP SHAFT INTO
SPLINED RECEIVER OF EACH PUMP PAD OF PDT. IF EXCESSIVE SHAFT ROTATION OCCURS, PULL PUMP OUT
OF PDT AND VERIFY CORRECT POSITION OF TIMING MARK OF THAT PUMP. RE-INSTALL PUMP.
3. TORQUE EACH PUMP RETAINING SCREW TO THE VALUE GIVEN IN THE TORQUE CHART ON SHEET 1.

REISSUE DATE 08-08-2013

Y

SECTION Y-Y

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ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BE
SUBJECT TO LIABILITY. C 2012 Bucyrus International, Inc. ALL RIGHTS RESERVED.

PDT - PUMP MOUNTING SURFACE
(TDC ORIENTATION)

DESCRIPTION

R

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1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

Bucyrus
International, Inc.

PWR MODULE,HYD CROWD,MECH ASSY
DWG SIZE

NO.

1579888

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

D

REV
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COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

11 TEETH
PUMP #4              

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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 carrera:
El rotor esta descentrado de la carcasa.
Al girar succiona el fluido desde la entrada de la bomba, generando al girar unos
espacios o cámaras entre las paredes del rotor, del estator y las paletas.
Cuando este espacio comienza a comprimirse la bomba deja salir el fluido por el
orificio de salida

.
Las paletas salen radialmente, apoyándose en la carcasa.

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.
Bomba de paletas de dos carreras:
Estas bombas tienen una carcasa o estator ovalado o doble excéntrico.
Con dos entradas y dos salidas, se sitúa un estator de palas en el centro, generando dos
zonas de cámara “amplia”.
El resto del funcionamiento es similar al de la bomba de paletas de una carrera, con la
diferencia de que realiza dos procesos por cada ciclo.

.

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 carreras
Bomba de paletas de caudal variable:
El funcionamiento de esta bomba consiste en desplazar el estator de tal forma que
variamos la excentricidad entre el rotor y el estator.
De esta manera variamos el caudal de la bomba, variando el volumen de las cámaras.
Estas bombas son de una sola carrera y disponen de tres dispositivos de
posicionamiento.


Tornillo de posicionamiento para cilindrada (9).
Tornillo de ajuste de altura (2).
Tornillo de ajuste de máxima presión (7).

Si la fuerza Ff que es la que produce el muelle (6), es mayor que la fuerza Fh, el estator
de la bomba permanece en su posición excéntrica según la figura.
A medida que aumenta la presión en el sistema, aumenta también la fuerza Fh y la
vence el resorte desplazando el estator a una posición concéntrica.
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 

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ContaminationSensor CS1000

Analog Output (ANAOUT)

ISO Code acc. to 4406:1999
The following ISO values can be output via the analog output:
x ISO 4 / ISO 6 / ISO 14
Only one value is output.
x ISO-Code, 3-digit (>4 µm(c) / >6 µm(c) / >14 µm(c))
All values are sequentially time-coded before output.
x ISO+T
All values are sequentially time-coded before output.
x HDA.ISO
All values are sequentially time-coded before output.
Primarily this signal was planned for the HDA 5500 (HYDAC digital display Unit),
however, this can use in other applications.
The current 4.8 - -19.2 mA or voltage 2.4 - 9.6 V of the output signal is dependent
on the ISO Contamination Class 0.0 - 24.28 (Resolution 1 Class) or an error as
shown in the table below.
Current I
I < 4.0 mA
4.0 mA < I < 4.1 mA
4.1 mA < I < 4.3 mA
4.3 mA < I < 4.5 mA
4.5 mA < I < 4.8 mA
I = 4.80 mA
I = 5.37 mA
I = 5.94 mA
I = 6.51 mA
I = 7.08 mA
I = 7.65 mA
I = 8.22 mA
I = 8.79 mA
I = 9.36 mA
I = 9.93 mA
I = 10.50 mA
I = 11.07 mA
I = 11.64 mA
I = 12.21 mA
I = 12.77 mA
I = 13.34 mA
I = 13.91 mA
I = 14.48 mA
I = 15.05 mA
I = 15.62 mA
I = 16.19 mA
I = 16.76 mA
I = 17.33 mA
HYDAC Filtertechnik GmbH
BeWa CS1000 3247149n en.doc

ISO contamination class / error
Cable break
Device error, device not ready
Not defined
Flow error (flow insufficient)
Not defined
ISO 0
ISO 1
ISO 2
ISO 3
ISO 4
ISO 5
ISO 6
ISO 7
ISO 8
ISO 9
ISO 10
ISO 11
ISO 12
ISO 13
ISO 14
ISO 15
ISO 16
ISO 17
ISO 18
ISO 19
ISO 20
ISO 21
ISO 22

en

Voltage U
U< 2.0 V
2.0 V < U < 2.05 V
2.05 V < U < 2.15 V
2.15 V < U < 2.25 V
2.25 V < U < 2.4 V
U = 2.40 V
U = 2.69 V
U = 2.97 V
U = 3.26 V
U = 3.54 V
U = 3.83 V
U = 4.11 V
U = 4.40 V
U = 4.68 V
U = 4.97 V
U = 5.25 V
U = 5.54 V
U = 5.82 V
U = 6.11 V
U = 6.39 V
U = 6.67 V
U = 6.96 V
U = 7.24 V
U = 7.53 V
U = 7.81 V
U = 8.10 V
U = 8.38 V
U = 8.67 V
Page 56 / 100
2008-08-20

ContaminationSensor CS1000

Analog Output (ANAOUT)

Current I
ISO contamination class / error
I = 17.90 mA
ISO 23
I = 18.47 mA
ISO 24
I = 19.20 mA
ISO 24.28
19.2 mA < I < 19.8 mA
Not defined
19.8 mA < I < 20 mA
No measured value

Voltage U
U = 8.95 V
U = 9.24 V
U = 9.60 V
9.60 V < U < 9.90 V
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 CS1000

Cleanliness classes - brief overview

Cleanliness classes - brief overview
Cleanliness class - ISO 4406:1999
For ISO 4406:1999 particle counts are determined cumulatively, i.e. > 4 µm(c),
>6 µm(c) and >14 µm(c) (manually by filtering the fluid through an analysis membrane
or automatically using particle counters) and allocated to key figures.
The goal of allocating particle counts to references is to facilitate the assessment of
fluid cleanliness.
In 1999 the "old" ISO 4406:1987 was revised and the size ranges of the particle
sizes to be analyzed were redefined. The counting method and calibration were also
changed.
Important for the user in his everyday work:
Even though the size ranges of the particles to be analyzed have changed, the
cleanliness code will change only in individual cases. When the "new" ISO
4406:1999 was created, not all the existing cleanliness provisions for systems were
changed.

Table - ISO 4406
Allocation of particle counts to cleanliness classes:
Number of particles / 100 ml
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

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

Campos de aplicación

zzSistemas hidráulicos y de
lubricación industriales
zzHidráulica móvil

Ventajas

zzOpcionalmente puede conmutar
entre ISO 4406:1999 /
SAE AS 4059 y ISO 4406:1987 /
NAS 1638
zzDetección temprana de estados
críticos de la máquina
zzControl continuo de los estados del
aceite
zzPlan de mantenimiento en función
del estado de la maquinaria

Datos técnicos
Datos generales
Autodiagnóstico
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
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 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 flujo)
-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 flexibles (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
Bifilar, semidúplex para transferir el protocolo HSI
en conexión con un PC
Monofilar, semidúplex

SP 7.958.0/07.12

Descripción

11

Código del modelo

Volumen de suministro
CS 1 2 2 0 - A - 0 - 0 - 0 - 0 / - 000 

Tipo
CS =

ContaminationSensor

Serie
1 =

Serie 1000,
4 canales de tamaño
de partículas

Codificación 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 flexible
1 = Conexión con brida

SP 7.958.0/07.12

Número de modificación
000= Estándar

12

–– Contamination Sensor
–– Software FluMoS 1000 e
instrucciones de servicio y
mantenimiento en CD
–– Certificado de calibración
–– Instrucciones breves
–– 2 juntas tóricas en la versión con
conexión por brida

Opciones

–– Caja de acoplamiento con 2 m de
cable, apantallado, 8 polos, M12x1,
Nº art.: 3281220
–– Caja de acoplamiento con 5 m de
cable, apantallado, 8 polos, M12x1,
Nº art.: 3281239
–– Cable prolongador 5 m, caja de
acoplamiento 8 polos, M12x1 /
enchufe de acoplamiento 8 polos,
M12x1, Nº art. 3281240
–– Caja de acoplamiento con borne
roscado, 8 polos, M12x1,
Nº art.: 3281243

Dimensiones

Tipos de conexiones hidráulicas

CS1x1x sin visualizador

Conexión de tubo rígido o flexible

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 flexible

∆p : presión
ν : viscosidad

Conexión con brida

SP 7.958.0/07.12

Junta tórica

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 flexible

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 especificaciones de aplicación.
En caso de presentarse diferentes especificaciones de aplicación y/o condiciones
de servicio, contacte con el departamento especializado que corresponda.
Sujeto a modificaciones técnicas.

