BI010305-Service Manual-141450-Pl002 PDF

®
BI010305
June 2012
Service Manual
7495 Electric Rope Shovel
141450
Toromocho Project
Purchase Order Number M-315
CERTIFIED
SM141450-EN
SAFETY.CAT.COM
BI010305
Amendments and alterations to this publication are not subject

to notification. Caterpillar Global Mining LLC reserves all rights
to this publication. Its content is protected by copyright laws.
No part of this publication may be reproduced or transferred

in any way or form without the prior written approval of
Caterpillar Global Mining LLC.
Caterpillar Global Mining LLC declines any liability for direct or

indirect consequences of printing errors.
© 2012 Caterpillar Global Mining LLC.
LatchFree™ and HydraCrowd™ © 2012 Bucyrus International, Inc.

Table of Contents
BI010305
Table of Contents
Table of Contents
SECTION S - SAFETY
PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 31, 2012

SECTION 1 - INTRODUCTION
SECTION 2 - LUBRICATION
LUBRICATION SPECIFICATIONS
SECTION 3 - PREVENTIVE MAINTENANCE
SECTION 4 - SERVICE PROCEDURES
SECTION 5 - BRAKES AND COUPLINGS
SECTION 6 - COMPRESSED AIR SYSTEM
SECTION 7 - AIR FILTRATION
SECTION 8 - ENGINEERING DATA
SECTION 9 - SCHEMATICS
SM141450-EN Electric Rope Shovel TOC – i

May 2012
Table of Contents
BI010305
TOC – ii Electric Rope Shovel SM141450-EN

May 2012
BI010306
PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 21, 2012

S Safety
Always refer to the safety section of this manual before starting any maintenance
procedure on this machine.
Safety
S.1 Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-iii

S.2 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-v
S.2.1 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-vi
S.2.2 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-vii
S.2.3 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-ix
S.2.4 Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-ix
Figure S-1 Fire Extinguisher Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S-x
S.2.5 Common Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xi
S.2.5.1 Emergency Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xi
Figure S-2 Emergency Lighting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xi
S.2.5.2 Mine Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xii
Figure S-3 Mine Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xii
Figure S-4 Mine Signal Horn Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xii
S.2.5.3 Dual Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xiii
Figure S-5 Right Side Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xiii
S.2.5.4 Propel Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xiv
Figure S-6 Right Side Warning Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xiv
S.2.5.5 Propel Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xv
Figure S-7 Propel Back-up Horn Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xv
S.2.5.6 Emergency Stop Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xvi
Figure S-8 Emergency Stop Button Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xvi
SM141450-EN Electric Rope Shovel S–i

June 2012
Safety
BI010306
S.2.5.7 Cameras. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xvii

Figure S-9 Camera Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xvii
S.2.5.8 Boarding Stairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xviii
Figure S-10 Right Side Boarding Stair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S-xviii
S.2.5.9 Vertical Boarding Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xviii
S.2.5.10 Man On Ground Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xix
Figure S-11 Left Side Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xix

S.2.5.11 Emergency Escape Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xx
S.2.6 Warning Signs And Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xxi
Figure S-12 Stored Energy Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xxii
S – ii Electric Rope Shovel SM141450-EN

June 2012
Safety
BI010306 Safety Symbols
Safety
S.1 Safety Symbols

Operating, maintaining or servicing this machine is dangerous unless performed properly. Each
person must satisfy himself and his employer that he is alert, has the necessary skills,

knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used
are safe and correct. Factory service representatives and specialists are available to provide
additional information or technical assistance. The operator must be alert, physically fit and free
from the influence of alcohol, drugs, or any medications that might impair his/her eyesight,
hearing or reactions.
The safety alert symbols displayed here and throughout this manual are used to call attention to
instructions concerning personal safety. Carefully read and follow these instructions and observe
all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine.
Be certain that anyone servicing this machine is aware of these SAFETY SYMBOLS and their
definitions. If it is impossible to safely perform any of the enclosed maintenance and operational
procedures, contact your regional service representative or the factory.
The following defines distinctions between safety instructions. In all these definitions the safety
alert signal is used.
This signal word denotes an imminently dangerous hazard which will result in death,
serious bodily injury, or serious damage to equipment if not acknowledged and
appropriate action taken.
This signal word denotes a hazardous situation which, if not avoided, could result in
death or serious injury.
This signal word denotes a hazardous situation which, if not avoided, could result in
minor or moderate injury.
This signal word indicates a situation related to protection of property. It is not directly
associated with a hazard or hazardous situation and is not used in place of DANGER,
WARNING, or CAUTION.
NOTE: This signal word denotes an item of required information pertaining to the equipment. A
loss of time, assets, or minor injury may result if the appropriate action is not taken.
SM141450-EN Electric Rope Shovel S – iii

June 2012
Safety
Safety Symbols BI010306
STORED ENERGY! These signal words are used when maintenance on or around
indicated hardware and/or components could potentially release dangerous amounts of
preloaded tension or pressure. Failure to properly support indicated components and/or
release the preloaded energy could result in death, severe personal injury, or damage to
the machine.
Safety must always be paramount!

Consult your supervisor when safety is in doubt.
S – iv Electric Rope Shovel SM141450-EN

June 2012
Safety
BI010306 Safety Precautions
S.2 Safety Precautions
This manual provides information and data for the maintenance and/or operation of this

machine. All electrical equipment must be serviced by qualified individuals who have
been properly trained to work with high voltage systems and variable frequency AC
drives. Failure to comply could result in personal injury or death.
Do not attempt mechanical or electrical maintenance on this machine without a full

understanding of each component’s operation and function. Components utilizing
electrical power, air pressure, hydraulic pressure and compression or tension springs for
operation must be deactivated and isolated prior to disassembly.
The FEEDER CABLE must contain a provision for a ground connection, especially
whenever 2,300 volts or greater are used. At the substation, the power line must terminate
(see paragraph on ground circuits) to a suitable permanent ground. At the machine, the
power line must securely terminate through a bolted connection to the machine frame.
This provides a constant ground for the machine and its electrical equipment. Failure to
provide this adequate ground endangers employees and equipment.
HIGH VOLTAGE! The need for a power line grounding circuit adequate for the machine
cannot be overemphasized. Without a good grounding system, high voltages exist
between the machine and the ground. The portable trail cable and power lines supplying
electric energy to the machine must have a ground wire, ample in capacity, running
parallel to the main wires over the entire distance from the transformer to the machine. A
suitable grounding system must be used at the transformer. Consult your local electrical
supplier for details.
Due to the inherent dangers in the operation of high voltage electrical equipment, a safe
grounding system is required that includes ground conductors in the cable, a neutral
grounding resistor, and related relays and switchgear. A ground continuity check system
is also recommended.
SM141450-EN Electric Rope Shovel S–v

June 2012
Safety
Safety Precautions BI010306
S.2.1 General Precautions

• The employment of qualified maintenance personnel, through a scheduled
maintenance program, is the best way to minimize machine downtime and maximize
productivity of equipment.
• Keep hands, feet and clothing away from rotating parts.

• Wear a hard hat, safety shoes and protective lenses at all times.
• Replace any and all safety and warning placards if they are defaced or removed from
the machine.
• Think before you act. Carelessness is one luxury the service person cannot afford.
• Excessive or repeated skin contact with sealants or solvents may cause skin irritation.
In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material
and the suggested method of cleanup.
• Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load
could slip off of the hook if they are not functioning properly.
• If a heavy item begins to fall, let it fall, don’t try to catch it.
• Keep your work area organized and clean. Wipe up oil or spills of any kind
immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall,
slipping or tripping.
• Floors, walkways and stairways must be clean and dry. After fluid draining operations
be sure all spillage is cleaned up.
• Electrical cords and wet metal floors make a dangerous combination.
• Regularly inspect for any loose bolts or locking devices and properly secure them.
• Use extreme caution while working near any electrical lines or equipment whether it be
high or low voltage. Never attempt electrical repairs unless you are qualified.
• Check limit switches for proper operation.
• After servicing, be sure all tools, parts or servicing equipment are removed from the
machine and secured in an appropriate storage area.
• Mechanical Brakes are designed for use as static holding brakes only. Use as a motion
(dynamic) brake in emergency situations only.
• Use proper interior and exterior lighting.
• Install and maintain proper grounding and ground fault protection systems.
• Allow electrical inspection and maintenance to be performed only by a qualified
electrician.
S – vi Electric Rope Shovel SM141450-EN

June 2012
Safety
S.2.2 Maintenance Precautions
• Do not wear rings, wristwatches or loose fitting clothing when working on machinery.
They could get caught on moving parts causing serious injury.
• Always wear a safety belt or harness when the danger of falling exists.

• Always have a second person to monitor the lifeline when working in confined spaces.
• Do not start an engine indoors unless adequate exhaust ventilators are provided and
in operation.
• Never utilize the machine air or hydraulic systems for support when working on the
machine. Deactivate or isolate the entire system prior to performing maintenance.
• Equipment should be parked on level ground at all times during machine servicing
and periods of idleness.
• Cranes and hoists must be of sufficient capacity to lift the heavier components
(gearcases, etc.) Always work within the limitations of the equipment being utilized.
• Be sure heavy items are properly rigged and supported from cranes or hoists before
removing supporting members from the machine.
• Utilize guide lines or ropes to minimize the swing of suspended heavy components.
• Have sufficient service personnel available when removing or installing large heavy
items to maintain control at all times.
• Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on
the jack or hoist to carry the load, they could fail.
• When disassembling a machine, be sure to use safety stands and adequate cribbing to
prevent tipping or rollover of components.
• When using an oxy/acetylene torch, always wear welding goggles and gloves. Keep a
charged fire extinguisher within reach. Be sure the acetylene and oxygen tanks are
separated by a metal shield and are chained to the cart.
• Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when
applicable. Use hammers, punches and chisels only when absolutely necessary.
Always be sure to wear safety glasses.
• Use extreme caution when using compressed air to dry parts. Use approved air
blowguns, do not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use
proper shielding to protect everyone in the work area.
SM141450-EN Electric Rope Shovel S – vii

June 2012
Safety
• Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or
servicing the machine.
• Protective eye goggles should be worn at all times when working on the air
conditioning system. Work on the air conditioning system only in a well ventilated
area.
• Wipe away excess lubricants around bearings and gears. Never lubricate parts in
motion.
• Always wear approved rubber gloves and use insulated hooks or tongs when handling
trail cable.
S – viii Electric Rope Shovel SM141450-EN

June 2012
Safety
S.2.3 Operating Precautions
• Wear hearing protection when exposed to the following noise levels in excess of the
period indicated:
8 hours at 90 dBa

4 hours at 95 dBa
2 hours at 100 dBa
1 hour at 105 dBa
30 minutes at 110 dBa
15 minutes at 115 dBa
• When in doubt about the noise level, wear approved hearing protection.
• Do not attempt to get on or off the machine while it is in operation. Notify the operator
prior to any attempt to board/exit the machine.
• Do not move or operate the machine without first knowing the location and purpose of
all personnel and test or support equipment on or near the machine.
• Do not allow unauthorized personnel on board the machine while in operation.
• Use audible signals to warn of machine movements. A signal horn button is provided
for this purpose.
• Do not propel until the travel route has been cleared of obstructions.
• Do not propel the machine on a slope greater than that specified in Operator’s Manual
- SLOPE LIMITATIONS.
• Prevent trail cable from being dragged on the ground for long distances or at high
speeds.
• Limit the amount of cable being pulled by the machine. Pulling too much cable will
damage both the cable and the machine.
S.2.4 Fire Prevention

• Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and
service the extinguisher as indicated on its instruction plate.
• DO NOT smoke while handling flammables or when near batteries.
• Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended
torque.
• Repair or replace loose or damaged lines, tubes and hoses as soon as possible.
• Make certain all clamps, guards and shields are replaced correctly so as to prevent vibration
and the chafing of parts during operation.
• DO NOT carry flammable fluids such as gasoline or solvents on board the machine.
SM141450-EN Electric Rope Shovel S – ix

June 2012
Safety
• DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged
lines, tubes, or hoses. Replace them immediately.
• DO NOT start the machine or move any of the controls if a warning tag is attached to the
controls or the start panel.
• Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.
• Keep all structural frame compartments, walkways and work areas clean and free of lubricant
residue.
• NEVER weld, burn, or perform service on the machine alone.
• If a motor or other component is running hot, shutdown the machine until it has cooled and
the cause is determined and repaired.
Figure S-1 Fire Extinguisher Locations
S–x Electric Rope Shovel SM141450-EN

June 2012
Safety
S.2.5 Common Safety Features
Most shovels can be equipped with the following safety features.
S.2.5.1 Emergency Lighting

In case of a power failure, there are 13 emergency lights and 3 self-luminating exit lights located
throughout the machinery house and near walkways similar to the figure below.
Figure S-2 Emergency Lighting Locations
SM141450-EN Electric Rope Shovel S – xi

June 2012
Safety
S.2.5.2 Mine Signal

A mine signal switch is located on either side of the machine at the back of the ballast box. A pull
cord, which can be reached from the ground, activates an air horn located at the top of the lube
room.
Figure S-3 Mine Signal Switch
Figure S-4 Mine Signal Horn Location
S – xii Electric Rope Shovel SM141450-EN

June 2012
Safety
S.2.5.3 Dual Mirrors
Dual convex mirrors are mounted outside right and left hand side of the operator’s cab. Mirrors
can be mounted and adjusted for best operator’s viewing.

Figure S-5 Right Side Mirror
SM141450-EN Electric Rope Shovel S – xiii

June 2012
Safety
S.2.5.4 Propel Warning Lights

Propel warning lights will flash when the machine is in motion.The amber lights are usually
mounted on both sides of the machine, outside of the electrical room.
Figure S-6 Right Side Warning Light
S – xiv Electric Rope Shovel SM141450-EN

June 2012
Safety
S.2.5.5 Propel Back-up Alarm
In addition to propel warning lights, machines can be equipped with a propel back-up warning
alarm. The horn is usually mounted on the right side of the ballast box, bellow the deck
extension.

Figure S-7 Propel Back-up Horn Location
SM141450-EN Electric Rope Shovel S – xv

June 2012
Safety
S.2.5.6 Emergency Stop Buttons

There are 5 Emergency Stop buttons on the Rope Crowd machines and 7 on HydraCrowd
machines. For more detailed information on use and locations refer to the Operator’s manual.
Figure S-8 Emergency Stop Button Locations
S – xvi Electric Rope Shovel SM141450-EN

June 2012
Safety
S.2.5.7 Cameras
There are 5 cameras located on the machinery house and boom. Video camera monitors are
located in the operator’s cab above the front windshield.

Figure S-9 Camera Locations
SM141450-EN Electric Rope Shovel S – xvii

June 2012
Safety
S.2.5.8 Boarding Stairs

A set of boarding stairs is attached to the machinery house platform - either on the left side of the
machine, the right side or both. These stairs must be in their raised and latched position to
enable the operator’s controls.
Figure S-10 Right Side Boarding Stair
S.2.5.9 Vertical Boarding Ladder

The vertical boarding ladder is one of the means for boarding the machine, located on the left-
hand side of the machine, at the rear of the machinery house. When the ladder is not latched in
place the operator's controls are deactivated.
S – xviii Electric Rope Shovel SM141450-EN

June 2012
Safety
S.2.5.10 Man On Ground Light
A rotating light is used to indicate to other mine personnel in the pit that a person is on the ground
in the vacinity of the shovel. This light is typically mounted to a handrail on the left side of the
machine.

Figure S-11 Left Side Warning Light
SM141450-EN Electric Rope Shovel S – xix

June 2012
Safety
S.2.5.11 Emergency Escape Chute

An emergency escape chute is located just outside the operator's cab side doorway. For more
information refer to the Operator’s manual or the manufacturer’s documentation.
S – xx Electric Rope Shovel SM141450-EN

June 2012
Safety
S.2.6 Warning Signs And Decals
The placards depicted are mounted on the machine as delivered from the manufacturer. These
hazard warning placards convey information to operators, maintenance personnel, or anyone
who will be on or near the machine. The information is designed to help prevent situations which
may result in injury to personnel or damage to the machine.
SM141450-EN Electric Rope Shovel S – xxi

June 2012
Safety
Figure S-12 Stored Energy Decals
S – xxii Electric Rope Shovel SM141450-EN

June 2012
BI010307

1 Introduction
Introduction
1.1 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.1.2 Organization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.1.3 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.1.4 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.1.5 Precautions and Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.1.6 Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.2 Swinging Restraint & Ballast Box Support . . . . . . . . . . . . . . . . . . . . . . 1-7
1.2.1 Ballast Box Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.2.2 Swinging Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3 Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Figure 1-1 Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4 Lower Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Figure 1-2 Truck Frame and Crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.4.1 Crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Figure 1-3 Right Crawler Assembly (Left Opposite) . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.4.2 Truck Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Figure 1-4 Truck Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.4.3 Swing Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
SM141450-EN Electric Rope Shovel 1–1

June 2012
Introduction
BI010307
Figure 1-5 Swing Rack and Roller Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1.4.4 Roller Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Figure 1-6 Roller Circle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.4.5 Propel Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.4.6 Collector Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Figure 1-7 Collector Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Figure 1-8 Collector Rings, High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.5 Rotating Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1.5.1 Revolving Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.5.2 Center Pintle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.5.3 Deck Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Figure 1-9 Deck Extensions and Ballast Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.5.4 Ballast Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.5.5 Machinery House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.5.5.1 Boarding Stairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Figure 1-10 Right Side Boarding Stairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.5.5.2 Vertical Boarding Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.5.5.3 Power Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.5.6 A-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Figure 1-11 A-Frame and Front End Support Components . . . . . . . . . . . . . . . . . . . 1-25
1.5.7 Hoist Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Figure 1-12 Hoist Machinery - Plan View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.5.8 Swing Machinery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Figure 1-13 Swing Machinery Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.5.9 Crowd Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Figure 1-14 Crowd Machinery Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
1.5.10 Operator's Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
1.5.11 Compressed Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
1.5.12 Automatic Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Figure 1-15 Lubrication Room. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.5.13 Lube Reservoir Fill / Overflow Plumbing. . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Figure 1-16 Lube Reservoir Fill / Overflow Plumbing . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1.6 Front End Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

Figure 1-17 Front End Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
1.6.1 Suspension Strands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
1.6.2 Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Figure 1-18 Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.6.3 Running Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Figure 1-19 Ropes - General Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
1.6.4 Saddle Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Figure 1-20 Saddle Block Bushing Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
1–2 Electric Rope Shovel SM141450-EN

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Introduction
BI010307
1.6.5 Dipper Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

1.6.6 Dipper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Figure 1-21 Dipper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
1.6.7 Padlocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Figure 1-22 Left and Right Padlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
1.6.8 Dipper Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41

Figure 1-23 Dipper Trip Motor and Dipper Trip Sheave . . . . . . . . . . . . . . . . . . . . . . 1-41
1.7 Typical Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

Table 1-1 - Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Table 1-2 - Front End Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Table 1-3 - Rope Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Table 1-4 - Typical Dimensions and Working Ranges . . . . . . . . . . . . . . . . . . . . . . 1-43
1.8 General Estimated Component Weights . . . . . . . . . . . . . . . . . . . . . . . 1-44

1.8.1 Lower Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
1.8.2 Upper Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
1.8.3 Front End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

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Introduction
BI010307

June 2012
Introduction
BI010307 About This Manual
Introduction
1.1 About This Manual

1.1.1 Purpose

This manual is designed to assist in the operation and maintenance of your machine. Inside, you
will find the following information: guidance on machine operation, disassembly procedures, and
maintenance procedures.
NOTE: This is not a parts book and cannot be used to order parts. A separate, detailed parts
book for this machine has been supplied with the machine.
1.1.2 Organization
• A main table of contents (TOC) is your guide to topics and subtopics. It is located at the front
of the manual. Main topics are listed as numbered Sections, with subtopics listed beneath
(and indented). Subtopics include the main topic's section number.
• Additionally, each section contains its own TOC.
• In the electronic version, all TOC items are hyperlinked to their respective topics.
1.1.3 Terminology
• The terms left, right, front, and rear refer to machine locations as viewed by the operator
sitting in the operator's seat in the cab.
• On the cover and at the bottom of each page there is an alphanumeric code to identify the
manual, formatted as follows:
XXnnnnnn-YY
• XX represents the manual type. Below is a list of all manual types.
• nnnnnn represents the serial number for machine-specific manuals, or a generic manual
number intended for several machines.
• YY represents the language code. Below is a list of common language codes.
Code Type Code Language
SM Service EN English
OM Operation ES Spanish
EM Electrical FR French
PM Parts book PT Portuguese
TM Troubleshooting
ZM Electrical training
AM Addendum
VM Vendor
MM Miscellaneous
For example, manual code EM141455-ES is an electrical manual written in Spanish for
machine #141455.

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Introduction
About This Manual BI010307
1.1.4 Revisions
This manual may be revised without notice. The most recent electronic version is available
online.
1.1.5 Precautions and Disclaimers

• Carefully study and follow all procedures in this manual. Safety guidelines are intended to
prevent accidents and are provided in the interest of all mine personnel. Overall safety
depends on the use of good judgment and the alertness of the entire mining crew.
• It is the owner/mine's responsibility to perform the necessary risk assessment to outline
proper safety precautions. A minimum of unplanned machine downtime and more reliable
machine operation should result when a systematic and thorough maintenance/service
procedure is adhered to for this machine.
• It is the policy of the manufacturer to improve its products whenever possible and practical to
do so. The company reserves the right to make changes or add improvements to its
machines at any time. This will be without incurred obligations to install such changes on
machines sold previously. Due to this ongoing program of product research and development
some procedures, specifications and parts may be altered in a constant effort to improve our
machines.
1.1.6 Contact
For more information or factory service assistance, contact your regional service representative
or:
Caterpillar Global Mining LLC

6744 S. Howell Ave.
Oak Creek, WI, USA 53154
Telephone (+1) 414.768.4000

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Introduction
BI010307 Swinging Restraint & Ballast Box Support
1.2 Swinging Restraint & Ballast Box Support

1.2.1 Ballast Box Support

Before performing any maintenance on the mining shovel, it should be resting on a firm,
level surface.
Any mining shovel field work that requires the removal or lowering of the boom must incorporate
additional support of the ballast box. The supports may be wooden cribbing or steel structures.
Two supports positioned side-by-side on level ground are recommended. These supports are
intended to accept vertical loads only. To prevent machine rotation use the swing brakes, cable
stays, welded ties, etc. Refer to SWING RESTRAINT in this section of the manual.
When electric-powered, cable-style mining shovels are properly ballasted and operational, the
center of gravity for the machine's upper works lies within the roller circle area. This assumes that
the boom is attached to the machine and in its elevated, working position. As such, the machine
should not be prone to tipping.
Boom removal or lowering will cause the center of gravity to shift toward the ballast box,
decreasing machine stability. Stability is further dependent on the orientation of the upper works
relative to the undercarriage. The machine may tip more easily over one of the four quadrants of
the crawler mounting than it may over others.
Normally the machine is more likely to tip over the rear-most lower-roller than over the side of a
crawler. Therefore, with the boom removed and the ballast box sitting over the rear of the
crawlers, the machine may be unstable. Because ballast quantities differ from machine to
machine and model to model, it is recommended that the ballast box be supported before
beginning any procedure to lower and/or remove the boom.

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Introduction
Swinging Restraint & Ballast Box Support BI010307
1.2.2 Swinging Restraint
Before performing any maintenance on the mining shovel, it should be resting on a firm,
level surface. A small ground slope is enough to cause the machine to freely rotate if the
brakes are not set or other restraints are not used. Once moving, it will keep going.
The following shows the relation between an out-of-level or slope and the resulting difference in
elevation over a 14 ft. swing rack:
Slope % Difference in Elevation

0.25° 0.4% 0.75”
1.0° 1.7% 2.9”
5.0° 8.7% 14.7”
Where possible, all work on the swing brakes, motors, gearcases, or rack pinions should occur
with the dipper attached to the machine and the full weight of the dipper on the ground. If the
dipper is not resting firmly on the ground, then an external means of preventing machine upper
works rotation is required. Tie the upper works to the lower works using the preferred method
mentioned below.
Mining shovels rotate using multiple swing units. Power is transferred from electric motors
through individual gearcases, to pinions and into a fixed swing rack. Electric motor control
prevents inadvertent machine rotation during operation. Should machine electric power be lost,
spring-set brakes on the swing drive motors lock the geartrain to prevent machine rotation.
When working on the brakes, motors, or geartrains, it is an accepted practice to set the dipper on
the ground. The weight of the dipper and handle will prevent machine rotation. EVEN IF ALL
BRAKES, MOTORS, OR SWING GEARCASES ARE REMOVED the machine should not rotate.
In certain circumstances it may not be possible to rest the full weight of the dipper firmly on the
ground. For instance, the dipper, handle or the boom may not be attached to the machine.
To prevent machine rotation, with any of the major structures removed, two swing motor brakes
should be set. A single brake in good operational condition is acceptable. However, a minimum
of two brakes is recommended due to the possibility that the proper operation of a single brake
may be unknown.
ON MACHINES USING PLANETARY DUAL-OUTPUT SWING DRIVES, BOTH SWING

PINIONS PER DRIVE MUST BE ENGAGED WITH THE SWING RACK IN ORDER FOR THE
SWING BRAKE TO BE EFFECTIVE. The internal differential drive in the gearcase allows
one pinion to rotate, even if the brake is set, when the other pinion has been removed.
An external means of preventing machine rotation must be used - if the dipper is not resting
firmly on the ground and if any of the following are true:
• Two brakes are not effectively set and coupled to the motors, or

June 2012
Introduction
BI010307 Swinging Restraint & Ballast Box Support
• The motors and geartrain are not fully coupled to the swing pinions, or
• The swing pinions are not engaged to the swing rack
The preferred method to prevent machine rotation is to use a pair of one inch diameter steel
cables to tie the upper works to the lower works. Other alternatives such as welded plates etc.
can also be used.

For typical part numbers and locating dimensions, refer to manufacturers drawing S022338.

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Introduction
Machine Overview BI010307
1.3 Machine Overview

This mining shovel is designed and constructed to provide efficient service under the most
severe conditions. The machine is built to the highest possible standards and will provide trouble
free operation if properly maintained. This section of the manual introduces the machine and its
functional capabilities and limitations.
Figure 1-1 Nomenclature
1 – 10 Electric Rope Shovel SM141450-EN

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Introduction
BI010307 Lower Works
1.4 Lower Works

The lower works is comprised of the truck frame, right and left crawler frames, crawler belts,
propel machinery, swing rack and roller circle.

Figure 1-2 Truck Frame and Crawlers
SM141450-EN Electric Rope Shovel 1 – 11

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Introduction
Lower Works BI010307
1.4.1 Crawlers
This machine is provided with a crawler system composed of 2 independently-driven crawler
frame assemblies, one on each side of the truck frame. Each crawler has its own belt driven by a
sprocket-type drive tumbler. Individual crawler links are heavy alloy steel castings connected by
heat treated pins.
Innovative drive tumblers made from large diameter steel castings have lugs extending beyond
the tumbler rims. They are mounted on forged alloy steel shafts which turn on large anti-friction
bearings mounted within the crawler frame. The sprocket type lugs provide a large area of
contact against the crawler links, extending the life of both links and tumblers.
Lower rollers rotate on forged steel shafts mounted within the crawler side frames. Eight smaller
rollers and 1 large roller per frame are specially suited to withstand the periodic single point
ground reaction caused by uneven pit floors. Slide bars on top of each frame support the upper
crawler belt, reducing propel friction and drag. These side frames are stress relieved weldments
comprised of steel castings and cold weather steel plates.
The crawler assemblies are bolted to the truck frame with large diameter rods and torque nuts.
Each crawler belt can be independently adjusted for tension.
Figure 1-3 Right Crawler Assembly (Left Opposite)

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Introduction
1.4.2 Truck Frame
The truck frame is a stress relieved welded cellular box structure which utilizes impact resistant
steel in the major load carrying members. The low temperature toughness of the steel assures
adequate strength and durability across a wide range of temperatures frequently encountered in
machine applications. A fabricated support structure welded integrally into the truck frame

supports the center pintle hub area.
The inner diameter of the hub is machined to accept the center pintle bushing. Truck frame
surfaces which mate to crawler side frames and swing rack are shop machined to assure proper
alignment and solid foundation.
Figure 1-4 Truck Frame

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Introduction
1.4.3 Swing Rack

The swing rack is a large diameter external tooth gear mounted on the top of the truck frame
concentric with the center pintle bore. The rack is a 4-piece gear bolted to the truck frame.
Figure 1-5 Swing Rack and Roller Circle

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Introduction
1.4.4 Roller Circle
The roller circle is composed of the upper rails, lower rails, thrust rails, 50 tapered rollers and
inner/outer roller cages. The lower rail segments are secured to the top surface of the swing rack
forming a continuous rolling path for the rollers. The upper rails are attached to the bottom of the
revolving frame, fore and aft of the center pintle. Upper rail ends are tapered to provide a smooth

approach for the rollers. Rollers are tapered to ensure non-skid contact with rails. The rollers are
spaced and aligned with pins and low maintenance polyurethane bushings.
Figure 1-6 Roller Circle Assembly

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Introduction
1.4.5 Propel Machinery

The propel machinery is driven by two AC motors, each horizontally mounted to the crawler
frames. Each motor is coupled to a right-angled planetary gearcase high up off the pit floor for
protection from water and rock damage. One spring-set, air-released, disc brake is mounted to
each of the two motors. The dual planetary configuration with separate drive motors permits
straight ahead or reverse propel as well as counter rotation steering.
1.4.6 Collector Rings

There are three sets of collector rings on the machine - low voltage, propel and high voltage. The
low voltage collector rings transfer power from the revolving frame back to the propel motors.
The propel collector rings provide control to the propel motors and power for the propel blower
motor.

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Introduction

Figure 1-7 Collector Rings
High voltage collector rings, on the bottom of the revolving frame, transfer electric power from the
truck frame to the revolving deck. Electric power enters the truck frame just below the propel
motors and is transferred by means of collector ring shoes to the collector rings. The shoes are
mounted between the cast center pintle hub and the swing rack.
Figure 1-8 Collector Rings, High Voltage

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Introduction
Rotating Deck BI010307
1.5 Rotating Deck

The rotating deck consists of a revolving frame, center pintle, right and left deck extensions,
operator’s cab and the machinery house. Also included are the electrical system components,
operating controls, air system, A-frame, along with the hoist, swing and crowd machinery units.
1.5.1 Revolving Frame

The revolving frame is the main structural member of the rotating deck. It is a welded, stress
relieved structure with integral lugs for mounting the A-frame, crowd machinery and boom.
Provisions are made for mounting deck extensions, operator’s cab, ballast box and swing
gearcases. Machined pads on the deck locate the hoist drive motor and machinery frames.
Refer to a view of the revolving frame assembly with deck extensions and ballast box in this
section.
The revolving frame is connected to the truck frame by the center pintle.
1.5.2 Center Pintle
HIGH VOLTAGE! EXTREME CARE MUST BE EXERCISED AT ALL TIMES WHEN

PERFORMING MAINTENANCE IN THE CENTER PINTLE AREA. High voltage can cause
serious or fatal injury. Installation, operation and servicing of components should be
performed only by qualified personnel. ALWAYS DISCONNECT the electrical power
BEFORE accessing the center pintle area.
The center pintle is a large diameter, hollow cylindrical forging with a flange at the top. It is
threaded at the bottom with a lower nut used to hold it in place. A bronze coated steel core
spherical thrust washer between the lower adjusting nut and the bottom surface of the truck
frame provides a wear surface for pintle loads. The upper clamping collar at the top of the center
pintle is doweled and bolted to the revolving frame to keep the center pintle from rotating.
The hollow pintle provides passage for air and grease lines and electrical cables from the
revolving frame to the lower works using a swivel and collector ring assembly.

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Introduction
BI010307 Rotating Deck

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Introduction
1.5.3 Deck Extensions

Right and left side deck extensions are bolted to each side of the revolving frame. They provide a
mounting area for the electrical transformers and accessory machinery as well as supporting the
machinery house walls.
Figure 1-9 Deck Extensions and Ballast Box
1.5.4 Ballast Box

The ballast box is an all-welded steel fabrication located at the rear of the main revolving frame.
A series of vertical plates in the box form compartments for holding ballast.

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Introduction
1.5.5 Machinery House
The machinery house encloses the revolving frame, ballast box and deck extensions. It is
constructed of self-supporting steel panels with built-in framing. Removable roof sections are
provided over the swing machinery and to the side and rear of the A-frame. The house also
provides mounting for the air ventilation and pressurization system. A separate electrical room is

located over the ballast box. Platforms and stairs facilitate access to the sides and tops of the
house for inspection and maintenance purposes. Boarding stairs permit easy access onto the
machine.
1.5.5.1 Boarding Stairs

machine, the right side or both. When lowered, the stairs allow entrance to the machinery house
from ground level. To activate the stairs, a pull cord attached to a lever arm is reachable from the
ground. An additional lever is available at the top of the stairs. These stairs must be in their
raised and latched position to enable the operator’s controls.
STORED ENERGY! System may be under hydraulic pressure which can cause severe
personal injury or death. Shut down pump and relieve system of all pressure before
removing components.

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Introduction
Figure 1-10 Right Side Boarding Stairs

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Introduction
1.5.5.2 Vertical Boarding Ladder
The vertical boarding ladder is one of the means for boarding the machine, located on the left
side of the machine, at the rear of the machinery house. Use the pull cord from ground level to
lower the ladder. This ladder must be in the raised and latched position to enable the operator’s
controls.

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Introduction
1.5.5.3 Power Step

The power step is one of the options for boarding the machine. It is located on the left or right
side of the machinery house, near the center of the lower platform. A lock / release handle is
pulled from ground level to lower the power step for boarding. The operator’s controls are
deactivated if the power step is NOT latched in place.

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Introduction
1.5.6 A-Frame
An A-frame with seamless tubular alloy steel front legs provides ample space for the retracted
dipper handle end. The rear legs are cold weather steel fabricated beams. Both front and rear
legs are pin connected to lugs integral with the revolving frame. The A-frame supports the boom
via structural strands.
Figure 1-11 A-Frame and Front End Support Components

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Introduction
1.5.7 Hoist Machinery

The hoist machinery consists of a motor coupled to two gear reductions which drive the hoist
drum. A spring-set, air-released disc brake is mounted to the motor. A hoist rotary encoder limits
hoist travel. The hoist motor is connected to the motor pinion shaft by a multiple coupling shaft
assembly.
The first reduction gear set is mounted in an oil lubricated, totally enclosed gearcase. The
second reduction gears are drip lubricated with open gear lubricant from the automatic
lubrication system. All shafts run on anti-friction bearings. The hoist bull gear is bolted to a spider
on the left hand side of the drum.
The hoist drum is manufactured with machined, flame hardened rope grooves. Drum spider stub
shafts turn on anti-friction bearings supported by side frames which are bolted to the rotating
deck.
Figure 1-12 Hoist Machinery - Plan View

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Introduction
1.5.8 Swing Machinery
Two planetary swing gearboxes, each driven by a vertically mounted motor, are mounted on
either side of the revolving frame. Dual output shafts from each gearbox are splined to pinions
which engage the swing rack. Bolt-on mounting permits easy field exchange or replacement of
either the planetary gearboxes or the splined pinions. The four pinions result in lower shared

tooth loads for longer pinion and rack life. A spring-set, air-released, disc brake is mounted on
each of the two swing motors.
Figure 1-13 Swing Machinery Components

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Introduction
1.5.9 Crowd Machinery

The crowd machinery is located at the front, center of the revolving frame. It consists of a motor,
spring-set, air-released disc brake, drum and gearing. A crowd rotary encoder prevents
overtravel of the dipper handle. With the crowd machinery on the revolving frame instead of the
boom, front end weight is substantially reduced - resulting in lower swing inertia and reduced
required swing effort. The entire machinery unit can be removed from the machine should
maintenance or overhaul become necessary.
The crowd drum drives the crowd and retract rope system. Rope grooves are machined into the
drum and flame hardened. The crowd and retract ropes are attached to the drum by ferrule-
becket anchors which greatly simplifies rope changes.
A spring set, air released disc type brake is mounted on the electric drive motor.
Figure 1-14 Crowd Machinery Components

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1.5.10 Operator's Cab
The isolated and elevated operator’s cab at the right, front of the machinery house provides a
comfortable, safe and efficient working environment for the operator. Sufficient space is provided
for the fully adjustable operator’s seat, an auxiliary seat and the standard operator’s display

panel.
The cab is sound and heat insulated with interior walls made of a sound deadening steel-plastic-
steel composite. An electric powered windshield wiper is provided for quiet, dependable
operation. A one-piece front window is supplied in a rugged, easy-to-change frame. A forward
front window slant with over hanging roof helps keep the window clean. Motorized sun shades
are provided in the front and side windows.
Visibility through both side and front windows is excellent. The operator has the best view in the
industry of the digging face and for truck spotting. This view is enhanced by the streamlined sides
and top surfaces of the boom, unencumbered by crowd machinery or dipper handles on the
outside of the boom.
The air conditioner utilizes environmentally friendly R-134a refrigerant in the cooling system.
Interior ducting distributes the airflow to best suit the comfort of the operator.

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Introduction
1.5.11 Compressed Air System

The compressed air system consists of dual rotary screw type air compressors, air receiver, air
brakes, controls and center pintle air swivel. Hydraulic high pressure hose is used throughout.
The air system is used to operate all machinery motion brakes and lubrication components and
to perform various other functions.

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Introduction
1.5.12 Automatic Lubrication System
The lube system is located in an insulated, double wall, lube room which can be heated for cold
weather operation. A one ton (907 kg) monorail-mounted electric chain hoist is provided to be
used to raise supplies from the ground onto the left house platform and into the lube room. Lube
points on the electric motors, suspension rope pins and some dipper pins are manually

accessed. All other lube points are fed from the automatic system or by oil bath.
A single-line automatic lubrication system applies open gear lubricant (OGL) and grease via a
programmable logic controller (PLC). The system has six lube pumps (four for OGL and two for
grease), each feeding individual PLC controlled circuits. Lincoln Powermaster Three, 75:1 air
powered pumps are mounted on two reservoirs. High pressure hoses with reusable fittings are
utilized.
The six separately controlled lube circuits provide selective distribution frequency and quantity
resulting in reduced lubricant usage and cost.
Figure 1-15 Lubrication Room

June 2012
Introduction
1.5.13 Lube Reservoir Fill / Overflow Plumbing

The lube reservoir fill/overflow plumbing is located in the support structure directly below the lube
room at the front, left side of the machine. Lubricants can be added at this location. The overflow
connections are also located here. DO NOT plug the overflow connections.
Figure 1-16 Lube Reservoir Fill / Overflow Plumbing

June 2012
Introduction
BI010307 Front End Equipment
1.6 Front End Equipment

The front end equipment consists of the boom, the boom point sheaves, padlock, saddle block,
dipper handle, dipper, dipper trip mechanisms, running ropes and boom suspension strands.
Figure 1-17 Front End Equipment

June 2012
Introduction
Front End Equipment BI010307
1.6.1 Suspension Strands

The suspension strands are designed to maintain the proper boom angle. These are fixed-length
strands that support the entire weight of the boom and the load.
1.6.2 Boom
The boom is a welded steel structure consisting of twin box girders integrally connected at the
boom point and in the lower section between the shipper shaft and boom feet. Impact resistant
steel is utilized, coupled with 100% penetration and UT quality welds on all main splice joints.
Design optimization has resulted in heavier outside skin plates, minimizing the need for internal
diaphragms. This reduction in weld related stress concentrations further enhances structural life.
Open manholes have been incorporated in the boom as a standard feature permitting periodic
structural inspection. Integral “ladders” within the upper boom sections permit internal access
without lowering the boom.
The boom is supported by four pre-stressed suspension (structural) strands attached to equalizer
links on the A-frame. These inherent long life structural strands carry the working loads of the
front end equipment. A boom limit switch with soft setdown prevents boom jacking shock loads.

June 2012
Introduction

Figure 1-18 Boom Assembly

June 2012
Introduction
1.6.3 Running Ropes

Hoist, crowd, retract and dipper trip ropes are all plastic impregnated for increased life and for
sheave and drum grooving life enhancement. The double twin hoist ropes are attached to the
center of the hoist drum using ferrule-becket anchoring for faster rope change out. Each rope
passes over a boom point sheave through the padlock and back over the boom point sheave to
the hoist drum. The dual twin hoist rope configuration stabilizes the dipper while digging by
attachment to the outer edges of the dipper body.
Crowd and retract ropes are attached to the crowd drum and work as an integral system. As the
crowd rope is wound on to the drum, the retract rope is reeled off.
Figure 1-19 Ropes - General Arrangement

June 2012
Introduction
1.6.4 Saddle Block
The saddle block is positioned between the boom side girders in the mid-section of the boom. It
pivots on manganese-bronze bushings about the shipper shaft. It acts as a guide for the
longitudinal movement of the dipper handle. The free-floating design of the handle in the saddle
block eliminates handle torsion.

Figure 1-20 Saddle Block Bushing Arrangement

June 2012
Introduction
1.6.5 Dipper Handle

The dipper handle assembly is a weldment consisting of a large diameter tube and a handle end
where the machine’s dipper is attached.
At the rear of the assembly is a crowd take-up mechanism that removes slack from the crowd
and retract ropes. The dipper tube moves in and out within the saddle block during operation.

June 2012
Introduction
1.6.6 Dipper
A general purpose dipper is usually constructed as a casting and plate weldment. The dipper lip
and lower front are alloy heat treated castings. The dipper body, back, upper sides and door are
made of steel plate. Removable tooth adapters and replaceable tooth points are attached to the
lip casting to penetrate the bank material.

The door is hinged and latched to the dipper body. A dipper trip mechanism controls the release
of the latch bar, allowing the door to swing open. The latch bar holds the door shut during
digging. Spring loaded snubbers dampen the door’s swinging action.
Figure 1-21 Dipper Assembly

June 2012
Introduction
1.6.7 Padlocks
Padlocks connect the hoist ropes to the outer edges of the dipper while still permitting fore and
aft and sideways movement.
Figure 1-22 Left and Right Padlocks

June 2012
Introduction
1.6.8 Dipper Trip
The dipper trip is a wire rope activated dipper door trip mechanism driven by 2 electric motors
through gear reduction mounted on the deck near the boom foot.
Figure 1-23 Dipper Trip Motor and Dipper Trip Sheave

June 2012
Introduction
Typical Machine Specifications BI010307
1.7 Typical Machine Specifications

This specification describes the principal mechanical features of a standard 7495 IGBT Acutrol
controlled machine. The machine is fully revolving, crawler mounted and equipped to operate
from an alternating current power source.
NOTE: These are typical machine specifications.

Table 1-1 - Weights
(pounds) (kilograms)
Working Weight (w/dipper) 3,047,670 1,382,400
3
General Purpose Dipper (73 yd , 56 m ) 3 177,700 80,603
Ballast 667,150 302,614
Net weight, minus ballast and dipper 2,202,820 999,182
Table 1-2 - Front End Equipment
Boom Welded, impact resistant steel

Boom Point Sheaves Twin grooved, flame hardened
Boom Point Sheave Diameter 96” 243.84cm
Shipper shaft sheaves Twin grooved, flame hardened
Shipper shaft sheave diameter 72” 182.88cm
Dipper Handle Diameter 34” 86.36cm
Dipper Handle Wall Thickness 3” (nominal) 7.62 cm
Table 1-3 - Rope Data
# Ropes Diameter Type Construction

Hoist 2 2 3/4” 69.88mm Twin Dual 6X37
Crowd 1 2 1/2” 63.5mm Single dual 6x37
Retract 1 2 1/2” 63.5mm Single dual 6x37
Dipper Trip 1 3/4” 19.1mm Single 6X37
Boom Suspension 4 3 1/4” 82.6mm Equalized Structural Strand

June 2012
Introduction
BI010307 Typical Machine Specifications
Table 1-4 - Typical Dimensions and Working Ranges
US Metric
Dipper capacity (tons nominal) 110 100 tonnes
Dipper capacities (range) 40-80 yd 3
30.6-61.2 m3
Length of boom 67' 20.4 m

Boom angle 43° 43°
Effective length of dipper handle 35’-10” 10.9 m
Overall length of dipper handle 47’ 14.3 m
A: Dumping height 33’ 10.0 m
A1: Dumping height at maximum radius 28’-3” 8.6 m
B: Dumping radius - maximum 71’ 21.6 m
C: Cutting height - maximum 58’-5” 17.8 m
D: Cutting radius - maximum 82’-8” 25.2 m
E: Radius of level floor 57’-4” 17.5 m
G: Clearance height @ boom point sheaves 68’-6” 20.9 m
H: Clearance radius @ boom point sheaves 64’-5” 19.7 m
I: Clearance radius @ revolving frame 28’-10” - 30’-8” 8.8 m - 9.3 m
J: Clearance - revolving frame to ground 12’-4” 3.8 m
K: Height of A-frame 46’ 14.0 m
N: Operator’s cab eye level 34’-10” 10.6 m

June 2012
Introduction
General Estimated Component Weights BI010307
1.8 General Estimated Component Weights
These are estimated weights only. Contact your service representative for the exact
weight of components on your specific machine before rigging and lifting.
1.8.1 Lower Works

Quantity Weight Each
(U.S. Pounds)
Truck Frame 1 191,410
Pintle Bushing 1 280
Lower Rail 9 570
Thrust Rail 9 170
Propel Brake Adapter 2 370
Propel Brake 2 650
Propel Brake Hub 2 60
Propel Motor 2 4,500
Propel Motor Blower 2 210
Propel Brake Guard 2 60
Coupling 2 90
Crawler Belt (2 per Machine) 2 245,500
Link, Crawler, 78.75 In. (47 per Belt) 47 2,480
Crawler Assembly~Shipping 2 128,500
Crawler Structure 2 83,880
Propel Gearcase 2 19,230
Front Idler 2 5,800
Shaft, Front Idler 2 1,150
Adjusting Block 4 370
Load Roller 8 2,020
Shaft, Load Roller 8 550
Rear Idler 2 3,800
Shaft, Rear Idler 1 700
Tumbler, Drive 1 7,120
Shaft, Drive Assy 1 4,330
Shaft, Drive 1 3,370
Sleeve, Center Pintle 1 9,100
Collar, Center Pintle, Upper 1 380
Washer, Thrust, Center Pintle 1 400
Nut, Lock, Assy. Center Pintle 1 1,470

June 2012
Introduction
BI010307 General Estimated Component Weights
1.8.2 Upper Works
(U.S. Pounds)
A-Frame Front Leg 1 23,000

A-Frame Rear Leg 2 6,650
Motor, Gear 2 610
Auxiliary Winch Assembly 1 3,820
Boom Foot Pin 2 600
Upper Rail 2 500
Swing Planetary Gearcase 1 10,600
Swing Pinion Shaft Assembly 2 1,980
Swing Pinion Shaft 4 1,460
Swing Bearing Carrier 4 230
Swing Shaft Bearing 4 100
Swing Brake Adapter 2 270
Swing Brake 2 490
Swing Motor (w/o tach) 1 3,600
Swing Motor (w/tach) 1 3,600
Crowd Drive Pinion, Bearings & Hardware 1 170
Crowd 2nd Intermediate Shaft 1 2,000
Crowd 2nd Intermediate Gear 1 4,690
Crowd Motor Shaft Coupling 1 150
Crowd Frame 1 11,500
Crowd Pinion Guard 1 280
Crowd Gearcase Cover 1 2,700
Crowd Upper Gear Guard 1 170
Crowd Gear Guard - Lower 1 340
Crowd Drum 1 12,800
Crowd Drum Spur Gear 1 5,140
Crowd 1st Intermediate Pinion Shaft 1 130
Crowd 1st Intermediate Gear 1 1,080
Crowd Brake 1 500
Crowd Brake Adapter 1 270
Crowd Motor 1 4,000
Reservoir, 300 Gal. Lube 1 930
Air Swivel 1 150
Collector Ring Assembly 1 230
Housing, Front 1 140
Housing, Rear 1 140
Hoist Planetary Gearcase 1 35,500

June 2012
Introduction
UPPER WORKS (Continued)

(U.S. Pounds)
Hoist Pinion (Shaft Pinion) 2 1,640
Hoist Pinion Bearing Carrier 2 460
Hoist Machinery Guard - Bottom 1 2,000

Hoist Machinery Guard - Rear 1 940
Hoist Machinery Guard - Front 1 1,300
Hoist Machinery Guard w/Cover 1 200
Hoist Bearing Housing 2 3,200
Hoist Drum 1 27,000
Hoist Spider 1 16,000
Hoist Drum Gear 1 10,750
Hoist Pedestal - R.H. 1 8,320
Hoist Pedestal - L.H. 1 8,700
Hoist Oil Cooler 1 2,650
Hoist Motor 1 15,000
Hoist Brake 1 1,350
Hoist Brake Adapter 1 500
Hoist Brake Hub 1 210
Coupling, Flexible,Gear 1 1,270
Blower 1 700
Adapter Plate, Hoist Blower 1 260
Guard, Hoist Coupling Assembly 1 300
R.H. Boarding Stairs 1 5,500
Ladder, L.H. Vertical Boarding 1 3,410
Machinery House Filter Assembly 2 1,330
Control Room Filter Assembly 1 1,700
Revolving Frame Ship Assy 1 167,410

June 2012
Introduction
BI010307 General Estimated Component Weights
1.8.3 Front End
(U.S. Pounds)
Boom (Bare) 1 148,480

Boom Bumper Assembly 1 6,630
Boom Point Sheave Assembly 1 16,500
Boom Point Shaft 2 1,040
Boom Point Sheave 2 4,900
Saddle Block & Liner Assemby 1 26,790
Bushing, Liner, Saddle Block 2 1,290
Bushing, Saddle Block/Shipper Shaft 2 100
Collar, Shipper Shaft 2 110
Shipper Shaft 1 4,880
Shipper Shaft Assembly 1 5,110
Crowd / Retract Rope 2 2,100
Hoist Rope 1 pair 10,750
Suspension Rope (Pendant) 4 2,750
Pendant Equalizer - R.H. 1 2,400
Pendant Equalizer - L.H. 1 2,400
Handle Weldment 1 49,440
Crowd Take-Up Shop Assy 1 11,210
Crowd Take-Up Guide 1 2,160
Crowd Take-Up Worm Gear 1 610
Crowd Take-Up Gear Housing 1 490
Crowd Take-Up Screw Rod 1 4,520
Crowd Half-Sheave 1 1,920
Retract Spreader & Stop 1 1,990
Crowd Sheave 2 2,600
Padlock - R.H. 1 5,230
Padlock - L.H. 1 5,230
Padlock Pin & Collar Assy (Kit) 2 530
Padlock Sheave Pin 2 370
Padlock Sheave 1 730

June 2012
Introduction
FRONT END (Continued)

(U.S. Pounds)
Dipper, 62YD, Field Assy 1 160,700
Body, 62YD w/Liners 1 106,870
Dipper Door and Liners 1 22,800

Dipper Door 1 20,480
Snubbers (RH) 1 1,750
Snubbers (LH) 1 1,750
Pitch Brace w/Bushings 1 3,170
Tooth, Dipper 9 300
Adapter, Tooth 9 690
Shroud, Upper Wing, RH 1 310
Shroud, Upper Wing, LH 1 310
Shroud, Center 360
Shroud, Lower Wing, RH 310
Shroud, Lower Wing, LH 310

June 2012
®
Amendments and alterations to this publication are not subject to notification. Caterpillar Global Mining
LLC reserves all rights to this publication. Its content is protected by copyright laws.
No part of this publication may be reproduced or transferred in any way or form without the prior written
approval of Caterpillar Global Mining LLC.
Caterpillar Global Mining LLC declines any liability for direct or indirect consequences of printing errors.
BI010308

2 Lubrication
Lubrication
2.1 Lubrication Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2 Greasing Main A.C. Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.1 Type of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.2 Initial Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.4 Regreasing Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 Lubricant Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Oil Fill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4.1 Types Of Lubricants And Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4.1.1 Quantities for First Fill of Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Gearcase Lubricant Replacement/Sampling . . . . . . . . . . . . . . . . . . . . . 2-8
2.5.1 Lubricant Change Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.6 Automatic Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.1 Lube Room. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-1 Lubrication Room Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.6.2 Lube Reservoir Fill / Overflow Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Figure 2-2 Lube Reservoir Fill / Overflow Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.6.3 Auto Lube Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

June 2012
Lubrication
BI010308
2.6.4 Lower Works Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.6.5 Revolving Frame Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.6.6 Hoist Rope Rollers Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Figure 2-3 Hoist Rope Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.6.7 Front End Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.6.8 Lubricant Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6.8.1 Lincoln Type SL-1 Lubricant Injectors . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.6.8.1.1 SL-1 Lubricant Injector Operation . . . . . . . . . . . . . . . . . . . . . . . .2-19
2.6.8.2 Lincoln Type SL-V Lubricant Injectors . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Figure 2-4 Lubricant Injectors (SL-V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Figure 2-5 Adjusting Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.6.8.2.1 SL-V Lubricant Injector Operation . . . . . . . . . . . . . . . . . . . . . . . .2-24
2.6.8.3 Injector Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.7 Propel Machinery Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.8 Hoist Machinery Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2.8.1 Hoist OGL Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.8.2 Hoist Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Figure 2-6 Hoist Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Figure 2-7 Hoist Oil Cooler Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2.8.3 Filter Element Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Figure 2-8 Filter Element Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
2.9 Swing Machinery Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Figure 2-9 Swing Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.10 Crowd Rope Take-up Mechanism Lubrication . . . . . . . . . . . . . . . . . 2-37

2.11 Crowd Machinery Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2.12 Air Compressor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
2.12.1 ACSL - Air Compressor (Screw-Type) Lubricant . . . . . . . . . . . . . . . . . . . 2-40

June 2012
Lubrication
BI010308 Lubrication Principles
Lubrication
2.1 Lubrication Principles

The proper lubrication of this machine is vital to its successful, continued operation. Application
of the CORRECT lubricant in the CORRECT amount at the CORRECT place as part of a

PROVEN maintenance program is required to keep the machine operating at a level of
productivity. Proper lubrication will provide better component service life with a reduction of
repairs and downtime. When not properly lubricated, moving parts wear quicker and fail sooner.
The primary wear items of this machine are lubricated by an automatic system that dispenses
lube to selected points at pre-selected, timed intervals during machine operation. This system is
covered in more detail further on in this section. It is important to the operation of this automatic
lube system that you become familiar with it and understand its operation in order to properly
maintain and service it, thus keeping it operable. It is also necessary that you inspect on a
regular basis the points for automatic lubricant application to ensure the system is performing its
job adequately.
Some components, due to their location and function, can not be readily covered by the
automatic lube system. You should become familiar with these points so you can service them
properly at the intervals listed. A listing of the parts covered by the automatic lubrication system
is included later in this section. The standard lubrication fittings used for manual service are the
hydraulic type, push-on fittings having 1/8 inch or 1/4 inch NPT threads.
Bushings and bearings operating in a highly contaminated atmosphere (dust, grit, etc.) should be
lubricated until clean grease seeps out around the journal or seal, or comes out the purge fitting,
if one is provided.
Overfilling an anti-friction bearing can cause it to run excessively warm. After lubricating anti-
friction bearings (those that are sealed such as in electric motors must use electric motor grease)
remove the pressure fitting, or the relief plug when provided, allowing the bearing to purge itself
of any excess lube during the first 10-15 minutes of operation. Replace the fitting or plug after
that time. Grease in a bearing generally deteriorates gradually, not suddenly. Only a small
amount needs to be added to it at regular intervals to maintain the proper lubricant level. Adding
a small quantity of grease to the bearing every 600 operating hours, unless otherwise specified,
is adequate.
Open gears and pinions require a constant coating of high grade lubricant which is specified for
operation. Inspect all open gear sets at least once daily (every 24 hours) to ensure they are
coated with OGL.
Contact with or ingestion of petroleum products can be harmful. Automatic lubrication

systems operate under pressure. Before opening any lube supply line, relieve the system
and that line in particular, of any residual pressure.

June 2012
Lubrication
Greasing Main A.C. Drive Motors BI010308
2.2 Greasing Main A.C. Drive Motors

Main drive motors are shipped from the factory with the bearings packed with grease. A
lubrication information plate is mounted on each motor with greasing instructions and the correct
quantity or grease to be added. Main drive motors have their inlet tube filled with grease and
include nameplates attached to the motor indicating “grease inlet” and “grease drain”.
An improper greasing procedure will cause premature bearing failure. Mixing of non-compatible
lubricants will result in lubricant breakdown and bearing failure. Proper lubrication is important for
all aspects of bearing life.
NOTE: This information covers main drive motors manufactured by Siemens, Norwood, Ohio. It
does not apply to NMA style motors manufactured by Siemens Germany.
2.2.1 Type of Grease

NOTE: Motors are shipped with Mobil SHC 100 NLGI #2 grease installed in the bearings. This
grease has a lithium complex soap thickener and a synthetic base fluid having a base
oil viscosity of 40 cSt @ 40°C.
Do not mix greases with different thickeners since the greases may not mix properly and
bearing failure may result.
2.2.2 Initial Commissioning

Prior to initial start-up, the bearings should be greased. The normal maintenance regreasing
procedure, item 3, should be used except the quantities should be doubled.
2.2.3 Maintenance
This procedure should be used for regular maintenance regreasing. Refer to the following table,
item 4, and/or lubrication information plate on each motor for regreasing intervals and type and
quantity of grease to be used.
a. Stop the motor and lockout the starter.
b. Remove and thoroughly clean the grease inlet fitting or plug.
c. Remove the drain plug and clean out any hardened grease.
d. Determine the correct amount of grease required for the bearings.
NOTE: The drive end bearing and the non-drive end bearings require different quantities of
grease.
e. Slowly pump the correct amount of grease into the grease inlet.
f. Reinstall the inlet plug that was removed.
g. Clear the lockout switch and start the motor.

June 2012
Lubrication
BI010308 Greasing Main A.C. Drive Motors
h. Allow the motor to run at least for one (1) hour to vent the bearing housing and to allow
the expulsion of any excess grease from the drain opening before reinstalling the drain
plug. (If it is not practical to run the motor for one hour and then stop the motor, it is
acceptable to reinstall the drain plug without damage to the bearings or seals.)
i. Stop the motor and lock out the starter. Reinstall the drain plug.
j. The motor is now ready to be put back in service.

2.2.4 Regreasing Intervals
The regreasing interval can be found in the following table. Follow either the recommended
operating hours, or the time interval, which ever comes first.
Motor Regreasing Interval Drive End Grease Non-Drive End Grease

Amount Grams (oz.) Amount Grams (oz.)
Hoist motor 2500 operating hours or every 6 months 88 (3.1) 140 (5.0)
Propel motor 2500 operating hours or every 6 months 54 (1.9) 94 (3.3)
Crowd motor 2500 operating hours or every 6 months 54 (1.9) 94 (3.3)
Swing motor 1250 operating hours or every 3 months 54 (1.9) 80 (2.8)
NOTES:
• It is critical that the drainpipe not be allowed to become plugged with caked or
contaminated grease. If it does, then the pipe must be cleared.
• A common mistake is over-lubrication of bearings. When grease is added without
removing the drain plug, the excess grease can be forced into and through the grease
seals leading to grease leakage along the shaft (out of the motor or into the motor and
possibly onto the motor windings). Proper lubrication is desired, but some
under-lubrication is less harmful than over-lubrication.
• PN: 59100651 is a 14 ounce cartridge of Mobilith SHC100 grease.

June 2012
Lubrication
Lubricant Selection BI010308
2.3 Lubricant Selection

The selection of the proper lubricants for use on this machine is critical to its reliability. Improperly
lubricated bearings, gears, couplings and other precision parts quickly fail. For this reason,
lubricants selected in accordance with the “American Standards Testing Material” (ASTM)
standards are recommended. These standards were compiled in cooperation with major
petroleum suppliers to ensure the consumer of an exact supply to specific requirements,

regardless of source.
We recommend you advise the petroleum supplier of the following information to assist in
selecting the proper product for each application of this machine.
Final acceptance of all lubricants supplied to this standard will be based upon their satisfactory
performance in the intended application and does not relieve the supplier of performance
responsibility for brand name products.
Operation of this machine in extreme temperatures (below -20°F/-29°C or above 110°F/44°C)
requires special lubrication. Note the temperature ranges on the following lubricant specification
sheets. Contact your local supplier, your manufacturer representative, or the service department
of your local manufacturer’s office for recommendations if you require additional information or
advice.
• STORE LUBRICATION DRUMS ON THEIR SIDE, WITH THE OPENING TOWARD THE
TOP.
• STORE ALL LUBRICANTS IN TIGHTLY COVERED CONTAINERS!
• WIPE OFF COVERS AND SURROUNDING AREA BEFORE OPENING!
• FILTER ALL OIL BEFORE ADDING IT TO THE SYSTEM!
• USE ONLY CLEAN and PROPER LUBRICANTS!
• DO NOT MIX TYPES or BRANDS of LUBRICANTS!
Even the best lubricants are less useful in preventing wear if they become contaminated by dirt
or water due to careless handling or storage.

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Lubrication
BI010308 Oil Fill Capacities
2.4 Oil Fill Capacities

The capacities listed below apply to Rope Crowd machines with a split-lube system.
2.4.1 Types Of Lubricants And Capacities

NOTE: Use the chart below as a guideline. Fill to the proper level as determined by the dipstick
or oil sensor.
Description Type Gallons

All open gearing, bushings & dipper handle OGL 275
Most, anti-friction bearings MPG 137
Crowd, enclosed gearing - 1st. reduction EGL 7
Crowd, enclosed gearing - 2nd. reduction EGL 10
Propel, final drive bearings MPG 27
Propel, planetary (horizontal) 2-cases EGL 140
Propel, planetary (angled 10°) 2-cases EGL 156
Swing, planetary 2-cases EGL 172
Hoist, planetary case w/cooler EGL 115
OGL bulk lube tank OGL 140
Grease bulk lube tank MPG 100
Hoist OGL bulk lube tank OGL 60
2.4.1.1 Quantities for First Fill of Lubricants

Gallons Drums Type Description
475 8.6 OGL Open Gear Lubricant
264 4.8 MPG Multi-Purpose Grease w/EP Additives
460 8.4 EGL Enclosed Gearcase Lubricant
NOTE: 1 drum = 55 gallons = 208 liters

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Lubrication
Gearcase Lubricant Replacement/Sampling BI010308
2.5 Gearcase Lubricant Replacement/Sampling

It is strongly suggested that the gearcase lubricant be part of a routine oil analysis program to
forecast impending issues and thereby reduce the possibility of premature failure. This analysis
should take place every 500-1250 machine hours to ensure that properties are maintained and
contamination is controlled to the following parameters:
Viscosity: Within 10% of the specified, new oil viscosity;

Water Content: Contain less than 0.05% (500 ppm);
Spectrometric oil analysis: Monitor the elements listed in the following table, at a minimum:
Element Normal Excessive Critical

Iron <400 400-700 >700
Copper <25 25-60 >60
Chromium <5 5-15 >15
Silicon <40 40-60 >60
NOTES:
• All values are Parts per Million.
• Particle count may be higher during the initial run-in period.
• The oil or filter (if equipped) should be changed when any value exceeds normal levels.
• Maintain an analysis record using the gearcase serial number and machine operating
hours.
• In gear cases with closed loop filtration systems, clogged filters require investigation into
the source of contamination.
2.5.1 Lubricant Change Cycle

For all machinery motions - Hoist, Crowd, Swing & Propel - the gearcase lubricant should
be first changed after approx. 500 machine operating hours.
Thereafter, the lubricant should then be changed every 6,000 hours or 12 months,
whichever comes first. Flush the gearcase prior to refilling with new oil.
To fill the propel gearcase, remove the inboard plug at the center of the gearcase. Remove the
oil breather at the top of the gearcase and fill the gearcase with oil until oil flows from the
unplugged port. Replace the removed plug. Oil capacity is approx. 70 US Gallons (265 liters).

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Lubrication
BI010308 Automatic Lubrication System
2.6 Automatic Lubrication System

THE AUTOMATIC LUBRICATION SYSTEM IS NOT DESIGNED TO PROVIDE INITIAL
COVERAGE. New parts installed or those cleaned during maintenance procedures must be fully
lubricated before commencing machine operation. Anti-friction bearings and bushings must be
hand packed or thoroughly coated with the correct lubricant. Open gearing and moving contact

surfaces must be completely covered with their lubricant. Do not permit the lack of lubricant at
start-up to cause you to redo a repair job!
STORED ENERGY! Automatic lubrication systems operate under pressure. Before

opening any lube supply line, relieve the system and that line in particular, of any residual
pressure.
NOTE: The greatest amount of wear to be experienced by any moving part will take place
during the first few cycles, or operating hours. A lack of proper lubrication can destroy a
new part at a dramatically increased rate over the normal wear patterns experienced.
Enclosed gearcases must have their recommended lubricant level maintained at the prescribed
level. Check the lubricant level at the oil level plug or with the dipstick at least once weekly (every
150 hours). Inspect them daily (every 24 hours) for leaks. Change the oil in the gearcase at their
recommended intervals while flushing each case with a light lube oil before adding the new gear
oil. ALWAYS STORE THE USED OIL IN A SAFE CONTAINER UNTIL PROPERLY DISPOSED.
DO NOT POLLUTE THE ENVIRONMENT!
The manufacturer recommends that scheduled oil samplings from the enclosed gearcases and
air compressor crankcase on this machine be taken and tested by an authorized, reputable lab to
determine the contamination level of the sump oil. These samples should be obtained and tested
every 30 operating days (600 hours). They should be taken when the oil is at its normal operating
temperature and is well mixed in the case, so the samples are representative of actual
conditions. This diagnostic maintenance procedure will permit you to determine the condition of
internal components within the operating gearcases. Increases in the presence of certain metallic
types can be analyzed with the manufacturers service personnel to determine the best time to
change the oil, thus obtaining its best service life. This will simultaneously allow you to monitor
the condition of the components and address situations in their infancy instead of after a
catastrophic breakdown. This program will pay you dividends in the long run.
If a sample diagnostic system is undertaken, it is imperative that adequate records be maintained
of the maintenance and component history of the items in question. Without these records there
will be no adequate date by which to compare any changes or occurrences and make realistic
determinations.
Wire rope lubrication dislodges with the movement of one strand against another. Moisture can
then enter the stranding and cause deterioration of the wire rope. The areas where the greatest
deflection occurs are most susceptible to this contamination and early failure. On pendants, it is
at or near the sockets. On other wire rope applications, such as the hoist rope, it is at the
sheaves or lagging. To increase the service life of any wire rope, apply the proper wire rope
lubricant (WRL) to the areas of its greatest deflection at periodic intervals.

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Lubrication
Automatic Lubrication System BI010308
Lubricant service life is adversely affected by unusually dusty or dirty environments and
atmospheres where extreme high humidity or temperatures exist. It shall, therefore, be the
responsibility of the owner/operator of this machine to determine the most effective lubricant and
lubrication interval for all the components according to the environmental conditions that prevail.
2.6.1 Lube Room

The lubrication room is located at the left front corner of the machinery house. The lube room can
be accessed by external walkways. The lube room contains the pumps, tanks, transducers and
the basic components associated with the automatic lubrication system of the machine.
Figure 2-1 Lubrication Room Details

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Lubrication
2.6.2 Lube Reservoir Fill / Overflow Plumbing
The lube reservoir fill/overflow plumbing is located in the support structure directly below the lube
room at the front, left side of the machine. Lubricants can be added at this location. The overflow
connections are also located here. DO NOT plug the overflow connections.
Figure 2-2 Lube Reservoir Fill / Overflow Plumbing PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 1, 2012

June 2012
Lubrication
2.6.3 Auto Lube Control Panel

The automatic lubrication control panel is mounted on the inboard most wall of the lubrication
room. The panel provides the switches and override functions required to activate, reset and
override the automatic functions.
POWER ON Allows electrical power to energize the system.

LUBE FAULT A light that, when lit, indicates that a fault is present in that system.
Reset the fault by turning the affected system OFF and then ON.
MANUAL LUBE A pushbutton that will disperse (on command) 1 measured quantity of
lubricant to the injectors on that system.
ON /OFF Energizes the system for normal operation.

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Lubrication
2.6.4 Lower Works Lubrication
Although this machine does not spend very much time being propelled between digging sites,
there are considerable forces exerted on the lower works of the machine. The severe loads and
oscillations created during the constant cycles of the digging process tend to squeeze the
lubricant out of bushings, creating a circumstance for wear if proper lubrication habits are

neglected.
With the high possibility of operation while submersed in water the applied lubricant should have
properties which allow for protection under theses circumstances.
When propelling over any long distances the machine should be lubricated at least every
1500 feet of travel, or every 1/2 hour. Bearings and bushings should be carefully watched and
force lubricated until they run cool if evidence of heat buildup is apparent.
Under extremely harsh conditions such as propelling up a hill, frequent turns, or through deep
water and mud the lubrication frequency should be increased.
2.6.5 Revolving Frame Lubrication

Always keep the swing rack and roller path coated liberally with the proper lubricant and check
daily. In the event of severe accumulations, remove accumulated material and re-lubricate the
area before placing the machine back into service.
Although the machinery contained within the house is not exposed to the extreme conditions of
some other machine components, the loading and stresses exerted on this equipment are
severe. Longevity of these components is largely dependent upon proper lubrication.
Spray valves are mounted at the same height on both sides of the pinion. The spray valves
receive air from the brake lines and lube from system B-1.

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June 2012
Lubrication
2.6.6 Hoist Rope Rollers Lubrication
The hoist rope rollers are located above and in front of the hoist drum, centered between the lube
room and the utility room. The rollers are supported with bearing blocks, which are lubricated
through the automatic lube system. Check for proper lubrication during daily inspection.

Figure 2-3 Hoist Rope Rollers

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Lubrication
2.6.7 Front End Lubrication

The front end equipment is exposed to the most extreme working environment of any part of the
machine. The proper amount of lubrication and its quality is imperative to achieving a substantial
service life from these components. Daily inspection and monitoring of the lubrication system will
result in both parts durability and the reduction of machine downtime.
Boom Foot Pins Although not under constant movement during the operation of the machine,
the boom point feet are subjected to high loads and oscillations in a variety of
directions. Virtually all movement of the front end equipment will exert a load
on the pins. OGL is introduced from lube system “A-1” to reduce wear.
Saddle Block The saddle block bears the brunt of movement from the dipper, dipper
handle, attached equipment and any material being moved. The saddle block
lube points need to be checked at least before each shift to avoid dry spots
and accumulations of foreign material. The saddle block lube to the handle is
received from lube system B-2. The crowd sheaves and shipper shaft
bushings lube is received from lube system A-1.
Sheaves Both fixed and rotating front end sheaves are subjected to loads introduced
by the ropes as they move the larger components of the machine. The
sheave bearings on the boom point, the crowd sheaves and the connection
points of the structural strands are lubricated by lube system “A-1”.
Wire Ropes Running and structural wire ropes have very specific requirements for
lubrication in order to survive the difficult conditions they are forced to operate
within. Without proper lubrication and maintenance the expected life from
costly wire ropes will be seriously degraded. Refer to ENGINEERING DATA
for general care and maintenance of wire ropes.
Suspension Ropes The suspension ropes support the boom as well as the rest of the front end
equipment. These ropes are under constant tension but also sustain
additional loads during machine operation. Lubricate the suspension rope
sockets approximately every 3 months or 1250 hours of machine operation.

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Lubrication
2.6.8 Lubricant Injectors
2.6.8.1 Lincoln Type SL-1 Lubricant Injectors
These pressure-operating, spring-reset, series-installed injectors are supplied in banks mounted

on manifolds or individually. Each injector expels a maximum of 0.08 cu. inch of lubricant from its
outlet port each cycle. Dual outlet ports on each injector permit the injectors to be piped in series
for increased lube supply to a common point. The quantity of lube to each point on this machine
has been carefully designed by our engineers for proper coverage. Each injector output can be
adjusted; however the manufacturer recommends that injectors initially be set and used at their
maximum setting.
NOTE:
MAXIMUM Operating Pressure: 3,500 PSI
RECOMMENDED Operating Pressure: 2,500 PSI
MINIMUM Operating Pressure: 1,850 PSI
MAXIMUM Recharge Pressure: 600 PSI
STORED ENERGY! Contact with or ingestion of petroleum products can be harmful.

Automatic lubrication systems operate under pressure. Before opening any lube supply
line, relieve the system and that line in particular, of any residual pressure.
To set an injector for maximum output:
1. Loosen locknut.
2. Turn adjusting screw until there is a small gap at the top of the stem.
3. Orient the adjusting screw so that the opening is toward the front of the injector.
4. Tighten the locknut.

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Lubrication
To reduce an injector’s output:

1. Loosen locknut.
2. Turn adjusting screw clockwise (CW) until desired discharge rate is obtained. This forces
the stem into the body, retarding the stem’s movement.
3. Set the locknut.
Do not turn adjusting screw down (clockwise) more than 5 full turns from the maximum
discharge setting. Check output flow from injector at this time to ensure it is still
operating. If not, back off adjusting screw until injector does consistently operate. Inspect
the adjusted injector for operation over 3 or 4 cycles after returning the machine to work
to ensure it is functioning.

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Lubrication
2.6.8.1.1 SL-1 Lubricant Injector Operation
STAGE 1
The injector piston is in its normal or reset position. The discharge chamber is filled with lubricant
from the previous cycle. Under the pressure of incoming lubricant, the slide valve is about to
open the passage leading to the piston.