SP 7.958.0/07.12

HYDAC Filter Systems GmbH

14

Industriegebiet
D-66280 Sulzbach / Saar
Tel.:+49 (0) 6897/509-01
Fax:+49 (0) 6897/509-846
Internet: www.hydac.com
E-mail: filtersystems@hydac.com

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

1

ISO 9001: 2000 Registered Firm

SIS Media Number: BI646664

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

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

Pressure

C

F

bar

psi

-40

-40

49.35

716

-35

-31

50.41

731

-30

-22

51.47

746

-25

-13

52.53

762

-20

-4

53.59

777

-15

5

54.64

793

-10

14

55.70

808

-5

23

56.76

823

0

32

57.82

839

5

41

58.88

854

10

50

59.94

869

15

59

60.99

885

20

68

62.05

900

25

77

63.11

915

30

86

64.17

931

35

95

65.23

946

40

104

66.29

961

45

113

67.34

977

50

122

68.40

992

2

ISO 9001: 2000 Registered Firm

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

CRGV
Accumulator

RECV
Accumulator

4

ISO 9001: 2000 Registered Firm

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

There should not be any interference issues connecting the gauging unit to the CRGV accumulator.

RECV Accumulator Mounting (Lot 183 and Newer)
The accumulator mounting bracket is tilted so the charging/gauging unit will not interfere with the RECV module
located above the accumulator when attached.

6

ISO 9001: 2000 Registered Firm

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 can be tilted away from the RECV
module so the gauging unit can be installed. Ensure the upper bolt is re-installed and both bolts are tightened after
accumulator charge is checked.
Fastener Information
Item

Qty

Part Number

Description

2.6

2

03951850

WASHER,FLAT,.625,HARDENED

2.7

2

03485281

SCR,SOC,.925X2.5,UNC,GR8

2.8

2

02786465

NUT,HEX,LOCK,.625,UNC

7

ISO 9001: 2000 Registered Firm

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
Inspection

BI010733

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY November 20,

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.

9.5.9.1 Intervals Between Checking Gas Pre-charge Pressure
If accumulator pressure monitoring system is installed:
The proper gas precharge pressure should be verified after each new installation or repair. The
proper gas precharge pressure should be checked, using the operator’s display, every 500 hours
or monthly, whichever comes 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 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

SM141494-EN

SIS Media Number: BI646664

Hydraulic Crowd Service Procedures
Inspection

BI010733

9.5.10 Accumulator Pressure Test & Charge

TOOLS:
Charging/Gauging Unit
Bottled Nitrogen

PN: S134578

NOTE:

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

NOTE:

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

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Electric Rope Shovel

9 – 51
November 2012

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY November 20,

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.

SIS Media Number: BI646664

Hydraulic Crowd Service Procedures
Inspection

BI010733

To pressure test and/or charge the accumulator:
1.

Position the machine for service using option A or B.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY November 20,

Option A

Position the handle so the accumulators can be accessed from the house roof.
Use the crowd motion to position the hoist ropes as close to vertical as possible in order to
minimize the force (pulling out or pushing in) the hoist ropes exert on the cylinder. The rod
end pressure can be monitored from the operator cab screen to ensure the hoist rope force
on the cylinder is minimized.

Option B

2.
3.

Place the dipper on the ground.
Shutdown the machine. Lockout and tagout controls in compliance with local regulations.
Verify that the rod end of the cylinder is void of pressure by bleeding excess oil pressure
from the rod end test port on the cylinder manifold. This can be achieved by attaching 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

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SIS Media Number: BI646664

Hydraulic Crowd Service Procedures
Inspection

BI010733

6.

On the CRGV accumulator, close the shutoff valve located on the safety/shutoff block.
On the CRGV accumulator, locate the manual bleed valve on the safety/shut-off block.
Relieve the oil pressure by turning the manual bleed valve spindle counter-clockwise. Drain
all fluid from the accumulator before connecting the pressure testing equipment.
If equipped with accumulator pressure monitoring system check accumulator pressure 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.

SM141494-EN

Electric Rope Shovel

9 – 53
November 2012

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY November 20,

4.
5.

SIS Media Number: BI646664

Hydraulic Crowd Service Procedures
Inspection

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY November 20,

Charging/Gauging Unit

BI010733

PN: S134578

Figure 9-28

7.

Remove the valve protection and the valve seal cap from the top of the accumulator. Clean
any dirt, debris or paint from the charging valve area and ensure that the threads and
sealing surface are in good condition.
8. Using an allen wrench, break loose the charging cap screw located at the top of the
accumulator. Do not rotate this screw more than 1/8 turn. Ensure that the charging gas
does not leak from the accumulator.
9. Attach the adapter and the charging/gauging unit to the accumulator.
10. Tighten the adapter to the top of the accumulator to ensure that a gas tight seal is formed.
11. With the charging unit connected to the regulator and nitrogen bottle as shown in the Figure
above, slowly turn the T-handle in a counter clockwise direction while pushing down slightly.
After the handle engages the screw, turn the screw out until the pressure reading can 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

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SIS Media Number: BI646664

BI010733

Hydraulic Crowd Service Procedures
Inspection

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

If the accumulator is new or has fallen below 100 psi, the accumulator must be charged at
a very slow rate. It should take 2-3 minutes for every 20-30 psi. Charge at this rate until
the accumulator pressure reaches 100 psi. Above 100 psi, the rate of charging can
increase to 100 psi per 2-3 minutes until the system is fully charged to the correct
pressure.
13. Allow 10 minutes for the gas temperature and pressure to stabilize. Recheck and adjust as
necessary.
14. If the gas precharge is still low, continue charging. If the gas pressure is high, bleed gas off
through the charging system. Allow 10 minutes for the gas temperature and pressure to
stabilize.
15. If accumulator is unable to maintain charge, replace accumulator.
16. Once the proper gas precharge pressure is reached, close the shut-off valve on the nitrogen
bottle and tighten the charging cap screw on the accumulator by rotating the T-handle. This
will seal the gas in the accumulator. Loosen the adapter and disconnect the charging/gauge
unit from the accumulator.
17. Using an allen wrench, tighten the charging cap screw to 15 Ft-Lbs and check the 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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Electric Rope Shovel

9 – 55
November 2012

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY November 20,

12. If the gas pressure is low, charge the accumulator until the correct pressure is reached. The
charging process should be done very slowly to ensure that the accumulator is not
damaged. With accumulator pressure monitoring system installed, charge to 900 psi (+15
psi / -0 psi) as shown on the operators display as the Temperature Corrected Value.
Without accumulator pressure monitoring system installed, charge to the pressure shown in
the chart above based on the current outside ambient temperature.

SIS Media Number: BI646664

Hydraulic Crowd Service Procedures
Inspection

BI010733

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY November 20,

18. Replace the protective cap on the top of the accumulator.
19. On CRGV accumulator, return the shutoff valve to the open position and install a bolt and
lock nut to lock this valve into this position.
20. On CRGV accumulator, tighten manual bleed valve spindle to close manual bleed valve.
Locate the spindle against the relief when complete.

9 – 56
November 2012

Electric Rope Shovel

SM141494-EN

SIS Media Number: BI646664

Hydraulic Crowd Service Procedures
Hydraulic Crowd Service Schedule

BI010733

9.10 Hydraulic Crowd Service Schedule
Interval (Hours)

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY November 20,

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 tank sight gauge) See SYSTEM TOP OFF in HYDRAULIC CROWD SERVICE
PROCEDURES section
Verify Pump Drive Transmission (PDT) Oil Level (Dipstick) See PDT OIL LEVEL CHECK in HYDRAULIC CROWD SERVICE
PROCEDURES section
Verify Correct Accumulator Pressure: - See ACCUMULATOR
PRESSURE TEST AND CHARGE in HYDRAULIC CROWD
SERVICE PROCEDURES section
Inspect Crowd Position Sensor (CPS)
Inspect Aux Unit Filters (2) and Prefill Filter - (Replace as
required)
Inspect and clean Coolers as required (Externally) - See
HYDRAULIC CROWD COOLER CLEANING in HYDRAULIC
CROWD SERVICE PROCEDURES section
Trend Hydraulic Oil - Main System - Send oil sample to
approved lab.
Inspect and Replace Electrical Wiring as required (Cylinder
Manifold, Circulation Manifold and Pump Control Manifold)
Change Circulation Filter (Power Module) - See CIRCULATION
FILTER REPLACEMENT in HYDRAULIC CROWD SERVICE
PROCEDURES section

**

Test Cylinder Leakage flow rate
Inspect and replace Dipper Handle Guide Bushings as
required - See DIPPER HANDLE GUIDE BUSHING
REPLACEMENT in SERVICE PROCEDURES section
Inspect Return Filters (Inspect for debris - clean and replace as
required) - See UPPER TANK RETURN FILTER REPLACEMENT in
HYDRAULIC CROWD SERVICE PROCEDURES section
Inspect Power Module (Loose bolts, chock blocks and leaks)
Lube Crowd Motor Bearing - See GREASING MAIN A.C. DRIVE
MOTORS in LUBRICATION section
Lubricate Cooler and Circulation Motor Bearings
Inspect Power Module Blower (Hardware, ductwork, clean and
replace as required)
Replace Crowd Position Sensor (CPS) - (if required) See
CROWD POSITION SENSOR REPLACEMENT in HYDRAULIC
CROWD SERVICE PROCEDURES section