STAGE 2
When the slide valve uncovers the passage, lubricant is admitted to the top of the piston, forcing
the piston down. The piston forces lubricant from the discharge chamber through the outlet port
to the bearing.
STAGE 3
As the piston completes its stroke, it pushes the slide valve past the passage, cutting off further
admission of lubricant to the passage. The piston and slide valve remain in this position until
lubricant pressure in the supply line is vented (relieved) at the pump.

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STAGE 4
After the pressure is relieved, the compressed spring moves the slide valve to the closed
position. This opens the port from the measuring chamber and permits the lubricant to be
transferred from the top of the piston to the discharge chamber.
NOTE: The injectors may be mounted individually, or grouped in a manifold at one location.

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Lubrication
2.6.8.2 Lincoln Type SL-V Lubricant Injectors
These pressure-operating, spring-reset, series-installed injectors are supplied in banks mounted
on manifolds or individually. Each injector expels a maximum of 0.08 cu. inch of lubricant from its
outlet port each cycle. Dual outlet ports on each injector permit the injectors to be piped in series
for increased lube supply to a common point. The quantity of lube to each point on this machine

has been carefully designed by our engineers for proper coverage. Each injector output can be
adjusted; however the manufacturer recommends that injectors initially be set and used at their
maximum setting.
NOTE:
MAXIMUM Operating Pressure: 6,000 PSI
RECOMMENDED Operating Pressure: 2,500 PSI
MINIMUM Operating Pressure: 1,850 PSI
MAXIMUM Recharge Pressure: 1,000 PSI
STORED ENERGY! Contact with or ingestion of petroleum products can be harmful.

Automatic lubrication systems operate under pressure. Before opening any lube supply
line, relieve the system and that line in particular, of any residual pressure.
To set an injector for maximum output:

June 2012
Lubrication
Figure 2-4 Lubricant Injectors (SL-V)
1. Remove protective cap.

2. Loosen locknut.
3. Turn adjusting screw until there is a small gap at the top of the stem and the top of the
adjusting screw during Stage 3 of the injector operation.
4. Orient the adjusting screw so that the opening is toward the front of the injector.
5. Tighten the locknut.
6. Install protective cap.
To reduce an injector’s output:

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Lubrication

Figure 2-5 Adjusting Injectors
1. Remove protective cap.

2. Loosen locknut.
3. Turn adjusting screw clockwise (CW) until desired discharge rate is obtained. This forces
the stem into the body, retarding the stem’s movement.
4. Set the locknut.
5. Install protective cap.
Do not turn adjusting screw down (clockwise) more than 5 full turns from the maximum
discharge setting. Check output flow from injector at this time to ensure it is still
operating. If not, back off adjusting screw until injector does consistently operate. Inspect
the adjusted injector for operation over 3 or 4 cycles after returning the machine to work
to ensure it is functioning.

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Lubrication
2.6.8.2.1 SL-V Lubricant Injector Operation

STAGE 1
The injector starts in its normal or rest position. Incoming lubricant is directed through the slide
valve to both sides of the piston. The pressure of the incoming lubricant acting on both sides of
the piston causes the piston to move downward against the shoulder and fills the measuring
chamber. The indicator stem is fully retracted away from the stop of the adjusting screw.
STAGE 2
A further increase in pressure causes the slide valve to move against the force of the springs. As
the slide valve moves, it closes passage 1 and opens passage 2 to the outlet port. The pressure
of the incoming lubricant is now acting only upon the bottom of the piston. The incoming lubricant
displaces the piston which forces the lubricant in the measuring chamber to be dispensed
through passage 2, through the slide valve and through the outlet port to the lube point.
STAGE 3

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Lubrication
The piston will dispense the lubricant until the indicator stem hits the stop of the adjusting screw.
The volume of lubricant dispensed can be adjusted by limiting the travel of the piston. The piston
and slide valve remain in this position until lubricant pressure in the supply line is vented.

STAGE 4
As the pressure in the supply line vents to 1000 psig [69 bar], the slide valve moves downward
and closes passage 2 and opens passage 1. The lubricant pressure in the supply line is now
acting on both sides of the piston causing it to move downward. As the piston moves downward,
a volume of the lubricant flows from the underside of the piston, past the slide valve, through
passage 1 and to the upper side of the piston. Since the volume on top of the piston is greater
than the volume under the piston, an additional volume of lubricant flows from the supply line to
the upper side of the piston. This volume of lubricant leaving the supply line causes the pressure
to drop very quickly. The piston may or may not fully return to the shoulder, depending on the
volume of lubricant in the supply line. The injector is now ready for the next cycle.
NOTE: The injectors may be mounted individually, or grouped in a manifold at one location.

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2.6.8.3 Injector Advantages


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Lubrication
BI010308 Propel Machinery Lubrication
2.7 Propel Machinery Lubrication

Propel planetary gearcases should be checked every 48 hours. Inspect the lubricant level with
the machine on level ground and add the required amount of the recommended lubricant if
necessary. If water has accumulated within the gearcases, remove the drain plug and drain into
a container for waste removal, then refill with clean lubricant.

For gearcases with the input shaft in a horizontal position, check the propel gearcase oil level
using the dipstick located at the input shaft housing. Gearcase capacity is 95 gallons (360 liters)
with the input shaft in a horizontal position.
For gearcases with the input shaft rotated 10° from horizontal, check the propel gearcase oil level
using the dipstick located at the input shaft housing. Gearcase capacity is 111 gallons (420
liters) with the input shaft rotated 10° from horizontal.
When radical changes in temperature, or at the recommendation of a testing facility, make it

necessary to change the lubricant within a gearcase, it is advised to drain the box immediately
after propelling the machine. This will allow for a more thorough removal of contaminants and
foreign material due to the elevated temperature and suspension of particles within the lubricant.

June 2012
Lubrication
Hoist Machinery Lubrication BI010308
2.8 Hoist Machinery Lubrication

The hoist machinery drive is comprised of 2 stages of gear reduction. The first stage gear
reduction is an enclosed system running submersed in lubricant. The gearcase housing is
equipped with lubricant level check plugs on the right side of the case. A filter breather is
provided to allow for air entry to equalize pressure differentials created by the warming and
cooling of the gearcase, allows moisture to escape and prevents contaminants from entering.
The second stage of gear reduction is operating as a semi-enclosed system lubricated by OGL.
The drum shaft bearings are grease lubricated by System “C-1” along with the intermediate shaft
of the hoist gearing. The motor pinion shaft bearings are splash lubricated from the 1st stage
gearcase.

June 2012
Lubrication
BI010308 Hoist Machinery Lubrication
2.8.1 Hoist OGL Reservoir
Inside the lube room, a dedicated 60 gallon reservoir supplies preheated open gear lubrication to PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 1, 2012
the hoist bull gear and gearcase pinions. A thermostat controlled strip heater is mounted directly
to the bottom surface of the hoist OGL reservoir providing uniform heat distribution. An optional
heated supply line between the lube room and the hoist gearcase injectors is available for cold
weather applications (temperatures below 0° C).
2.8.2 Hoist Oil Cooler

The hoist gearcase temperature is maintained by recirculating lubricating oil through a gearcase
oil cooler.

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Lubrication
The gearcase cooler is located beneath the revolving frame, on the left side of the machine, just
behind the hoist machinery. It is supported by a set of beams bolted to the bottom of the
revolving frame.
Should the cooler assembly require removal or replacement:
1. Drain any fluid from the cooler, oil pump and lines between the cooler and the hoist
gearcase.
2. Shut off the valves and disconnect the fluid lines at the oil pump and at the oil filter.
3. Support the cooler and support beam assembly with a jack(s) beneath the base of the
cooler.
DO NOT PROCEED UNTIL THE COOLER AND SUPPORT ASSEMBLY IS FULLY

SUPPORTED. The weight of the cooler assembly and support beams is approximately
2870 Lbs.

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Lubrication

Figure 2-6 Hoist Oil Cooler Installation
4. With the supports and the cooler fully supported, remove the 0.75 inch capscrews
(16 places) that fasten the 4 vertical posts of the supports to the revolving frame.
5. Carefully lower the cooler and support assembly down and out from beneath the revolving
frame.
The cooler, cooler motor and/or oil pump can now be repaired or replaced.
The cooler pump and pump gearcase can be serviced without removal of the cooler or support
structure. The filter assembly is in the output line at the rear of the cooler assembly. The filter
cartridge can be replaced by removing the screws and cover at the top of the filter canister.
The relief pump is factory set at 150 PSI for protection of the pump and should not be changed.
The cooler relief valve is factory set at 100 PSI for protection of the cooler core and should not be
changed. The 51 PSI relief valve built into the filter downstream of the cooler is for the protection
of the filter element. The check valve downstream of the filter is intended only as a means of
preventing backflow from the gearcase when the filter element is being serviced.

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Lubrication
The plumbing on the gearcase has varying orifices that are not adjustable. Based on the
temperature/viscosity of the oil in the system, the operating pressure will vary considerably from
cold start to fully stabilized conditions. The operating pressure may not be the same between
different sized gearcases and may vary somewhat between individual units. Normal operating
conditions will be acceptable for a pressure range of 20 PSI to 150 PSI without causing a trip
condition.

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Figure 2-7 Hoist Oil Cooler Schematic

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Lubrication
2.8.3 Filter Element Cleaning

The oil filter for the hoist planetary gearcase oil cooler has a removable, wire mesh filter element
that can be cleaned and reused several times. Use the following method:
1. Clean any coarse dirt from the pressure side of the element with normal cleaning solvents
and a smooth bristled brush (not a wire brush). This process can be done under a jet-
stream, not a bath, to help prevent the removed particles from reaching the clean side of the
element.
2. After cleaning, use compressed air to blow through the element from the clean side.
NOTE: Filter elements which are filtered from inside to outside must use a dirt pan as shown in
the figure.
Figure 2-8 Filter Element Cleaning
3. Next dip the cleaned element in cleaning fluid to pick up any remaining dirt particles. Use
compressed air to blow out the element as in step 2 above.
4. Repeat the above steps until all dirt particles have been removed from the filter element.
NOTES:
• Handle the mesh of the element carefully to avoid damage through improper handling.
• The filter element cannot be 100% cleaned. Therefore, the element should be cleaned a
maximum of 3 times then discarded.
• Filter seals should be inspected and replaced as required during filter cleaning and
maintenance.

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Lubrication
BI010308 Swing Machinery Lubrication
2.9 Swing Machinery Lubrication

The swing machinery is primarily composed of an enclosed planetary gearcase on either side of
the machine’s swing rack. The gearcases are self contained units with their own individual pump,
filtering system and lubricant reservoir. Lubricant levels should be checked at least every 48
hours with a visual inspection for leakage at the start of each shift.

A filter breather is provided on each planetary gearcase to allow air entry to equalize pressure
differentials created by the warming and cooling of the gearcase. The filter breather allows
moisture to escape and prevents contaminants from entering.
The swing pinions and lower swing shaft bearings are lubricated with open gear lubricant from
System “B-1”

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Swing Machinery Lubrication BI010308
Figure 2-9 Swing Machinery

June 2012
Lubrication
BI010308 Crowd Rope Take-up Mechanism Lubrication
2.10 Crowd Rope Take-up Mechanism

Lubrication
Whenever the hydraulic motor adapter is installed in the crowd rope take-up mechanism to
tension the crowd rope, fresh OGL lubricant should be applied to the assembly. Refer to

CROWD ROPE TIGHTENING in this manual.
1. Hoist the dipper until the dipper handle is horizontal, parallel to the ground. Retract the
handle until the crowd half-sheave is within reach of the hydraulic unit on the machinery
house roof behind the operator’s cab. (With the hoist ropes supporting the dipper and the
handle just retracted, any slack that exists should be in the crowd rope.)
2. Refill the crowd rope worm gear housing with OGL, if required. (Total capacity is
approximately 3.0 gallons.)
• Add, at the least a small amount of OGL through all four of the lube fittings in the crowd
rope worm gear housing, to lubricate friction surfaces adjacent to those fittings.
• Look for OGL to bleed from the relief valve fitting in the side of the worm gear housing,
when lubricant capacity of the housing is reached.
• Pump a small amount of OGL through the fitting on the half-sheave clevis pin.
NOTE: During initial assembly, prior to shipping, grease lubricant is applied to all friction
surfaces of the assembly. Traces of grease lubricant will be visible during initial
maintenance, but for all lubrication procedures in the field, use Open Gear Lubricant
(OGL) – not grease.

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Lubrication
Crowd Machinery Lubrication BI010308
2.11 Crowd Machinery Lubrication

The crowd machinery includes 2 gearcases. The crowd first and second stages of gear reduction
are totally enclosed systems submerged in gear lubricant. The gearcase is provided with an oil
level plug to check for adequate lubrication, and a filter breather. The third stage of gear
reduction, the crowd drum gear, is lubricated by OGL from lube system “B-1”. The bearings of the
crowd drum, along with the shafts of the crowd reduction system are lubricated by grease from
lube system “C-1”.

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Lubrication
BI010308 Air Compressor Lubrication
2.12 Air Compressor Lubrication

The air compressor supplied with the machine has very specific lubrication needs. For the details
of servicing, refer to the manufacturer’s instructions and the specific lubricant recommendations
made later in this section. Also refer to COMPRESSED AIR SYSTEM in this manual.

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Lubrication
Air Compressor Lubrication BI010308
2.12.1 ACSL - Air Compressor (Screw-Type) Lubricant

SCOPE
Lubrication performance requirements and recommendations for Air Compressor (Screw-type)
Lubricants.
These lubricant performance requirements for screw-type air compressors are only good
for Sullair screw compressors. If the machine is equipped with air compressors
manufactured by other than Sullair you must refer to the vendor’s maintenance
information provided with the machine and LUBRICATION section of this manual.
LUBRICANT RECOMMENDATIONS
The following are listed service requirements (including lubrication) of the Sullair Air Compressor:
Ambient Fluid & Filter Separator Change Air Filter Change

Temperature Lubrication Period (Hrs) Period (Hrs) Period (Hrs)
-10ºF to +90ºF Sullube 8000 8000 4000
(-23ºC to +32ºC) Sullair LLL-4-32 8000 8000 4000
SRF 1/4000 4000 4000 4000
NOTES:
• For additional information, refer to the Vendor supplied manual provided. For additional
questions, please contact either the vendor or the manufacturer.
• For light-duty, high-humidity service where condensed moisture and emulsification may
occur, the fluid change interval should be reduced to 300 hrs maximum. A non-detergent
fluid with rust, oxidation and foam inhibitors, and good water separation characteristics
should be used.
• These performance requirements are benchmarks and not specifications. Therefore,
meeting these limits as described above does not relieve the supplier of the responsibility
associated with brand name products.

June 2012
®
BI010196
May 2012
Special Instruction
Lubrication Specifications
Electric Rope Shovels
AM11093-EN
SAFETY.CAT.COM
BI010196
Amendments and alterations to this publication are not subject

to notification. Caterpillar Global Mining LLC reserves all rights
to this publication. Its content is protected by copyright laws.
No part of this publication may be reproduced or transferred

in any way or form without the prior written approval of
Caterpillar Global Mining LLC.
Caterpillar Global Mining LLC declines any liability for direct or

indirect consequences of printing errors.

BI010196
Table of Contents
EGL - Enclosed Gearcase Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MPG - Multipurpose Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OGL - Open Gear Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AM11093-EN Electric Rope Shovel

May 2012
May 2012
Electric Rope Shovel
BI010196
AM11093-EN
BI010196
Lubrication Specifications
EGL - Enclosed Gearcase Lubricant
SD4720 (March 2006)

SCOPE
This specification covers the requirements for “Enclosed Gearcase Lubricant” used on models
7495, 7495 HF and 7495 HD Electric Rope Shovels and is also applicable to former models
495BII, 495HF, 495HR and 495HD.
The materials furnished under this specification are intended to lubricate spur, helical and spiral
bevel gears as well as anti-friction bearings at the interior of enclosed planetary and non-
planetary type gearcases (Hoist, Swing, Crowd and Propel).
This specification covers “Enclosed Gearcase Lubricants” that may be applied in service at
temperatures ranging from –50ºC (-58ºF) to the highest ambient temperature conditions.
Guidelines for Selecting an Approved Lubricant
1. Using Table 1, determine the recommended oil type (Mineral or Synthetic) based upon the
anticipated ambient temperature range.
AMBIENT TEMPERATURE RANGE
Ambient Temperature: The ambient temperature is defined as the air temperature in the
immediate vicinity of the gearcase.
a. Use atmospheric temperature for gearcases located outside of the machinery house
(Swing, Crowd and Propel Gearcases).
b. Use machinery house temperature for gearcases located inside of the machinery
house (Hoist Gearcase) for some machines are equipped with machinery house
heaters.
c. If the ambient starting temperature approaches the lubricant pour point, external
heaters may be required to facilitate starting and ensure proper lubrication. Use oil
temperature for gearcases having oil immersion heaters.
Table -1 - Guidelines for Selecting Approved Lubricant
Ambient Temperature Range ISO Viscosity Grade / Oil Type

14°F to 100°F (-10°C to 37°C) ISO VG 320 / Mineral or Synthetic (poly-a-olefin) Oil
Less than 14°F to 120°F ISO VG 320 / Synthetic (poly-a-olefin) Oil
(Less than -10°C to 50°C)
Under normal circumstances, an ISO VG 320 oil viscosity is required for all Gearcases (Hoist,
Swing, Crowd and Propel). For cold weather applications, an ISO VG 220 oil viscosity may be
used for the Propel Gearcases to help ensure that the lubricant pour point remains below that of
the ambient starting temperature. The pour point and flash point of individual brand name gear
oils must be observed. Refer to the oil manufacturers technical data sheets for these properties.
2. Select an approved lubricant for the Hoist, Swing, Crowd and Propel Gearcases from the
Approved Lubricant Table 2 & Table 3.
AM11093-EN Electric Rope Shovel 1

May 2012
BI010196
APPROVED LUBRICANTS
Lubricants that have been approved for use by the gearcase manufacturers are listed in the
Approved Lubricant Table 2 & Table 3. The use of non-approved lubricants may invalidate the
manufacturers product warranty obligation.
Specific product selection is the responsibility of the equipment operator/owner and is dependent
on climate, application, performance and regional/regulatory requirements.
Table -2 - Approved Mineral Oil Lubricants (ISO VG 320)
Manufacturer Product Description

Bel-Ray Bel-Ray 100 Gear Oil 90
BP Energol GR-XF 320
Castrol Alpha SP 320
Alpha MAX 320
Optigear BM 320
Tribol 1100/320
Chevron Chevron Ultra Gear Lube 320
Gear Compound EP 320
Esso Spartan EP 320 (Only Product Originating from Europe)
Fuchs Renolin CLP 320 Plus
LE (Lubrication Engineers) Almasol 605
Mobil Mobilgear XMP 320
Petro-Canada Ultima EP 320
Shell Omala F 320
Texaco Auriga EP 320
Meropa 320
Meropa WM 320
Whitmore Mfg. Co. Paragon 320
Shaded lubricants are approved for use in the Planetary Hoist, Swing and Propel Gearcases as
well as the Non-Planetary type Crowd Gearcase.
Non-shaded lubricants are approved for use only in the Planetary Propel and Non- Planetary
type Crowd Gearcase.
2 Electric Rope Shovel AM11093-EN

May 2012
BI010196
Table -3 - Approved Synthetic (Poly-a-olefin) Oil Lubricants (ISO VG 320)
Manufacturer Product Description

Bel-Ray Synth. Gear Oil 6692
BP Enersyn EP-XF 320

Enersyn HTX 320
Castrol Optigear Synth. A 320
Optigear Synth. X 320
Alphasyn EP 320
Alphasyn T 320
Tribol 1510/320
Tribol 1710/320
Chevron Tegra Synth. Gear Lube 320
Fuchs Renolin Unisyn CLP 320
Mobil Mobil SHC 632
Mobilgear SHC XMP 320
Petro-Canada Ultima Synth. EP 320
Traxon E Synth. 80W-140
Shell Omala HD 320
Texaco Pinnacle EP 320
Whitmore Mfg. Co. Decathlon F 320
Shaded lubricants are approved for use in the Planetary Hoist, Swing and Propel Gearcases as
well as the Non-Planetary type Crowd Gearcase.
Non-shaded lubricants are approved for use only in the Planetary Propel and Non-Planetary
type Crowd Gearcase.
Specification Revisions
This specification is subject to change without notice.

May 2012
BI010196
MPG - Multipurpose Grease

SD4711 (November 2011)
SCOPE
1. This specification covers “Multi-Purpose Grease”.

2. Materials furnished under this specification are primarily intended to lubricate heavy duty
ball, roller, and plain bearings.
3. The material furnished under this specification must be dispensable through the distribution
lines of a centralized lubrication system to the most remote application point, at the lowest
anticipated operating temperature. It must not plate or plug components of the centralized
lubrication system such as injectors or metering blocks.
4. The particular grade or consistency selected must perform within the specific temperature
range in which it is utilized.
PHYSICAL CHARACTERISTICS
1. Heat Resistance - Shall be thermally stable, should not flow or harden in service.
2. Retention - Shall not exhibit high leakage.
3. Stability - Shall work continuously with a minimum change in consistency.
4. Water Resistance - Shall withstand water washout or leaching.
5. Reversibility - Shall be stable with repeated heating and cooling.
6. Pressure Separation - Shall resist oil-soap separation.
7. Extreme Pressure - Shall withstand heavy shock loading.
8. Compatibility
a. Low temperature greases shall be compatible with mineral oil base greases.
b. Grease must be compatible with oil seal lip materials (Nitriles, Viton), and all
centralized lubrication system components (i.e. gaskets, o-rings, vent valves, etc.).
Reference ASTM D 4289-03.
9. Compounding
a. Suitable for producing the extreme pressure characteristics (without inert fillers)
required for heavy duty ball, roller, and plain bearing lubrication.
b. Base fluid is to be mineral or synthetics which are compatible with mineral base.
c. Thickener types are to be of the following varieties: Aluminum, Lithium, or Calcium.

May 2012
BI010196
MINIMUM PERFORMANCE REQUIREMENTS
Property Reference Requirement

Ambient Temperature -1°C to +43°C -18°C to +27°C Less than -12°C
(See Note #1) (+30°F to +110°F) (0°F to +80°F) (Less than +10°F)

NGLI Consistency # ASTM D-217 2 1 1, 0, 00
(See Note #2)
Dropping Point °C (°F) ASTM D-2265 177 (350) 177 (350) 177 (350)
Minimum
Timken O.K. load-lbs (kgf) ASTM D-2509 50 (23) 50 (23) 50 (23)
Minimum
Four Ball EP ASTM D-2596 65 65 65
Load wear index (LWI) kg
Minimum
Load Weld kg Minimum ASTM D-2596 400 400 400
Four Ball Wear ASTM D-2266 0.6 0.6 0.6
Wear Scar mm
Maximum 40KG for 1 hour
@ 75°C @ 1200 RPM
Copper Strip Corrosion ASTM D-4048 2e 2e 2e
24 Hrs @ 100°C (212°F)
Rust Test ASTM D-1743 Pass Pass Pass
Viscosity of Base Fluid ASTM D-445 460cSt @ 40°C 220cSt @ 40°C 130cSt @ 40°C
Minimum
Motormatic Grease Worker ASTM D-217A 10% 10% 10%
Mechanical Stability 10,000
strokes, Maximum change
Roll Stability Test ASTM D-1831 15% 15% 15%
Maximum change in 2 hours
Wheel Bearing Test ASTM D1263 10% 10% 10%
6 hours @ 104°C (220°F) (NLGI #1 Only)
Maximum loss
Water Washout Test ASTM D-1264
Loss @ 38°C (100°F), 5% 5% 5%
Maximum (NLGI #1 Only)
Loss @ 80°C (175°F),
Maximum 15% 15% 15%
(NLGI #1 Only)

May 2012
BI010196

Pressure Oil Separation The Lubrication Engineers Manual U.S. Steel test method - Cake
(United States Steel). penetration not less than 25% of
grease penetration.
Grease Mobility The Lubrication Engineers Manual U.S. Steel method - not less than
(United States Steel). 0.10 grams flow per second at the
lowest anticipated ambient

temperature. (Testing temperature
not less than -34°C/-30°F).
Pumpability, The Lubrication Engineers To vent from 1800 psi
Lincoln Ventmeter Manual (United States Steel). (127 kgf cm^2) to less than or
equal to 600 psi (42 kgf/cm^2)
within 30 seconds at the lowest
anticipated ambient temperature
(Testing temperature not less than
-25°C/-13°F).
Lubricating Solids Less than or equal to 5%
(Molybdenum Disulfide,
Graphite, Etc.) % by Weight
Lubricating Solids 10 Microns
(Molybdenum Disulfide,
Graphite, Etc.) Particle Size,
(Microns, max.)
NOTES:
1. Ambient Temperature - The ambient temperature shall be the temperature at the point of
lubricant application.
2. Low Temperature Grease - For extended use in low temperature (-12°C to -46°C / +10°F
to -50°F) areas, this product should be capable of slumping in containers and should be
pumpable through lube lines without the aid of heat tracing. This product should meet the
Mobility and Pump-ability criteria for the lowest anticipated ambient temperature. In order
to minimize compatibility problems, it is desirable that the thickener and additive system
be compatible with the additional grades that are suitable for the other ambient
temperatures.

May 2012
BI010196
LUBRICANTS
on climate, application, performance and regional/local regulatory requirements. Lubricants shall
be certified by their manufacturers as complying with this specification. Quality Control
Documentation may be requested pertaining to viscosity, weld point and scar per batch to

validate properties.
The use of lubricants not meeting this specification may invalidate the manufacturers product
warranty obligation.
SPECIFICATION REVISIONS
This specification is subject to change without notice. Please contact the following for the latest
specification:

6744 S. Howell Ave.
Telephone (+1) 414.768.4000

May 2012
BI010196
OGL - Open Gear Lubricant

SD4713 (June 2011)
SCOPE
3. This specification covers "Open Gear Lubricant."

4. Materials furnished under this specification are primarily intended to lubricate open gears,
but may also be used to lubricate racks, bushings, rails, rollers, dipper handles and propel
mechanism components.
5. The material furnished under this specification must be dispensable through the distribution
lines of a centralized lubrication system to the most remote application point, at the lowest
anticipated operating temperature. It must not plate or plug components of the centralized
lubrication system such as injectors, metering blocks, or spray nozzles.
6. This specification covers open gear lubricants that may be applied in service at
temperatures ranging from -50°C (-58°F) to the highest ambient temperature conditions.
The particular grade or consistency selected must perform within the specific temperature
range in which it is utilized. The temperature may vary significantly between external
components in cold climates and components located within heated enclosures and must
be considered during lubricant selection.
PHYSICAL CHARACTERISTICS
1. Materials furnished under this specification are produced with highly fortified blends of
viscous fluids combined with additives to form stable, long lasting, high load carrying, wear
resistant films that lubricate under mixed film and boundary conditions. Lubricants
addressed under this specification may be defined by AGMA 6014-A06 Annex D as (1)
Residual [asphaltic (bitumen)] compounds, (2) High viscosity oils, (3) Compounds or (4)
Greases.
2. Open gear lubricants supplied under this specification must have excellent adhesive and
cohesive qualities, must not chip or throw off, and must provide sufficient film thickness and
scuffing resistance to prevent metal to metal contact between applications of the lubricant
under all operating conditions. Therefore: (2) High viscosity oils are NOT recommended
due to performance characteristics at relatively slow speeds and frequent stop/start
application; and (4) Greases inherently provide marginal film thicknesses at low speed
which requires properly designed additive packages and thickener selection, stringent
break in procedures and more frequent lubricant intervals.
3. Various grades or consistencies of open gear lubricants may be required to provide proper
lubrication and application properties over a wide range of ambient temperatures. The
consistency of the lubricant as applied must be appropriate for the method of application,
and the in-service consistency shall be appropriate for the lubricant to meet or exceed the
minimum performance requirements listed in the "MINIMUM PERFORMANCE
REQUIREMENTS" section.

May 2012
BI010196
4. Viscosity, a fluid's resistance to flow, is the principal physical characteristic of a fluid in

terms of its ability to produce a lubricating film between two interfacing surfaces. All
lubricating fluids possess a natural viscosity that may be altered (enhanced) by additives
such as resins or polymers. Some "viscosity enhancers" are shear sensitive, which could
result in insufficient protection of the lubricated components under high load, elevated
temperatures and/or high shear conditions. The viscosity of the fluids utilized in the open
gear lubricants shall be sufficient under operating conditions for the product to meet or

exceed the performance requirements listed in the "MINIMUM PERFORMANCE
REQUIREMENTS" section.
5. Open gear lubricants supplied under this specification must be specifically formulated to
protect surfaces, reduce wear, and provide satisfactory service life under all anticipated
operating conditions.
6. Open gear lubricants supplied under this specification must have excellent water tolerance
and rust preventive qualities, as well as minimal dripping qualities for operation over wide
temperature ranges.
7. Should the material furnished under this specification contain a diluent to improve
dispensability, special care must be exercised to ensure its compatibility with all centralized
lubrication system components, i.e., gaskets, o-rings, vent valves, etc., and oil seal lip
materials (Nitriles, Viton). Reference ASTM D 4289-03.
8. For extended use in low temperature areas, open gear lubricants supplied under this
specification should be capable of slumping in containers and should be pumpable through
lube lines without the aid of heat tracing. In order to minimize compatibility problems, it is
desirable that the thickener and additive system be compatible with the additional grades
that are suitable for the other ambient temperatures.

May 2012
BI010196
MINIMUM PERFORMANCE REQUIREMENTS

Flash point of product as applied, minimum ASTM D92 / ISO 2592 61°C (142°F)
(base product with diluent) 80°C (176°F)
Ambient Temperature (See Note #1)
-50°C(-58°F) to + 10°C (50°F)

Above +10°C(50°F)
Flash point of base fluid(s), minimum ASTM D92 / ISO 2592 140°C (284°F)
Rust protection ASTM D 1743 Pass
Copper strip corrosion ASTM D 4048 2a
Maximum rating
24hr. @ 100oC (212oF)
Four ball EP test ASTM D 2596 800
weld point, minimum kgf
(base product without diluent)
Load wear index (LWI), minimum ASTM D 2596 120
Four ball wear test ASTM D 2266 0.7
60 minutes @ 40 kgf.
Maximum scar, mm
Adhesive properties Must adhere to surfaces at the lowest anticipated
ambient temperature. (See Note)
Minimum Base Fluid Viscosity ASTM D 445 680 cSt at 40°C
Ambient Temperature (See Note #1) 1860 cSt at 40°C
All - Except Electric Mining Shovel Hoist Drum Gear 3600 cSt at 40°C
°C (°F)
-50 to +10 (-58 to +50)
-20 to +40 (-4 to +104)
+10 to +50 (+50 to +122)
Minimum Base Fluid Viscosity ASTM D 445 3600 cSt at 40°C
Ambient Temperature (See Note #1) 5000 cSt at 40°C
Electric Mining Shovel Hoist Drum Gear
°C (°F)
+10 to +35 (+50 to +95)
+25 to +50 (+77 to +122)
Pumpability, Lincoln Ventmeter To vent from 1800 psi (127 kgf/cm^2) to less than or
equal to 600 psi (42 kgf/cm^2) within 30 seconds at the
lowest anticipated ambient temperature.
Molybdenum Disulfide 2% Minimum
Lubricating Solids 15 Micron Nominal
(Molybdenum Disulfide, Graphite, Etc.) 44 Micron Maximum
Particle Size
NOTE: Ambient Temperature - The ambient temperature shall be the temperature at the point
of lubricant application. The Electric Mining Shovel Hoist Drum Gear is enclosed in a
heated machinery room which should not be below 10°C (50°F).

May 2012
BI010196
LUBRICANTS
on climate, application, performance and regional/local regulatory requirements. Lubricants shall
be certified by their manufacturers as complying with this specification. Quality Control
Documentation may be requested pertaining to viscosity, weld point and scar per batch to

validate properties.
The use of lubricants not meeting this specification may invalidate the manufacturer’s product
warranty obligation.
SPECIFICATION REVISIONS
This specification is subject to change without notice. Please contact the following for the latest
specification:

6744 S. Howell Ave.
Telephone (+1) 414.768.4000

May 2012
12
May 2012
Electric Rope Shovel
BI010196
AM11093-EN
®
Amendments and alterations to this publication are not subject to notification. Caterpillar Global Mining
LLC reserves all rights to this publication. Its content is protected by copyright laws.
No part of this publication may be reproduced or transferred in any way or form without the prior written
approval of Caterpillar Global Mining LLC.
Caterpillar Global Mining LLC declines any liability for direct or indirect consequences of printing errors.
BI010309

3 Preventive Maintenance
Preventive Maintenance
3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.1.1 Preventive Maintenance Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.2 Elements of an Effective Maintenance Program . . . . . . . . . . . . . . . . . . . . . . 3-4
3.1.3 Scheduled Preventive Maintenance Program . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.1.4 General Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2 Maintenance During Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.1 Maintenance Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3 Preventive Maintenance for Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3.1 Lubricant Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4 Frequency of Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . 3-10
3.5 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.1 Maintenance Inspection Check Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.1.1 Daily. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5.1.2 Every 100 Hours or Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5.1.3 Every 500 Hours or Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.5.1.4 Every 1250 Hours or Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.5.1.5 Every 2500 Hours or Semi-Annually . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.5.1.6 Every 5000 Hours or Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

June 2012
BI010309
3.6 Major Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Figure 3-1 Machine Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Figure 3-2 Lower Works and Crawlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Figure 3-3 Crawler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Figure 3-4 Crawler Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Figure 3-5 Propel Machinery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Figure 3-6 Roller Circle Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Figure 3-8 Collector Rings, Auxiliary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Figure 3-9 Collector Rings, High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Figure 3-10 Center Pintle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Figure 3-11 Revolving Frame Deck Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Figure 3-12 Hoist Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Figure 3-13 Swing Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Figure 3-14 Crowd Machinery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Figure 3-15 Lubrication Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Figure 3-16 Operators Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Figure 3-17 Right Hand Boarding Stairway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Figure 3-18 Boarding Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Figure 3-19 Power Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Figure 3-20 Machinery House Walkways and Platforms . . . . . . . . . . . . . . . . . . . . . 3-47
Figure 3-21 Front End Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Figure 3-22 Boom Support Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Figure 3-23 Boom Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Figure 3-24 Dipper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

June 2012
BI010309 Introduction
3.1 Introduction
This section of the manual describes those aspects of preventive maintenance on the machine
such as inspection, adjustment and routine repetitive tasks. Information related to lubrication

techniques, frequency and service points is also partially included. Further detailed information
can be found in LUBRICATION and SERVICE PROCEDURES sections of this manual.
3.1.1 Preventive Maintenance Program

A Preventive Maintenance Program is a systematic series of operations performed periodically
on equipment to prevent breakdowns.
Any breakdown WILL reduce productivity and increase overhead expense. Machinery is only
new at one point in time. From that moment on, the machinery begins to deteriorate through use
and aging. A well organized maintenance program will avoid unexpected high-cost breakdowns
and will increase component life.
A systematic approach to the program should be followed and detailed records of all findings
kept, to detect potential problem areas. Valuable time and effort can be saved if defects are
corrected before they lead to a major breakdown. The records should be reviewed often and kept
on file for future reference.
Personnel involved in the program should go through an established training program, to know
WHAT to check and HOW to rectify any potential problem area. When personnel are able to do
routine maintenance and normal repairs efficiently, downtime is reduced and machine
productivity increased. Also, to keep the machine in good running condition, the necessary parts,
tools and current information should be kept on hand.
Equipment maintenance is a science and its practice an art that can be divided into 6 types of
operations - they are:
• Inspection is probably the most important operation. Careful observation is required of all
parts of the equipment. Slight abnormalities may not interfere with the equipment
performance BUT those that are a deviation from the normal should be discovered early.
When inspecting, notice placement, state of cleanliness, color, etc. of part(s). Example:
discoloration indicates overheating; all guards, bolts in place and good housekeeping.
• Cleaning and keeping clean is essential for good operation. Periodic cleaning should be
more frequent on exposed parts than those which are contained within cabinets. Parts,
connections and joints should be free of dust, corrosion and other foreign matter.
• A Feeling operation is used more often to check guarded rotating machinery for vibration
due to worn parts, lack of lubrication, overheating, etc. Feeling operation on electrical items
should be performed as soon as possible AFTER power has been removed and the circuit
grounded. Feeling of excessive heat may indicate an overloaded condition and should be
corrected.

June 2012
Introduction BI010309
• A Tightening operation should be done on all connections that have worked loose due to
vibration, etc. Loose parts are a definite hazard because they may fall out of place and
damage nearby components. The importance of firm mounting and tight connections cannot
be overemphasized. Always replace missing or broken bolts with the proper size and use the
correct tools.
• Adjusting should be done when inspection indicates that it is required to maintain normal
operating conditions. Specific adjustment is contained in the MECHANICAL ADJUSTMENT

section of this manual, the electrical manual or the component manufacturer’s manual.
• Lubrication refers primarily to the application of CORRECT LUBRICANT in the CORRECT
AMOUNT to bearings and other rotating parts. It also means the application of a light oil to
door hinges or other sliding surfaces. Use only clean and proper lubricant.
Planned maintenance, common sense and good judgment is less costly and more effective than
panic maintenance. Action taken on recommendations made on the following suggested
inspection Check Lists by the maintenance department, should reduce repair and maintenance
costs and increase production.
Replacing worn components with genuine manufacturer parts on a scheduled basis will avoid
costly down times and emergency repairs. The cost of parts is small when compared to
unscheduled breakdowns that result in excessive overtime man-hours and lost machine
production.
Whenever a problem is indicated, the inspector should briefly explain it on the maintenance
report (a suggested form is at the end of this section) along with his signature. Then, an
authorized person should briefly explain a solution to the problem. Finally, CORRECT THE
PROBLEM.
3.1.2 Elements of an Effective Maintenance Program

• Preventive Maintenance Program.
• Well Trained and Motivated Work Force.
• Effective Communications.
• Proper Equipment Selection and Procurement.
• Meaningful Documentation.
• Cooperation with the Operations / Maintenance Department.
• Warehouse Support.
• Good Shop Facilities.

June 2012
BI010309 Introduction
3.1.3 Scheduled Preventive Maintenance Program
Economically maintaining the productivity and performance of a electric rope shovel requires
maintenance and inspection activities in a scheduled manner. Manpower requirements and
performance of needed maintenance during scheduled downtime dictates a system which
recognizes the recommended inspection interval. For example, dipper and crawler assemblies

are exposed to severe service and should be inspected every maintenance period, while other
components can be reasonably expected to operate twice this interval before inspection. By
staggering the inspection or servicing of these items, labor time and work-force size is balanced.
Maintenance and component inspection should be performed simultaneously during scheduled
downtime. History of machine maintenance practices has shown that parts replacement and
component rebuild in advance of destructive failure yields the lowest operating costs. Keeping
good records is vital to support any preventive maintenance program. Early “change-out”
reduces unscheduled downtime and prevents secondary damage. Record keeping should be an
“easy to use” format and contain enough detail to isolate the function. For instance, shovel rope
and dipper teeth wear will often directly relate to tons of material loaded, rather than machine
operating hours. However, power transmission shafting and bearings wear rates correspond
closer to operating hours. Since basic machine life extends over thousands of operating hours,
maintenance records can be utilized to forecast budgets for maintenance expenditures. This
makes records a very valuable planning tool for mine management.
Use the manufacturers maintenance program that is outlined here to formulate a schedule suited
to the work-force and mining environment. Over a period of time, additional inspection or planned
work may supplement the activities described in this manual.
3.1.4 General Safety Considerations

The importance of overall safety in the maintenance of a mobile machine should always be
emphasized; excavating operations may involve a variety of hazardous conditions. Many critical
components are subject to wear and other deterioration which limits their useful life; thus making
them expendable. When new, all such parts have built in reserve strength against unknown
factors and reasonable loss of durability from gradual wear. If inspection and adjustment are
neglected, these parts eventually reach a condition where they become a potential problem.
Similarly, failure to replace various mechanisms to ensure proper performance of the machine
could constitute a problem. Study this manual carefully to avoid unsafe conditions. Review the
manual periodically to refresh knowledge of these procedures. Supervisors, operators and
maintenance men should continuously follow safe practices.

June 2012
Maintenance During Machine Operation BI010309
3.2 Maintenance During Machine Operation

Safety requirements dictate that all machines in active service be inspected at regular intervals
for proper adjustment of operating mechanisms, excessive wear of components, system
cleanliness and any other defects. Deficiencies during machine operation should be carefully
investigated. It should be determined if a safety problem exists. Maintenance is vital to safe
operation! It should be performed systematically by competent personnel.

From an economic standpoint, it is advisable to perform as much of the upkeep as can be safely
accomplished while the machine is running. Obviously, there are some maintenance procedures
such as gear tooth inspections and replacement which require machine shut down. Many
support duties can be effectively handled at shift change when the machine is still activated.
Automatic lubrication systems function throughout the operational cycles of the machine. These
systems release pre-measured lubricant which extends the wear life of the machinery units.
Other parts of the machine may be manually lubricated in a safe manner through extended
grease or oil fittings designed to keep the operator’s hands at a safe distance. Where this is not
possible, the machine must be shut down during the required lubrication.
A repair or maintenance job is not complete until all guards, plates and other safety
devices have been replaced before the equipment is restored to operation.
3.2.1 Maintenance Precautions

The operator must be sure that the machine equipment is in a safe position before repairs or
adjustments are made. The machine should not be endangered by falling rock or a possibly
yielding support surface. Before beginning repair or adjustment, the operator shall:
1. Set the dipper on the ground.
2. Set all brakes.
3. De-energize control functions.
4. Do whatever else is necessary to prevent accidental movement of the machine.
HIGH VOLTAGE! IF POWER IS ESSENTIAL TO THE REPAIR, SUCH AS FOR TESTING, IT

SHOULD ONLY BE ENERGIZED WHEN ALL PERSONNEL ARE CLEAR OF ELECTRICAL
AND MECHANICAL HAZARDS. The power should only be energized during the testing
period and not when repair work is actually being done.

June 2012
BI010309 Maintenance During Machine Operation
Prior to undertaking any work, maintenance personnel should notify the operator about the
nature and location of the job. If work is to be done on or near moving parts, the starting controls
should be locked in the OFF position and tagged. The lock and tag should only be removed by
the maintenance people who installed them, or other authorized personnel. During all phases of
maintenance, use extreme caution when working near electrical equipment. Never work near
exposed, energized high voltage connections.

Approved protective equipment such as gloves and insulated hooks or tongs should always be
used when high voltage electrical cables are handled.
Only qualified electricians are permitted to directly maintain electrical equipment such as
motors, transformers and switches.
While performing maintenance, the awkward positions assumed and the handling of heavy parts
often increases the possibility of injuries. As a precautionary measure, use mechanical handling
equipment whenever possible. The mining foreman can facilitate safer and easier maintenance
work by providing blocking materials. Service crews should have a fundamental knowledge of
lifting practices so their knees and legs are used rather than their backs.
Many of the components comprising the machine are heavy, bulky items. EXTREME
CAUTION SHOULD BE USED WHEN LIFTING THESE ITEMS. PERSONNEL SHOULD BE
CERTAIN OF THE WEIGHTS OF COMPONENTS BEFORE ATTEMPTING TO LIFT THEM,
EITHER MANUALLY OR WITH A LIFTING DEVICE. ALL APPLICABLE SAFETY RULES
MUST BE FOLLOWED WHEN USING A CRANE OR OTHER LIFTING DEVICE. Be aware of
the load rating, lifting height and swing radius of the lifting device before lifting a load.
Failure to follow all applicable safety rules when performing maintenance could result in
serious injury, or death.

June 2012
Preventive Maintenance for Lubrication BI010309
3.3 Preventive Maintenance for Lubrication

Lubrication may well be the most important portion of a preventative maintenance program. Do
not allow anything to interfere with the lubrication of the machine. Experience will dictate how to
adjust the amount of lubricant to use at each servicing. The extra effort will result in a smooth
running machine with less wear and breakdowns.
It is difficult to predict how much lubricant should be applied to a particular bearing. It varies with
how hard the machine is being worked, how much the bearing has previously worn and the grade
of lubricant being used. Watch all the bearings closely to ensure that the lubricant added with
each servicing will last to the next.
Most wearing parts require that lubricant be applied regularly in small quantities as with the
automatic lubrication system instead of large amounts applied occasionally. Make regular
inspections of the machine and watch for signs of improper lubrication such as the accumulation
of excess lubricant or discolored lubricant. Ensure that the lubricant has not come from a broken
or disconnected line or lubricant pipe. Normally excess lubricant pumped into a plain bearing is
not used. However, certain bearings in locations which may collect dirt (such as the lower works)
should have extra lubricant added to purge all of the old lubricant that may have collected
abrasive dirt.
New bushings sometimes overheat because they are too tight to allow normal distribution of
lubricant. Old bushings may overheat because they are so worn that lubricant will not stay in until
the next time of servicing. In the case of the new bushing, it may be necessary to lubricate it
more frequently until it is worked in. It may be necessary to do the same for the old bushing, until
it can be replaced. It is much better to lose a little time on a shift to give some extra lubricant to a
point that needs it rather than trying to run it to the end of the shift.
The most common cause of overheating a anti-friction bearing is churning of the lubricant. This
happens when the bearing is packed excessively full. If lubricant leaks out of an anti-friction
bearing, it is almost a sure sign that too much lubricant was added to the bearing. Continue to
lubricate it as often as before, but use less lubricant.
The LUBRICATION section of this manual will provide more detailed and specific information on
lubricants and their usage.

June 2012
BI010309 Preventive Maintenance for Lubrication
3.3.1 Lubricant Cleanliness
Even the best lubricant is a useless wear preventative if it has become contaminated by careless
handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep
it clean. It is the responsibility of the person performing the machine lubrication to make certain
that no dirt gets into the lubricant.

Follow these points of good lubrication practice:
• Keep all oil and other lubricants in tightly covered containers.
• Wipe off covers before opening containers.
• Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off with a clean lint-
free cloth before using.
• Wipe off each fitting before attaching the lubricant gun.
• Wipe off oil filler caps or covers and the surrounding area before removing them.
Refer to the topic LUBRICANT BENCHMARKS in the LUBRICATION section of this manual for
an explanation of each type of lubricant required for servicing this machine. Make sure the
lubricant was not dirty or of improper viscosity. When the machine is operated for more than one
shift each day, all crews must cooperate on checking lubrication. This is to ensure that no
lubrication point will be missed or over-lubricated. It is usually best to do this at the beginning of
each shift. Reproducible service schedules are provided for recording service information.
NOTE: Lubrication instructions provided by any vendor for a vendor supplied item have priority
over the manufacturers lubrication intervals and procedures.
When it is not possible to work on the machine with a safety harness, use an arial lift to
inspect or service elevated areas. A slip or fall can result in severe personal injury or
death.

June 2012
Frequency of Inspection and Maintenance BI010309
3.4 Frequency of Inspection and Maintenance

The suggested maintenance schedule is developed on a planned usage of 5,000 operating
hours per year. This is a planned reference only. The actual conditions within the mine site,
operator’s abilities and habits, along with the quality of components and consumables will
ultimately drive the inspection schedule used on the machine.
Care should be taken to properly evaluate the maintenance approach during the initial period
after machine commissioning.
3.5 Maintenance Schedules

The following maintenance schedule is based on a typical machine. Certain features or
configurations may be different on a specific machine. This maintenance schedule is intended to
outline the intervals for the various repetitive maintenance requirements. For any assistance,
refer to the appropriate section in this Maintenance Manual. This maintenance schedule is not to
be substituted for the Maintenance section of this manual.
For locations of the specified components, refer to the graphics

at the end of this section.
3.5.1 Maintenance Inspection Check Points

The recommended check point schedules in this section are scheduled inspection guides.
Perform inspection based on hours of use or time lapse intervals, which ever comes first. To
verify inspection, copy the schedule pages of this manual, check all items inspected. If needed,
add comments to the Noted Discrepancy column.

June 2012
BI010309 Maintenance Schedules
3.5.1.1 Daily
Check Points - Daily
Location Check Noted Discrepancy
1. Crawlers Check the areas under and around the

crawlers for signs of oil leaks. If single
droplets are noticed, leakage is minimal.
Determine the point of leakage and note it on
the log sheet. If pooling of oil is noticed,
determine the source and begin maintenance
or repair activity immediately. Determine if
loose hardware, a defective gasket, a
combination of both, or a similar problem is
responsible. Tighten hardware or replace
defective gaskets.
2. Crawler Belts Inspect for missing links or lock pins,
excessive belt sag, cracked shoes or other
deterioration.
3. Swing Rack Check the pinions and pinion guards for
rocks, dirt and other debris that will interfere
with the operation of the machine. Inspect the
swing rack gear and rollers for the proper
lubricant film.
4. Propel Motor Inspect for debris, adequate lubrication and
Couplings evidence of damage. Apply MPG as required.
HIGH VOLTAGE! The machine trail cable carries a lethal voltage. Handle the cable in an
approved manner with appropriate rubber gloves and insulated hooks or tongs.
5. Machinery Visually inspect for damage or evidence of
House Exterior internal leakage.
6. Dipper Trip Inspect the dipper trip mechanism, rope, latch
bar and associated hardware for damage,
adjustment and wear.
7. Dipper Door Inspect the door structure, hardware and
bumpers (if included) for damage and
excessive wear.
Date
Shift
Inspected By
Supervisor

June 2012
Maintenance Schedules BI010309

8. Dipper Handle Inspect the crowd and retract rope
attachment points and dipper handle for
damage, excessive wear and evidence of
adequate lubrication.
9. Boom Inspect for security and damage.
Bumpers
10. Dipper Inspect the dipper structure for cracks and
deformations. Check the tooth adapters for
security and excessive wear.
11. Padlocks Inspect for damage, wear.
12. Ropes Check both the running ropes and the boom
structural strands for broken strands, loose
sockets or any additional visual indications
that would indicate a loss of structural
integrity.
13. Gearcases Visually inspect the swing, crowd and hoist
gearcases for oil levels and leaks. Repair or
service as required.
14. Gearcase Visually inspect all machinery for loose bolts,
Machinery. nuts, clamps or unusual conditions. Repair as
required.
15. Open Gears Visually inspect the open gears of the swing,
crowd and hoist machinery for proper
lubricant film and evidence of adequate
lubrication from the automatic lubricant
dispensing system.
16. Hoist and Visually inspect for wear, lubrication and
Crowd Ropes evidence of birdcaging near the drum
attachment beckets.
17. Air Check the oil level, add ASCL if required.
Compressor(s)
18. Air and Lube Check the lubricant supply level.
System
Lubricators
Date
Shift
Inspected By
Supervisor

June 2012
19. Automatic Inspect the central pumping stations for any
Lubrication signs of malfunctioning. Check the lubricant
System supply and refill tanks if required with OGL or

MPG.
20. Swing Brake Visually inspect for damage, wear and
Assemblies overheating.
21. Crowd Brake Visually inspect for damage, wear and
Assemblies. overheating.
22. Hoist Brake Visually inspect for damage, wear and
Assemblies overheating.
23. Operator’s Cab Check for cleanliness and the visual condition
of the controls. Check the location of special
equipment that may be required by the mine
site. Check all operating controls for freedom
of movement. The controls should move
freely without binding.
24. Operator’s Cab Clean all windows.
25. Walkways and Inspect to ensure there are no obstructions,
Stairways damage or fluids creating a safety hazard.
26. Boarding Stairs Ensure all are raised and properly stowed
and/or and latched.
Boarding
Ladders
HIGH VOLTAGE! The machine trail cable carries a lethal voltage. Handle the cable in an
approved manner with appropriate rubber gloves and insulated hooks or tongs.
27. Trail Cable Visually inspect the trail cable for cuts,
abrasions or other damage.
28. Cable Reel At the Cable Reel, if equipped, check the
Hydraulic Fluid Reservoir for proper fluid
level. Add fluid if required.
Date
Shift
Inspected By
Supervisor

June 2012

29. Cable Reel Visually check the Cable Reel Hydraulic
Hydraulic System for leaks. Tighten, repair or replace
System components as necessary.
30. Operator’s Cab Clean filter and pressurizer in dusty

HVAC conditions. Observe charge.
Date
Shift
Inspected By
Supervisor

June 2012
3.5.1.2 Every 100 Hours or Weekly
Check Points - Every 100 Hours or Weekly
1. Hoist Drum Check the operation of the auto lube system

Bearing Lube for the bearings and open gears.
2. Hoist Check the lube valves for bypassing in valves
Automatic and injectors.
Lubrication
System
3. Crowd Lube Check the operation of the injectors, condition
System and connection of all hoses, cycle each
injector to ensure proper lubricant delivery.
4. Gearcase Fluid Check the fluid level.
5. Gearcase Clean, verify condition and security. Check
Breathers both crowd and hoist gearcases.
6. Lower Rail Verify the proper function of the automatic
Lubrication lubrication system.
7. House Rollers Verify roller axle lube and lube on the roller
and Rails surfaces.
8. Automatic Check all lube lines for damage and replace
Lube System as required.
9. Automatic Check each lube injector for proper operation
Lube System and adequate dispensing of lubricant.
10. Boarding Stairs Check all components, including: safety chain
and/or and gate, mounting bolts, hydraulic line and
Boarding fittings, cylinder pin, arm pins and pin
Ladders retainers. Replace any worn or damaged
components. Lubricate the arm pins and
cylinder pins. Check the lock pin and lubricate
as necessary.
Date
Shift
Inspected By
Supervisor

June 2012
3.5.1.3 Every 500 Hours or Monthly

Check Points - Every 500 Hours or Monthly
1. Hoist Drum Clean off lubricant and inspect the tooth
Gear and condition of the gear.

Pinion
2. Hoist Brake Check proper operation, lining wear and
adjustment. Refer to Brakes and Couplings
section for adjustment procedure.
3. Crowd Check both gearcases for leaks, lubricant
Gearcase Lube level and the condition of the gearcase
breather. Clean or repair as needed.
4. Crowd Brake Check operation, linings for excessive wear,
quick release operation and solenoid valve
operation.
5. Crowd Auto Inspect the lube injectors, fittings and hoses.
Lube System Verify correct operation of the system.
6. Swing Operate the machine while listening for
Gearcases unusual noises and vibrations. Contact the
manufacturer if problems are encountered.
7. Swing Gear Check levels and correct as required.
Lubricants
8. Swing Brake Check for proper operation, lining wear,
proper release and solenoid operation.
9. Air System Inspect all air gauges, regulators, filters and
Controls oil-to-air line lubricators.
10. Air System Inspect all tubing, hoses and fittings for
Lines damage and leaks. Repair all leaks.
11. Lube Lines Inspect all lines and fittings. Repair all leaks
and damaged hoses.
12. Auto Lube Check lubricant levels and re-service. Repair
Control Panel, all leaks and clean up spillage.
Lube
Reservoirs
Date
Shift
Inspected By
Supervisor

June 2012
13. Boom Inspect the entire boom structure (man
Structure basket recommended) for damage, cracks -
repair immediately.

14. Boom Foot Inspect the boom foot pins, clearance
Pins keepers and retainers for damage, repair or
replace as required.
15. Boom Ladders Inspect for damage and repair immediately.
and Handrails
16. Front and Rear Inspect visually for cracks and indications of
Legs stress.
17. Suspension Check for broken wires. If 30% of the outer
Ropes wires are broken, or 10% of the total wires are
broken, replace the suspension cable.
18. Dipper Corner Check for tightness, repair as required.
and Center
Shrouds
19. Dipper Tooth Teeth should be tight to adapters or dipper
Points lips. Rebuild or repair as required.
20. Dipper Lip, Completely check the front structure for wear,
Front rebuild as required. Inspect for cracks and
pay special attention to weld joint areas,
repair immediately.
21. Dipper Back Inspect for cracks/damage, repair
Structure immediately.
22. Dipper Door Check for bushing and pin wear. Rebuild as
required. Check the door structure for cracks
or damage, repair immediately.
23. Latch Bar/ Inspect the latch bar for wear, rebuild as
Mechanism required. Adjust the mechanism for proper
operation.
24. Latch Bar Rebuild as required, replace after 3 rebuilds.
Dutchman
25. Dipper Door Inspect the linkage, pins, bushings, replace
Snubbers as required. Adjust if door swings too freely or
does not close completely.
Date
Shift
Inspected By
Supervisor

June 2012

26. Dipper Heel Inspect and record wear to assure proper
Band rebuild timing.
27. Dipper Check wear internally to plans. Correct
rebuild timing. Refer to the manufacturer for

reline recommendations.
28. Dipper Inspect all connecting bushings and pins,
Connecting replace as necessary.
Bushings and
Pins
29. Dipper Pitch Check for missing or loose bolts. Tighten or
Brace (If replace as required.
Adjustable)
30. Crowd Rope Inspect the ropes, replace badly worn, frayed
or damaged ropes.
31. Retract Rope Inspect the ropes, replace badly worn, frayed
or damaged ropes.
32. Dipper Trip Inspect the ropes, replace badly worn, frayed
Rope or damaged ropes.
33. Hoist Drum Check for damage and excessive wear.
Lagging
Grooves
34. Upper Rail Tighten the clamps and verify the integrity of
Clamps the rail end chocks.
35. Propel Pull the bottom plug and collect a 1/2 gallon
Planetary of lubricant. Inspect the sample for metal
Gearcases particles.
36. Boarding Stairs Check all components, including: safety chain
and/or and gate, mounting bolts, hydraulic line and
Boarding fittings, cylinder pin, arm pins and pin
Ladders retainers. Replace any worn or damaged
components. Lubricate the arm pins and
cylinder pins. Check the lock pin and lubricate
as necessary.
Date
Shift
Inspected By
Supervisor

June 2012
37. Operator’s Cab Evaporator: check for leaks, fans for tightness
HVAC on shafts, clean coils, flush drains and
replace return air filter.

Date
Shift
Inspected By
Supervisor

June 2012
3.5.1.4 Every 1250 Hours or Quarterly

Check Points - Every 1250 Hours or Quarterly
1. Crawler Links Adjust the tension as required.
2. Take-Up Check the condition of the bushing.

Tumbler
3. Lower Rollers Check for cracks, unusual wear, O.D. of the
rollers, bushing wear, seal leakage and
proper lubrication.
4. Crawler Links Check the drive tumbler O.D. and the link pins
for wear and/or an out of pitch condition.
5. Gearcases Check all covers and plugs for leakage - seal
as required.
6. Propel Verify mounting bolt tension.
Gearcase
7. Propel Brake Verify proper brake operation. Replace worn
Assembly friction linings as required. Check the air
cylinder piston travel and the adjustment of
the springs.
8. Roller Circle Verify roller integrity, replace broken or
Rollers cracked rollers.
9. Center Pintle Verify the proper adjustment of the pintle
locking nut and the security of the locking
bars. Clean spent grease from under the
lower nut.
10. Center Pintle Verify for correct spherical washer and truck
Lube frame pintle bushing lubrication.
11. Warning/Safety Replace all missing safety and warning signs.
Placards
12. Left Hoist Inspect the spider for cracks, the fit to the
Drum Spider drum and bolt tension.
13. Hoist Drum Inspect the bearings, retainers and seals for
Assembly damage and correct as needed.
Bearings
Date
Shift
Inspected By
Supervisor

June 2012
14. Hoist Motor Inspect the coupling, replace as required.
Coupling
15. Hoist Motor Inspect the mounting bolts for security, the

blower duct work for damage and security.
16. Hoist Brake Air Check the operation of the solenoid valve,
System release and set operations, hoses, fittings
and quick release valve.
17. Crowd Inspect for loose bolts or chock blocks, worn
Machinery mount pins and cracks. Repair as required.
Frame
18. Crowd Drum Inspect the retainer, bearing retainer bolts,
Bearing seals and condition of bearings.
Journals
19. Bearing Cap Check for tightness.
Mounting Bolts
20. Crowd 1st Inspect the gear and pinion teeth for the
Gear proper wear pattern, excessive wear and
Reduction alignment. Correct as required.
21. Crowd 2nd Inspect the gear and pinion teeth for the
22. Crowd 3rd Inspect the gear and pinion teeth for the
23. Crowd Inspect the bearings, retainers and seals. Re-
Machinery tighten the retainer bolts.
Bearings
24. Crowd Motor Check for lubrication and wear.
Coupling
25. Air Change the crankcase oil, clean the intake
Compressor(s) filter and, if so equipped, refill the anti-freeze
with the required agent.
26. Compressor Check the belt tension, readjust as required.
V-Belts Maintain belt/pulley alignment.
Date
Shift
Inspected By
Supervisor

June 2012

27. Compressor Inspect the intercooler tubing, replace as
Intercooler required.
28. Center Pintle Inspect the upper end for leaking or broken
fittings. Check the lube and air swivel for a

worn spindle housing seal and/or bypassing.
Repair immediately as required.
29. Lube Pressure Verify that all pressure transducers operate
Switches properly per machine requirements.
30. Boom Inspect and repair as required.
Bumpers
31. Boom Point Inspect both sheaves and bearings for
Machinery damage, repair as required.
32. A-Frame Legs Check the mounting pins and retainers,
replace worn parts.
33. Suspension Inspect the links for worn pins, cracks,
Links replace as required.
34. Boom Inspect and lubricate the sockets at each end
Suspension of each rope.
Rope Sockets
35. Dipper Tooth If used, check the fit of the adapters to the lip.
Adapters Must be tight fitting, repair as required.
36. Padlock Check the clearance in the dipper padlock
Connection bearing, replace worn parts as required.
Check the padlock link-to-bucket pin for wear.
37. Hoist Ropes Inspect the ropes, replace badly worn, frayed
or damaged ropes.
38. Operator’s Cab Check structure, hoses and fittings.
HVAC
Date
Shift
Inspected By
Supervisor

June 2012

39. Swing Motor Regrease drive end and non-drive end
bearings.
40. All Gearcase Take an oil sample from the gearcase and

Oils send to an approved lab for analysis.
Date
Shift
Inspected By
Supervisor

June 2012
3.5.1.5 Every 2500 Hours or Semi-Annually

Check Points - Every 2500 Hours or Semi-Annually
1. Crawler Link Check, record average link pin clearance as
Pin Clearance per Service Procedures of this manual.

2. Crawler Inspect the crawler frames for cracks in the
Frames wear plates and bottom plates of the
crawlers. Also inspect the connection of the
crawler frames to truck frame for loose and/or
missing hardware.
3. Lower Rollers Check for wear and/or cracks.
4. Propel Motor Inspect the coupling gear teeth for wear, re-
Coupling lubricate.
5. Drive Tumbler Check for presence of lube in the relief fitting.
Lube must be present! If fresh lube is not present, attempt to purge the lube through. If
still no lube, remove the tumbler and shaft to investigate the problem
6. Propel Motor Re-lubricate.
Bearing Lube
7. Propel Blower Verify security and condition of the blower
Mounts motor.
8. Truck Frame Visually inspect the internal structure for
cracks and damage. Repair as required.
9. Roller Circle Verify all frame splice plate bolts and roller pin
Assembly bolts are tight.
10. Propel Blower Check the blower ducts and connections and
clean the fan.
11. Hoist Check the connection between the hoist
Machinery gearcase and the revolving frame.
Pedestals
12. Center Pintle Remove the cover and verify the condition of
Upper Box all lube and air lines through the center of
rotation.
Date
Shift
Inspected By
Supervisor

June 2012
13. Center Pintle Check the test port for signs of air or lube
Air Swivel leakage.
14. Walkways/ Repair all damaged sections. Replace or

Ladders/Stairs, repair all damaged hand rails, toe plates and
Hand Rails/ skid protection.
Skid Protection
15. Hoist Drum Check all bolts for tension and retainers.
Lagging Bolts
16. Hoist Drum Check bolts for tension and retainers on left
Gear Bolts and right sides.
17. Crowd Bearing Check the tightness of all bolts.
Case Bolts
18. Crowd Drum Inspect the condition of the rope grooves and
Lagging anchors for excessive wear and distortion.
19. Crowd Auto Check all valves and injectors for bypassing.
Lube System
20. Crowd Gears/ Photograph all crowd machinery gears/
Pinions pinions for future comparison. Ensure all
teeth are clean for photo. Record the date
and machine hours.
21. Swing Air Inspect all air lines and fittings for leaks.
System Repair as required.
22. Swing Motor Inspect and tighten all swing motor mounting
Mounting bolts.
23. Air System Verify the correct function and setting of
Pressure switches and regulator.
Switches
24. Lube Room, Inspect all valves electrically and manually for
Air Control proper operation. Repair/replace as required.
Valves
25. Lube Pump Verify that all pumps and controls are
Stations operating properly, repair as required.
26. Boom Point Check all bearings, adjustments, retainers,
Machinery seals - repair or replace as required.
Date
Shift
Inspected By
Supervisor

June 2012

27. Suspension Check for worn pins, lug ends. If wear
Sockets exceeds 0.25 inch replace bridge pendant.
28. Operator’s Cab Pressurizer: Change motor brushes and
HVAC clean filter.
Date
Shift
Inspected By
Supervisor

29. Hoist Motor Regrease drive end and non-drive end
bearings.
30. Propel Motor Regrease drive end and non-drive end
bearings.
31. Crowd Motor Regrease drive end and non-drive end
bearings.
Date
Shift
Inspected By
Supervisor

June 2012
3.5.1.6 Every 5000 Hours or Annually
Check Points - Every 5000 Hours or Annually
1. Propel Check for leaks, cracks - repair as required.

Gearcase
2. Crawler Frame Check for wear, cracks, damage.
Underside
3. Crawler Frame Tighten all crawler frame connecting rod jack
bolts per Service Procedures section in this
manual.
4. Propel Motors Verify motor coupling clearance and
alignment using a dial indicator. (Refer to
manufacturer’s information.)
5. Propel Pull the bottom plug and collect a 1/2 gallon
Gearcase of lubricant. Inspect the sample for metal
particles.
6. Final Drive Lube must be present! If fresh lube is not
Shaft Bearing present, investigate the problem.
7. Swing Rack Verify the tension of the rack-to-truck frame
mounting bolts and the rack joint assembly
bolts.
8. Roller Circle Check for wear. Replace rails or rollers when
and Rails wear exceeds 1/2”.
9. Center Pintle Check the truck frame bushing and replace if
Bushing required.
10. Center Pintle Verify that the lock bars and retaining dowels
Upper Nut are in place. Check that the nut is flush with
the top of the pintle - if not, investigate the
problem.
11. Revolving Thoroughly inspect the revolving frame
Frame integrity. Repair damage from cracks and
wear. (Includes the ballast box weld joint and
swing gearcase support welds.)
12. Revolving Check the extension bolts for security and
Frame retension as required.
Extensions
Date
Shift
Inspected By
Supervisor

June 2012
Check Points - Every 5000 Hours or Annually

13. Machinery Repair all damaged sections, panels, doors
House and latches.
14. House Clean the filter units, inspect the blowers and
Filtration fan blades closely. Repair or replace

damaged and worn parts.
15. Hoist Motor Inspect the bearings, retainers and seals for
Pinion Shaft damage. Correct as needed. Inspect oil
passages for obstructions.
16. Hoist Drum Clean out excessive OGL.
Gear Cover
17. Hoist Brake Inspect the mounting bracket bolts for
Mounts damage and alignment.
18. Crowd Motor Inspect the mounts, chocks, coupling and
blower for damage or wear. Correct as
required.
19. Crowd Brake Inspect mounting bracket for security and
Mounting damage.
20. Crowd Check the torque on the taper lock pin
Machinery retainers on the crowd module-to-deck
mounts. Lubricate with spray lube.
21. Swing Brake Inspect the mounting brackets and check the
tightness on all mounting bolts.
22. Lube System Check all valves, injectors and pumps for
proper operation and damage. Repair as
required.
23. Operator’s Cab Evaporator: thoroughly clean system, check
HVAC motor bearings and replace if necessary.
Pressurizer: replace motors, filter and main
relay.
Date
Shift
Inspected By
Supervisor

June 2012
BI010309 Major Component Locations
3.6 Major Component Locations

Figure 3-1 Machine Nomenclature

June 2012
Major Component Locations BI010309
Figure 3-2 Lower Works and Crawlers

June 2012

Figure 3-3 Crawler Assembly

June 2012
Figure 3-4 Crawler Link Assembly

June 2012

Figure 3-5 Propel Machinery

June 2012
Figure 3-6 Roller Circle Section View

June 2012


June 2012
Figure 3-8 Collector Rings, Auxiliary

June 2012
Figure 3-10 Center Pintle Assembly

June 2012
Figure 3-11 Revolving Frame Deck Extensions

June 2012

Figure 3-12 Hoist Machinery

June 2012
Figure 3-13 Swing Machinery

June 2012
Figure 3-14 Crowd Machinery PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 1, 2012

June 2012
Figure 3-15 Lubrication Reservoirs

June 2012

Figure 3-16 Operators Cab

June 2012
Figure 3-17 Right Hand Boarding Stairway

June 2012
Figure 3-18 Boarding Ladder

June 2012
Figure 3-19 Power Step

June 2012

Figure 3-20 Machinery House Walkways and Platforms

June 2012

June 2012

Figure 3-22 Boom Support Ropes

June 2012
Figure 3-23 Boom Bumpers

June 2012

Figure 3-24 Dipper Assembly

June 2012

June 2012
BI010310

4 Service Procedures
Service Procedures
4.1 Lower Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.1.1 Truck Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Figure 4-1 Truck Frame and Crawlers Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.1.2 Swing Rack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.1.2.1 Roller Circle Rail Replacement - Lower. . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.1.2.2 Roller Circle Rail Replacement - Upper. . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-2 Revolving Frame Assembly (Viewed from the bottom) . . . . . . . . . . . . . . . 4-9
Figure 4-3 Section A-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.1.3 Roller Circle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Figure 4-4 Swing Rack and Roller Circle Section View. . . . . . . . . . . . . . . . . . . . . . . 4-11
4.1.3.1 Roller Circle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.1.3.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.1.3.3 Run-in Procedure for the Roller Circle. . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.1.3.4 Roller Circle Segment Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.1.3.5 Roller Circle - Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.1.4 Crawler Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.1.4.1 Crawler Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.1.4.1.1 Crawler Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Figure 4-6 Crawler Belt Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Figure 4-7 Correct Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.1.4.1.2 Crawler Shoe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

June 2012
Service Procedures
BI010310
4.1.4.1.3 Crawler Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Figure 4-8 Crawler Belt and Shoe Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.1.5 Crawler Side Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.1.5.1 Crawler Side Frame Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Figure 4-9 Crawler Assembly - Right Shown, Left Opposite. . . . . . . . . . . . . . . . . . . 4-22
4.1.5.1.1 Slide Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Figure 4-10 Crawler Mounted Slide Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4.1.6 Crawler Front Idler Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Figure 4-11 Crawler Front Idler Assembly - Left Shown, Right Opposite . . . . . . . . . 4-24
Figure 4-12 Front Idler Assembly - Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.1.6.1 Load Rollers and Rear Idler Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.1.6.1.1 Roller Removal or Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Figure 4-13 Load Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.1.7 Propel Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Figure 4-14 Propel Drive Shaft Assembly - Exploded View . . . . . . . . . . . . . . . . . . . 4-30
Figure 4-15 Propel Drive Shaft Assembly - Section View . . . . . . . . . . . . . . . . . . . . . 4-31
4.1.7.1 Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4.1.7.2 Main Propel Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Figure 4-16 Fixtures for the Main Propel Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Figure 4-17 Propel Shaft Pilot Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Figure 4-18 Propel Shaft End Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4.1.7.3 Main Propel Shaft - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Figure 4-19 Main Propel Shaft - Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.1.7.4 Tumbler Rebuild Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Figure 4-20 Crawler Tumbler Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Figure 4-21 Crawler Drive Tumbler Rebuild Template . . . . . . . . . . . . . . . . . . . . . . . 4-40
4.1.8 Propel Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.1.8.1 Propel Planetary Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.1.8.1.1 Propel Gearcase Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
4.1.8.1.2 Propel Gearcase Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Figure 4-22 Propel Gearcase - Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Figure 4-23 Propel Shaft Face Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Figure 4-24 Threaded Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.1.8.2 Propel Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4.1.8.2.1 Propel Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4.1.8.2.2 Propel Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48
4.2 Rotating Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
4.2.1 Revolving Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
4.2.2 Center Pintle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Figure 4-25 Center Pintle – Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4.2.2.1 Center Pintle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
4.2.2.2 Center Pintle Sleeve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

June 2012
Service Procedures
BI010310
4.2.3 Collector Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Figure 4-26 Collector Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Figure 4-27 Collector Rings, High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4.2.3.1 Collector Ring Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4.2.3.2 Collector Ring Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4.2.4 Cable Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

4.2.4.1 Do’s and Don’ts of Reel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
4.2.4.2 Cable Reel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
4.2.4.3 Hydraulic Drive Start Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
4.2.4.4 Unloading Valve Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . 4-62
4.2.4.5 Cable Reel Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4.2.4.6 Cable Reel Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4.2.4.7 Cable Reel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4.2.4.8 Level Wind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4.2.4.9 Collector Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4.2.4.10 Cable Reel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.2.4.11 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.2.4.12 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.2.5 Swing Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
4.2.5.1 Swing Support Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
4.2.5.2 Swing Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4.2.5.2.1 Swing Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4.2.5.2.2 Swing Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4.2.5.2.3 Swing Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
4.2.5.3 Swing Planetary Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4.2.5.3.1 Swing Gearcase Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4.2.5.4 Swing Pinion Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
Figure 4-28 Dual Vertical Swing Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4.2.5.4.1 Swing Pinion Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4.2.5.4.2 Swing Pinion Shaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4.2.5.4.3 Swing Pinion Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
Figure 4-29 Swing Pinion Shaft - End View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4.2.5.4.4 Swing Pinion Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
4.2.6 Hoist Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
Figure 4-30 Hoist Machinery Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
Figure 4-31 Hoist Machinery - Plan View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
4.2.6.1 Hoist Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Figure 4-32 Hoist Motor Mounting - Plan View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
4.2.6.2 Motor Coupling Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Figure 4-33 Guard Over Coupling Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Figure 4-34 Coupling Alignment Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
4.2.6.3 Hoist Gearcase Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