** After initial start up only

9 – 184
November 2012

Electric Rope Shovel

SM141494-EN

SIS Media Number: BI646664

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 CHARGE in
HYDRAULIC CROWD SERVICE PROCEDURES section
**

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

**

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

**

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

**

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

**

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY November 20,

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

Replace select hoses - See HYDRAULIC HOSE REPLACEMENT
in HYDRAULIC CROWD SERVICE PROCEDURES section
Lubricate Power Module Motor Coupling
- Refer to BRAKES & COUPLINGS section
Replace Circulation Pump and Coupling - See OIL
CIRCULATION PUMP REMOVAL AND REPLACEMENT in
SERVICE PROCEDURES section
Replace Hydraulic Oil for the entire Hydraulic System - See
COMPLETE SYSTEM FLUSHING AND FILTRATION, See SYSTEM
OIL DRAIN - COMPLETE, See INITIAL SYSTEM OIL FILL, See
SYSTEM TOP OFF in HYDRAULIC CROWD SERVICE
PROCEDURES section
Replace Main Pumps - See MAIN PUMP REMOVAL, See
PUMP TIMING AND INSTALLATION in SERVICE PROCEDURES
section
Replace Main Pump Hoses - See MAIN PUMP PRESSURE
HOSE REPLACEMENT in HYDRAULIC CROWD SERVICE
PROCEDURES section
Replace Hydraulic Cylinder - See SLEEVE AND CYLINDER
REMOVAL, See HYDRAULIC CROWD CYLINDER REMOVAL in
SERVICE PROCEDURES section
Replace Flushing/PDT Lubrication Pump and Coupling - See
FLUSHING/PDT LUBE MOTOR DISASSEMBLY AND
REPLACEMENT in SERVICE PROCEDURES section
Replace Pump Drive Transmission (PDT) - See PDT
REMOVAL in SERVICE PROCEDURES section

** After initial start up only

SM141494-EN

Electric Rope Shovel

9 – 185
November 2012                       

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February 8, 2012

HydraCrowd Initial Start-up Procedure

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

1

HydraCrowd Initial Start-up Procedure
This procedure is to be used when the system is started for the first time,
when the oil has been drained and re-filled, or after a major repair
procedure has been completed.
An electrical engineer may be required to “force” the PLC to advance or
remain in the heating mode.
The S127020 HydraCrowd Commissioning Tool Kit contains the pressure
gauges required to take the required measurements listed below.
Section 9 of the Maintenance Manual contains additional information
related to HydraCrowd Servicing.
NOTE: IT IS ESSENTIAL THAT ALL APPROPRIATE SAFETY MEASURES SUCH
AS THOSE SET FORTH IN THE APPLICABLE MACHINE MAINTENANCE
MANUAL ARE FOLLOWED DURING THE PERFORMANCE OF THIS
WORK.

Procedure
1. Fill the main hydraulic system with clean hydraulic oil.
a. Begin by filling the auxiliary tank (approximately 120 gallons)
as described in Section 9.6.9 (Auxiliary Power Unit Fill & Filter
Replacement) of the Maintenance Manual.
b. Circulate the oil through the auxiliary unit filters until the
contamination monitor reads 16/14/12 or lower.
c. Transfer the hydraulic oil into the upper tank as described in
Section 9.6.6 (System Top Off) of the Maintenance Manual
d. Repeat steps a, b and c until the hydraulic system is full
(approximately 1000 gallons)
Note: Replace the Pressure, Return and Pre-fill filters as required
during the system fill process by monitoring the filter indicators. As
the filters become contaminated, the gauge will move from green to
red.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

2

2. Fill the PDT with clean gear oil. The transmission holds 5.75 gallons
and the cooler core, circulating pump and lines will hold an additional
3.25 gallons. Refer to Section 9.6.10 “PDT – Initial Oil Fill” in the
Maintenance Manual.
3. Purge the 4 main pumps to insure that the 4 pump cases are full of
oil. Loosen the hose connection on top of each pump and allow the
air to bleed out (Figure 1). When oil is flowing from the fitting, tighten
the hose fitting. (See Section 9.9.1 “Purging The Main Pumps” in the
Maintenance Manual)

Figure 1
4. Verify correct rotation of the main crowd motor and couple the motor
to the PDT. (See Figure 2)
Note: Turning the pumps in the wrong direction may cause
damage to the pumps.
5. Verify correct rotation of the flushing pump. (See Figure 2)
Note: Turning the pumps in the wrong direction may cause
damage to the pumps.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

3

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

Figure 2
7. Start warm-up mode to heat the oil. State 1A will turn the immersion
heaters on.
8. With the warm-up mode in state 1B, the immersion heaters and the
circulation pump will be on. Oil will be flowing over the relief valve in
the circulation manifold (HOCCV). This will heat the oil. (No oil will
be flowing through the crowd cooler.)
Alternate Method: If the oil in the tank is above 25 degrees C
(77 degrees F) force the circulation pump on in the heating
mode. The pump should start in low speed and then go to full
speed. (This is not always noticeable if the oil temperature in
the upper tank is above -7degrees C [20 degrees F].)
Check the hydraulic oil pressure in the circulation manifold.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

4

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

Figure 3
9. When the oil is warm, the HOCCV will energize and oil will flow
through the hydraulic oil cooler and return to the lower tank through
the flow meter and circulation filter. (State 2A) This will clean the oil.
Check the oil cooler circuit for leaks.
Alternate method: Force the circulation manifold to go into the
cooling mode.
Observe the flow meter on the right side of the power module. In the
cooling mode, the expected pump flow is 90 gpm.
Record the flow meter reading ______________
Check the hydraulic oil pressure in the circulation manifold.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

5

Install a 0- 600 psi pressure gauge on outlet pressure port GCP.
Expected pressure reading is approximately 120 psi.
Record the pressure reading __________________
(Spec. is 120 psi if there are 2 crowd oil coolers in series)
(Spec. is 150 psi if there are 3 crowd oil coolers in series)
(Spec. is 70 psi if there is only one crowd oil cooler)
Note: Pressures are preset and cannot be adjusted in the field.
10. Bleed the circulation return oil filter using a Stauff test hose on the
test port (Figure 4) on top of the filter housing and run the other end
of the test hose into an empty 5 gallon pail. There will be very little
flow and very low pressure. Wait until there is a continuous stream
of oil and then disconnect the test hose.

Figure 4
11. Bleed the crowd cooler core. Air can be trapped in the cooler core.
(Optional)

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

6

12. Energize the flushing pump. This will turn the contamination monitor
(HOCM) on. Check the flushing circuit for leaks. This can be “forced
on” by the electrical engineer, or the crowd control can be turned on.
Warning: if the crowd control is on, the handle can move if
the crowd joystick is moved.
13. When the flushing pump is running, check the screens on the four
flow meters (Figure 5) located on the power module. Insure that
they are reading. Expected reading is approximately 2 gpm. There
is no need to record the readings at this time.

Figure 5
14. Filter the oil in the main system until the cleanliness is 16-14-12
before proceeding. The circulation pump filters the oil when the
system is the cooling mode. The flushing pump sends oil through
the contamination monitor (Figure 6) and shows the oil cleanliness
reading.
Record the cleanliness reading ________________

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

7

Figure 6
15. When the flushing pump is turned on, the PDT oil pump will move
PDT oil through the PDT oil cooler. The PDT oil level may need to
be topped off several times until the system is full. Check the PDT
oil circuit for leaks. If the oil level is too low, the crowd system will
shut down. The operator’s screen will show a low PDT pressure
fault (CDA 218-2).
Verify the PDT oil level _________
16. Install a 0- 8000 psi pressure gauge on the outlet pressure port of
each main hydraulic pump (Figure 7). It is important to be able to
monitor all four pumps at the same time. The Parker digital
pressure gauge in the S127020 Commissioning Tool Kit has this
capability.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

8

Figure 7
17. When the oil meets the cleanliness requirement of 16-14-12, run the
crowd motor in the “Pump Unloaded” mode. (State 1C) The crowd
motor will turn at 250 RPM. This causes oil to flow from the pumps,
through the pump manifold, and back to the upper tank. Check for
hydraulic oil leaks. Allow the flushing to continue for at least 15
minutes to insure complete flushing of the pump, hoses and pump
manifold.
18. After step 17, the contamination monitor values may increase,
indicating that the system is cleaning the oil. Before proceeding to
the next step, continue to circulate the oil until the cleanliness value
returns to below 16-14-12.
Verify that the cleanliness reading on the power module
contamination monitor is 16-14-12 or lower and record it here.
______________
19. Advance the heating mode to State 2B. The main pump heating
mode is active. All four PICV solenoids will be turned on. The crowd
motor will turn at 250 RPM. Hydraulic oil will be flowing past two
PUV valves, back to tank, causing the oil to heat. The PUV valves
are turned on and off in pairs to prevent the valves from overheating.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

9

Each PUV pressure relief valve limits the maximum pressure in its
corresponding pump to 3700 psi.
Alternate method: Force the crowd motor to run at 200 RPM
with the 4 PICV valves forced “on” and PUV 1 and 3 forced on.
Check the pressures and adjust if necessary. Then stop the
crowd motor and force PUV 2 and 4 on. Run the crowd motor
at 200 RPM and check the pressures and adjust if necessary.
Record the pressure readings on the chart shown above.
PUV 1 and PUV 3 are turned on together. Read the pressure on the
pump 1 and pump 3 pressure gauges. Expected pressure is 3700
psi.
Record the Pump 1 pressure reading __________________ (Spec.
is 3700 psi.)
Record the Pump 3 pressure reading __________________ (Spec.
is 3700 psi.)
PUV 2 and PUV 4 are turned on together. Read the pressure on the
pump 1 and pump 3 pressure gauges. Expected pressure is 3700
psi.
Record the Pump 2 pressure reading __________________ (Spec.
is 3700 psi.)
Record the Pump 4 pressure reading __________________ (Spec.
is 3700 psi.)
Note: The individual pressure relief valves (Figure 8) on the pump
manifold can be adjusted if required. The pressure relief valve
should be replaced if it does not respond when adjusted.

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

10

Figure 8
20. Advance the heating mode to state 2C, manifold heating. Note: this
is the same as “hose flushing” and will clean the hydraulic hoses and
manifold. Allow the hose flushing to continue for at least 15 minutes.
Alternate method: Activate the Hose Flushing Mode using the
button on the operators screen. Hose Flushing runs for
approximately 15 minutes.
Record the reading on the 4 pump case drain flow meters (PCDM) at
this time.
PCDM1 ___________
PCDM2 ___________
PCDM3 ___________
PCDM4 ___________

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

11

Observe the pressure readings of the 4 main pumps on the digital
pressure gauge. The expected reading on each pump should be
approximately 500 psi. It is not necessary to record the readings.
21. Record the reading of the contamination monitor at the conclusion of
hose flushing. ____________
22. After step 21, the contamination monitor values may increase
indicating that the system is cleaning the oil. Before proceeding to
the next step, continue to circulate the oil until the cleanliness value
returns to below 16-14-12.
Verify that the cleanliness reading on the power module
contamination monitor is 16-14-12 or lower and record it here.
______________
23. When the contamination monitor indicates the oil is clean, continue
the heating mode until cylinder motion in allowed.
Alternate method: If the system is not in heating mode, turn
on the crowd control and operate the crowd from the operator’s
seat.
24. Raise the cylinder to the horizontal position.
25. Bleed the cylinder using Step 4 of the “HydraCrowd Cylinder
Bleeding Process”. (See Section 9.6.1 in the Maintenance Manual)
26. Operate the cylinder in mid-stroke (between 8’ and 15’ of crowd
extension) until the operational temperature is reached.
Warning: Do not fully extend or retract the cylinder when
the hydraulic oil is below operating temperature. Damage
to the cylinder snubbers could occur.
27. When the hydraulic oil has reached operating temperature, set the
crowd limits. (See Section 4.4.17 “Hoist and Crowd Limit Systems”
in the Maintenance Manual)

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

12

28. When full crowd motion is permitted, check the speeds in extend and
retract. These numbers are viewable on the operator’s display on
the “HydraCrowd Status” screen (Figure 9).
Full speed extend ________________ feet per minute
(Spec. is 140 fpm)
Full speed retract ________________ feet per minute
(Spec. is 120 fpm)

Figure 9

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

13

29. Take WinDaq recordings. (See Section 3.7 “HydraCrowd Health
Monitoring Checks” in the Maintenance Manual) Send the WinDaq
recordings to South Milwaukee Service Department for
interpretation.
30. Remove the two auxiliary quick disconnect couplings (Figure 10)
from the cylinder manifold and install two “Zero Leak” plugs.

Figure 10

Commissioning Engineer

Caterpillar Confidential: YELLOW / WHEREVER THERE’S MINING.

Date

14

Media Number: BI643125
Media Number: BI643125
Publication Date: 2/11/2014

Special Instruction
________________________________________________________________
________________________________________________________________

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

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

Important Safety Information

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

Required Parts and/or Tools
Man lift
Feeler Gauges – 12 inch length
Ruler
Camera
Calipers

Media Number: BI643125

Component Replacement
The saddle block liners should be replaced when the 0.38 inch chamfer has been worn off the
end of the liner bushings.
Note: The subsequent measurements can be used for monitoring and trending purposes, but the
determination for liner replacement should be made based on the condition of the wear chamfer.
The Handle Guide bushings should be replaced when the 0.37 inch wear chamfer is no longer
visible upon inspection.

Illustration 1 – Saddle Block Liner and Handle Guide Bushing

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

Liner

1
8

2

7

Handle

1

2

3

6

3

4

4

5
5

6

7

8

Media Number: BI643125

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

1
8

2

7

3

6

4
5

Illustration 2 – Position Reference

Media Number: BI643125

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

Illustration 3 - Measuring of OD Flange

1

2

3

4

5

6

7

8

The nominal distance from the ID of the saddle block liner to the OD of the flange as shown
above is 5.315 inches.

5) Measure the distance from the end of the chamfer to the OD of the saddle block liner as shown
in Illustration 4.
Measurement Step 5 _____

Media Number: BI643125

Illustration 4 - Measuring of Chamfer to OD

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

Current hours on liners
Measurement from Step 5
Position

1

Measurement from
Step 4

Remaining Chamfer =
Step 4 - Step 5
% Remaining Chamfer
(0.38/Remaining
Chamfer)*100

Units are Inches for Formula above

2

3

4

5

6

7

8

Media Number: BI643125

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

Wear Chamfer

Illustration 5 - Manhole Inspection Port

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

Illustration 6 - Guide Bushings

________

Media Number: BI643125

8) Additional Information Requested
• Inspect dipper handle for adequate OGL coverage and any signs of pitting or other
damage. Refer to Illustration 6 for handle pitting example.
• Inspect the top of the handle end retainer and the top surface of the sleeve for any signs
of wear. Refer to Illustration 7 and 8

Illustration 7 – Example Dipper Handle Pitting
Dipper Handle Adequate OGL Coverage

Yes

No

Signs of Pitting On Handle

Yes

No

Top of Handle End Retainer Wear

Yes

No

Top of Sleeve Wear

Yes

No

OGL Type
Injector Type
Guide Bushing Change Out Frequency

SL1 or SLV
Hours

Media Number: BI643125

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

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

Illustration 9– Handle End Retainer Metal Flow

Media Number: BI643125

Procedure – Saddle Block Liner Removed From Machine
1) Mark the top of each saddle block liner so its position as it was installed on the saddle block is
recorded.
2) Measure the grease groove depth at the following locations for the front and rear saddle block
liners (Refer to Illustration 9):
• Front and Rear of each grease groove
• Both sides of each grease groove
• Repeat for all 8 grease grooves
Ensure each grease groove position relative to its position on an installed machine is recorded.
If the grease groove is completely worn away, measure the flange width as shown in Illustration
10.

B Side

A Side

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

Illustration 9 – Saddle Block Liner Measurement Locations

Media Number: BI643125

Illustration 10 – Alternative Measurement Location if Grease Groove is Gone

Illustration 11 – Example Measurement Method

Media Number: BI643125

8

1

7

2

6

3
5

4

Illustration 12 – Grease Groove Position Reference

Media Number: BI643125

Front Liner
Groove
Position
Location
1
2
3
4
5
6
7
8

Flange
End

Inboard
End

Rear Liner
Flange
End

A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
Grease Groove Measurement Table

Location

Front Liner

Rear Liner

Flange End

Flange End

1
2
3
4
5
6
7
8
Flange Width Measurement Table

Inboard
End

Media Number: BI643125

3) Additional Information Requested
Dipper Handle Adequate OGL Coverage

Yes

No

Signs of Pitting On Handle

Yes

No

Top of Handle End Retainer Wear

Yes

No

Top of Sleeve Wear

Yes

No

OGL Type
Injector Type

SL1 or SLV

Guide Bushing Change Out Frequency

Hours

Saddle Block Liner Component Hours When
Removed

Hours

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

©2012 Caterpillar
All Rights Reserved

Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge
trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

Media Number: BI643161
Publication Date: 27 June 2014

Service Magazine
New Band Clamps Available for 7495 and 7495HF HydraCrowd™Equipped Electric Rope Shovels
Electric Rope Shovel
Model

Identification Number

Expanded Product Line
Serial Number

7495

ER601418

141418

ER601439

141439

ER601452

141452

ER601441

141441

ER601455

141455

ER601462

141462

ER601463

141463

ER601469

141469

ER601470

141470

ER601473

141473

ER601474

141474

ER601477

141477

ER601482

141482

ER601481

141481

ER601494

141494

ER601516

141516

ER601509

141509

ER601508

141508

ER601514

141514

ER601511

141511

ER801325

141325

ER801327

141327

ER801333

141333

ER801424

141424

ER801429

141429

7495HF

Media Number: BI643161
ER801517

141517

ER801518

141518

ER801433

141433

ER801209

141209

ER801483

141483

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

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

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

©2012 Caterpillar
All Rights Reserved

Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge
trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

Media Number: BI643161

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

Media Number: BI643161

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

MR Flow Transmitter
Installation & Maintenance
Instructions
FORM #HLIT 306

DIVISION OF RACINE FEDERATED INC.