June 2012
Service Procedures
BI010310
Figure 4-35 Installation of the Hoist Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

4.2.6.3.1 Hoist Gearcase Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Figure 4-36 Hoist Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Figure 4-37 Hoist Gearcase Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
4.2.6.4 Hoist Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Figure 4-38 View A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Figure 4-39 View B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92

4.2.6.5 Hoist Gear Start-Up Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Figure 4-40 Hoist Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Figure 4-41 Arrow Showing Location of Dial Indicator . . . . . . . . . . . . . . . . . . . . . . . 4-94
Figure 4-42 Record Dial Indicator Readings, Specifying Inches or Millimeters . . . . 4-95
Figure 4-43 Dial Indicator Placed on Right-Hand Gear Face . . . . . . . . . . . . . . . . . . 4-96
Figure 4-44 Lead Impression Wires to Pinion Teeth. . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Figure 4-45 Contact Pattern Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98
4.2.6.6 Hoist Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
Figure 4-46 Hoist Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
4.2.6.6.1 Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102
4.2.6.6.2 Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
4.2.7 Hoist Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
Figure 4-47 Hoist Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
4.2.7.1 Hoist Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105
4.2.7.2 Hoist Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106
4.2.8 Crowd Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107
Figure 4-48 Crowd Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108
4.2.8.1 Crowd Gearcase Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-109
Figure 4-49 Crowd Motor Pinion - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . 4-110
Figure 4-50 Crowd 1st Reduction - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . 4-111
Figure 4-51 Crowd 2nd Reduction - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . 4-112
4.2.8.2 Crowd Gearcase Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-113
4.2.8.3 Crowd Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-114
4.2.8.4 Crowd Gear and Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-116
Figure 4-52 Crowd Gear and Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-116
4.2.8.4.1 Crowd Drum Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117
4.2.9 Operator’s Cab Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119
Figure 4-53 Operator’s Cab Isolator Mount Components . . . . . . . . . . . . . . . . . . . . 4-119
4.2.9.1 Operator's Cab Isolator Mount Replacement . . . . . . . . . . . . . . . . . . 4-120
Figure 4-54 Operator’s Cab Lifting Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-121
Figure 4-55 View Looking UP Into Roof Truss . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-121
Figure 4-56 Removing Lower Components Of Each Isolator Mount. . . . . . . . . . . . 4-122
Figure 4-57 Alignment Locations (Looking UP Into Roof Truss). . . . . . . . . . . . . . . 4-123
Figure 4-58 Operator’s Cab Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . 4-124
4.2.10 Operator’s Seat Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-126
Figure 4-59 Operator's Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-126
Figure 4-60 Access Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127

June 2012
Service Procedures
BI010310
Figure 4-61 Shift the Seat Backward To Expose 2 Front Mounting Holes . . . . . . . 4-128
4.2.11 Joystick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-130
4.2.11.1 Joystick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-132
4.2.12 Wiper Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134
4.2.13 Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-136
4.2.14 Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137

Figure 4-62 View A - Wiper Motor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-139
4.3 Machinery House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-140

4.3.1 Walkways, Stairways, and Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141
4.3.1.1 Boarding Stairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-142
Figure 4-63 Right Side Boarding Stairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-142
4.3.1.2 Vertical Boarding Ladder, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-143
Figure 4-64 Vertical Boarding Ladder, Miscellaneous Views . . . . . . . . . . . . . . . . . 4-144
4.3.1.3 Power Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-145
4.4 Front End Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-146
Figure 4-65 Front End Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-146
4.4.1 Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-147
Figure 4-66 Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-148
4.4.1.1 Boom Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-148
4.4.2 Boom Limit Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-149
Figure 4-67 Boom Limit Switch Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-149
Figure 4-68 Boom Inductive Proximity Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-150
4.4.3 Boom Point Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-151
4.4.3.1 Boom Point Sheave Removal and Disassembly . . . . . . . . . . . . . . . . 4-152
4.4.3.2 Boom Point Sheave Reassembly and Installation . . . . . . . . . . . . . . . 4-154
4.4.4 Boom Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-155
4.4.5 Saddle Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-156
Figure 4-69 Saddle Block Bushing Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . 4-156
4.4.5.1 Saddle Block Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-157
4.4.5.2 Saddle Block Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-158
Figure 4-70 Saddle Block Sheave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-159
4.4.6 Dipper Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-160
4.4.6.1 Dipper Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-162
4.4.6.2 Crowd Rope Take-Up Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-164
4.4.6.2.1 Crowd Rope Take-Up Mechanism Disassembly. . . . . . . . . . . . 4-165
4.4.6.2.2 Crowd Rope Take-Up Mechanism Assembly . . . . . . . . . . . . . . 4-167
4.4.7 Dipper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-169
Figure 4-71 Dipper Door Latch Bar and Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-170
4.4.7.1 Latch Bar Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-171
4.4.7.2 Dipper Door Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-172
Figure 4-72 Dipper Door Bumper Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-172

June 2012
Service Procedures
BI010310
4.4.7.3 Dipper Door Snubbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-173

4.4.7.3.1 Snubber Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-174
4.4.7.3.2 Allowable Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-174
4.4.7.4 Dipper Pitch Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-175
Figure 4-73 Adjustable Pitch Brace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-175
4.4.7.5 Dipper Padlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-176
4.4.8 Dipper Removal & Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-179

Figure 4-74 View A-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-180
Figure 4-75 View B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-181
Figure 4-76 Section C-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-182
Figure 4-77 Section D-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-183
4.4.9 Dipper Trip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-184
4.4.10 Crowd Rope Take-up Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-186
Figure 4-78 Hydraulic Schematic – Crowd Screw Hydraulic Unit . . . . . . . . . . . . . . 4-187
4.4.11 A-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-188
4.4.12 Auxiliary Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-190
4.4.13 Hoist Rope Support Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-191
4.4.14 Boom Support Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-192
4.4.15 Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-193
4.4.15.1 Wire Rope Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-194
4.4.16 Hoist Rope Reeving & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-194
Figure 4-79 Shim for Hoist Rope Socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-198
4.4.17 Crowd Rope Reeving & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 4-198
Figure 4-80 Crowd Rope Reeving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-200
Figure 4-81 Crowd Rope Termination Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-201
4.4.18 Retract Rope Reeving & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 4-202
Figure 4-82 Retract Rope Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-203
4.4.19 Crowd and Retract Rope Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-205
Figure 4-83 Worm Drive During Crowd Rope Adjustment . . . . . . . . . . . . . . . . . . . 4-206
Figure 4-84 Worm Drive During Normal Machine Operation . . . . . . . . . . . . . . . . . 4-206
4.4.20 Dipper Trip Rope Reeving & Replacement. . . . . . . . . . . . . . . . . . . . . . . 4-207
4.4.21 Hoist and Crowd Limit Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-207
4.4.21.1 Setting Limits In The Hoist & Crowd System . . . . . . . . . . . . . . . . . 4-208
Figure 4-85 View A - Calibration Limits Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-209
4.4.21.1.1 Crowd Slowdown/Stop Limits. . . . . . . . . . . . . . . . . . . . . . . . . 4-210
4.4.21.1.2 Retract Slowdown/Stop Limits . . . . . . . . . . . . . . . . . . . . . . . . . 4-211
4.4.21.1.3 Lower Slowdown/Stop Limits . . . . . . . . . . . . . . . . . . . . . . . . . 4-212
4.4.21.1.4 Hoist Slowdown/Stop Limits. . . . . . . . . . . . . . . . . . . . . . . . . . .4-213

June 2012
Service Procedures
Service Procedures
4.1 Lower Works
4.1.1 Truck Frame Assembly

The truck frame assembly consists of the bolt-on crawler assemblies with belts, truck frame
structure, propel motors and planetary gearcases, center pintle, roller circle, swing rack and
lower roller circle rails.
Figure 4-1 Truck Frame and Crawlers Assembly
The truck frame is the primary support structure for the machine. The two bolt-on crawler side
frames each have a propel motor and planetary gearcase. This assembly provides the operator
complete independent control of each crawler.
Both the truck frame and crawler structures should be inspected during each maintenance period
for areas of distress. If cracks are found in any of the structural welds or plates these should be
repaired during the next scheduled maintenance period.

June 2012
Service Procedures
Each propel motor is equipped with a spring set, air released disc brake. These brakes require
no adjustment. Inspect friction disc wear by removing the assembly cover and observe remaining
amount of friction material on the disc. When wear reaches the change notch, replacement is
required. Since these are holding brakes, wear rate will be slow. For brake maintenance, refer to
BRAKES & COUPLINGS section in this manual.
4.1.2 Swing Rack Assembly

The swing rack or swing gear assembly includes a 4-piece cast gear and 9 lower roller circle rail
segments. Capscrews fasten the lower rail flanges to the gear. Capscrews also fasten the swing
rack to the truck frame structure.
Should the swing rack need to be replaced, it can be installed without complete separation of
upper and lower frame structures. Maintenance inspection of the swing rack consists of a
periodic check of torque on capscrews (semi-annual or 2500 hours, whichever comes first).
HIGH VOLTAGE! DO NOT ENTER THE TRUCK FRAME, OR THE AREA BETWEEN THE
REVOLVING FRAME AND THE TRUCK FRAME, UNLESS THE POWER SUPPLY TO THE
MACHINE HAS BEEN DISCONNECTED. Isolate the machine from the mine substation and
confirm that the collector rings have been grounded by a qualified electrician. Failure to
comply with these instructions could result in serious injury or death.
4.1.2.1 Roller Circle Rail Replacement - Lower

The lower roller circle rail is composed of 9 segments. The entire set of segments can be
replaced without separating the upper and lower frame structures. To replace the rail segments:
1. Park the machine on a level work area. Allow room to swing the machine if more than one
segment is to be removed.
2. Rotate the machine to align a roller circle segment over the rail segment to be removed. Be
sure that both segments are at one side of the revolving frame.
3. Remove the 2 thrust rails which cover the rail to be removed.
4. Remove the roller circle segment. Refer to the proper removal procedure.
5. Remove the rail segment.
6. Clean and deburr the mating surfaces of the new rail, thrust rail and the swing gear. Install
the parts.
7. Check the height between adjacent rails. The variation should be 0.005 inch maximum.
8. Wedge the thrust rails into position at each capscrew, tighten all capscrews and check the
offset between adjacent rails. The rail ends are tapered to allow for variation between the
segment ends. If the rail offset is greater than the taper depth, remove the rails, clean and
reinstall. There must be no ledge for the rollers to catch on during operation.
9. Reinstall the roller circle segment that was previously removed.

June 2012
Service Procedures
NOTES:
• Tighten the 36 - 1.00 inch hex screws to the torque value indicated below.
Lubricated threads: 680 Ft-Lbs
1-1/2 Inch Hex
(922 N•m)
Dry threads: 904 Ft-Lbs (1226
N•m)

• A typical gap of 0.04 inch should exist between rail ends.
• The inside diameter of lower rails must be tight against the counterbore of the swing rack
and the outside diameter of the thrust rails must be tight against the inside diameter of the
swing rack.
3
4.1.2.2 Roller Circle Rail Replacement - Upper
Figure 4-2 Revolving Frame Assembly (Viewed from the bottom)
The upper roller circle rails are composed of 6 rail segments bolted to the revolving frame. To
replace the upper rail segments:
1. Park the machine in a level work area. Rotate the upper frame to position a roller circle
retainer bar directly below the rail or rails to be removed.
2. If the rear rails are to be removed, raise the rear of the machine with jacks (or by hoisting
the dipper into a bank). If the front rails are to be removed, jack the boom by crowding the
dipper into the ground.

June 2012
Service Procedures
BLOCK THE MACHINE IN PLACE AFTER RAISING THE FRONT OR REAR UPPER RAILS
OFF THE ROLLER CIRCLE. DISCONNECT THE POWER SUPPLY. Failure to comply could
result in serious injury.
3. Remove the roller circle outer retaining bar or bars as required.

4. Remove the bolts which secure the upper rail(s) to be removed from the revolving frame.
Figure 4-3 Section A-A
5. Slide the rail(s) along the roller circle to the nearest side of the revolving frame and lift the
segment (approximately 500 Lbs.) clear of the machine.
6. Installation of new rails is the reverse of removal.
• Clean and deburr all mating surfaces.
• Be sure the rail flange is tight against the machined register on the revolving frame.
• Check the rail height between adjacent rails. The variation in rail thickness is 0.005 inch
maximum.
• Tighten the mounting bolts to specification.

June 2012
Service Procedures
4.1.3 Roller Circle Assembly
The roller circle assembly is a tapered roller thrust bearing which supports the revolving frame
assembly. It is composed of 50 tapered rollers which are held in position by a steel cage. The
cage is divided into eight (8) subassemblies - 7 sections contain 6 rollers each and 1 section
contains 8 rollers. The rollers are supported with a steel spacer and a self-lubricating nylatron

bushing.
Figure 4-4 Swing Rack and Roller Circle Section View
Inspect the roller lube coverage daily. Only a light coat of OGL is required on the roller face and
thrust rail. Check the roller and rail bolts monthly (420 hours), replace broken bolts and re-tighten
all loose screws. Keep the lube drains open. Inspect the rollers and inside of the thrust rail for
spalling. If this condition is found, check for proper ballast and roller alignment.

June 2012
Service Procedures
NOTE: Tack weld keeper plate at assembly.

June 2012
Service Procedures
4.1.3.1 Roller Circle Adjustment
Roller circle adjustment is required to prevent damage to the rollers, roller cage, or rails if
vibration, popping, snapping, or crackling occurs during rotation. Rapid wear and/or damage to
roller circle components results from any one or a combination of the following:
• Roller spacers misaligned.

• Roller spacers or capscrews worn.
• Cage diameter too large or out of round.
• Incorrect roller or rail hardness.
• Improper machine ballast.
• Continuous operation on a steep grade.
4.1.3.2 Adjustment Procedure

1. Place the machine on a level work area. The roller circle capscrews should be uniformly
snug - not tight and not loose.
2. Slowly rotate the machine two revolutions with the dipper extended just above grade at its
maximum radius.
3. Check to see that all the rollers are seated against the thrust rail. If not, further loosen the
circle capscrews and repeat step two.
4. Check the gap between each roller and its thrust washer. If it is not a 0.12 inch nominal gap
at all rollers, then wrap a chain or wire rope sling around the circumference of the outer
roller circle cage and draw it up until the gap at each is 0.12 inch nominal. Loosen the roller
circle capscrews further if needed.
5. Tighten the 14 - .625 inch hex screws to the torque value indicated below.
15/16 Inch Hex 210 Ft-Lbs (285 N•m)
NOTE: These should be tightened in the circle at the rollers which are engaged between the
upper and lower rails. Rotate the machine to position the successive rollers between
the rails for tightening. Remove the tensioning device from around the outer
circumference of the roller circle.
6. Rotate the machine up to working speed, plugging and reversing it several times. Shut
down and check that the rollers are seated against the thrust rail and that the gap between
each roller and its thrust washer is 0.12 inch nominal.
7. Re-tighten all the roller circle capscrews after one full shift of operation. With the dipper
extended, tighten the capscrews at the rollers that are engaged between the upper and
lower rails. Rotate the machine to position the successive rollers there for tightening.

June 2012
Service Procedures
4.1.3.3 Run-in Procedure for the Roller Circle

For the first few days after installing a new roller circle or new rollers, rotate the machine 360°
every four hours. Check the torque of the roller capscrews at the end of this period and adjust as
required.
It is normal practice to rotate the upper frame one full revolution (360°) at the start of each shift to
relocate the rollers 180° so they wear evenly.
4.1.3.4 Roller Circle Segment Removal

1. Place the machine on a level work area. Rotate the machine so that the segment to be
replaced is near the front or the rear of the machine.
2. If a rear segment is to be removed, raise the rear of the machine with jacks (or by hoisting
the dipper into a bank). If a front segment is to be removed, jack the boom by crowding the
dipper into the ground.
OFF THE ROLLER CIRCLE. SHUT DOWN THE MACHINE, SET THE BRAKES AND
DISCONNECT THE POWER SUPPLY. Failure to comply could result in serious injury.
3. Remove the 4 splice bars (2 inner and 2 outer) from the ends of the segment.
4. Replace the through capscrews in the end rollers. Replace the nuts on the ends of the
capscrews after the splice bars are off the segment.
5. Carefully lift the roller segment (approximately 1300 Lbs.) up off the lower rail and move it
away from the machine.
NOTE: This segment removal provides access to the upper and lower roller rails for rod and
bolt tightening and/or replacement. The entire roller circle can also be replaced by
systematically removing a segment, replacing the rollers, reassembling the segment
into the circle, rotating the machine to the next segment, and so on until the entire roller
circle is installed.
Reassembly is the reverse of disassembly:
a. Refer to ROLLER CIRCLE ADJUSTMENT.
b. Tighten the roller capscrews as specified in the procedure after the roller circle
assembly is situated correctly.
c. Refer to ROLLER REMOVAL OR REPLACEMENT for lubrication and matching of
adjacent roller diameters.

June 2012
Service Procedures
4.1.3.5 Roller Circle - Roller Replacement
NOTE: Replace a broken or flat roller immediately.
1. Place the machine on a level work area. Rotate the machine so that the roller to be replaced
is near the front or the rear of the machine.
2. If a rear roller is to be removed, raise the rear of the machine with jacks (or by hoisting the

dipper into a bank). If a front roller is to be removed, jack the boom by crowding the dipper
into the ground.
OFF THE ROLLER CIRCLE. SHUT DOWN THE MACHINE, SET THE BRAKES AND
DISCONNECT THE POWER SUPPLY. Failure to comply could result in serious injury.
3. If enough room exists above the roller cage to allow passage of the roller, remove the roller
directly:
a. Remove the capscrews from the roller to be replaced.
b. Lift the roller with bushing and thrust washer from the cage.
c. Remove the thrust washer as soon as it clears the inner cage.
4. If not enough room exists to allow passage of the roller above the roller cage, remove the
outer cage:
a. Remove the 2 outer splice bars from the ends of the roller segment containing the
roller to be replaced.
b. Remove the capscrews securing the rollers within the roller circle segment containing
the roller to be replaced.
c. Remove the outer cage member, then lift the roller with bushing and thrust washer
from the roller circle.
d. Remove the thrust washer as soon as it clears the inner cage.
5. Place the roller on some cribbing at ground level. Remove the spacer and bushing.
6. Inspect the parts and replace as needed.
Reassembly is the reverse of disassembly:
a. The diameter of the new roller must be within ±.001 inch of adjacent rollers. Measure
the diameter of its adjacent rollers and grind the new roller(s) to match.
b. Lubricate roller bushing I.D. with Molykote at assembly
c. With the roller seated against the thrust rail, the gap between the thrust washer and
roller is to be 0.12 inch nominal. Refer to ROLLER CIRCLE ADJUSTMENT.
d. Tighten the 2 - .625 inch hex screws to the torque value indicated below.
15/16 Inch Hex 210 Ft-Lbs (285 N•m)

June 2012
Service Procedures
4.1.4 Crawler Belts

The crawler belts contact the ground and transfer the entire weight of the machine from the truck
frame to the ground. Each belt is an endless shoe assembly that is moved by the propel
machinery around the crawler side frame. One belt on each crawler consists of 47 cast alloy
steel, non-cleated, double-pin connected shoes. The pins are retained in the shoes by lock bolts.
All the shoes assemble into the belt so that the male lugs on each shoe are toward the front of
the machine when the shoe is on the bottom of the crawler frame.

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Service Procedures
4.1.4.1 Crawler Belt Maintenance
1. Replace any missing or broken shoe pin lock bolts immediately.
2. To remove old shoe pins - drive them out if possible, burn them out if necessary.
3. Annually (5000 hrs) remove any metal flow from the roller path on each shoe that interferes
with belt motion. Use arc air to within 0.125 inch of final surface, then grind the remainder.

4. Monitor the fit of the shoes or belt to the drive tumbler monthly (420 hrs)
• Record wear rate.
• Replace shoes or rebuild drive lugs as needed.
• Replace the tumbler or rebuild wear areas as needed.
5. Replace or rebuild the slide bars on the crawler side frame BEFORE the drive lugs on the
shoes touch the top of the crawler.
PROPERLY ADJUSTED BELTS REDUCE THEIR WEAR RATE AND PROLONGS THEIR
SERVICE LIFE!
4.1.4.1.1 Crawler Belt Tension Adjustment
1. Propel the machine forward on level ground until most of the slack in the crawler belt is on
top of the crawler.
2. Safely park the machine. Remove the auto lube line from the end of the front idler shaft.
3. Position 2 identical hydraulic jacks to the rear of the adjusting blocks on each side of the
front idler in the crawler side frame. Seat the jack ram into the counterbore provided in the
adjusting block.
4. Remove the 2 shim retainer bars on each side to free the shims, and remove the shims
from the storage space in front of each adjusting block.
5. Extend both hydraulic jacks in unison to move the front idler assembly forward to tighten the
belt. Do not permit the adjusting blocks to misalign in the side frame.
6. Tighten the belt until all slack is removed and the crawler shoes start to lift off any slide bar.
7. Insert shims into the space on each side behind the adjusting blocks until a gap of 1.5
inches exists between the shims and the blocks.
NOTE: Shims of the same thickness and quantity must be used in the space on each side to
maintain correct idler alignment in the crawler.
8. Release both hydraulic jacks and remove them from the crawler.
9. Put the remaining shims in the storage space in front of each adjusting block. Reassemble
the shim retainer bars to the crawler. Reconnect the auto lube line.
NOTE: Both crawler belts should be adjusted to the same tension and the same overall length.
This is to ensure that the machine will propel in a straight line. The machine will have a
tendency to turn toward the shorter belt when propelling forward.

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Service Procedures
Figure 4-6 Crawler Belt Tension Adjustment
NOTE: Moving the adjusting blocks 1.00 inch results in a belt adjustment of 2.00 inches.
Figure 4-7 Correct Belt Tension

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Service Procedures
NOTES:
• BEFORE the drive lugs on the shoes touch the top of the crawler frame, replace or
rebuild the slide bars to their original height.
• To check for the correct belt tension - while propelling the machine ensure that the
crawler shoes effectively engage the drive tumbler. This is achieved when there is a
minimum of radial shoe movement as it enters the load area of the drive tumbler.

4.1.4.1.2 Crawler Shoe Replacement
STORED ENERGY! SECURE THE CRAWLER BELT BEFORE SEPARATING IT SO

UNEXPECTED MOVEMENT UNDER ITS OWN WEIGHT IS PREVENTED. Failure to secure
the belt could result in bodily injury or death.
1. Park the machine safely on a level work area with the shoe to be replaced at the front idler
at the belt separation point.
2. Add blocking between the top of the crawler frame and the shoes to remove any slack in the
belt.
3. Using hydraulic jacks, remove any belt tension by removing the shims behind the adjusting
blocks on each side of the front idler shaft.
NOTE: Propel the machine slightly back and forth to unseat the adjusting blocks rearward in
the frame slots if they do not move on their own.
4. Block or support the shoe below the one to be removed. To separate the belt, remove the
pin locking hardware and the pin from 2 places on the bottom of the shoe to be removed.
5. Sling and support the shoe to be removed and then remove the pin locking hardware and
the pin from 2 places on the top of the shoe to be removed. Remove the shoe from the belt.
6. Position the new shoe into the belt. To fasten one end of the new shoe to the belt, insert the
pins and locking hardware in 2 places to secure one end of the shoe. Remove the sling.
7. Align the other end of the shoe to the existing shoe to close the belt. Install the pins and
locking hardware in 2 places to secure the shoe. Tighten the 4 - 36 mm hex screws (that
retain the 4 pins) to the following torque value.
M55 Hex 1045 Ft-Lbs (1417 N•m)
8. Remove the blocking and adjust the belt tension.

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Service Procedures
4.1.4.1.3 Crawler Belt Replacement

1. Park the machine in a level work area. Assemble the new belt forward of the machine, in
line with the one to be replaced.
2. Add blocking between the top of the crawler frame and the shoes to remove any slack in the
belt.
3. Remove any belt tension. To separate the belt, at the lowest point forward of the front idler,
remove the locking hardware and pin from 2 places on the shoe.
4. Connect the new belt to the front shoe under the front idler roller at the separation of the old
belt. Install both pins and their locking hardware. Tighten the 4 - 36 mm hex screws (that
retain the 4 pins) to the following torque value.
M55 Hex 1045 Ft-Lbs (1417 N•m)
5. Attach a wire rope to the upper portion of the old belt at the separation point, then to a truck
or dozer.
6. Pull on the top portion of the old belt to maintain engagement with the shoe lugs on the drive
tumbler and SLOWLY propel the machine forward until the new belt has replaced the old on
the crawler. Park the machine.
7. Disconnect the old belt from the new and remove it from the work area. Pin the new belt
together at the front idler. Tighten the 2 - 36 mm hex screws to the following torque value.
M55 Hex 1045 Ft-Lbs (1417 N•m)
8. Adjust the belt tension.
Figure 4-8 Crawler Belt and Shoe Replacement

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Service Procedures
4.1.5 Crawler Side Frame Assembly
The crawler side frame assembly provides the motion path and support structure for each
crawler belt. Each assembly bolts to the truck frame structure and contains the propel machinery
to drive its respective belt.

Each side frame assembly consists of the following components:
• 8 load rollers which transfer machine weight to the belt.
• 1 front idler roller.
• 1 rear idler roller.
• Drive tumbler shaft.
• Planetary propel gearcase, totally enclosed with right angle input.
• Propel motor with a single-disc, spring-set, air-released brake.
• Heavy duty fabricated frame structure with slide bars to guide the belt.

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Service Procedures
4.1.5.1 Crawler Side Frame Maintenance

Maintenance and inspection requirements for each crawler side frame includes:
• Check the tension of the rod bolts joining the crawler side frame to the truck frame. (Refer to
PROCEDURE FOR USE of MECHANICAL TENSIONER ON CRAWLER RODS in
ENGINEERING DATA section of this manual.)
• Inspect the crawler side frame structure for cracks quarterly (1250 hrs).
• Inspect lubrication coverage daily.
• Check auto lube injector operation daily.
• Change the oil in the gearcase yearly (5000 hrs) or as determined by lab analysis of oil
samples.
Figure 4-9 Crawler Assembly - Right Shown, Left Opposite

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Service Procedures
4.1.5.1.1 Slide Bar Replacement
Eight cast manganese slide bar caps guide the crawler belt over each crawler side frame. These
slide bar caps are welded to 4 supports on each crawler and are intended to be replaced when
worn.
The procedure for replacement is as follows:

1. Park the machine in a level work area.
2. Remove all tensioning shims in the front idler. This will provide as much slack as possible in
the crawler belt. Raise the shoes over the slide bar(s) to be removed at least 6.5 inches.
3. Remove the 6 welds which attach the slide bar cap to be removed to its support and remove
the slide bar cap.
4. Grind the new slide bar cap as required for a proper fit.
5. Install the new slide bar cap and weld in place. Refer to the Figure 4-10.
Figure 4-10 Crawler Mounted Slide Bars

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Service Procedures
4.1.6 Crawler Front Idler Roller Assembly

Figure 4-11 Crawler Front Idler Assembly - Left Shown, Right Opposite
NOTES:
1. Install the idler shaft with the lube grooves toward the front of the crawler and the lube
supply holes toward the machine centerline (inboard).
2. Install the thrust washer with its lube grooves toward the idler roller.
3. Heat and bend the pin at assembly.
The front idler roller carries the machine weight in conjunction with the load rollers. The roller
turns about the idler shaft on bronze bushings. The idler shaft mounting consists of a pair of
adjusting blocks which can be moved to the front or rear to compensate for crawler belt wear.
Shims located on either side of each adjusting block are used to maintain the roller position.
To remove the front idler:
1. Park the machine in a level area leaving several inches of clearance under the front idler to
be removed.

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Service Procedures
2. Rotate the revolving frame to provide crane access to crawler belt and idler.
3. Remove the shim retainer bars, lube lines and shims ahead of the adjusting blocks.

Figure 4-12 Front Idler Assembly - Section View
4. Using the jacks provided, push the adjusting blocks on both sides of the idler shaft forward
to allow removal of the remaining shims.
NOTE: When using jacks to move the adjusting blocks, pressurize and release both jacks at
the same rate to prevent binding of the idler shaft.
5. Release the belt tension by slowly releasing the jack pressure to allow the adjusting blocks
to move to their rear-most position.
6. Separate the crawler belt behind the top of the idler and lay the forward crawler shoes on
the ground in front of the crawler.

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Service Procedures
SECURE THE CRAWLER BELT BEFORE SEPARATING IT SO UNEXPECTED MOVEMENT

UNDER ITS OWN WEIGHT IS PREVENTED. Failure to secure the belt could result in bodily
injury or death.
7. Support the idler (approximately 5100 Lbs.) with a crane.

8. Remove the shaft locking pins, the adjusting block screws (4 places per block) and the
adjusting blocks.
9. Use the tapped hole in the CENTER of either end of the idler shaft to remove the shaft.
STAND CLEAR OF THE AREA AS THE SHAFT IS REMOVED. The Thrust Washers and
Shims are fastened to the adjusting blocks with long hex-socket-head screws. THESE
PARTS MAY FALL OUT AS THE SHAFT IS REMOVED.
NOTE: Do not use the off-center lube supply holes at one end of the shaft for removal.
10. Lift the idler clear of the crawler frame.
11. Inspect all parts for wear or damage. Replace or repair as required.
Installation of the front idler is the reverse of removal.
NOTES:
1. Install the idler shaft with the 2 lube grooves toward the front of the crawler and the lube
supply holes toward the CL machine (Inboard).
2. If removed, install the thrust washers with their lube grooves toward the idler roller. Verify
that the proper running gap exists between the thrust washer and the idler on each side of
the idler.
3. After installation, lubricate and check auto-lube. Adjust belt tension. Refer to proper
procedures in this section of the manual.
4. Install the adjusting block with the jack depression toward the rear of the crawler.
5. Install the required shims to achieve the indicated gap between the idler and the thrust
washer on each side of the idler.

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Service Procedures
4.1.6.1 Load Rollers and Rear Idler Rollers
The load rollers and rear idler rollers are located at the bottom of each crawler side frame. The
load rollers and rear idler distribute the machine weight on the crawler belt.
Each of the load rollers and rear idler rollers turn on a fixed shaft secured in the crawler side
frame by a lock collar and pin. Each roller is fitted with a bronze bushing.

Thrust washers are located between the rollers and inner frame bosses to retain lubrication and
prevent the entry of dirt.
4.1.6.1.1 Roller Removal or Replacement
To remove a roller from the crawler side frame:

1. After a pit has been prepared, position a handling fixture under the roller for support when
the shaft is removed.
2. Propel the machine forward to a position where the roller to be removed is directly over the
hole. Separate the belt by removing the lock bolts. Lower each end of the belt into the pit
exposing the roller for removal.
3. Disconnect the auto lube line from the end of the roller shaft. Plug the line to prevent dirt
entry.
4. Remove the shaft retaining bolt.
5. Drive or pull the shaft out of the crawler frame, being careful to support the roller on a
handling fixture, jack or cribbing. Remove the thrust washers as they come free.
The same procedure can also be used to remove the rear idler roller.
To install or replace a load or rear idler roller:
1. Position the replacement roller in the pit on some cribbing, a handling fixture or jack.
2. Start shaft through the outside crawler side frame member. When the shaft begins to exit
the other side, install the thrust plate.
3. Raise the roller or idler into position and continue to drive the shaft through the roller or
idler.
4. As the shaft exits the roller, install the other thrust plate.
5. Continue to drive the shaft through the crawler frame until the bolt retainer aligns with the
hole in the collar.
NOTE: Install the load or idler roller shafts with their lubrication hole toward the front of the
machine. The punch mark on the end of the shaft indicates the lube hole location.
6. Install the lock bolt.
7. Install and purge the automatic lube lines. Check the lube system operation and reinstall the
guards.

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Service Procedures

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Service Procedures
Since the rollers are captured between the sides of the crawler frame, removal or replacement
requires the separation of the crawler belt and the lowering of the roller below the crawler side
frame. This is best accomplished by digging a pit to the dimensions shown in the following chart:
Pit Size Height Width

REAR IDLER 55 inches 79 inches

LOAD ROLLER 39 inches 63 inches
Figure 4-13 Load Roller Removal

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Service Procedures
4.1.7 Propel Shaft Assembly

Figure 4-14 Propel Drive Shaft Assembly - Exploded View
The drive shaft transmits propel effort from the planetary gearcase to the crawler belt. Anti-
friction bearings support the assembly at each end.

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Service Procedures

Figure 4-15 Propel Drive Shaft Assembly - Section View

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Service Procedures
4.1.7.1 Installation Notes

1. Install the retainer with the lube hole on the horizontal centerline of the propel shaft and in
line with the access hole.
2. After thorough cleaning, coat the exterior splines and interior mating surfaces with Optimoly
grease paste (part number 62055366).
3. Pack the rear of the spline cavity with 1 pint of lubricant; grease paste
(part number 62055366), prior to installing the shaft assembly.
4. Shim Procedure For Gap “A”:
a. After bearing installation, assemble the retainer to the shaft and tighten the capscrews,
for the gap measurement, to the torque value indicated below.
1-1/2 Inch Hex 185 Ft-Lbs (251 N•m)
b. Measure through the 3 small holes in the retainer with a depth micrometer to
determine the distance from the outer face of the retainer to the end of the shaft.
c. Remove the retainer and measure the retainer thickness at the 3 small holes.
d. Take the average of the 3 measurements from Step B and subtract the average of the
3 measurements from Step C. From this difference subtract 0.001 - 0.004 inch to
obtain the shim thickness.
e. Install the shims and tighten the capscrews to the torque value indicated below.
738 Ft-Lbs (1001 N•m)
5. Shim Procedure For Gap “B”:

June 2012
Service Procedures

a. Add the required amount of shims at Gap “C” to obtain a gap of 0.08 ±0.02 inch at Gap
“B”.
6. Shim Procedure For Gap “D”:
a. Install the retainer and tighten the capscrews, for the gap measurement, to the torque
value indicated below.
b. Measure the gap at 3 places equidistant around the O.D. of the retainer.
c. Take the average of the 3 measurements and subtract 0.001 - 0.004 inch to obtain the
shim thickness.

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Service Procedures
d. Install the shims and tighten the capscrews to the torque value indicated below.
738 Ft-Lbs (1001 N•m)
e. Fill the bearing cavity with Multiplex EP2 grease (part number MP380900).
7. If these shims are 2-piece, install with the split line horizontal and seal the split with RTV.
4.1.7.2 Main Propel Drive Shaft Removal

1. Park the machine safely on a level work area.
2. Rotate the revolving frame to gain access to the propel machinery.
3. Release the tension in the crawler belt to unpin the belt.
4. Have a qualified electrician disconnect the trail cable from the machine and move it out of
the way.
HIGH VOLTAGE! Only qualified personnel are permitted to perform this operation.
Failure to comply could result in bodily injury or death.
5. Remove the walkway from the front of the wing, above the propel machinery.
6. Separate the belt on top of the crawler, forward of the drive tumbler.
Secure the belt before separating it so that it cannot move unexpectedly under its own
weight. Failure to do this could result in personal bodily injury.
7. Lift the belt from the drive tumbler and lay it on the ground.
8. Mark the tumbler and the shoe under it with a visible mark (paint) so that the tumbler can be
repositioned to the belt in same location.
9. Remove the guard from the propel motor coupling and disassemble the coupling.
10. Support the propel gearcase (approximately 19,300 Lbs.) with a crane.
11. Unbolt the propel gearcase and remove it. Store in a clean area.
12. Remove the lube line to the inboard propel bearing at the inside of the gearcase housing.
13. Disconnect and plug the lube line to the outboard bearing retainer. Remove the retainer with
its shim pack from the end of the main propel shaft. Support the tumbler with the crane.
14. Pull the outboard bearing cartridge from its bore using 3 - M24 x 3 x 200 jack screws in the
tapped holes provided in the cartridge flange.
15. Remove the retainer plate from the outboard end of the tumbler shaft.

June 2012
Service Procedures

16. Use the spacer between the bearing race and shaft shoulder as a puller. Six tapped holes
(M20 x 25) are provided to attach the threaded rods and hardware required. Hydraulic
expansion of the inner race is also provided to ease the pulling force. Attach the hydraulic
pump provided with the machine to the 0.25 inch hole in the end of the drive shaft. Use
hydraulic pressure and pulling force simultaneously to remove the bearing race.
17. Remove the 18 - 1 Inch capscrews which secure the inboard bearing cartridge and retainer
to the crawler. DO NOT remove the 6 capscrews which secure the retainer to the cartridge.
NOTE: The 6 socket head capscrews in the bearing cartridge of the Main Propel Shaft are
present only to hold the subassembly of the cartridge and bearing to the shaft. They are
not to be removed after installation, or during removal of the Main Propel Shaft.
18. Install a pulling eye in the (M42 x 4.5 x 44 mm) tapped hole provided in the end of the propel
shaft. Manufacture or acquire the fixtures as indicated in “DETAILS FOR PROPEL SHAFT
FIXTURES”. Install the end support and pilot rod fixtures as shown in the following view,
then remove the shaft by pulling it toward the CL of the machine.