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

I. INTRODUCTION
The MR Flow Transmitter 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
circuitry including:



Non-contact sensor electronics
Electronic signal conditioning circuit
Digital flow rate and total indication
Proportional analog output

The product is sealed against industrial contamination
by a NEMA 12 and 13 (IP 52/54) rated enclosure and is
available for either liquid or gas service.
The MR Flow Transmitter is capable of calculating
and displaying both 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. 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)
• Viscosity compensation (petroleum-based fluids)
• Pressure and temperature compensation
(pneumatic applications)

US Patent 7,130,750

Figure 1 - MR Flow Transmitter

All meters include an analog output that can be
configured for 0-5 Vdc, 0-10 Vdc, or 4-20 mA current
loop.
Applications for the MR Flow 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 °F (-29 °C to +116 °C)
• Ambient: -20 °F to +158 °F (-29 °C to +70 °C)
Environmental
• Humidity: 0-90% non-condensing
Pressure Rating Aluminum/Brass
• Liquids (¼” to 1-½”): 3500 psi (241 bar)
maximum with a 3:1 safety factor
• Gases (¼” to 1-½”): 1000 psi (69 bar)
maximum with a 10:1 safety factor
Pressure Rating Stainless Steel
• Liquids (¼” to ½”): 6000 psi (414 bar)
maximum with a 3:1 safety factor
• Liquids (¾” to 1-½”): 5000 psi (345 bar)
maximum with a 3:1 safety factor
• Gases (¼” to 1-½”): 1500 psi (103 bar)
maximum with a 10:1 safety factor
Accuracy
• ±2% of full scale
Repeatability
• ±0.5%
Pressure Drop
• See Appendix for specific meter information

Electrical
Power Requirement:
• 0-5 Vdc Output 10-30 Vdc @ 0.75W maximum
• 0-10 Vdc Output 12-30 Vdc @ 0.75W maximum
• 4-20 mA Output loop-powered, 30 Vdc maximum
Power Consumption:
• 25 mA maximum
Analog Outputs:
• 0-5 Vdc and 0-10 Vdc into 10,000 Ohms minimum
• 4-20 mA into 1000 Ohms maximum (see Figure 2)
Circuit Protection:
• Reverse polarity and current limiting
Transmission Distance:
• 4-20 mA limited by cable resistance
• 0-5 Vdc 1000 feet (300 m) maximum
• 0-10 Vdc 1000 feet (300 m) maximum
Isolation:
• Inherently isolated from the piping system
Rate and Totalization Display
• Fixed or toggle modes of operation for rate and
totalizer display
• 8 digit, .70” high numeric display for rate and total
• 8 digit, .34” high alphanumeric display for units
and setup
Temperature Drift
• 50 ppm / °C (maximum)
Analog Output
• Resolution - 1:4000
Compliance
• Meets the requirements of EN61000-6-4 for a
Class A product for emissions and EN61000-6-2
for immunity tests of an ISM product.
Dimensions
• See Appendix

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

Page 2

Form #HLIT 306 10/10

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

4

A2

QTY

ITEM NO.

1

1

KIT,HOSE,PUMP TO CONTROL MAN

S089090

1

2

KIT,HOSE,PWR MODULE DRAIN

S046545

1

3

HOSE ASSY,-64 CD61,STR-STR

650422-165

1

4

PIPE ASSY,10.0 TANK CONNECTION

1

5

SUPPORT,CLAMP,10 PIPE

1

6

BRACKET,10 PIPE

1

7

U-BOLT,.75UNC,10 PIPE,RUB.COAT

2

8

BAR,3x3

S046547

1

9

SHIM PACK,0.38 THK

S046548

4

10

SUPPORT,HOSE,WELDED

S049659

4

11

BAR,.25x4

S049660

4

12

BAR,.25x4

S049661

2

13

PL,.5

S046549

1

14

THERMOWELL,1/2 NPT,4.00,304SS

1546777

1

15

TRANSMITTER,TEMP,-40 TO 240F

12844169

4

16

FLANGE,HALF,4

53303641

16

17

FLANGE,HALF,1.5,6000 PSI

20325237

1

18

FTG,EL,90 D,1.0MP#12MORB

20287452

1

19

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

79091440

1

20

PLUG,PIPE,SQ HD,1,150#

20767800

1

21

CONN,#6 ORS-#16 ORB

78554360

2

22

CONN,#16 ORS-#16 ORB

78554231

1

23

CONN,#8 ORS-#12 ORB

78554232

8

24

O-RING,-225,VITON,90 DUROMETER

68136132

2

25

O-RING,-245,VITON,70 DUROMETER

68760801

1

26

LABEL,HOTSL

16

27

SCR,HEX,M16x2.0x50mm,CL8.8

03552118

4

28

SCR,HEX,.5x2,UNC,GR5

03285640

16

29

SCR,HEX,.625x1.25,UNC,GR 5

03291400

24

30

SCR,HEX,.625x2.25,UNC,GR 5

03291720

16

31

SCR,HEX,.875x4.5,UNC,GR5,PLTD

03552119

40

33

WASHER,BELLEVILLE,.625

03955004

4

34

WASHER,FLAT,.562

03951700

4

16

35

WASHER,FLAT,.875,HARDENED,PLTD

03552121

4

16

36

WASHER,BELLVILLE,.875

03955011

16

37

NUT,HEX,FULL,.625,UNC

02713050

USE AS NEEDED TO SUPPORT 4
-24 HOSE FROM KIT S089090

32

38

NUT,HEX,FULL,.875,UNC

02715100

2

39

STRAP,HOSE BUNDLE,VELCRO

17431970

2

40

STRAP,VELCRO BUNDLE,20 DIA MAX

17431971

2

41

STRAP,VELCRO BUNDLE,24 DIA MAX

17431972

1

42

COMPOUND,THREAD LOCKING

82833862

8

46

WIRE,LOCK,#16(.0625)

84280000

1

47

CONN,STR,-12 MORB - .5FNPT

78553919

1

48

XDCR,PRESSURE,0-10000PSI

12858367

12

4 PLCS

20.00
3 PLCS

22.50

10

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

F5

C2
S5

T3

B4
31

35

36

2

38

1

5

T3

1

SEE NOTE 3
24

27

B4

F5

4

17

S5

4

3
39

33

4 PLCS

40

41

G3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

*

3

PART NO.

S038915
17112576

4

S046546
49032527

S052002

5

* QTY MEASURE IN FEET

2

5
4

E3
NOTE:
1. X = COMPONENTS FROM KIT (ITEM 1), SEE DRAWING S089090.
2. X = COMPONENTS FROM KIT (ITEM 2), SEE DRAWING S046545.
3. SEE DWG S038986 FOR SPLIT FLANGE INSTALLATION INSTRUCTIONS.
4. APPLY LOCTITE 7471 PRIMER T (P/N 1561393) AND LOCTITE 545
THREAD SEALANT (P/N 1561392) TO ALL NPT THREADS UNLESS
STATED OTHERWISE.
5. SEE SHEETS 6 & 7 FOR INSTALLATION OF PIPE (ITEM 4) AND
TORQUE PROCEDURE FOR EXPANSION JOINTS.

E3

6

L4

L4

G3

A2
19

20

38

36

35

31

53574
ECN

04-17-2012
DATE

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

DESCRIPTION

Quella P.
BY

4
COPYRIGHTED-CUSTOMER INFORMATION DRAWING

REISSUE DATE 04-17-2012

REVISION DATA

SEE NOTE 4

DELETED ITEM 32, QTY 8 OF 03552120; ITEM
35, QTY 16 WAS 24; ITEM 36, QTY 16 WAS 24;
ITEM 38, QTY 32 WAS 48; UPDATED REF
GEOMETRY IN ALL VIEWS; SHT 1, DIM 22.50 WAS
REF, DELETED DIM 16.00; SHT 3, DIM 1.43 WAS
0.60, NOTE - PMOPT IN PORT GSP2 WAS IN PORT
SP; SHT 6, NOTES 1,2,5, AND 18 REVISED; SHT
7, DIM 0.25 WAS 0.25 REF, 14.63 TO 15.38
REF WAS 15.13

18

REV

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

DESCRIPTION

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

11
4

3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

SOLIDWORKS
DRAWING

THIS DOCUMENT IS PROTECTED UNDER APPLICABLE COPYRIGHT LAWS TO THE EXTENT AVAILABLE.
ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BE
SUBJECT TO LIABILITY. C 2006 Bucyrus International, Inc. ALL RIGHTS RESERVED.
ALL DIMENSIONS IN INCHES-UNLESS OTHERWISE SPECIFIED
MACHINING TOLERANCES-UNLESS OTHERWISE SPECIFIED
1.
2.
3.
4.

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

Bucyrus
International, Inc.

R

FABRICATING TOLERANCES-UNLESS OTHERWISE SPECIFIED
1.

2.

MATERIAL THICKNESS
A. LESS THAN .12

DIMENSIONS
TOLERANCE
0 TO 36
.03
OVER 36
.06
0 TO 36
.06
B. .12 TO .50
OVER 36
.12
0 TO 36
.09
C. .50 TO 1.00
OVER 36
.19
0 TO 36
.19
D. OVER 1.00
OVER 36
.25
BENT ANGLES
1 (.017 IN/IN) FOR EACH .37 OF MATERIAL
THICKNESS (MAX 3 )

WELDMENT TOLERANCES-UNLESS OTHERWISE SPECIFIED
1. DIMENSION
A. UP TO 36"
B. 36" TO 10'
C. 10' TO 30'
D. OVER 30'

MATERIAL THICKNESS
UP TO 1"
1" AND GREATER
UP TO 1"
1" AND GREATER
UP TO 1"
1" AND GREATER
ALL

TOLERANCE
.06
.12
.12
.19
.19
.25
.25

DESCRIPTION

PLUMBING,HYD CROWD HOUSE,FLD
REF DWGS
MODEL

S038972
495

UNIT

1600
12-12-2008

DET

ALBRECHT K.

DATE

ENG
CONTACT

FUERST J.

DWG
SIZE

NO.

S089091

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

FIN WGT

1013.6

REV

4

E
SHEET

1 OF 7

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

6

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

4

BALL VALVE IN BOTTOM
OF UPPER TANK

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

4

6

21

8

1

22

5

5
2

2
16

25

30

28

33

34

42

9

SEE NOTE 3
35

36

38

7

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

DETAIL C2

31

35

38

LUBE ROOM
BULKHEAD

D

6

6

SECTION A2-A2

5

13

.13

3 SIDES
WHERE
ACCESSIBLE

WELD ITEM 13 TO
LUBE ROOM FLOOR
4 SIDES WHERE ACCESSIBLE
CENTER ITEM 13 UNDER
ITEM 5

DETAIL D

REISSUE DATE 04-17-2012

SOLIDWORKS
DRAWING

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

R

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

Bucyrus
International, Inc.

PLUMBING,HYD CROWD HOUSE,FLD
DWG SIZE

NO.

S089091

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

E

REV
SHEET

4

2 OF 7

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

.13

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

36

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

31

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

4

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

4

42.50
INSIDE OF FRONT
WALL TO 10" PIPE

5

5

4
14

47

15

26

HOTSL

31

35

36

38
COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1.43

SEE
NOTE 4

LABEL "HOTSL"
LOCATE AS SHOWN

SECTION E3-E3

6

4

PMOPT
48 IN PORT "GSP2"

SECTION T3-T3
18

19

REISSUE DATE 04-17-2012

20

SEE NOTE 4

SOLIDWORKS
DRAWING

SECTION G3-G3

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

ORIENT ITEMS 18, 19 AND 20
TOWARDS FRONT OF MACHINE

DESCRIPTION

R

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

Bucyrus
International, Inc.

PLUMBING,HYD CROWD HOUSE,FLD
DWG SIZE

NO.

S089091

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

E

REV
SHEET

4

3 OF 7

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

6

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

K

K

23

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

2

J

4

4

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

1

5

39
31

35

36

38

40

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

5

41

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

SECTION B4-B4
2

3
4

SEE NOTE 3
25

30

2

33

2

3

6

6

22

2
5
5.25
TRIMMED
LENGTH

17

24

30

33
REISSUE DATE 04-17-2012

SEE NOTE 3

SECTION L4-L4

1

SOLIDWORKS
DRAWING

DETAIL J

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

VIEW K-K
COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

R

Bucyrus
International, Inc.

PLUMBING,HYD CROWD HOUSE,FLD
DWG SIZE

NO.

S089091

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

E

REV
SHEET

4

4 OF 7

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

4

4
29 16 PLCS

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

11

10

LUBE
ROOM
SIDE

11

10

10

11

ROOF PANEL
CROSS MEMBERS

11

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

37

ROOF PANEL
CROSS MEMBERS

FRONT OF
PANEL/MACHINE

5

10

12

10

12

10

12

5

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

SECTION S5-S5

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

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

ADJUST HEIGHT OF SUPPORTS
BY MOVING ITEM 10 UP OR DOWN
TO DESIRED BOLT HOLE LOCATION.
LOCATE AS REQUIRED 4PLCS
3

6

6

.13

8 PLCS
.13
(USE ITEM 10 AS
LOCATION FIXTURE)

29

37

11

12

REISSUE DATE 04-17-2012

SOLIDWORKS
DRAWING

10
2

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

SECTION F5-F5
R

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

Bucyrus
International, Inc.

PLUMBING,HYD CROWD HOUSE,FLD
DWG SIZE

NO.

S089091

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

E

REV
SHEET

4

5 OF 7

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1.16

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

ITEM 4 INSTALLATION PROCEDURE:
4

4

4

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

4

2) ATTACH TRANSFER TUBE (ITEM 4) ONTO LOWER TANK EXPANSION JOINT USING SUPPLIED HARDWARE, ITEMS 35, 36, 38, 31. INSTALL
HARDWARE LOOSELY. RE-ATTACH CONTROL ROD RETAINER PLATES USING HARDWARE RETAINED FROM STEP 1, LESS 5 FLAT WASHERS
ON NUT SIDE (SEE DETAIL P7).
3) PLACE PANCAKE JACK UNDER TRANSFER TUBE IN SPECIFIED LOCATION, AS SHOWN.
4) RAISE PANCAKE JACK UNTIL THE TOP FLANGE OF THE TRANSFER TUBE CONTACTS THE LOWER FLANGE OF THE EXPANSION
JOINT THAT IS ATTACHED TO THE UPPER TANK.

4

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

SEE NOTE 14

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

46

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

6

7) LOWER AND REMOVE PANCAKE JACK.
8) POSITION UPPER TUBE SUPPORT CLAMP (ITEM 6) AND BASE (ITEM 8) ONTO TRANSFER TUBE. LOCATE ITEMS AGAINST LUBE
ROOM WALL TO SPECIFIED DIMENSIONS, AS SHOWN, USING SUPPLIED HARDWARE (ITEM 28 & 34).
USE SHIMS (ITEM 9) AS REQUIRED. WELD ITEM 8 IN PLACE AS SHOWN.
8.60±1.0
FOR TORQUING SCREWS 31
SEE NOTE 15 THIS SHEET

35

36

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

38

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

8
WELD ITEM 8 TO
LUBE ROOM WALL
2 PLCS

.13

9
28

11) TIGHTEN FLANGE HARDWARE (ITEMS 35, 36, 38, 31) ON UPPER EXPANSION JOINT, NO MORE THAN 10FT.LBS. SEE TIGHTENING SEQUENCE
BELOW.
12) INSPECT EXPANSION JOINT DIMENSIONS AT POINTS A, B, C & D TO ENSURE THEY ARE WITHIN TOLERANCES AS EXPLAINED IN TABLE "X-X",
SECTION N7-N7 AND DETAIL P7. IF REQUIRED, ADJUST TRANSFER TUBE AND/OR UPPER TANK TO BRING EXPANSION JOINT DIMENSIONS
INTO SPECIFICATION. ENSURE DIMENSIONS OF BOTH EXPANSION JOINTS ARE AS CLOSE A POSSIBLE TO THE MIDDLE OF THE ACCEPTABLE
RANGE AS INDICATED BY TABLE "X-X".

34

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

5

5

14) TORQUE DRILLED HEAD EXPANSION JOINT BOLTS PER THE FOLLOWING TORQUE SEQUENCE DIAGRAM, FOLLOWING THE TORQUE STEPS
BELOW. SECURE BOLTS WITH LOCKWIRE (ITEM 46) FOLLOWING THE PROCEDURE LISTED IN THE ENGINEERING DATA SECTION OF THE
MAINTENANCE & OPERATION MANUAL.
STEP 1. TORQUE TO 30 FT-LBS, THEN REST FOR 30 MINUTES.
STEP 2. TORQUE TO 50 FT-LBS, THEN REST FOR 60 MINUTES.
STEP 3. TORQUE TO 75-85 FT-LBS.
15) HAND TIGHTEN VALVE FLANGE H.H.C.S. THEN FOLLOW THE TORQUE SEQUENCE DIAGRAM, FOLLOWING THE TORQUE STEPS BELOW:
STEP 1. TORQUE TO 30 FT-LBS, THEN REST FOR 30 MINUTES.
STEP 2. TORQUE TO 50 FT-LBS, THEN REST FOR 60 MINUTES.
STEP 3. TORQUE TO 75-85 FT-LBS.
STEP 4. AFTER TORQUING SCREWS (ITEM 31) INSTALL SECOND NUT (ITEM 38) AS SHOWN.