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Service Procedures
Figure 4-16 Fixtures for the Main Propel Shaft
19. Lift the tumbler clear of the crawler after the shaft has been removed.
20. Inspect all parts for damage or wear. Replace or repair as required. Refer to the MAIN
PROPEL SHAFT - DISASSEMBLY for disassembly and rework.
21. Reassembly is the reverse of disassembly.
a. To assist in the assembly of the propel shaft, the end support and pilot rod fixtures
may be installed as shown in the previous view.
b. Replace all seals and bearings.
c. Coat the internal and external spline surfaces and all pilot surfaces with Optimoly
grease paste (part number 62055366).
d. The inner race for the outboard bearing on the main propel shaft may be heated to fit it
to the shaft. Use a dry heat source and do not heat the race over 250°F (121°C). Allow
the race to cool to ambient temperature before installing the rest of the bearing.
e. Lube access on both bearing retainers of the main propel shaft must be installed on a
horizontal centerline toward the front of the crawler.
f. Shim the gaps as indicated on the accompanying sketches.
g. Pack the rear of the spline cavity in the propel gearcase for the main propel shaft with
1 pint of lubricant; grease paste (part number 62055366).
h. Fill the bearings and cavities manually with Multiplex EP2 grease (part number
MP380900) at assembly. Reconnect and purge the lube line.
i. Observe the match marking when installing the tumbler and propel gearcase, and
when assembling the propel motor coupling.
j. Propel motor coupling reassembly can be assisted by releasing the brake with the
manual override on the air control valve to allow the motor shaft to rotate freely.

June 2012
Service Procedures
22. Reconnect the crawler belt and adjust the belt tension. Reinstall the walkway to the front of
the wing.
23. Have a qualified electrician reconnect the trail cable to the machine.

HIGH VOLTAGE! ONLY QUALIFIED PERSONNEL ARE PERMITTED TO PERFORM THIS
OPERATION. Failure to comply, could result in bodily injury or death.
Details for the Propel Shaft Fixtures
Figure 4-17 Propel Shaft Pilot Rod
Figure 4-18 Propel Shaft End Support

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Service Procedures
4.1.7.3 Main Propel Shaft - Disassembly

1. Remove 2 locking capscrews from the bearing nut, and unscrew the bearing nut from the
shaft using the special wrench provided with the machine.
2. Lift the lip seal from the back face of the bearing cartridge, if it is still in place.
3. Remove 6 hex socket head capscrews holding the retainer to the cartridge.
4. Remove the retainer and seal spacer from the shaft.

5. Pull the cartridge from the bearing in the opposite direction.
6. Use a bearing puller to remove the bearing from the shaft.
7. Remove the bearing spacer from the shaft.
8. Inspect the final spacer that may remain next to the splines on the shaft. Remove if required
for replacement.
9. Inspect all parts and replace as required.
10. Reassembly is the reverse of disassembly:
a. The double tapered bearing may be heated for assembly to the shaft. Use a dry heat
source and do not permit the temperature of bearing to exceed 300°F (149°C). Allow
the bearing to cool to ambient temperature before assembling any other parts to it.
b. Install the bearing retainer and new seal without shims. Shim the gap at the retainer/
cartridge as indicated in the accompanying sketch.
c. Fill the bearing cavity with Multiplex EP2 grease (part number MP380900) at
assembly.
d. Spray the lip seal area with lubricant (part number MP170025) at assembly.
11. Assemble the main propel shaft into the tumbler and crawler.
Figure 4-19 Main Propel Shaft - Section View

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Service Procedures
NOTES:
1. If the bearing is heated for assembly purposes, do not exceed 300°F (149°C).
2. After installing the bearing and bearing cartridge, pack the bearing with Multiplex EP2
grease (part number MP380900).
3. Shim Procedure:

a. Install the retainer and tighten the capscrews to 179 Ft-Lbs for gap measurement.
b. Measure the gap at 3 places equal distance from each other around the O.D. of the
retainer.
c. Take the average of the 3 measurements and subtract 0.001-0.004 inch to obtain the
shim thickness.
d. Install the shims and tighten the capscrews to 739 Ft-Lbs. If the shims are 2-piece,
install them with the split as close as possible to the lube hole and seal the split with
RTV.
4.1.7.4 Tumbler Rebuild Procedure

The drive tumbler can be repaired by a buildup of weld applied to the 9 drive lugs. To build up the
lugs, proceed as follows:
1. Prepare a template as indicated in the sketch below. The template can be made of sheet
metal, wood or template paper. Contact the manufacturer for details.
2. Clean the tumbler of all spalled or loose material, grease and contaminants. Use a grinder
to remove imperfections. DO NOT USE A TORCH.
3. Preheat the tumbler rim to 550°F (273°C). Keep the hub area below 200°F (93°C). Maintain
this temperature during welding.
4. Hold a medium length arc - slight weaving action permitted but keep it to a minimum to
prevent local overheating. Weld beads must be applied adjacent to each other without
removing the slag. This will result in a smooth overlay. Remove the slag between layers,
maximum of 3 layers permitted.
5. Weld to within 0.19 inch of the final contour with weld rod that conforms to AWS E-9018.
Use only low hydrogen electrodes.
6. Finish the contour buildup using Hobart “Tufanhard 550” electrode, or its equivalent. Use
small diameter electrodes and deposit with stringer bead technique.
7. Allow the tumbler to cool slowly.
8. If needed, grind to a final lug contour.

June 2012
Service Procedures
Figure 4-20 Crawler Tumbler Rebuild
Figure 4-21 Crawler Drive Tumbler Rebuild Template

June 2012
Service Procedures
4.1.8 Propel Machinery
The propel machinery is interchangeable between the left and right crawler assemblies. Both the
planetary gearcases and motors mount inboard at the rear of the crawlers. Before installing a left
gearcase onto a right crawler side frame, exchange the oil breather with oil drain and exchange
eye bolt with screw plug. (As the same gearcase can be used on either the right or left side note

that following the previous instructions, either hole can be used as an oil drain.) The drive motors
are also interchangeable between the right and left crawler frames. A disc brake mounts on the
rear of each motor frame.
General maintenance and inspection of the propel machinery includes:
1. Inspection of the gearcase and electric motor mounting bolts.
2. Check the gearcase oil level daily by removing the oil level plug in the gearcase.
3. Change the oil in gearcase annually or as indicated by lab test analysis. Flush the gearcase
before refilling with oil. (See Lubrication section.)
4. Inspect the motor coupling quarterly for lube level and keep full.
5. Lubricate the motor bearings semi-annually with EMG (Electric Motor Grease). Application
of grease should be performed by qualified personnel as an excess could cause motor
failure.
6. Inspect the operation of the brakes daily. Monitor wear rate of friction disc. Replace when
wear ring indicates lining is worn out. For more detailed information on the description and
maintenance of the propel brakes, see BRAKES AND COUPLINGS section in this manual.
4.1.8.1 Propel Planetary Gearcase

The propel gearcase assembly includes three reductions - a right angle spiral bevel 1st
reduction, a planetary 2nd reduction and a planetary 3rd reduction.
STORED ENERGY! Gearing or drum must be blocked prior to performing maintenance

in order to prevent unwanted movement. Death, serious injury, or damage to the machine
can result in failure to take proper prevention measures.
To minimize down time, it is recommended that the gearcase be replaced as a complete unit, if a
problem should develop within the case. If the case is to be disassembled, it should be taken to a
maintenance shop for repairs.
NOTES:
• The reduction spiral bevel (palloid) gear & pinion are manufactured as a matched set. Do
not interchange or order separately.
• When replacing the single row tapered bearings on the spiral gear shaft & pinion
cartridge, the end play must be adjusted & new spacers ground to fit.
• Check the 1st reduction tooth contact when a new bearing & new gears are installed.
• Change the planet gears in sets of 3 only.

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Service Procedures
• For LUBRICANT REPLACEMENT, refer to LUBRICATION section in this manual.
4.1.8.1.1 Propel Gearcase Removal

To remove the left or right propel gearcase use the following procedure:
1. Park the machine on a level work area.
2. Rotate the upper frame to gain access to the propel gearcase with a crane or hoist.
3. Disconnect the trail cable from the machine and move it out of harms way.
HIGH VOLTAGE! A QUALIFIED ELECTRICIAN SHOULD DISCONNECT THE TRAIL

CABLE. Failure to comply could result in bodily injury or death.
4. Remove the cable reel if furnished.

5. Drain the oil from the gearcase.
6. Remove the guard from the propel motor coupling.
STORED ENERGY! Once grid is removed, machinery is free to rotate and brake will no
longer hold. Gearing or drum must be blocked prior to doing any maintenance to prevent
unwanted movement. Death, serious injury, or damage to the machine can result from
failure to take proper measures to prevent movement due to release of energy.
7. Open the propel motor coupling and remove the spring grid. Note the match marking on the
coupling covers.
8. Remove the inspection cover from the housing on the crawler bell housing for viewing the
main propel shaft/gearcase junction.
9. Support the gearcase (approximately 22,000 Lbs.) with a crane line through the lifting eye
on the gearcase.
10. Remove all 32 capscrews and 4 threaded rods that fasten the gearcase to the crawler side
frame bell housing. Match marks on the gearcase and crawler bell housing flange are for
coupling alignment assistance if the SAME gearcase is reinstalled.
11. Use 3 of the removed capscrews in tapped holes in the flange of the gearcase as jacking
screws to evenly withdraw the gearcase from the pilot bore in the crawler bell housing.
12. Remove the gearcase from the splines of the main propel shaft and lift it away from the
crawler to some cribbing.
13. If a new or exchange gearcase is to be installed, use a bearing puller to remove the
coupling hub from the input shaft.
NOTE: The planetary gearcase design requires close tolerances and special tools for
disassembly and rebuild. DO NOT ATTEMPT TO DISASSEMBLE THESE UNITS
WITHOUT A QUALIFIED FACTORY REPRESENTATIVE PRESENT.

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Service Procedures
4.1.8.1.2 Propel Gearcase Installation
Figure 4-22 Propel Gearcase - Section View PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 1, 2012
The installation procedure for the propel gearcase is as follows:
1. Install the coupling hub onto the gearcase input shaft. The coupling hub should be heated to
assist installation onto the shaft. Use a dry heat source and DO NOT permit temperature of
the hub to exceed 350°F (177°C). Allow the hub to cool to ambient temperature before
assembling any other coupling parts.
2. Install a new face seal onto the propel shaft as shown in the sketch.

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Service Procedures
Figure 4-23 Propel Shaft Face Seal
3. Pack the rear of the spline cavity in the propel gearcase for the main propel shaft with 1 pint
of Optimoly grease paste (PN: 62055366) or equivalent.
4. Coat the internal and external spline surfaces and all shaft pilot surfaces with Molub-Alloy
grease paste or equivalent.
5. Install the gearcase by engaging the splines of the gearcase with the main propel shaft and
the pilot register of the gearcase with the crawler housing. Insert the 4 threaded rods into
the gearcase prior to installing on the crawler frame. Install the 32 fasteners and tighten all
to 7,380 Ft-Lbs (10,006 N-m).
Figure 4-24 Threaded Rods

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Service Procedures
NOTE: Align the match marks if the same gearcase is being reinstalled. This will minimize the
time required to align the coupling. If a NEW gearcase is being installed, add new
match marks after the gearcase has been installed and the coupling aligned.
6. Fill the gearcase with the proper lubricant to the specified capacity. Refer to the
LUBRICATION section in this manual. Be sure to install the breather and case plugs.
7. The reassembly of the propel motor coupling can be assisted by releasing the disc brake

with the manual override on the air control valve. This will allow the rotation of the motor
shaft.
8. Align the motor coupling per the specifications in the BRAKES AND COUPLINGS section in
this manual. Install the grids and cover.
9. Fill the propel motor coupling to the recommended level with special long term grease (PN:
MP295148).
10. Install the cable reel, if furnished, with the machine and reconnect the trail cable.
HIGH VOLTAGE! - RE-CONNECTION OF THE TRAIL CABLE SHOULD ONLY BE

PERFORMED BY A QUALIFIED ELECTRICIAN. Failure to comply could result in severe
bodily injury or death.
4.1.8.2 Propel Motors

For lubrication of the drive motor, refer to GREASING MAIN AC DRIVE MOTORS in the
LUBRICATION section of this manual.
STORED ENERGY! Gearing or drums must be blocked prior to performing maintenance

in order to prevent unwanted movement. Death, serious injury, or damage to the machine
can result from failure to take proper prevention measures.
Each Propel Motor is bolted to a mounting pad located inside each crawler side frame. The motor
output shafts are coupled to the planetary gearcase with grid type couplings. Coupling alignment
is assisted with jacking screws located at six positions on the motor mounting pads. Each propel
motor is equipped with a spring-set, air-released disc brake.

June 2012
Service Procedures
4.1.8.2.1 Propel Motor Removal

1. Park the machine on a level work area and rotate the upper frame to gain access to the
propel motor.
2. Have a qualified electrician disconnect the power from the machine and wiring from the
propel motor.
HIGH VOLTAGE! ONLY QUALIFIED PERSONNEL ARE PERMITTED TO PERFORM HIGH

VOLTAGE ELECTRICAL SERVICE AND MAINTENANCE. Failure to comply could result in
bodily injury or death.
3. Remove any dirt guards and/or cable support from around the motor and brake assembly.
4. Remove the guard over the motor coupling. Open the coupling and remove the grid.
NOTE: Match marking on the coupling covers is for use in reassembly.
5. Disconnect and plug the air supply at the disc brake.
RELEASE THE AIR PRESSURE TO THE BRAKE BEFORE DISCONNECTING THE AIRLINE.
Plug the line immediately after disconnecting. Failure to comply could result in personal
injury.
6. Support the motor (approx. 6,200 lbs.) with a crane.

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Service Procedures

7. Remove the 4 capscrews and related hardware that fasten the motor to the crawler
mounting pad. Lift the motor away from the machine to the cribbing. Secure the shims at the
4 motor mounting points at the time of removal so that they are available for reassembly.
8. To remove the disc brake from the propel motor, loosen the 6 capscrews that fasten the
brake housing to the motor frame. Remove all but 2 of the capscrews. These should be
opposite each other. Support the brake assembly and remove the remaining 2 capscrews.
NOTE: If the motor is to be replaced, remove the coupling hub and the brake rotor hub from
each end of the electric motor armature shaft. For further information and a complete
description of the propel brakes, refer to the BRAKES AND COUPLINGS section in this
manual.

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Service Procedures
4.1.8.2.2 Propel Motor Installation

The following procedure assumes that the propel motor being installed is new and that it has
none of the additional parts required for the application.
1. Install the drive coupling hub and brake rotor hub onto the motor shaft. The rotor hub installs
on the commutator end of the motor. Follow the hub/gear installation procedure in the
ENGINEERING DATA section of this manual.

2. Install the brake assembly so the air inlet is at the bottom after the motor assembly is
installed onto the machine. Refer to the BRAKES AND COUPLINGS section of this manual
for installation and adjustment.
3. Install the motor and brake assembly onto the crawler frame. Check the coupling alignment.
With the motor shaft at midpoint of its axial float, the gap, angular offset and radial offset
must all be within specification. Refer to GEAR COUPLINGS in the BRAKES AND
COUPLINGS section of this manual for specifications and mounting instructions.
4. If alignment is required, use the 4 jacking screws and mounting bolts to move the motor
horizontally and the 2 jack screws under the motor to move it vertically. Once aligned,
determine the shim thickness required and install the shims.
5. Install the 4 motor mounting capscrews and related hardware.
6. Re-check the alignment. Position chock and wedge blocks under the motor if required.
7. Install all guards, air lines and wiring.
ALL WIRING MUST BE DONE BY A QUALIFIED ELECTRICIAN.

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Service Procedures

4.2 Rotating Deck
The rotating deck consists of a revolving frame, center pintle, right and left deck extensions,
operator’s cab and the machinery house. Also included are the electrical system components,
operating controls, air system, A-frame, along with the hoist, swing and crowd machinery units.
4.2.1 Revolving Frame

The revolving frame is the main structural member of the rotating deck. It is a welded, stress
relieved structure with integral lugs for mounting the A-frame, crowd machinery and boom.
Provisions are made for mounting deck extensions, operator’s cab, ballast box and swing
gearcases. Machined pads on the deck locate the hoist drive motor and machinery frames.
Refer to a view of the revolving frame assembly with deck extensions and ballast box in this
section.

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Service Procedures
The revolving frame is connected to the truck frame by the center pintle.
4.2.2 Center Pintle


The center pintle is a large diameter, hollow cylindrical forging with a flange at the top. It is
threaded at the bottom with a lower nut used to hold it in place. A bronze coated steel core
spherical thrust washer between the lower adjusting nut and the bottom surface of the truck
frame provides a wear surface for pintle loads. The upper clamping collar at the top of the center
pintle is doweled and bolted to the revolving frame to keep the center pintle from rotating.
The hollow pintle provides passage for air and grease lines and electrical cables from the
revolving frame to the lower works using a swivel and collector ring assembly.

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Service Procedures
1. To inspect for worn thrust washers, rails, or rollers proceed as follows:

June 2012
Service Procedures
Every 6 months, check the amount of clearance between the top of pintle thrust washer and
lower face of truck frame hub by the following procedure:
a. Position the shovel on level ground (6" maximum elevation difference between front to
back or side to side over crawlers).
b. Orient boom over right side crawler for ease of access from front of machine to the
center pintle nut.
c. With an empty dipper, dipper door open, and horizontal handle, position dipper so
hoist ropes are vertical. (Rollers should be in full contact at front and rear, and center
pintle should be fully "unloaded" axially.)
d. Before performing pintle nut clearance check, make sure all brakes are set, joysticks
are in neutral position. Press "Control Stop". Press and Tag the Main Power Off
Button.
e. Use access holes into center upper compartment of truck frame to take feeler gauge
measurements between the bottom surface of the truck frame center hub and the top
surface of the thrust washer, dimension "T" in sketch. This measurement should be
recorded for at least 8 locations around the circumference and then averaged. (Note
there are 8 slots in the nut to assist in getting equidistant measurements.)
f. The minimum average gap with an empty dipper should be .030 inch. A range of
.030 to 0.107 inch is acceptable.

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Service Procedures
g. If "T" is greater than 0.107 inch, the pintle lower nut should be adjusted to reduce the
amount of lift. Refer to Center Pintle Adjustment.
2. The thrust washer, rails, or rollers may be sufficiently worn to require replacement rather
than center pintle nut adjustment. If necessary, replace a worn thrust washer per the center
pintle repair procedure and replace a worn roller and/or rail per the applicable repair
procedure.

3. Clearance for free rotation of the revolving frame must be provided between the truck frame
bushing and the sleeve. Such clearance, however, cannot be excessive or premature wear
of the truck frame bushing or sleeve will occur.
To determine this clearance, proceed as follows:

a. Disconnect the power to the machine. Enter the truck frame through the bottom
access opening.
b. Remove the cover from the top of the truck frame and gain access to the space
between the pintle and the rollers. Insert a feeler gauge between the sleeve and the
bushing of the truck frame. Any measurement over 0.250" diametral clearance is
considered excessive and replacement of the bushing and/or sleeve is necessary.

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Service Procedures
Figure 4-25 Center Pintle – Section View

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Service Procedures
4.2.2.1 Center Pintle Adjustment
To adjust a center pintle nut due to a worn thrust washer, worn rollers, or worn rails, tighten the
nut as follows:
NOTE: All adjustment of vertical clearance is to be made at the Lower Locknut. NEVER tighten
to the point of removing all vertical clearance. Adjustment is to be done with machine in

Maintenance Mode and "Tighten Pintle Nut Screen" active.
1. Use access holes into center upper compartment of the truck frame to gain access to the
pintle lower nut and adjusting pin.
2. Cut the lock wires and remove the capscrews attaching the lock bars to the lower nut.
Remove the lock bars.
3. Pull down the pin handle and rotate it 90° so that the pin can be moved into one of the slots
in the lower pintle nut. The upper works may need to be rotated slightly to line up a slot with
the adjusting pin.
4. To calculate the required rotation of the center pintle to bring average clearance back into
the recommended range of 0.030 to 0.107 inch, use the following formula:
R = Maximum rotation allowed (in degrees) without over-tightening nut

T = Average clearance (inches) between underside of truck frame pintle hub and
the top of the pintle thrust washer. Determine "T" by inspection procedure.
0.030 inch = Minimal desired clearance
0.308 inch = Thread pitch (in)
Example: If measured lift is .31”, then:
R = (.31 - 0.030) x (1/.308) x 360° = 327° (Use 270° to avoid over-tightening.)
The actual adjustments must be made in 90° increments to allow reinstallation of the nut-lock
bars. After determining the required rotation, select the degree of turn closest to 90°, 180°, 270°,
or 360° - WITHOUT GOING OVER. In the above example 216° is closest to 180°. When there is
a choice of selecting a higher or lower degree of turn from the formula’s result, ALWAYS use the
lower degree turn to prevent overtightening of the pintle nut.
5. Install the lock bars and capscrews. Secure the capscrews with lock wire.
6. Disengage the adjusting pin. Make sure the pin handle is turned parallel to the pin and
locked in the slot on the pin to prevent the pin from accidentally reengaging the pintle lower
nut.
7. Apply power to the machine and check the lift as described in Inspection.

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Service Procedures
4.2.2.2 Center Pintle Sleeve Removal

Remove the center pintle sleeve and thrust washer through the top of the revolving frame as
follows:
1. Position the machine on a level work area with the dipper lip and front flat on the ground.
Set all brakes.
2. Disconnect electrical power to the machine.

PERFORMING MAINTENANCE IN THE CENTER PINTLE AREA OF ELECTRICAL ENERGY.
High voltage can cause serious or fatal injury. Installation, operation and servicing of
components should be performed only by qualified personnel. ALWAYS DISCONNECT
the electrical power BEFORE ACCESSING the center pintle area.
3. Remove the coupling cover, the coupling, and shaft spacer. Disconnect, plug and tag all
lube and lines.
4. Remove hose guard and collector ring cover. Disconnect and tag electric leads.
5. Remove shoes, spacers and insulators from the collector ring housing.
6. Remove the control collector rings from the swivel shaft. Remove the swivel assembly
retainer. Lift the swivel assembly and disconnect and tag the air and lube lines. Remove the
retainer with swivel assembly attached. Remove the collector ring support and remove the
support and collector rings as a unit.
7. Secure the swivel support at the top so that when it is removed it will not fall. Remove the
access cover from the bottom of the truck frame and enter the truck frame. Disconnect and
tag the electrical cables and tie them out of the way.
8. Remove the swivel support base from the truck frame and lower the swivel support with
base out of the truck frame.
9. Remove the hoist drum shaft assembly. Refer to HOIST DRUM SHAFT in this section of the
manual.
10. Remove the lock bars, lower nut, and thrust washer from the lower end of the pintle sleeve.
11. Install the lifting lug, supplied with the machine, to the top of the pintle and connect the
auxiliary winch to the lifting lug.
Before proceeding, be sure to apply a load to the center pintle lifting lug sufficient to lift
the center pintle.
12. Remove the bolts, lockwashers and dowels that fasten the upper collar to the revolving
frame. Remove the upper lock bars and their hardware. Remove the upper collar from the
pintle sleeve.

June 2012
Service Procedures
13. Using the auxiliary winch, lift the sleeve out of the revolving frame. Replace a worn or
damaged sleeve with a new one. Check the pintle sleeve bushing for wear or damage.
Replace if required. Check the truck frame around the pintle structure for cracks. If the pintle
structure area needs repair, contact the manufacturer for instructions.
Center pintle sleeve installation is the reverse of disassembly.

HIGH VOLTAGE! Be sure the electrical lines are correctly connected and all connections
are tight. Also make sure that the air and lube lines are connected to the correct outlets in
the swivel assembly and that the connections do not leak.
4.2.3 Collector Rings

There are three sets of collector rings on the machine - low voltage, propel and high voltage. The
low voltage collector rings transfer power from the revolving frame back to the propel motors.
The propel collector rings provide control to the propel motors and power for the propel blower
motor.
Figure 4-26 Collector Rings
High voltage collector rings, on the bottom of the revolving frame, transfer electric power from the
truck frame to the revolving deck. Electric power enters the truck frame just below the propel
motors and is transferred by means of collector ring shoes to the collector rings. The shoes are
mounted between the cast center pintle hub and the swing rack.

June 2012
Service Procedures
4.2.3.1 Collector Ring Inspection

Inspect the collector rings and shoes frequently for grease and contaminant accumulations on
the rings, shoes, insulators and incoming wires.
Clean the collector rings and related parts with an approved solvent regularly to prevent high
potential grounds. Make sure each shoe bears firmly against the collector ring. The shoes are
spring-loaded to maintain constant contact.
Solvents may be toxic or flammable. Adequate ventilation must be provided to minimize

fire and health hazards caused by using solvents for cleaning. Use away from sparks,
heat or flame to prevent fire or explosion. Follow the manufacturer’s instructions.
Check the insulators for cracks or chipping and replace promptly if damaged. Verify that the
screws securing the rings to the insulators do not protrude beyond the countersunk holes of the
rings.
A cracked or chipped insulator or an excessive amount of contaminants may cause an

electrical fault. This could result in death or serious injury.

June 2012
Service Procedures
4.2.3.2 Collector Ring Repair

Repair of the collector rings involves replacement of damaged insulators or defective shoes. The
collector ring life expectancy exceeds the life expectancy of the machine. However, to replace
the insulators or shoes:

1. Disconnect electrical power to the machine.
HIGH VOLTAGE! Do not access the collector rings unless power to the machine has
been disconnected and locked-out. Only authorized personnel should service the
collector rings.
2. Remove the attaching hardware securing the insulator or shoe to the mounting. Access to
the shoes mounted to the truck frame is obtained by entering the truck frame through the
bottom access opening.
3. Install new insulators or shoes. Make sure all electrical leads are securely attached to the
shoes and collector rings.
Do not attempt to inspect the underside of the revolving frame until power to the machine
is disconnected.
4.2.4 Cable Reel
HIGH VOLTAGE! WHEN ACCESSING THE CABLE REEL, THE TRAIL CABLE MUST BE
DISCONNECTED FROM ITS POWER SOURCE. The trail cable carries high voltage which
can cause serious or fatal injury.
The cable reel is used to store excessive lengths of trail cable, and also to retrieve and pay out
cable as needed during machine propel. The cable reel should be checked daily to assure that it
is working properly and that the trail cable is being spooled on and off the reel correctly.

June 2012
Service Procedures
Before initial operation of the cable reel, be sure to check the following:
• Security and completeness of the cable reel mounting.
• Correct wiring of the electrical system.
• Correct piping of the drive system.
• Oil level of reducers and drive system.
• Lubrication of guide rollers, trolley wheels, and reel bearings.
After initial operation check for the following:
• The level wind mechanism works freely.
• All drive chains are properly tensioned and well lubricated.
• The control valve lever works freely.
• The hydraulic reservoir for the proper level of fluid. Add fluid if required. Check the
hydraulic lines for leaking.
• All structural components for cracking.
4.2.4.1 Do’s and Don’ts of Reel Operation

Do:

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Service Procedures
• Install flexible power cable that is specifically suited and approved foe cable reel service.
• Decrease amperage rating of cable for each layer installed on reel.
• Check condition of cable over entire length of reel on a regular basis.
• Check cable reel during normal maintenance inspections.
• Turn off cable reel drive system when equipment is shut down for any period of time.

Don’t:
• Install more than two layers of cable on reel unless voltage drop is recognized and
acceptable to operating personnel.
• Work reel beyond rated capacity.
Following these few rules, along with good judgment, will result in longer reel life, less downtime
and increased safety.
4.2.4.2 Cable Reel Operation

It is important that equipment operators understand the following:
1. Cable Reels are designed to pick up cable as the equipment moves toward its power
source, and pay out when moving away from. Cable Reels are not designed to pull cable
over the ground.
2. The angle of the cable in relation to the cable reel should be kept to a minimum. If angle is
too great, damage to the cable and/or level wind may occur.
3. The correct line pull is when there is sufficient pull on the cable to wind it on the reel but not
to great to put unnecessary strain on the cable. Line pull is proportional to hydraulic
operating pressure.
4. The correct line speed is slightly faster than the travel speed of the machine that the cable
reel is mounted on.
The cable reel is driven by a 5 HP, 1100 PSI, 7 GPM variable volume-pressure compensated
hydraulic system. During initial operation of the cable reel, some adjustments will be necessary
to determine the correct line pull and speed that is best suited for each application. For most
applications, adjusting the operating pressure to 600 PSI has been a good starting point. Refer to
the hydraulic drive start up and adjustment instructions for additional information.
Normally cable reels are operated with the control valve set to the wind in position. When
properly adjusted, the cable reel will pick up cable when it moves toward the power source, the
reel will stall when it is stationary and the reel drive system will be over powered when moving
away from the power source, allowing cable to be unwound from the reel. The only time the cable
reel should be operated in the unwind position is when there is a need to replace or inspect
cable. When the cable reel is stationary for long periods of time, the drive system should be
turned off and/or the control valve set to the off position.
DO NOT operate cable reel manually when equipment is in motion unless pendant control,
boom mounted control, or extensions of existing control lines have been provided to
allow safe operation of the cable reel.

June 2012
Service Procedures
4.2.4.3 Hydraulic Drive Start Instructions

1. Fill the hydraulic tank and pump case with 10 gallons of premium grade hydraulic fluid
specifically suited for the temperature range that the machine will be operating in.
2. Place the control valve in the off (center) position.
3. The hydraulic pump is set for maximum flow.
4. Jog the electric motor and check pump rotation. If the pump rotation does not correspond
with arrow on the pump, change the motor wiring.
5. Start the hydraulic system and let the oil circulate for 5 minutes.
6. Check all of the hydraulic connections for leaks.
7. Close the flow valve slowly and watch hydraulic pressure. If pressure exceeds 1100 PSI,
adjust the pump pressure to a lower setting.
8. Close the flow valve and relief valve completely. Adjust the pump pressure to 900 PSI.
9. Loosen the lock nut on the relief valve adjusting screw. Open the relief valve until pressure
drop is noticed on the gauge. This is your relief valve operating pressure. Lock the
adjustment screw.
10. Adjust the pump pressure down to 600 PSI. The hydraulic pump pressure compensator is
normally set at 300 PSI below the relief valve setting.
11. Open the flow valve full. This valve is normally left in the full open position. The flow valve is
not meant to be used as a speed control.
12. Place the control valve in the wind position and check operation of the cable reel.
13. All hydraulic cable reels are shipped with the hydraulic system adjusted as per the above
procedure. Repeat step 4 after installing on the equipment.
If the cable tension is too great or not enough, repeat steps 8 through 12. Increase or decrease
the pump pressure and relief valve settings in 100 PSI increments until the cable tension is
satisfactory.
If the line speed is too fast, adjust the pump volume flow to a lower setting. Adjustment is located
at the port end of the pump.
After 48 hours of operation in the field, change the return line filter and replace the hydraulic oil
with a suitable fluid for your operating conditions.
4.2.4.4 Unloading Valve Operating Instructions

The purpose of this valve is to unload the cable reel hydraulic system when the cable reel is
stationary. This is accomplished by using a spring offset, pilot operated, control valve. The
unloading valve pressure port is connected to a vent opening on the cable reel relief valve and
the 'B' port is connected to the hydraulic tank return line. Pilot air pressure is supplied by a shuttle
valve connected to the shovel clutch or brake air line. When 20 PSI of air pressure is applied to
the unloading valve pilot port, the 'A' port is blocked and the cable reel hydraulic system becomes
operational. When air pressure is removed, the 'A' port is open and cable reel hydraulic system is
bypassed. During start up adjustments the shut off valve in the vent line is closed. After start up
adjustments are complete, the shut off valve is normally left in the full open position.

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Service Procedures
4.2.4.5 Cable Reel Frame
The cable reel frame is fabricated from standard structural sections in accordance with AISC
standards for structural fabrication. No special alloy steels are used and standard structural
quality materials can be used for replacement and repair of damaged frame members.

4.2.4.6 Cable Reel Drum
The cable reel drum is fabricated from standard structural plate and pipe. Two u-bolts are
furnished for anchoring the power cable to the reel drum. The drum is mounted on the reel frame
with two spherical roller pillow block bearings.
If repair is required and assuming the power cable is clear of the level wind, the entire reel drum
and collector rings may be removed as a unit by removing part of the collector base plate and
unbolting the reel bearings. The reel shafts should be checked for concentricity after repairs are
complete.
BE SURE POWER IS OFF BEFORE OPENING ELECTRICAL ENCLOSURES!
4.2.4.7 Cable Reel Drive

Hydraulic drive cable reels are chain driven by a variable volume-pressure compensated
hydraulic system.
If repairs are required the electric motor and hydraulic pump assembly can be removed as a unit
by unplugging the electric motor, disconnecting the hydraulic lines and unbolting the motor base
plate.
4.2.4.8 Level Wind

The level wind drive is chain driven from the reel drum. Trolley travel is adjusted by changing
sprockets on the output shaft of the right angle reducer. Before winding power cable on the reel,
refer to the level wind sprocket table, remove the chain between the reducer and level wind drive
shaft and install the correct sprocket on the reducer. Allow approximately 1/8 inch clearance
between wraps for cable variables. Start winding power cable on reel drum opposite from
collector end of reel, after several wraps are installed, position trolley on center line of cable and
install chain on right angle reducer. Continue winding cable on the reel slowly and check the
trolley travel. If not correct, adjust position of the trolley and/or sprocket ratio.
4.2.4.9 Collector Ring

The collector ring assembly has five rings, three power rings, one ground ring and one ground
fault ring. The collector ring is enclosed in a fiberglass enclosure which is protected by a metal
cover. Junction boxes are provided for connecting the owner's power cable to the collector ring
assembly.

June 2012
Service Procedures
4.2.4.10 Cable Reel Maintenance

It is extremely important that high voltage electrical systems be inspected, cleaned and
maintained on a regular basis. Dust and dirt contamination can cause electrical failures. Only use
cleaning materials specifically suited and approved for high voltage electrical systems.
BE SURE POWER IS OFF BEFORE OPENING ELECTRICAL ENCLOSURES!
4.2.4.11 Lubrication
A routine inspection (every 3 months) and lubrication (every 6 months) should be observed to
maintain reliable operation and detect problems before they cause break-downs. Extremely
harsh environments may require more frequent service intervals. Premium grade, industrial
lubricants are recommended.
• The level wind reducer requires 1-1/2 pints of gear oil.
• Add grease to reel bearings, trolley wheels and guide rollers slowly with shafts revolving
wherever possible.
• Remove dirt from chain drives and clean thoroughly before lubricating.
• Check the reducer for leaks when changing oil.
4.2.4.12 Hydraulic System

The hydraulic reservoir should be check daily for proper fluid level. Visually check for any fluid
leakage. Generally, a fluid change interval of 2000 hours is adequate. A more frequent change is
required if the fluid has become contaminated by water or other foreign material or has been
subject to abnormal operating conditions. A premium grade, industrial anti-wear type hydraulic
fluid suitable for use with Sundstrand, Double A, Continental and Char-Lynn products is
recommended. The return line filter element and breather filler cap should be replaced when
changing fluid. The sump filter should be replaced and the inside of the reservoir should be
cleaned yearly. During extremely cold weather, the hydraulic system should be run continuously
to maintain operating temperature.

June 2012
Service Procedures
4.2.5 Swing Machinery
The swing machinery is mounted on both the left and right sides of the revolving deck. Each
machinery installation consists of a blower-cooled electric motor mounted vertically on top of a
planetary gearcase. The motor drives the planetary gear system through a single input coupling.
Each swing motor is equipped with a spring-set, air-released disc brake. Each planetary

gearcase includes an individual motor driven lubrication pump to provide positive lubrication to
the critical bearing surfaces of the gearcase.
Each gearcase transmits torque to a pair of pinion shafts. The pinions at the bottom of the shafts
mesh with the swing rack on the lower works and provides rotational movement for the swing
cycle.
The swing machinery should be inspected daily for proper lubricant level within the planetary
gearcases. If lubricant level is found to be low it must be serviced prior to machine operation. The
area of the mesh between the rack and pinions must be inspected. Proper lubrication, damage
and the presence of foreign material are some of the items to look for in this area.

June 2012
Service Procedures

June 2012
Service Procedures
4.2.5.1 Swing Support Mounting Bolts
NOTES:
• Tighten the superbolts using the procedures listed in SWING TORQUE ROD &
TAPERED SLEEVE & 3.25 INCH TORQUE NUT in ENGINEEERING DATA section in
this manual.