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

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

17) VERIFY EXPANSION JOINT DIMENSIONS AS EXPLAINED IN TABLE "X-X", SECTION N7-N7 AND DETAIL P7. ADJUST AS NECESSARY.
4

18) INSTALL CONTROL ROD ASSEMBLIES TO SPECIFIED DIMENSIONS AS SHOWN IN DETAIL P7.
A) TIGHTEN THE TWO OUTSIDE NUTS AGAINST EACH OTHER SO THAT THE FACE OF THE WASHER
MEASURES 0.25" FROM THE FACE OF THE CONTROL ROD RETAINING PLATE, AS SHOWN IN DETAIL P7.
B) TIGHTEN THE TWO INSIDE NUTS AGAINST EACH OTHER SO THE FACE OF THE WASHER NEAREST TO THE TWO OUTSIDE NUTS IS 1.38"
FROM THE NEAREST FACE OF THE WASHER, AS SHOWN IN DETAIL P7.
19) WELD TRANSFER TUBE SUPPORT CLAMP BASE & SHIMS (ITEM 5 & 13) IN PLACE AS INDICATED IN DETAIL D.

FOR TORQUING SCREWS 38
SEE NOTE 15 THIS SHEET

36

35

31

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

N7

4

P7
11

6

6

1

7
5

13

TORQUE
SEQUENCE
FOR 12 BOLT
FLANGE

10
COPYRIGHTED-CUSTOMER INFORMATION DRAWING

N7

9

4

6

8

2
PANCAKE JACK
LOCATION

12
REISSUE DATE 04-17-2012

SOLIDWORKS
DRAWING

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

R

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

Bucyrus
International, Inc.

PLUMBING,HYD CROWD HOUSE,FLD
DWG SIZE

NO.

S089091

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

E

REV
SHEET

4

6 OF 7

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

5

3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

4

4

A

D
C

TABLE X-X

.50±.25
OFFSET
MIS-ALIGNMENT
ALLOWED

46
SEE NOTE 14 (SHEET 6)

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

A

D

DIMENSIONAL REFERENCE
FOR POINTS A, B, C, D
AROUND CIRCUMFERENCE

5

B

6

6

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

CONTROL ROD
RETAINING PLATE

CONTROL ROD
RETAINING PLATE

.25

C

4

.37
REF
1.38 (SPACING BETWEEN WASHERS)

SECTION N7-N7

14.63 TO 15.38 REF
(WASHER TO WASHER)

MEASUREMENT POINTS AROUND
EXPANSION JOINTS

4

REISSUE DATE 04-17-2012

DETAIL P7

SOLIDWORKS
DRAWING

TYPICAL EXPANSION JOINT INSTALLATION
UPPER AND LOWER TANK

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

R

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

Bucyrus
International, Inc.

PLUMBING,HYD CROWD HOUSE,FLD
DWG SIZE

NO.

S089091

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

E

REV
SHEET

4

7 OF 7

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

5

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

B

C8-CDB Module

2

See Assembly Note 5

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

CLAMP ASSEMBLY
2

X.X
2.1
2

From Tank Port at
Accumulator Safety
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

DO5 Valve

2

2.6

See Assembly Note 2

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2.3
From Pressure Port at
7
Accumulator Safety
Relief Valve (Item #3)

REF WGT(#)
EACH

PART NO.

37.61

S134546

CLAMP,HOSE,ASSY

5.8

1561322

2.1

BASE,CLAMP,HOSE

3.3

1561313

2

2.2

ROD,THD,.5,UNCx5.5

0.3

1561319

2

2.3

NUT,HEX,LOCK,.5,UNC

0.1

02786425

1

2.4

PL,COVER,SINGLE CLAMP,6S,HEAVY

0.93

1561321

1

2.5

BODY,CLAMP,54.4mm,PAH,6S,HVY

0.6

1561324

1
1

2.6
3

SCR,SOC,M16x2.0x35,CL12.9
ACCUMULATOR,CYL MANIFOLD ASSY

0.02
73.41

1561328
S134589

1

4

MODULE,D05 DIVERSION,HYD ASSY

5.59

S134571

4

5

SCR,SOC,M6x1.0x75,CL12.9

0.1

S134577

2

6

SCR,HEX,M16x2.0x35mm,CL12.9

0.2

S134579

2

7

HOSE ASSY,-6,STR-90,ORS

1.2

650474-35

10

8

O-RING,-014,VITON,70 DUROMETER

0.01

68787027

1

9

ELBOW,90D,#6 ORS-#8 ORB

0.7

57141121

2

10

WASHER,BELLEVILLE,.625

0.1

03955004

1

11

COMPOUND,RETAINING

0.2

82833859

1

12

ORING,-219,VITON,70

0.019

S134950

QTY

ITEM NO.

DESCRIPTION

1

1

MODULE,CECV,HYD ASSY

1

2

1

2

A

Notes:
2.2

X.X

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

3

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

= Denotes item numbers from assembly S134553

2
Note orientation of
machined relief groove
in block to face down 4
towardsCRGV module.

C4-CRGV Module
See Assembly Note 1

4

ENGINEERING REF: CECV Modification
for Cylinder Manifold S134500 ONLY.
Accumulator is "PED/CRN/AS1210" Certified.
REISSUE DATE 03-17-2011

REVISION DATA

C5-CECV Module
See Assembly Note 3 & 4

Tank connection

Ref Manual Bleed Valve.
Turn clockwise to close.

1

See Section E-E

2

BY

ISOMETRIC VIEW
COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

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

3 See Assembly Note 6

DESCRIPTION

Szpek F. DATE 03-17-2011 ECN

A Pressure connection
B

SOLIDWORKS
DRAWING

33011

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

REV

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

Relief Valve (RV3)
By-Pass Hose Ref.

THIS DOCUMENT IS PROTECTED UNDER APPLICABLE COPYRIGHT LAWS TO THE EXTENT AVAILABLE.
ANY UNAUTHORIZED AND UNLAWFUL REPRODUCTION, DISTRIBUTION OR OTHER USE SHALL BE
SUBJECT TO LIABILITY. C 2011 Bucyrus International, Inc. ALL RIGHTS RESERVED.
ALL DIMENSIONS IN INCHES-UNLESS OTHERWISE SPECIFIED
MACHINING TOLERANCES-UNLESS OTHERWISE SPECIFIED
1.
2.
3.
4.

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

R

FABRICATING TOLERANCES-UNLESS OTHERWISE SPECIFIED
1.

2.

DIMENSIONS
TOLERANCE
0 TO 36
.03
.06
OVER 36
B. .12 TO .50
0 TO 36
.06
.12
OVER 36
C. .50 TO 1.00
0 TO 36
.09
.19
OVER 36
D. OVER 1.00
0 TO 36
.19
.25
OVER 36
BENT ANGLES
1 (.017 IN/IN) FOR EACH .37 OF MATERIAL
THICKNESS (MAX 3 )

Bucyrus
International, Inc.

MATERIAL THICKNESS
A. LESS THAN .12

WELDMENT TOLERANCES-UNLESS OTHERWISE SPECIFIED
1. DIMENSION
A. UP TO 36"
B. 36" TO 10'
C. 10' TO 30'
D. OVER 30'

MATERIAL THICKNESS
UP TO 1"
1" AND GREATER
UP TO 1"
1" AND GREATER
UP TO 1"
1" AND GREATER
ALL

TOLERANCE
.06
.12
.12
.19
.19
.25
.25

DESCRIPTION

MOD,CECV,CYLINDER MANIFOLD

REF DWGS

S134500,S134569

MODEL

495HF/HR

UNIT

SZPEK F.
FUERST J.

DATE

DET
ENG
CONTACT

NO.

DWG
SIZE

5600
(MM-DD-YYYY)

01-08-2011
D

S134590

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

FIN WGT
(LBS)

REV

121.0

2

SHEET

1 OF 2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

4

Nut Hex
Size
0.75

Torque (Lubricated) Torque (Lubricated)
(N-m)
(Ft-Lbs)
26 +/- 1
19 +/- 1.0

Straight
Thread

Nut Hex
Size

#8

.75-16

0.88

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

12

Assembly Notes Cylinder Manifold Modifications:

3

1

75 +/- 7

55 +/- 5

2

4

2.6
2

Socket Head Cap Screws
Style
Metric
Metric
Metric

Pressure
connection 7

Socket Hex Torque (Lubricated) Torque (Lubricated)
Thread
Key Size
(N-m) 12.9 Class
(Ft-Lbs)
M6 x 1
6 mm
18 +/- 0.6
13 +/- 0.5
M10 x 1.5
8 mm
55 +/- 2.7
41 +/- 2
M16 x 2
14 mm
273 +/- 27.3
201 +/- 20

A

7

B

Pressure
Connection 7

Tank
connection

7

5

B

5x

6
9

8

A

Pressure
connection

Pressure
connection

10

2.2

6

A

C8-CDB
Module

4

A

7

6

7

B

Tank
connection

2.4

2.3
2

2.4

2

2.6

4

C4-CRGV
Module

Remove #8 plug.
See Assembly Note 5.