• Tighten the 1.5 inch capscrews using the turn-of-the-nut method with an additional 1/3
turn per ENGINEEERING DATA section in this manual.

June 2012
Service Procedures
4.2.5.2 Swing Motor

For lubrication of the drive motor, refer to GREASING MAIN AC DRIVE MOTORS in
BEFORE ATTEMPTING TO DISCONNECT ANY POWER LEADS, PRESS THE MAIN POWER
OFF BUTTON AND TAG IT TO AVOID INADVERTENT ENERGIZING OF THE ELECTRICAL
CIRCUIT. Electrocution or serious injury may occur if appropriate safety measures are not
followed. Electrical connections should only be handled by trained electrical personnel.
4.2.5.2.1 Swing Blower

The blower assembly is mounted with the use of common hardware to the side of the swing
motor. The blower is essentially a complete unit and will normally be replaced as a complete
assembly.
4.2.5.2.2 Swing Motor Removal

NOTE: Removal of the appropriate roof panel is required for the removal/replacement of either
the left or right swing motor. Complete instructions for the removal and replacement of
the motor coupling hub and swing brake hub may be found in BRAKES AND
COUPLINGS section in this manual.
1. Position the machine with the dipper lip and front flat on the ground. Set all brakes.
2. Have a qualified electrician tag and disconnect the electrical leads to the motor.
3. Remove the swing motor blower and duct assembly.
STORED ENERGY! RELEASE THE AIR PRESSURE TO THE BRAKE BEFORE

DISCONNECTING THE AIRLINE. Plug the line immediately after disconnecting. Failure to
comply could result in personal injury.
4. Release the air pressure in the line to the swing brake, and disconnect the airline.
NOTE: The swing motor and brake can be removed as a unit if desired. If so skip the next step.

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Service Procedures

in order to prevent unwanted movement. Failure to comply could result in death, severe
personal injury, or damage to the machine. Refer to INTRODUCTION - SWING
RESTRAINT.

5. Remove the swing brake from the motor per the proper instructions. The weight of the
swing brake is approximately 490 Lbs.
6. Remove the bolts securing the motor drive coupling halves together per the proper
instructions in BRAKES AND COUPLINGS section of this manual.
7. Attach a lifting device to the motor and remove slack from sling.
8. Remove the bolts securing the motor to the planetary gearcase housing.
9. Remove the motor from the planetary gearcase and store in a dry location if to be
reinstalled. The weight of the motor is approximately 4,600 Lbs.
4.2.5.2.3 Swing Motor Installation

Installation of the swing motor is the reverse operation of the removal procedure covered above
with the following exception:
Alignment of the motor coupling is critical to the longevity of the bearings within the
motor and the planetary gearcase. Check and adjust the coupling alignment in
accordance with the instructions found in the BRAKES AND COUPLINGS section in this
manual.

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Service Procedures
4.2.5.3 Swing Planetary Gearcase

The swing planetary gearcase is a self-contained unit designed to provide extended service
under adverse conditions. With regular oil changes, inspections and normal preventative
maintenance, the gearcase should operate continuously for 25,000 hours before requiring
replacement of bearings and seals and 40,000 hours between major overhauls.

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Service Procedures
4.2.5.3.1 Swing Gearcase Removal
Use the following procedure to remove a swing gearcase:
1. Position the machine with the dipper lip and front flat on the ground. Set all brakes.

2. Remove the appropriate section of the machinery house roof panel over the gearcase.
3. Refer to the appropriate instructions in this section of the manual and remove the swing
motor and brake assembly.

personal injury, or damage to the machine. Refer to INTRODUCTION - SWING
RESTRAINT.
4. Lift off the removable floor panels surrounding the gearcase.

5. Remove the 18 - 1.5 inch capscrews, nuts and lockwashers attaching the gearcase to the
swing girder on the revolving frame. Note the location of the 6 shorter capscrews.
2-1/4 Inch Hex
6. Attach a suitable lifting device to the gearcase. Lift it up and clear of the machinery house.
The weight of the gearcase is approximately 9,300 Lbs.

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Service Procedures
Installation of the gearcase is the opposite of removal. However, apply Molykote to the splines at
the top of the 2 swing shafts and also inside the output gears at the bottom of the gearcase. Align
the motor coupling per the procedures in BRAKES AND COUPLINGS section in this manual.

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Service Procedures
4.2.5.4 Swing Pinion Shafts
Dual swing pinion shafts transfer torque from each planetary gearcase to the swing rack on the
truck frame. Each pinion shaft is a 1-piece unit.
Figure 4-28 Dual Vertical Swing Shaft Installation

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Service Procedures
4.2.5.4.1 Swing Pinion Shaft Removal
BE EXTREMELY CAUTIOUS WHEN REMOVING THE SWING PINION SHAFT ASSEMBLY

THROUGH THE BOTTOM OF THE REVOLVING FRAME. AFTER LOOSENING THE
BEARING CARRIER BOLTS THE SHAFT IS UNSUPPORTED AND MAY FALL.
1. Rotate the machine to place the swing shaft to be removed at the front of the truck frame.
2. Set the dipper lip and front flat on the ground. Set all brakes.
3. Disconnect the power leads to the swing motor that is connected to the shaft to be removed.
BEFORE ATTEMPTING TO DISCONNECT ANY POWER LEADS, PRESS AND TAG THE
MAIN POWER OFF BUTTON. THIS WILL AVOID INADVERTENT ENERGIZING OF THE
ELECTRICAL CIRCUIT. Electrocution may lead to serious injury or death if appropriate
safety measures are not followed. Electrical connections should only be handled by
trained electrical personnel.
4. Support the swing pinion shaft to be removed (approximately 2200 Lbs.) by using a jack or
other suitable device beneath the inspection cover.
STORED ENERGY! Equipment must be blocked prior to performing maintenance in

order to prevent unwanted movement. Failure to comply could result in death, severe
personal injury, or damage to the machine. On machines using planetary dual-output
swing drives, both swing pinions per drive must be engaged with the swing rack in order
for the swing brake to be effective. The internal differential drive in the gearcase allows
one pinion to rotate, even if the brake is set, when the other pinion has been removed.
Refer to INTRODUCTION - SWING RESTRAINT.
5. Remove the capscrews that attach the lower carrier retainer to the swing machinery
structure.
6. Lower the swing pinion shaft and set on cribbing.
7. Inspect all parts. Repair or replace any worn or broken components.

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Service Procedures
4.2.5.4.2 Swing Pinion Shaft Disassembly
With the pinion shaft assembly resting in a near horizontal position, disassemble the shaft as
follows:

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Service Procedures
1. Remove the 6 capscrews that attach the lower carrier retainer to the carrier. Remove the
retainer.
2. Remove the inspection cover and its 6 capscrews. Separate the O-Ring from the inside of
the inspection cover.
3. Pull the bearing carrier from the bearing. Separate the O-Ring from the top side of the
carrier.
4. Remove the 5 capscrews from the bearing retainer. Remove the bearing retainer and the
shim pack from the end of the shaft.
5. Use a suitable puller to remove the bearing from the end of the shaft.
6. Remove the 8 capscrews from the back side of the labyrinth seal.
7. Disassemble the upper bearing retainer, the oil seal and the labyrinth seal and remove
these components from the shaft.
8. Inspect all parts. Repair or replace any worn or broken components.
4.2.5.4.3 Swing Pinion Shaft Assembly

Reassembly of the pinion shaft is opposite disassembly. However, use the following to determine
the bearing shim pack thickness:
1. With the end retainer fastened to the end of the shaft, through the 3 holes in the lower
bearing retainer, obtain a measurement of the distance between the end of the shaft and
the outside of the pinion retainer. Average this measurement.
2. Measure the thickness of the retainer using the 3 holes and average this measurement.
3. Subtract the averaged plate measurement from the averaged overall dimension. Subtract
0.002 inch from this dimension. This results in the required shimpack thickness for use
beneath the retainer and will allow for proper advance of the tapered bearing on the tapered
shaft.
4. Remove the retainer and capscrews. Install a shimpack equal to the final dimension
calculated above.
5. Using a crisscross pattern, tighten the 5 - 0.75 inch hex screws in stages of 50 Ft-Lbs (68
N•m) to the torque value indicated below.
This staged tightening procedure is critical to allow for proper seating of the tapered
portion of the shaft within the bearing surface. A sharp rise in torque value will indicate
proper seating of the bearing to the shaft.
6. After the final torque value is reached lockwire the capscrews in place.

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Service Procedures

Figure 4-29 Swing Pinion Shaft - End View

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Service Procedures
4.2.5.4.4 Swing Pinion Shaft Installation

1. Remove the outer cover on the gearcase support for access to the guide bushing near the
top of the pinion shaft.
2. Prior to assembly, apply a thin coating of MolyKote lubricant to the splined sections at the
end of the shaft and to the flat area of the shaft that accepts the guide bushing.
3. Ensure that the upper V-Ring face seal is in place in the bottom of the gearcase.
4. Ensure that the guide bushing is resting in its place on the support plate within the gearcase
support structure.
5. Install the assembled swing pinion shaft into the swing gearcase support from beneath.
NOTE: Be sure that the guide bushing slides over the end of the pinion shaft as the shaft is
inserted through the support plate within the gearcase support structure.
6. Tighten the lower carrier retainer capscrews and lockwire in place.
7. Install the split guide bushing retainer around shaft and over the guide bushing, install the
capscrews and tighten.

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Service Procedures
4.2.6 Hoist Machinery
The hoist machinery consists of:
• Large diameter hoist drum
• Integral single-helical hoist gear

• Dual-output planetary gearcase,
• Hoist motor and brake assembly
Frequently check the hoist machinery for loose or missing hardware. At least once a month,
check the hardware on the hoist motor, shaft, couplings and right and left pedestals for tightness.
Retighten or replace any missing hardware. Every 12 months remove the upper hoist gear guard
inspection covers and the gearcase inspection covers and inspect the gear and pinions for
pitting, abrasion, scratching, spalling, galling and/or other tooth wear. Check the gearcase for
evidence of lubricant leakage. Replace any defective seals.
Figure 4-30 Hoist Machinery Assembly

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Service Procedures
Figure 4-31 Hoist Machinery - Plan View
4.2.6.1 Hoist Motor Removal

LUBRICATION section of this manual. If removal of the hoist motor is required, use the following
procedure:
1. Position the machine so that the dipper lip and front are flat on the ground.
2. Remove the appropriate roof panels above the hoist motor.

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Service Procedures

3. Disconnect and identify the electrical leads to the hoist blower motor and the hoist motor.
4. Remove the hoist blower motor and duct as a unit from the hoist motor.
5. Disconnect the piping to the hoist brake. Remove the brake from the motor. Refer to
BRAKES AND COUPLINGS section.
RELEASE THE HOIST BRAKE TO REMOVE ALL TENSION FROM THE HOIST DRUM
BEFORE REMOVING THE BRAKE.
6. Remove the motor coupling guard(s). (Weight = approximately 295 Lbs.)

personal injury, or damage to the machine.
7. Support the coupling shaft with a suitable lifting device. (Weight = approximately 1270 Lbs.)
Remove the bolts from the couplings at each end of the coupling shaft to separate both
couplings. Remove the shaft with the coupling halves on it.
8. For repair of the original motor: remove the two chocks and wedges located on the side of
the motor towards the hoist drum. For replacement of the original motor with a new motor:
remove the four chocks and wedges located on both the front and rear sides.

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Service Procedures
Figure 4-32 Hoist Motor Mounting - Plan View
9. Remove the 4 - 2.0 inch nuts that fasten the motor to its mounting pads on the deck. Using
a suitable crane, lift the motor and brake assembly through the house roof and away from
the machine. The weight of the hoist motor is approximately 15,000 Lbs. Wire the shims
together, if used, and identify their location for future use.
Installation of the hoist motor is the reverse procedure.
NOTES:
• If replacing the original motor with a new motor, remove the alignment chocks and
wedges from the motor mount, reinstall after setting and aligning the new motor.
• Align the coupling(s) using the procedure in BRAKES AND COUPLINGS section in this
manual.
• The hoist motor is fastened to its mounting pads using 2.0 inch nuts and rods. To tighten
use the Torque Nut tightening procedure at the end of this section of the manual.

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Service Procedures
4.2.6.2 Motor Coupling Shaft
Power is transferred from the hoist motor to the gearcase through a motor coupling shaft with 2
couplings. Using the inspection doors on the coupling guard, check the couplings for evidence of
lubricant leakage. Under normal circumstances, a coupling will operate for 3 to 5 years before
service is required. However, if leakage from a coupling is noticed, the coupling should be

disassembled and repaired.
Figure 4-33 Guard Over Coupling Shaft
When reinstalling the coupling shaft it is recommended to use a laser alignment procedure.
Refer to HOIST COUPLING SHAFT ALIGNMENT in BRAKES AND COUPLINGS section of this
manual for tolerances.

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Service Procedures
.
Figure 4-34 Coupling Alignment Reference
4.2.6.3 Hoist Gearcase Assembly
Figure 4-35 Installation of the Hoist Gearcase

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Service Procedures
The hoist gearcase is a split-power, planetary gearcase. Power is transferred from the hoist
motor through a single input shaft to dual helical output pinions mated to the main hoist gear.
Three pins fasten the gearcase to the left hoist pedestal. The gearcase utilizes an oil circulating
system to lubricate internal gearcase components and to maintain cooling.

STORED ENERGY! Equipment must be blocked prior to gearcase removal to prevent
unwanted rotational movement. Failure to comply could result in death, severe personal
injury, or damage to the machine. On machines using planetary dual-output swing drives,
both swing pinions per drive must be engaged with the swing rack in order for the swing
brake to be effective. The internal differential drive in the gearcase allows one pinion to
rotate, even if the brake is set, when the other pinion has been removed.
The hoist gearcase can be removed or replaced without removing the hoist motor or the hoist
gear. To remove the gearcase:
2. Apply sufficient force on the crowd to “jack” the boom enough to unwind the suspension
strands. Set the crowd brake. On machines equipped with hydraulic crowd, there is no
crowd brake.
3. Remove the appropriate roof panels above the hoist gearcase.
4. Remove the left-upper-rear A-Frame leg pin. Swing the A-Frame leg to the rear of the
machine.
BEFORE PERFORMING ANY MAJOR MAINTENANCE ON THE HOIST MACHINERY, PRESS

AND TAG THE MAIN POWER OFF BUTTON. Failure to comply may result in injury or
death.

5. Remove the upper-rear section of the hoist gear guard. Use blocking to prevent accidental
movement of the hoist drum.
6. Pull the gearcase bearing drain hoses up from the deck and tie back out of the way.
7. Remove the guard covering the oil cooler piping. Drain the oil from the gearcase.
Disconnect the oil pump-to-radiator line and the radiator-to-manifold line.
8. Remove the coupling guard(s). Separate and remove the couplings from both ends of the
motor coupling shaft and remove the shaft. (Shaft weight is approximately 940 Lbs.) Refer
to BRAKES AND COUPLINGS section.

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Service Procedures
9. Using a suitable crane, support the gearcase using the 4 lifting lugs at the top of the
gearcase. Apply enough lift to just support the weight of the gearcase. (Gearcase weight is
approximately 35,500 Lbs.)
10. Remove the locking assemblies from the 3 mounting pins that attach the gearcase to the
hoist pedestal.
NOTE: The gearcase is attached to the deck at the bottom of the gearcase with 1 long pin on
the forward side and 2 unique short pins on the rear side. Mark the short pins to ensure
correct re-installation.
•Forward Pin (long) 509 Lbs.
•Rear Pins (short) 109 Lbs.
11. With the gearcase supported, it may be necessary to use a come-a-long or other suitable
pulling device to pull the gearcase slightly toward the rear of the machine, in order to
disengage it from the hoist gear.
12. Once the gearcase will clear all obstructions, lift it through the house roof and away from the
machine.
The hoist gearcase can be reinstalled using the reverse procedure. To install the gearcase
mounting pins with locking assemblies:
1. Move the gearcase back into position and align the gearcase and pedestal bores.
2. Install the gearcase’s rear locking assemblies “B” and “C” and two rear pins using the pilot
bushings with assembly “B”. Maintain pin and bushing dimensions in Section B-B and
torque as specified below.

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Service Procedures

3. Install the gearcase’s front locking assemblies “B” and “C” and front pin using pilot bushings
with assembly “B”. Maintain pin and bushing dimensions in Section C-C and torque as
specified below.
4. Clean and lightly oil all parts of locking assembly, shaft & housing bore.
5. Loosen all locking screws, remove 3 of the locking screws from "A" and "C" assemblies
shown in the drawing above and place them in the "push off threads" to keep the inner and
outer ring of the collar separated while locating the locking assembly in the bore.
6. Insert 3 equally spaced pilot bushings into assembly "B" and tighten longer socket head
screws furnished with the bushing set.
7. Install locking assembly "B" into housing and onto end of the pin.
8. After locating the bushing, remove the 3 locking screws from assemblies “A” and “C” and
replace them in their original location.
9. Hand tighten the locking screws.

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Service Procedures
10. Using a torque wrench, tighten the locking screws to 5% over the final tightening torque
(see table below).
NOTE: Determine wrench size and quantity of locking screws at final assembly.
a.Tighten locking screws using only 1/4 turns. Once a full 1/4 turn is no longer achieved,
continue to over torque for 1 or 2 more passes.
b. Once at least 50% of the final torque requirement has been satisfied, remove the long
socket head screws and pilot bushings from assembly "B". Replace with screws
furnished with locking assembly. Tighten these screws to "catch up" to the other
screws. This pilot bushing set should then be retained for future use.
11. Reset the torque wrench to the final torque and check all locking screws. No screw should
turn at this point. If a screw turns, repeat Steps 9-10 for 1 to 2 more passes. DO NOT
OVER-TIGHTEN!
Final Tightening Torque 5% Over Final Torque
"A" - 170 Ft-Lbs (231 N•m) "A" - 179 Ft-Lbs (243 N•m)
"B" - 138 Ft-Lbs (188 N•m) "B" - 145 Ft-Lbs (197 N•m)
"C" - 166 Ft-Lbs (226 N•m) "C" - 174 Ft-Lbs (236 N•m)
NOTES:
• Verify that the planetary output pinion-to-drum gear alignment has the proper backlash
and contact patterns. For more information, refer to Hoist Gear Start-Up Inspections and
Hoist Gear Break-In procedures in this section of the manual.
• Install the motor coupling shaft and check the alignment. Refer to BRAKES AND
COUPLINGS section in this manual. Install the coupling guard(s).
• Re-install the gearcase drain lines into the openings in the deck.
• Re-install the oil cooling hoses. During re-installation, apply joint compound to all NPT
threads.
• Ensure that the gearcase is filled with the proper type and amount of oil.
4.2.6.3.1 Hoist Gearcase Repair

Repair of the hoist gearcase is best completed with the gearcase removed from the machine and
in a shop environment. Basic “Level-1” repair involves replacement of seals and O-Rings in the
pinion shaft area. Install oil seal with spring toward the bearing.
STORED ENERGY! Equipment must be blocked prior to gearcase removal in order to

prevent unwanted rotational movement. Failure to comply could result in death, severe
personal injury, or damage to the machine. On machines using planetary dual-output
pinions such as on hoist or swing, both per drive must be engaged in the bull gear or
swing rack to prevent rotation. The internal differential drive in the gearcase allows one
pinion to rotate, even if the brake is set, when the other pinion has been removed.

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Service Procedures

Figure 4-36 Hoist Gearcase

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Service Procedures
Figure 4-37 Hoist Gearcase Section View

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Service Procedures
4.2.6.4 Hoist Drum Assembly
The hoist drum shaft uses a single-helical hoist gear fastened to a large-diameter drum with the
hoist spider and rotates on double-row, tapered roller bearings.
Removal of the hoist drum shaft will require lowering and supporting the boom. To remove the
hoist drum shaft:

BEFORE PERFORMING ANY MAJOR MAINTENANCE ON THE HOIST MACHINERY, PRESS

AND TAG THE MAIN POWER OFF BUTTON. Failure to comply may result in injury or
death.
2. Remove the hoist ropes.

3. Remove the A-Frame ladders and platforms.
4. Remove the two machinery house fan/filter assemblies.
5. Remove the A-Frame shrouds.
6. Remove the center front roof panel, the 6 center roof panels and the 3 left roof panels over
the left deck extension. Save all indicated items for re-use.
NOTE: To remove the center roof panel, cut the welds between the channels on the front wall
panels and the center roof panel - both sides. The rubber sheets can remain attached to
the roof panel. All front wall panels can remain in place, however the upper left and
upper center wall panels can be removed, with their hardware, and saved for later re-
use.
7. Remove 4 center roof cross-beams, 2 left roof cross-beams and 4 center roof fore/aft truss
beams.
8. Using the crowd machinery (or a separate crane) support the weight of the boom to unload
the A-Frame and main suspension strands.
9. Remove the upper A-Frame pins from the rear A-Frame legs. (Will require a cherry picker.)
10. Rotate the rear A-Frame legs back toward the rear of the machine and secure to the control
room roof.
11. Using the crowd machinery (or a separate crane) lower the boom until the front A-Frame
legs are pulled forward so that they are at an 80° to 85° angle to the top of the revolving
frame. Set the crowd brake and block the boom in position. Install a safety cable to prevent
the front A-Frame from being inadvertently over center. On machines using hydraulic crowd
in place of rope crowd, a separate crane will be required.
12. Remove the drain lines from the bearing housings. Disconnect and remove the lube lines
from the hoist bearing housings and the gear guard.
13. Disconnect the hoist limit switch wiring. Remove the hoist limit switch assembly from the
drum shaft.

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Service Procedures
Figure 4-38 View A
14. Remove the three upper hoist gear guards shown in Figure 4-38. Use a suitable lifting
device to remove one guard at a time (maximum weight 1,250 Lbs. each).
15. Use a crane to support the hoist drum shaft assembly (approximately 65,000 Lbs.)
16. Remove the 3 outer 1 inch capscrews from the retainers of each of the 4 pins that attach the
bearing housings to the hoist pedestals. See Figure 4-39. To remove each pin, attach a
suitable puller to the 3 tapped holes of the retainer and pull toward the outside of the
pedestal. Note that each pin assembly weighs approximately 240 Lbs.
Figure 4-39 View B
17. The drum assembly can now be lifted from the machine.
Installation is the reverse procedure.

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Service Procedures
4.2.6.5 Hoist Gear Start-Up Inspections
This procedure outlines inspections to be performed on a new hoist gearcase and drum/bull gear
assembly at machine erection or for replacement assemblies. The checks include hoist gear
runout, backlash and contact. Complete as indicated and submit all findings to the manufacturers
engineering department, with additional copy to the machine's erection documentation.

STORED ENERGY! Equipment must be blocked prior to hoist gear/hoist pinion inspection
to prevent unwanted rotational movement. Failure to comply could result in death or
severe personal injury.
Figure 4-40 Hoist Components
NOTE: It is recommended that the remote drum control be used whenever possible. If remote
drum control is not available, establish uninterrupted radio contact with the machine
operator. Several of the steps in the procedure involve engaging the hoist machinery.
Constant radio contact with the operator helps prevent accidents.

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Service Procedures
Maintain a safe distance from any open gears when the hoist machinery is in motion.
Failure to comply with this warning could result in death or serious injury.
TOOLS:
Dial Indicator
Start-Up Kit PN: 1544025
Duct Tape
Solvent
Shop Rags
Digital Camera
1. Obtain the Hoist Drum Gear Radial Runout Data.

a. Mark the first tooth location using a marker.
Paint Marker- White PN: 1455232
b. Stage a dial indicator on the Hoist Backlash Pin, placed into the gear teeth at the first
marked position. Refer to Figure 4-41.
Dial Indicator
Hoist Backlash Pin PN: 1544230
Figure 4-41 Arrow Showing Location of Dial Indicator
c. Zero the dial indicator.

d. Without moving the dial indicator, rotate the hoist gear 45° (approximately 18 teeth)
and mark the second location.

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Service Procedures
e. Place the backlash pin in the gear teeth. As the gear rotates under the dial indicator,
measure the runout value at the second location. Record the runout value in Figure 4-
42.
f. Continue runout recordings every 45° (approximately 18 teeth) until all 8 locations
have been recorded in Figure 4-42.
g. Return to the first location and ensure dial indicator returns to initial zero value.

NOTE: If it does not return to zero, repeat Step 1.
Figure 4-42 Record Dial Indicator Readings, Specifying Inches or Millimeters
NOTE: The allowable radial runout on the gear should not exceed 0.02 inches (0.51 mm). If the
radial runout is not within the above specified limits, contact the manufacturer’s
engineering for final resolution.
2. Obtain the Hoist Drum Gear Face Runout Data
a. Place a dial indicator on the side face of the gear teeth as shown in Figure 4-43

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Service Procedures
.
Figure 4-43 Dial Indicator Placed on Right-Hand Gear Face
b. Zero the dial indicator.

c. Rotate the gear 45° (approximately 18 teeth) and record the new reading.
d. Repeat the gear rotation 360° and record a reading every 45°.
NOTE: The allowable axial runout on the gear should not exceed 0. 016 inches (.41 mm). If the
axial runout is not within the above specified limits, contact the manufacturer’s
3. Measure and record hoist pinion/hoist gear backlash:
a. Using the results obtained in Step 1, rotate the hoist machinery until the pinion is in
mesh with the drum gear in the vicinity of the high point of O.D. runout.
NOTE: The high point of O.D. runout is the location where the dial indicator reading for the O.D.
runout is the shortest, or smallest recorded value.
b. Thoroughly clean all surfaces of the pinion teeth. Any residual oil must be removed
before applying the lead impression wires.
Solvent & Shop Rag

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Service Procedures
c. Attach 3 lead impression wires (PN: 1544231) using duct tape. Tape each wire at the
top and in the root of each tooth. The wire must be placed in 3 separate locations.
Place one strand in the middle of the face width and two strands roughly 1.00 inch (25
mm) in from each side of the pinion. Each wire must cover a minimum of both drive
and back flank on 4 consecutive teeth. Refer to Figure 4-44.

Figure 4-44 Lead Impression Wires to Pinion Teeth
d. Using the hoist machinery, rotate the pinion one revolution in the raising direction until
the wire completely passes through mesh.
e. To determine average backlash values, remove the compressed lead wire from the
gear tooth and measure the thinnest wire thickness on both the drive and back flanks
for each of the 3 middle teeth.
NOTE: Ignore the first and last flank to eliminate entry and exit variation.
f. For each impression wire, add the drive and back flank thicknesses for all 3 pinion
teeth (3 drive flank thicknesses plus 3 back flank thicknesses).
g. Divide the sum of the 6 measurements by 3 to obtain the average backlash value.
h. Repeat measurement and average for all three impression wires.
Left End Center Right End
Upper
Pinion
Lower
Pinion

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Service Procedures
NOTE: Backlash 0.035 inches (0.89 mm) minimum for thermal expansion. If the gearset
backlash is not within the minimum specified value, contact the manufacturer’s
4. Check the hoist pinion / gear bump contact pattern on both upper and lower pinions:
a. Clean a minimum of three teeth on the pinion and three teeth on the gear using
solvent. Follow solvent manufacturer's safety procedures. Select tooth locations so the
cleaned pinion teeth will mesh with the cleaned gear teeth.
Solvent & Shop Rag
b. Paint the cleaned pinion teeth with blue marking fluid.

Paint Brush PN: 1544237
Blue Marking Fluid PN: 1544228
c. Slowly roll the hoist so the dyed pinion teeth roll through the gear mesh against the
cleaned gear teeth. Stop and reverse as soon as the dye has gone through the mesh.
d. Using a digital camera, record the drive flank static contact pattern of the dye
transferred from the pinion onto the gear teeth. Make sure it is possible to identify the
entire gear face width (both ends of tooth are visible).
Digital Camera
e. Repeat this check for both upper and lower pinions. The contact pattern is to be
obtained on both flanks of three adjacent teeth.
Figure 4-45 Contact Pattern Checks
NOTE: Ideal bump contact pattern check for low speed pinion with crown only should resemble
the figures above.
The bump check contact pattern acceptance criteria are as follows:
• The center of the static contact bump check is to be located between 30% and 70% of the
face width.
• The location of the contact pattern is the critical attribute in the no load bump contact pattern
check.

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Service Procedures
• The length of the contact pattern will not cover the length of the gear tooth due to the amount
of crowning modification on the pinion.
NOTE: If the center of the bump contact pattern check is not within the above specified limits,
contact the manufacturer’s engineering for final resolution.
5. Prepare hoist pinion / gear for dynamic contact pattern check:

a. Clean all upper and lower pinion teeth using solvent. Follow solvent manufacturer's
safety procedures.
Solvent & Shop Rag
b. Paint all pinion teeth with a hardening layout dye. Allow sufficient time for the dye to
dry completely.
Layout Dye PN: 1544229
c. Once the dye has dried, apply open gear lubricant onto the teeth over dye. Hoist is
now ready for Break-In period, which is covered under the OPEN GEAR BREAK-IN
procedure located in the ENGINEERING DATA section of this manual.

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Service Procedures
4.2.6.6 Hoist Gear Replacement

The hoist gear can be reversed on the hoist spider to provide more useful life. To reverse or
replace the hoist gear, the hoist drum shaft must be removed from the machine. Remove the
drum assembly using the above procedure.
1. Once removed, support the hoist drum assembly on cribbing in a vertical position, with the
gear end down and the cribbing supporting the hoist gear only. Ensure that the bearing
housing on the gear end of the shaft or the stub shaft is not resting on the ground. This may
require cribbing approximately 30 inches in height.
2. If replacing the hoist gear with a new one, ensure that the new gear is resting flat on
cribbing just as the old one (approximately 30 inches above the ground). If reversing the
existing gear, provide suitable cribbing (approximately 30 inches in height) to rest the hoist
drum and spider assembly while turning the hoist gear.
3. Support the old drum and spider assembly with a crane. Do not attach the crane support to
the hoist gear.
4. Remove the 36 - 1.75 inch body-fit bolts that fasten the hoist gear to the spider.
5. Lift the drum and spider assembly away from the hoist gear.
6. Place the drum and spider assembly onto the new hoist gear (resting on cribbing).
NOTE: If reversing the existing hoist gear, set the drum and spider assembly on cribbing, turn
over the existing gear with an additional crane, then set the drum and spider assembly
on the gear. The hoist gear weighs approximately 12,000 Lbs.
7. Install the 36 body-fit bolts and tighten.
8. The drum shaft can now be reinstalled in the machine using the above procedure.
Verify the planetary output pinion-to-drum gear alignment has the proper backlash and contact
patterns. Refer to HOIST GEAR START-UP INSPECTIONS in this section of the manual and
OPEN GEAR BREAK-IN located in the ENGINEERING DATA section.

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Service Procedures

Figure 4-46 Hoist Drum Assembly

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Service Procedures
4.2.6.6.1 Bearing Removal

To remove or replace the hoist drum shaft bearings, it is best to remove the drum shaft assembly
from the machine. Refer to HOIST DRUM ASSEMBLY, then proceed as follows:
1. Ensure the drum shaft assembly is resting horizontally on cribbing (not shown).
2. Remove the 6 - 1 inch hex screws that fasten each of the outer retainers to the bearing
housings. See View A.

3. Mark then remove each outer retainer. Each retainer weighs approximately 325-400 Lbs.
NOTE: These parts are not interchangeable. Inspect the O-Ring on the inside of each retainer.
Replace if required.
4. Using a suitable lifting device to support the weight of the bearing housing (approximately
3,200 Lbs. each), pull the bearing housings from the bearings.
5. Remove the lockwire from the end plate capscrews. Remove the 6 - 1.5 inch capscrews
that fasten each drum shaft end plate to the shaft. Refer to View B.

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Service Procedures
6. Mark then remove each end plate (approximately 230 Lbs. each). Tag and save the shim
packs for later reuse.
7. Use a bearing puller to pull each bearing from the shaft. Each roller bearing weighs
approximately 675 Lbs.
Inspect the bearings, the spacer and seal remaining on the shaft ends, and the O-Ring on each
seal. Repair or replace any parts as needed.

4.2.6.6.2 Bearing Installation
NOTE: The bearings are assembled with an interference fit. Preheat the bearings in an oil bath
to ease assembly.
1. Ensure the ends of the drum shaft are free of any burrs prior to assembly.
2. Assemble the preheated bearing on the shaft snug against the locating shoulder. Refer to
View C.
3. Assemble the end plate to the drum shaft using 6 - 1.5 inch capscrews. Preload the bearing
and allow the entire assembly to cool.
4. Remove the end plate. Measure the gap “X” as shown in View C.
5. Assemble shim pack with thickness equal to the gap measurement (0.002 - 0.005 inch).
6. Assemble the end plate and secure with 6 - 1.5 inch (Gr. 5) hex screws. Using a STAR
pattern, snug all hex screws to 15 Ft-Lbs (21 N•m).
2-1/4 inch hex
7. Continue to tighten hex screws using a STAR pattern until all reach a torque value 1/3 the
torque value, which is indicated below.
750 Ft-Lbs (922 N•m)
8. Continue to tighten capscrews using a STAR pattern until all reach a torque value 75% of
proof load torque, which is indicated below.
1460 Ft-Lbs (1980 N•m)
9. Install lockwire to hex screws. Refer to WIRE LOCKING CAPSCREWS in ENGINEERING

DATA section of this manual.

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Service Procedures
10. Ensure O-Ring is properly positioned against labyrinth seal. Using a suitable lifting device,
assemble bearing housing (approximately 3,200 Lbs. each), to roller bearings.
11. Position O-Ring inside each bearing retainer. Assemble each outer retainer using 6 - 1 inch
hex screws.
4.2.7 Hoist Oil Cooler

The hoist gearcase temperature is maintained by recirculating lubricating oil through a gearcase
oil cooler.
Figure 4-47 Hoist Oil Cooler
For information on the hoist oil cooler, refer to HOIST MACHINERY LUBRICATION in

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Service Procedures
4.2.7.1 Hoist Mounting Bolts
Use the following view to identify the correct installation of the mounting bolts for the hoist
machinery.
NOTE: Fasteners used for rear portion of the LH pedestal are installed in the shop and ship
with the revolving frame.
For tightening the torque nuts, refer to TORQUE NUT INSTALLATION in the ENGINEERING
DATA section in this manual.

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Service Procedures
4.2.7.2 Hoist Limit Switch

The hoist limit switch is used to prevent the padlocks on the dipper from being pulled into the
boom point sheaves. The switch electrically cuts the reference signal. It is mechanically
connected to the hoist drum shaft. It is composed of a gear reducer, an input shaft connected to
the hoist stub shaft and an optical encoder. Setting the hoist limit switch is a function of the
Operator’s Display in the operator’s cab. To set the hoist limit switch refer to SETTING ROPE
LIMITS.

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Service Procedures
4.2.8 Crowd Machinery
The crowd machinery is located on the deck at the front of the machine, forward of the center of
rotation. This machinery consists of the crowd drum assembly for take-up of the crowd and
retract ropes, a gearcase and a motor with a spring-set, air-released disc brake.
Weekly, check both the crowd gearcases for lubrication leaks at all cover and case junctions and
at the bearing retainers. Replace seals or rings if lubrication leaks are excessive. Replace
sealant as required.
Weekly, check the electrical connection of the crowd motor and blower motor for tightness.
Tighten the connection hardware if necessary.

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Service Procedures
Figure 4-48 Crowd Gearcase
Every six months remove the inspection covers of the gearcases and inspect the gears and
pinions for pitting, abrasion, scratching, galling, spalling and other abnormal tooth wear.
Check the crowd machinery attachment pins for movement under load. Tight attachment pins
minimizes wear on the pins and pin holes. Check every 100 hours.
Weekly, remove the pipe plugs in the first reduction gearcase and the second reduction gearcase
and check the lubricant level. The first reduction gearcase lubricant level plug is located at the
rear of the gearcase cover, to the rear of the first reduction pinion.

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Service Procedures
The second reduction lubricant level plug is located on the inboard side of the second reduction
portion of the gearcase. Maintain the lubricant level at the bottom of the pipe plug opening. When
lubricant sample tests prove it necessary, drain the gearcase immediately after operation; flush
out the gearcase and refill with the recommended lubricant. Refer to Section 3 for the correct
lubricant.

4.2.8.1 Crowd Gearcase Disassembly
Repair of the crowd reduction gears is basically a matter of component replacement. Use the
following procedures to disassemble the crowd machinery whether the crowd is on the machine
or separated from the revolving frame.
NOTE: Removal of the appropriate roof panel is necessary to facilitate this procedure.
1. Remove the crowd ropes and retract ropes from the crowd drum. Refer to the instructions in
FRONT END EQUIPMENT in this manual.
2. Disconnect any lubrication lines attached to the crowd gearcases and covers. Drain the
lubricant from the gearcase.
3. Disconnect the electrical leads to the crowd motor and the blower motor. Identify the leads
to ensure correct installation.
STORED ENERGY! Gearing or drum must be blocked prior to removal of components in

4. Remove the motor coupling guard and separate the coupling.

5. Remove the motor shaft outboard end cover and the inboard bearing retainer. Remove the
two first intermediate shaft end covers. Remove the second intermediate shaft end cover
and the inboard bearing retainer. Remove the bolts that secure the second intermediate
shaft left side bearing cover and inner retainer.