2.1

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

"X" See note 7
3

D

F

D
B Tank

Handle store position
See Note 8.

Connection

A Pressure

Connection
1

C5-CECV
Module

1

SECTION A-A

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

3

6

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

B Tank

connection

A Pressure

connection

C5-CECV
Module

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

SECTION E-E

Ref - Main Shut-Off
Valve Handle. Shown
in open position.

(See Note 8)

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

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

Refer to: Assembly Note 4
for Torque Procedure.

Pre-Mod CECV Module
before removal.
Pressure
connection 3

Remove paint from
cross-hatched area.
See Assembly Note 3

3

1

Tank 3
connection

A

3

1

DETAIL F

B

10

2

10

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

1

C5-CECV
Module

3

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

2.3
2.2

3

10

3

10

Tank
connection
7

2.5

E

DO5 Valve

Connection

2.1

E

A Pressure

C8-CDB
Module

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

A

DETAIL B

4x

10

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

Torque (Lubricated) Torque (Lubricated)
(N-m.)
(Ft.-Lbs.)

3

4

9

4

ORB Fittings

SAE
Size

B

7

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

Straight
Thread
.69-16

Refer to: Assembly Note 2
for Torque Procedure.

5x

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

SAE
Size
#6

8

5 4x

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

See Assembly Note 5

Tank
Connection

ORS Fittings

2

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

7. By-Pass Hose Support Bracket Installation:
• Apply, Loctite (Item No. 11) to end of rod (Item No. 2.2) with 0.75 inches
of thread. Install into Base (Item No. 2.1) tighten until threads are fully
engaged, 0.75 inch.
• Apply Loctite (Item No. 11) to Socket Head Screw (Item No. 2.6) and fasten
hose support base to manifold assembly using supplied M16 screw. Note
hose orientation shown and verify clearance in location indicated with "X".
Tighten per torque specification chart. Do not apply Loctite to locknuts
(Item No. 2.3).
• Fasten hose to bracket with Stauff clamp.
8. Manual Bleed Valve Handle Positioning:
• Verify that the Manual Bleed Valve is completely closed by turning
clockwise. After closing valve, pull out handle to disengage it from needle
valve. Without re-opening valve, rotate handle to position shown in Section
E-E to prevent accidental opening of valve.

4

REISSUE DATE 03-17-2011

SOLIDWORKS
DRAWING

C5-CECV Module Cover

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

180

DESCRIPTION

SECTION D-D
COPYRIGHTED-CUSTOMER INFORMATION DRAWING

DETAIL C
1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

R

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

2

Bucyrus
International, Inc.

MOD,CECV,CYLINDER MANIFOLD
DWG SIZE

NO.

S134590

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

D

REV
SHEET

2

2 OF 2

4

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

1

COPYRIGHTED-CUSTOMER INFORMATION DRAWING

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 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 no gap between mounting plate and cylinder manifold. Parts will be provided at
no charge to customer. Labor will not be included.
The following items will be provided per machine:
- SHIM PACK,HYD CROWD CYL ASSY (P/N 1577755) – Quantity 1
- SCR,SOC,M12X1.75X55,CL 12.9 (P/N 1573785) – Quantity 7
- WASHER,BELEVILLE,M12 (P/N 1573597) – Quantity 7
Shimming Procedure:
- Fit mounting plate to cylinder manifold.
- Install all bolts each side to 20% of final torque value (20 N-m) per torque sequence and procedure. Do not
use Loctite on the bolts at this time.
- Ensure there is no gap between mounting plate and cylinder before taking measurements.
- Measure the gap between the mounting plate and cylinder manifold at Location A and B. Measurements
should be taken at inboard sides of mounting plate as shown below.
- Shim amount should be the average of the two measurements = (A measurement + B measurement)/2
- Install equal amount of shims on both sides.
- Install all bolts with Loctite 243 (Blue).
- Torque bolts to 100 N-m per torque sequence and procedure.
- Ensure no gap between mounting plate and cylinder manifold.
- Ensure no gap between mounting plate and cylinder.

Ensure there is no gap between
mounting plate and cylinder.
Cylinder

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.

3

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

5

ISO 9001: 2000 Registered Firm

SPANISH • ESPAÑOL

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.

2

Instrucciones
Con los tensionadores SuperboltTM usted ha elegido un un producto tecnológicamente superior.
Se trata de un producto puramente mecánico y, por tanto, muy seguro.
Los siguientes pasos sencillos le ayudarán con su aplicación. Al seguir éstas instrucciones podrá
incrementar la seguridad, reducir el tiempo de parada y ampliar la vida en servicio.

Contenido

page/s

1. Procedimiento de apriete

4/5

2. Procedimiento de aflojado

6/7

3. Lubricante y herramientas

8/9

4. Mantenimiento

10

5. Indicaciones generales

11

12

6. Contacto

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

3

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 principal y las superficies de
contacto, engrase bien el producto con el
lubricante apropiado (A) y coloque la arandela
(B).
– Asegúrese de que los tornillos de presión en el
lado de carga no sobresalen del tensionador
Superbolt y que están bien engrasados. Si
resulta necesario, reengrase con el lubricante
Superbolt recomendado (véase el certificado).

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!

6

1/4

2.2 Empleo a altas temperaturas (> 100 °C)
Preparación:A temperaturas elevadas la base de
petróleo del lubricante se evapora, y por lo tanto el
esfuerzo de aflojado se incrementa.
Paso 1:
Aplique de ser posible el aceite penetrante durante
el enfriamiento de la instalación (a unos 150º C). A
temperaturas superiores, emplear aceite sintético.
Paso 2:
Comenzando con el tornillo Nº 1 (elegido
arbitrariamente) y en sucesión circular afloje ¼ de
vuelta cada uno de los tornillos del tensionador
(basta iniciar el aflojado).

Nota: No gire ningún tornillo de presión más allá
del inicio del aflojado. Si se usan varios 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.

1/4

7

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 tornillos

de presión Superbolt alcanzan solamente entre un
30 y 50% de su potencia (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).

8

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


– 130-200 Nm

– 200-270 Nm

– más de 270 Nm

– más de 400 Nm

atornillador de impacto de 3/8“ o trinquete por aire
atornillador de impacto de 1/2“, estrangulado (Atención: No rebasar Ia
capacidad!)
atornillador de impacto de 1/2“
atornillador de impacto de 1/2“ (manual) o de 3/4“
atornillador de impacto de 3/4“
atornillador de impacto de 3/4“

9

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
especificado en el certificado de Nord-Lock. Posteriormente recolocar el tornillo de presión y volver
a apretarlo al 100%. Repitan el proceso para cada tornillo de presión.
- Ahora tensar de nuevo según el procedimiento de apriete- Paso 5, es decir, apretar de forma
circular todos los tornillos al 100% del par recomendado, hasta que todos estén apretados.

4.2 Mantenimiento preventivo

P. ej.desinstalación para realizar tareas de
mantenimiento:
– Desafloje siguiendo el procedimiento de
aflojado.
– Limpie la rosca y los extremos de los tornillos
de presión Superbolt y trate con el lubricante
indicado en el certificado. No use disulfuro de
Molibdeno (MoS2) si no está expresamente
indicado en el certificado.
– Las arandelas endurecidas se pueden reutilizar
a pesar de las marcas de contacto simplemente
dándolas la vuelta. Son normales las huellas de
algunas centésimas de mm.
– Apriete de nuevo según el procedimiento de
apriete.

4.3 ¿Qué hacer en caso de problemas?


Problema: Los tornillos no pueden aflojarse:
– Intente retirar al menos un tornillo de presión.
– Rengrase adecuadamente y apriete al 110 % del par de apriete recomendado.
– Los 2 tornillos de presión contiguos se deberían aflojar.
– Retírelos también, engrase y apriete de nuevo al 110 % del par de apriete recomendado.
– Los dos tornillos de presión siguientes se deberían de aflojar.
– Realice el mismo paso.
– A continuación, suelte todos los tornillos de presión según el procedimiento de aflojado.

Problema: Las arandelas endurecidas están dañadas tras un largo tiempo en servicio:
– Sustitúyalas por arandelas endurecidas Superbolt originales.
Problema: Los tornillos de presión están dañados o se han perdido:
– Sustitúyalas por tornillos de presión originales Superbolt. No utilice tornillos comerciales ya
que no son apropiados para cargas tan altas.

10

Otros problemas: Para más información, por favor diríjase a su oficina Nord-Lock más cercana.

5. Indicaciones generales
5.1




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

5.2 Apriete de anclajes 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 recorridos de 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 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.

11

6. Contacto

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, registered 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: info@nord-lock.ch
Nord-Lock Group
Tel: +46 (0)31 7192 300, Fax: +46 (0)40 240 851
Email: info@nord-lock.com
www.nord-lock.com

English • Printed in Switzerland • 2014-05 • 5.5-016

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 

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