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Service Procedures
Figure 4-49 Crowd Motor Pinion - Exploded View
6. Attach a crane to the gearcase cover and remove the bolts securing the cover to the
gearcase. Remove the bearing cap rods, nuts and washers.
NOTE: When removing torque nuts, refer to the proper removal procedure in the
ENGINEERING DATA section.
7. Lift and remove the cover from the gearcase. Remove the cover seal from the gearcase.
8. Attach a crane to the motor shaft and lift the shaft assembly from the gearcase. Remove the
first and second intermediate shafts in the same manner.

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Service Procedures

Figure 4-50 Crowd 1st Reduction - Exploded View
9. Dismantle the shafts as required.

a. For any shafts that are dismantled, inspect the bearings for pitting, scoring and other
defects. Replace damaged bearings.
b. Check the oil seals for cuts, abrasions and other damage to the sealing surface.
Replace as necessary.
c. Install new O-Rings and gaskets where required.
d. Some bearings and spacers are interference fit and must be preheated in an oil bath
prior to installation on the shafts.

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Service Procedures
Figure 4-51 Crowd 2nd Reduction - Exploded View

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Service Procedures
4.2.8.2 Crowd Gearcase Assembly
To reassemble the crowd gearcase:
1. Install the shafts in the gearcase, using the crane to lift the shaft units.
2. Be sure the flanges of the gearcase and gearcase cover are clean. Install the seal in the
groove in the gearcase. Apply a continuous bead of Loctite #515 to the gearcase flange

halfway between the bolt pattern and the inside of the flange. Install the gearcase cover
securing it with the necessary hardware.
3. Preload the second intermediate bearing cap against rear hook of frame with a 1-1/2" by 4"
GR5 capscrew. Apply Loctite and tighten to 1,700 Ft-Lbs.
4. Install the rods and their associated hardware into the bearing caps and hand tighten.
NOTE: The bearing caps and rods are assembled with torque nuts. Refer to ENGINEERING
DATA section for tightening instruction.
5. Tighten the torque nuts on the rods using the proper procedure.
6. Install the retainer hardware. Install and secure the shaft end covers. Be careful not to pinch
the O-Rings.
7. Attach the lubrication lines and lubricate the bearings. Fill the gearcases with oil to level with
the bottom of the oil filler opening. Attach the electrical leads to the motor and the blower
motor.
8. Install the crowd and retract ropes on the drum. Refer to FRONT END EQUIPMENT.
NOTE: For repairs involving torque nuts, refer to the proper tightening and loosening
procedures.

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Service Procedures
4.2.8.3 Crowd Motor

LUBICATION section of this manual. If removal of the crowd motor is necessary, follow the
instructions below.
NOTE: Removal of the appropriate roof panel is necessary to facilitate this procedure.
Crowd the dipper outward and place the dipper on the ground.
1. Disconnect and identify the electrical leads to the crowd blower motor and the crowd motor.
2. Remove the blower motor and duct as a unit from the crowd motor.
3. Remove the brake from the motor. Refer to the BRAKES AND COUPLINGS section.
STORED ENERGY! Gearing or drum must be blocked prior to removal of components in


June 2012
Service Procedures

4. Remove the motor coupling guard and separate the coupling.
5. For repair of the original motor, remove the two chocks and wedges located on the side of
the motor towards the boom.
6. For replacement of the original motor or motor pinion, remove the four chocks and wedges
located on both the front and rear side. Also remove the two chocks at the brake end of the
motor.
7. Remove the bolts securing the crowd motor to the crowd machinery frame. Use a crane to
lift the motor from the frame. The weight of the crowd motor is approximately 4,000 Lbs.
8. For reinstallation of the original motor and pinion, position the motor against the two in-place
chocks and wedges. Reinstall the two chocks and wedges on the boom side of the motor.
Re check coupling alignment.
9. For replacement of the original motor with a new motor refer to the BRAKES AND
COUPLINGS section in this manual. Align the motor coupling per the instructions in
BRAKES AND COUPLINGS. Install the four chocks and wedges on both sides of the motor.

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Service Procedures
4.2.8.4 Crowd Gear and Drum

Inspect the drum gear-to-drum mounting hardware for loose or missing nuts and bolts. These
bolts and nuts were tightened at the factory using Turn-of-the-Nut torque method. Loose bolts
and nuts should not be retightened but replaced with new bolts and nuts. Tighten the new bolts
and nuts using the Turn-of-the-Nut method per the ENGINEERING DATA section in this manual.
Check the drum for cracks. Check the drum grooves for rough edges and other defects which
would damage the crowd and retract ropes. Check the retract rope for any damage. Inspect the
drum gear teeth for pitting, abrasions, spalling, galling and other damage.
Figure 4-52 Crowd Gear and Drum

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Service Procedures
4.2.8.4.1 Crowd Drum Removal
If repair of the crowd drum is needed:
1. Remove the crowd ropes and retract ropes from the drum. Refer to FRONT END
EQUIPMENT.
2. Remove the gear guard from the drum gear.

3. Disconnect the lubrication lines at the shaft end covers. Remove the end covers.
4. Remove the bolted-on crowd frame lower-front cross tie.
5. Attach a crane to the drum and apply enough force to support the weight of the drum.
Support the bearing caps separately.
For repairs involving torque nuts, refer to the proper tightening and loosening
procedures.
6. Loosen the torque nuts on the bearing caps. Refer to the procedures in the ENGINEERING
DATA section. Remove the preload screw from each bearing cap.
7. Remove the torque nuts and washers securing the bearing caps then carefully remove the
bearing caps. The drum can then be lowered to the ground.

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Service Procedures
NOTE: The bearing cap rods are threaded into the bearing housing supports. These can
remain in place.
8. Cut the lock wire and remove the retainer bolts from each end of the shaft. Remove the
bearing retainers. Remove the shim pack, bearings, bearing spacer and labyrinth seals and
wire together for future use.
9. If necessary, remove the hardware securing the drum gear to the drum and remove the
gear. Consult the manufacturer for repair procedures for the drum and gear.
10. Inspect the bearings for pitting, scoring, scratches and other defects. Replace defective
bearings.
To reassemble the crowd drum:
1. If removed, reinstall the drum gear using new bolts and nuts.
2. Tighten the nuts to 1120 Ft-Lbs (lubed threads, 100% proof load) or tighten the nuts to 224
Ft-Lbs followed by 1/3 turn of the nut (dry threads).
3. Let the joint set for 24 hours then loosen and retighten. When retightening use retaining
compound, part number 82833859, on nuts.
4. The bearings and spacers are interference fit and must be preheated in an oil bath prior to
installation.
5. Attach a crane to the drum unit and position it in the frame.
6. Install the bearing caps. Preload the bearing caps against the front hook using 3/4" x 7-1/2"
GR8 bolts and lockwashers. Lubricate threads and tighten to 385 Ft-Lbs.
7. Secure the bearing caps in place with special torque nuts. Refer to the proper torque nut
tightening procedures in the ENGINEERING DATA section.

June 2012
Service Procedures
4.2.9 Operator’s Cab Mounting
The operator’s cab is mounted to the machinery house using a series of 14 isolators. These
isolator mounts eliminate metal-to-metal contact and break the vibration or shock transmission
path. The isolators should be inspected every 1,250 hours for deterioration and degradation.

For more information, refer to OPERATOR’S CAB ISOLATOR MOUNT REPLACEMENT
procedures in this section of the manual.
Figure 4-53 Operator’s Cab Isolator Mount Components

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Service Procedures
4.2.9.1 Operator's Cab Isolator Mount Replacement

The operator's cab is mounted to the machinery house using a series of 14 isolators. These
isolator mounts eliminate metal-to-metal contact and break the vibration or shock transmission
path. The isolators should be inspected every 1250 hours for deterioration and degradation.
A mobile crane capable of lifting 25,000 Lbs. will be required. DO NOT use hydraulic
(pancake) jacks to raise the cab at its base! It is recommended that all 14 isolator mounts
be replaced at the same time. Access to the isolator mounts and attaching hardware is
somewhat restricted. Use a safe working platform (or scaffolding) to safely reach the
isolator mounts located above the entry way and utility room. A certified electrician is
recommended to oversee the procedure and limit potential damage to electrical wiring
between the machinery house and the cab.
The crane operator should be aware that raising the cab should be limited to 2.50-3.50 inches.
Exceeding this limit WILL damage electrical wiring! Maintain constant 2-way radio
communication between the crane operator and the service mechanics.
DO NOT lift the cab any more than 3.50 inches off its base! Significant damage to
electrical connections and wiring could result. Take time to identify all possible electrical
problems associated with the lift in order to eliminate potential damage to electrical
wiring.
To replace all cab isolator mounts:

TOOLS:
1-7/8 Inch Hex
Torque Wrench
Fabreeka Pad (28) PN: 1561905
Fabreeka Bushing (14) PN: 1561906
Threaded Rods (4) 1.25-7 x 18.00 Inch
Wood Blocks 2.5 - 3.50 Inches Thick
1. Park the machine on level ground with the dipper on the ground and the hoist ropes slack.
2. Shutdown the machine. Lockout and tagout controls in compliance with local regulations.
3. Prepare electrical wiring for cab removal from its base. Have a certified electrician oversee
the procedure in order to limit potential damage to electrical wiring between the machinery
house and the cab. Consider the following:
• Unclamp video camera cables to allow adequate slack to raise the cab 2.50 to 3.50
inches without damage.
• Power off the cab related electrical devices, disconnect wires where necessary.
• Unclamp conduit to provide necessary slack for 2.50 to 3.50 inch lift.

June 2012
Service Procedures
4. Establish 2-way radio communication between the crane operator and the service
mechanics.
5. Taking into account the cab's approximate center of gravity (C.G.), attach rigging to the four
lifting lugs on the roof of the operator's cab. Do not lift the cab at this time.

Figure 4-54 Operator’s Cab Lifting Lugs
6. The 14 isolator mounts are located above the entry way and utility room. Ensure that you
have access to all the isolator mounts at the top of the roof truss. Refer to Figure 4-55.
Figure 4-55 View Looking UP Into Roof Truss
7. Set-up a safe working platform for each set of isolator mounts before proceeding. Although
the individual components of the isolator mounts are not heavy, working with all the
components can be problematic. Never work directly below the mounts!
Use caution and remove the components of each location one at a time. Be careful not to
drop any components on yourself or anyone below.

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Service Procedures
8. At all of the 14 locations, remove the lower components which consist of:
• 1.25 Inch Hex Head Screw
• Bottom Plate
• Backup Plate
• Fabreeka Pad
• Stepped Plate
1-7/8 inch Hex
Figure 4-56 Removing Lower Components Of Each Isolator Mount
NOTE: The isolator pins should remain in place. If the Fabreeka bushings need to be replaced,
contact the manufacturer. A special removal fixture will be required to remove the
isolator pins and replace the Fabreeka bushings.
9. At the 4 locations (2, 5, 9 & 12) shown in Figure 4-57, install 1.25-7 x 18 inch long threaded
rod with nuts on both ends. These rods will help maintain proper alignment during lifting.

June 2012
Service Procedures

Figure 4-57 Alignment Locations (Looking UP Into Roof Truss)
10. Instruct the crane operator to slowly lift the operator's cab only 2.50 to 3.50 inches. This will
allow enough room to remove and replace the upper components of the isolator mounts.
DO NOT lift the cab any more than 3.50 inches off its base! Significant damage to
electrical connections and wiring could result. Take time to identify all possible electrical
problems associated with the lift in order to eliminate potential damage to electrical
wiring.
11. Install cribbing all along the base between the roof truss and the operator's cab. Ensure the
cribbing is used on structurally solid areas. The wooden blocks (cribbing) are used to safely
block the cab in the raised position. The operator's cab can be lowered until the cribbing is
touched, but keep the crane rigging taut (supporting the majority of the cab's weight).
Ensure the 4 threaded rods (2, 5, 9 & 12) retain proper alignment.
12. Remove the upper components from all 14 locations. Mark the shims (with hole location) as
they are removed. It will be necessary to temporarily remove the 4 threaded rods from
locations 2, 5, 9 & 12. Replace one at a time and reinsert rod to retain alignment.
NOTE: If the Fabreeka bushings need to be replaced, contact the manufacturer. A special
removal fixture will be required to remove the isolator pins and replace the Fabreeka
bushings.

June 2012
Service Procedures
Figure 4-58 Operator’s Cab Mounting Hardware
13. Replace upper components with new Fabreeka pads. The shims, stepped plates and
backup plates can be reused if not damaged or distorted. Replace the shims for each
location as marked in removal.
14. When all the upper components are in place, instruct the crane operator the lift the cab just
enough for the cribbing to be removed.
15. Remove cribbing (all wood blocks) between the cab and the roof truss.
16. Carefully lower the operator's cab into place, using the 4 threaded rods for alignment. Allow
the full weight of the cab to rest on the roof truss. Ensure that upper mount components are
seated properly at all 14 locations.
17. With the cab properly aligned, loosely assemble the remaining components. Do not tighten
the hardware.
18. Measure and record the gap between cab and roof truss at all 14 locations.
19. Calculate the amount of additional shims required at each location by subtracting the
minimum gap measured from all gaps within 0.06 inches.
20. Select a combination of shims for each location that will equalize the gaps within 0.06
inches.
21. Raise the cab just enough to install the necessary shims.

June 2012
Service Procedures
22. Lower the cab and re-measure the gap in all locations. Repeat steps 18-22 until all gaps are
within 0.06 inch of each other.
23. Replace the 4 - 1.25 inch threaded rods with 4 - 1.25 inch hex screws.
1-7/8 Inch Hex
24. Tighten all locknuts to a snug tight value of 224 Ft-Lbs (304 N•m).

25. Continue to tighten locknuts working your way around the perimeter of the cab. Gradually
tighten all hardware to the torque value indicated below.
1810 Ft-Lbs. (2454 N•m)
26. Visually inspect shims for gaps.

27. Have a certified electrician re-establish all electrical connections. Consider the following:
• Secure video camera cables back to their original location.
• Re-establish the connection to any cab related electrical devices.
• Secure any conduit back to its original location.
28. Remove lockout tagout from controls.

June 2012
Service Procedures
4.2.10 Operator’s Seat Replacement

The operator's seat assembly has adjustable armrests with joystick controllers. The electronic
components (joystick, pushbuttons) need to be removed from the seat assembly prior to removal
from the base.
Figure 4-59 Operator's Pod
To remove the operator's seat assembly:
TOOLS:
Allen Head
1-1/8 Inch Hex
M13 Hex
Torque Wrench
5/16 Inch Hex Key
M5 Hex Key
1. Park the machine on level ground.

2. Set all brakes.
3. Shutdown the machine. Lockout and tagout controls in compliance with local regulations.

June 2012
Service Procedures
4. Turn OFF the PLC Node 17 Power Supply Breaker to remove power from both joysticks.
5. Mark the joysticks left and right.
6. Remove the joysticks. Refer to JOYSTICK REPLACEMENT in this section of the manual.
NOTE: The pod pushbuttons will also need to be removed from both joystick pods.

Cables are easily damaged by pulling them too tight, scraping on sharp edges or pinching
them between two objects.
7. Disconnect and remove the pushbuttons and the wiring harness associated with each
joystick and pod assembly.
8. Secure the wire harness and the operator displays out of harms way.
9. To access the seat mounting hardware, remove the access panel secured in place with 6 -
0.375 inch button head screws.
Allen Head
Figure 4-60 Access Panel
NOTE: Mounting screws for the operator's seat are inaccessible unless the seat isolators are
moved forward and backward.
10. Loosen the seat isolator fore/aft locking handle and shift the seat backward. This will allow
access to the 2 front mounting screws. Refer to Figure 4-61.
11. Lock the fore/aft locking handle. Remove the 2 front screws from above and the 2 flange
nuts (from below) which attach the operator's seat to the operator's pod.
M13 Hex
M5 Hex Key

June 2012
Service Procedures
Figure 4-61 Shift the Seat Backward To Expose 2 Front Mounting Holes
12. Loosen the fore/aft locking handle and shift the seat forward to gain access to the 2 rear
mounting screws.
13. Lock the fore/aft locking handle. Remove the 2 rear screws from above and the 2 flange
nuts (from below) which attach the operator's seat to the operator's pod.
M13 Hex
M5 Hex Key
14. Use a nylon sling to lift the operator's seat assembly (approximately 190 Lbs.) out of the
operator's pod.
NOTE: Without additional equipment, lifting the operator's seat assembly out of the operator's
console, may require 2 people.
To install the operator's seat assembly:
1. Position the operator's seat assembly (approximately 190 Lbs.) in the operator's pod.
NOTE: Without additional equipment, lifting the operator's seat assembly out of the operator's
console, may require 2 people.
Use caution so that the operator displays and wire harness are out of harms way.
2. Loosen the seat isolator fore/aft locking handle and shift the seat backward to gain access
to the front mounting holes. Lock the fore/aft locking handle, then align the seat and
mounting holes.
3. Insert the front 2 M8 flat head screws through the seat base and mounting holes in the pod.
4. Loosely assemble with 2 M8 flange nuts from below.

June 2012
Service Procedures
5. Loosen the fore/aft locking handle and shift the seat forward to gain access to the rear
mounting holes in the base of the seat. Tighten the fore/aft locking handle.
6. Insert the rear 2 M8 flat head screws through the seat base and mounting holes in the pod.
7. Loosely assemble with 2 M8 flange nuts from below.
8. Tighten all 4 - M8 flange nuts to the torque value indicated below.
M13 Hex 25 Ft-Lbs (34 N•m)

9. Install the access panel and secure in place with 6 - 0.375 inch button head screws.
Allen Head
10. Install the joysticks. Refer to JOYSTICK REPLACEMENT in this section of the manual.
NOTE: The pushbuttons also need to be installed on both joystick pods.
Cables are easily damaged by pulling them too tight, scraping on sharp edges or pinching
them between two objects.
11. Connect the pushbutton wiring to the wiring harness associated with the joysticks.
12. Remove lockout tagout from controls.
13. Turn on the PLC Node 17 Power Supply Breaker.
The joysticks may need to be re-calibrated. Refer to JOYSTICK CALIBRATION in this

section of the manual.

June 2012
Service Procedures
4.2.11 Joystick Replacement

NOTE: The left and right joysticks are not identical. When replacement is required, ensure the
correct joystick is being used! Refer to the machine parts book for the correct part
numbers. If the joysticks are being removed (but not replaced) in order to replace the
seat assembly, tag and mark each joystick LEFT or RIGHT to ensure correct
reassembly.
To remove the joystick:
1. Park the machine on level ground.
2. Set all brakes.
3. Shutdown the machine by pressing the Control OFF button then the Main Power OFF
button on the CONTROL screen.
4. Turn OFF the PLC Node 17 Power Supply Breaker to remove power from both joysticks.
5. Remove the 3 screws securing the top pod cover to the pod bracket. Save any hardware for
reassembly.
6. It may be necessary to disconnect button switches temporarily so the pod cover can be
removed from the joystick.
7. With the top pod cover removed, remove the 4 screws securing the joystick to the aluminum
pod bracket.
8. Disconnect the wire harness and remove the joystick.
To install the joystick:
1. Connect the wiring harness and position the joystick into the aluminum mounting bracket.
Align the holes, ensuring the handle is oriented properly.
2. Fasten the joystick to the pod bracket with 4 screws.
NOTE: Leave enough slack in cable to allow for full range of seat pod adjustment.

June 2012
Service Procedures
3. Reposition the top pod cover over the joystick and reconnect any button switches
disconnected in Step 6.
4. Secure the top pod cover to the pod bracket with 3 screws, making sure no wires are
pinched in the process.
5. Ensure there is enough slack in cable to allow for full range of seat pod adjustment.

6. Reconnect power at the PLC Node 17 Power Supply Breaker.
7. After machine start-up, the new joystick will need to be calibrated. Refer to JOYSTICK
CALIBRATION procedure.

June 2012
Service Procedures
4.2.11.1 Joystick Calibration

To calibrate the joystick:
1. Press the Set Deadband button. The deadband (sometimes called a neutral zone) is an
area where no action occurs.
2. The recommended joystick deadband is 5%.
3. Ensure that all brakes are set and the joysticks are in the neutral position.
4. Press the Set Neutral button.
5. Move both joysticks to travel extent in both vertical and horizontal directions.
6. Press the Set Max Travel button.
NOTE: The maximum travel extents can be seen in the following diagrams.

June 2012
Service Procedures

7. Press the Set Maximum Position button.

June 2012
Service Procedures
4.2.12 Wiper Arm Replacement
For safety, always use a man basket for this procedure. Do not attempt to perform this
procedure without it!
1. With the wipers in the "parked" position, note the exact position of the wiper arms BEFORE
you proceed. Match mark arms with wax pencil if necessary.
2. Remove the cap from one arm to expose the nut holding the arm in place. Repeat for the
second arm.
3. Remove one of the two nuts.
4. Using a small block of wood, set it just under the wiper arm where it attaches to the
threaded wiper arm stud.
5. Using a large bladed screw driver, position it just under the lip of the wiper arm head and pry
upward towards you. The wiper arm should slide off the splined wiper arm stud.
6. Remove the remaining nut.
7. Tether the wiper arm if necessary to ensure it does not fall to the ground.
8. Repeat Step 5 for the remaining arm.
9. Before installing the new wiper arm assembly, examine the splines of each wiper arm stud
for debris. Clean the splines with a small knife or wire brush if needed.
10. To install the new wiper arm assembly, realign as noted in Step 1 and carefully tap each
arm onto the splines of each wiper arm stud.
NOTE: Some wiper motors have a flat spot on the threaded stud that will not allow you to
misalign the wiper arm during re-assembly.
11. Install the two locknuts and tighten to the torque value indicated below.
Adjustable wrench 26-33 Ft-Lbs (35-45 N•m)

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Service Procedures

12. Verify operation. Wiper blades should never contact the window frame. Realignment will be
necessary if there is less than a 3.00 inch clearance on either side.
13. Verify that both locknuts are tightened to 26-33 Ft-Lbs (35-45 N•m).
14. Reinstall the two caps.

June 2012
Service Procedures
4.2.13 Wiper Blade Replacement

The wiper blade assembly can be replaced while standing on the left side walkway, at the front-
left corner of the cab. The wiper blade assembly contains two wipers but must be replaced as
one piece. In moderate climates, wiper blades should be replaced every 6 to 12 months. In
climates with extreme heat or cold, the time between replacements may be significantly shorter.
To replace the wiper blade assembly:

1. Disconnect the washer fluid hose from the base.
2. Remove the locknut and lockwasher.
3. Holding the blade assembly with one hand, remove the capscrew with the other.
4. Save the hardware for reassembly.
NOTE: If provided, pretreat the rubber prior to assembly.
5. Position the new blade assembly into the sleeve of the arm, aligning the holes.
6. Reassemble the hardware and tighten to the torque value indicated below. DO NOT over-
tighten.
6-7 Ft-Lbs (8-10 N•m)
7. Connect the washer fluid hose to the base.

June 2012
Service Procedures
4.2.14 Wiper Motor Replacement
The windshield wiper motor is located in the center of the cab front wall behind the video
monitors. One or more of the monitors will need to be removed in order to gain full access to the
wiper motor.

NOTE: If the windshield wiper arm has not already been removed, it must be removed before
the wiper motor can be replaced. For a step-by-step procedure, refer to WIPER ARM
REPLACEMENT in this section of the manual.
For safety, always use a man basket when removing the wiper arm. Do not attempt to
perform this procedure without it!
To remove the wiper motor:

1. Shut-down the machine.
2. Turn OFF the PLC power supply breaker to remove power to the wiper motor.
3. Remove the wiper arm assembly. For more information, refer to WIPER ARM
4. After removing the wiper arm, remove the 2 protective caps from the shafts of the wiper
motor. Remove the 2 nuts and washers. The motor can now be removed from inside the
cab.
5. Remove two access panels located underneath the wiper motor.

6. With the access panels removed, disconnect the video monitor cable of any monitor to be
removed.

June 2012
Service Procedures
NOTE: Mark the cables if necessary to ensure they are reconnected to the same monitor
location they where removed from.
7. Hand loosen the video monitor supports and carefully remove the video monitor.
8. Repeat steps 6 and 7 for the remaining video monitors necessary to gain complete access
to the windshield wiper motor.
9. Disconnect the motor wire harness.
10. Remove the remaining mounting hardware and wiper motor.
To install the new wiper motor:

1. Assemble the new wiper motor to the cab front wall using the hardware configuration shown
in View A. Mounting hardware is supplied with the motor.

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Service Procedures

Figure 4-62 View A - Wiper Motor Installation
2. Connect the motor wire harness.

3. Replace the video monitors removed in steps 6-7. Ensure the video cables have been
properly connected and the monitors are securely in place.
4. Replace the two access panels removed in step 5.
5. Install the wiper arm assembly. For more information, refer to WIPER ARM
6. Turn power supply breaker back ON.
7. Verify proper operation.

June 2012
Service Procedures
Machinery House BI010310
4.3 Machinery House

The machinery house has separate structural members consisting of front and rear main truss
and interconnecting beams. These form the permanent house structure.
Roof panels are individually fastened to the interconnecting beams. Any panel can be removed
separately to provide access to a machinery house unit. All roof panels are secured with hold
down bolts on retainer bands. Vinyl tape weather stripping is installed between the retainer band
and roof panel.
Shroud covers around the A-frame legs have vinyl tape between the leg and shroud. Shroud
support joints are sealed with rubber cement or silicone caulking.
All mating surfaces of the machinery house wall panels are sealed with rubber cement or silicone
caulking to ensure weather tight seal.
Frequently inspect all house panels and structural members for cracking. Include a close
examination of all roof structures. Examine all struts, beams and braces used to reinforce the
machinery house.
Always restore defective structural members to their original state by repair welding.
Periodically observe the hinges and closure mechanisms on all doors and windows to ensure
they will remain closed during machine operation. Verify the sealing of the leg closures of the A-
frame. Tighten all loose bolts and replace all missing hardware. The absence or looseness of
these fasteners can result in excessive vibration and wear of house components. Individually,
these faults can be considered minor, but taken collectively, they represent a major exposure of
the electrical and mechanical elements of the house to dust and water.
Check the condition of the house paint. Paint is not impervious to deterioration. A well-painted
machine is less susceptible to rust, corrosion and progressive failure.
Be sure the pressurization system is functioning properly to keep the house well-ventilated at a
pressure higher than atmospheric pressure.

June 2012
Service Procedures
BI010310 Machinery House
4.3.1 Walkways, Stairways, and Handrails
Each day inspect all walkways, platforms, stairways and handrails on the machine. Maintenance
personnel should do the inspecting. Should a structural member become damaged, repair or
replacement may be necessary. Replace nuts and bolts where required or repair weld to

restructure individual access members such as steps and railings.
Eliminate accumulations of wiping rags, oil and grease, dust and dirt and mislaid maintenance
tools. They can create a safety hazard. Keep new and used wiping rags in barrel containers
rather than draped or tied to railings. Clean off oil and grease in the primary walking and working
areas to prevent workers from slipping. Maintain a tool bench and rack for the storage of all tools
used in the machine upkeep. Do not let tools lie scattered upon walkways and stairways.

June 2012
Service Procedures
4.3.1.1 Boarding Stairs

machine, the right side or both. When lowered, the stairs allow entrance to the machinery house
from ground level. To activate the stairs, a pull cord attached to a lever arm is reachable from the
ground. An additional lever is available at the top of the stairs. These stairs must be in their
raised and latched position to enable the operator’s controls.
Figure 4-63 Right Side Boarding Stairs

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Service Procedures
4.3.1.2 Vertical Boarding Ladder, left

The vertical boarding ladder is one of the means for boarding the machine, located on the left-
hand side of the machine, at the rear of the machinery house. Use the pull cord from ground level
to lower the ladder. When the ladder is not latched in place the operator's controls are

deactivated.

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Service Procedures
The ladder is a movable structure with a bracket and two rollers at four locations on the ladder.
The rollers straddle a rail on each side of the ladder frame. Wire ropes (one on each side of the
ladder) connect to the top of the ladder, pass up through sheaves and down to a counterweight
inside each side of the ladder mounting frame.
The ladder should be in the UP position when at rest, with the weight of the counterweights
holding it in place. If not, or if rough action is noted, check for binding in the rail structure,
damaged or missing rollers, or binding with the counterweights.

Periodically check for lubricant in the sheaves at the top of the ladder.
Figure 4-64 Vertical Boarding Ladder, Miscellaneous Views

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Service Procedures
4.3.1.3 Power Step

The power step is one of the options for boarding the machine. It is located on the left or right
side of the machinery house, near the center of the lower platform. A lock / release handle is
pulled from ground level to lower the power step for boarding. The operator’s controls are
deactivated if the power step is NOT latched in place.

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Service Procedures
4.4 Front End Equipment

The front end equipment consists of the boom, the boom point sheaves, padlock, saddle block,
dipper handle, dipper, dipper trip mechanisms, running ropes and boom suspension strands.

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Service Procedures
4.4.1 Boom Assembly
Maintenance of the front end equipment requires at minimum a weekly visual check for cracks or
other damage to the boom structure. It will include checking the ladders and the boom point
platform. Also, check for signs of wear and cracks on the sheaves. Replace, if necessary. There
should always be a sign of fresh grease on both sheave bearing areas. Visually check sheave

bearing retainer bolts. Inspect the boom foot lugs for any signs of cracking. Also check to see
that the boom foot pins are being properly lubricated. Unusual problems should be referred to the
manufacturer for solutions.
The welding of ANY attachments to the surface of the boom, other than those specified on an
official manufacturer engineering drawing, is to be prohibited during erection or maintenance of
this machine. Any existing unauthorized attachments should be removed by grinding in order to
prevent damage to the boom.
STORED ENERGY! Removal of bolts and pins requires the attached items to have
proper support to release the load. Failure to comply could result in death, severe

June 2012
Service Procedures
Figure 4-66 Boom Assembly
4.4.1.1 Boom Repair

Repair of the boom is normally limited to very minimal additional damage sustained following the
failure of an attached component. If any structural damage is found on the boom assembly
contact the manufacturer immediately.
DUE TO THE HIGH LOAD CARRYING POSTURE OF THE BOOM ASSEMBLY, ANY
QUESTIONABLE DAMAGE ON THE BOOM MAY SERIOUSLY ENDANGER HUMAN LIFE
AND MUST BE INVESTIGATED BY QUALIFIED PERSONNEL BEFORE CONTINUED
SERVICE CAN BE UNDERTAKEN.

June 2012
Service Procedures
4.4.2 Boom Limit Switch Installation
To adjust the boom limit switch:
1. Ensure that the machine is level, the dipper is resting on the ground, and that the hoist
ropes are slack. The crowd must be allowed to unload all forces against the rack.

Figure 4-67 Boom Limit Switch Location

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Service Procedures
Figure 4-68 Boom Inductive Proximity Switch
2. Loosen the 0.38 inch capscrews that fasten the proximity switch bracket to the mounting
angle. The slotted holes in both pieces allow for both horizontal and vertical adjustment.
3. Adjust the position of the proximity switch to the dimensions shown in Section A-A, Figure
4-68.
Overall sensitivity can be further adjusted from this initial position to suit conditions.

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Service Procedures
4.4.3 Boom Point Sheaves
This machine uses 2 boom point sheave assemblies to redirect the hoist ropes from the dipper
padlock to the hoist drum. Check the boom point sheaves monthly for unusual wear. Check that
the sheave bearings are receiving proper lubrication and that the lube lines are not damaged or
crimped. For detailed sheave inspection procedure refer to the topic near the end of this manual.

June 2012
Service Procedures
4.4.3.1 Boom Point Sheave Removal and Disassembly

Use the following procedures to remove ONE boom point sheave assembly:
1. Position the machine in a clear and level area.
2. It is not necessary to lower the boom when removing the boom point sheaves. However, lift
the hoist ropes, with a suitable crane, and set them at the center of the boom away from the
sheave assemblies.
THE HOIST ROPES MUST BE SECURED TO THE BOOM FOR SAFETY UNTIL THE REPAIR
IS COMPLETED. USE BLOCKING BETWEEN THE ROPES AND THE BOOM STRUCTURE
TO PREVENT DAMAGE TO THE ROPES.
ADEQUATE PRECAUTIONS MUST BE TAKEN TO ENSURE THE SAFETY OF PERSONNEL

WHEN EQUIPMENT IS REMOVED AND REPLACED. USE EXTREME CAUTION AND
PROPER SAFETY DEVICES WHEN WORKING AT THE BOOM POINT.
3. Disconnect and plug the lubrication lines to the sheave pins.

4. Use a suitable crane and provide just enough lift to the boom point sheave to be removed to
carry its weight. The approximate weight is 7,000 Lbs. DO NOT APPLY TOO MUCH
FORCE WITH THE LIFTING DEVICE.
5. Remove the sheave clamp collar from each end of the boom point shaft.
6. Ensure that the sheave assembly is supported with a sufficient sling or chain and loosen the
four 1.5 inch capscrews that retain the bearing caps on the shaft to be removed.
7. With the shaft assembly secured, remove the capscrews and bearing caps.
8. Lift the sheave assembly away from the boom point and set on the ground.
NOTE: When lifting the sheave assembly, locate the key at the bottom of the outboard end of
the shaft and retain for reinstallation.
THE SHAFT KEY MAY FALL WHEN THE SHAFT IS LIFTED!
To disassemble the boom point sheave:

1. Remove the spacer from the shaft.
2. Remove the bearing retainer, bearing clamp and associated hardware from both sides of
the sheave.

June 2012
Service Procedures

NOTE: Refer to SHIM INSTALLATION procedures in BOOM POINT SHEAVE REASSEMBLY
AND INSTALLATION.
3. Use caution and remove the O-Ring and seal from each retainer.
4. Remove the bearing clamp from each side of the sheave and also the O-Ring from each
bearing clamp.
5. Remove the shims from the inboard side of the sheave.
6. Remove the sheave and bearing from the sleeve. Separate the bearing from the sheave.
7. Remove the sleeve from the shaft.
8. Check and repair all damaged or worn parts.

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Service Procedures
4.4.3.2 Boom Point Sheave Reassembly and Installation

1. Apply a thin coat of Molycote G to the shaft. Install the sleeve onto the shaft. Install the
bearing and sheave onto the sleeve.
Use the following steps to install the shims:
a. Install the inside and outside bearing clamps. Ensure they are tight against the boom
point sheave sleeve.
b. Use a depth mic through the 4 holes to measure the depth of the outside bearing
clamp. Average this dimension.
c. Remove the outside bearing clamp and measure the thickness at the same 4 points.
Average this dimension.
d. Subtract the averaged second outside dimension from the averaged first hole
dimension.
e. Subtract 0.002 - 0.005” from this dimension and use this as the new shim thickness.
f. Install the shims. Assemble the O-Ring to each bearing clamp then install the bearing
clamps.
g. Tighten the 16 - 0.75 inch socket head hex screws in a crisscross pattern to the torque
value indicated below.
5/8 inch Hex Key 53 Ft-Lbs (72 N•m)
h. Continue to tighten the capscrews 1/3 of the required torque value at a time, until a
torque of 200 Ft-Lbs (272 N•m) is achieved.
NOTE: For more information on torque values, see ENGINEERING DATA in this manual.
2. Assemble the seal and O-ring to each bearing retainer then install the bearing retainers.
Tighten the 12 - 0.75 inch hex screws and lockwire in place.
3. Slide the spacer onto the end of the shaft opposite the keyway.
To reinstall the boom point sheave assembly:
1. Insert the shaft key into the proper slot in the boom point structure.
2. Using a suitable crane, lift the sheave assembly into place at the boom point.
NOTE: The sheave assembly must be oriented with the spacer near the end of the shaft toward
the center of the boom, and also the key slot on the shaft must be at the bottom and
toward the outside of the boom. Ensure that the ends of the shaft in the bearing cap
area are coated with Molycote G.
3. With the shaft in place, attach the bearing caps and capscrews.
4. Tighten the 1.5 inch hex screws to 1460 Ft-Lbs (1980 N•m).
5. Slide the shaft toward the center of the boom as far as possible. Attach the clamp collar on
that end and tighten its capscrews.
6. Slide the shaft as far as possible toward the outside of the boom. Attach the clamp collar on
that end and tighten its capscrews.
7. Reconnect all lube lines.
8. Using a crane lift and set the hoist ropes back onto the sheaves. DO NOT CROSS THE
HOIST ROPES. If required, refer to HOIST ROPE REEVING & REPLACEMENT.

June 2012
Service Procedures
4.4.4 Boom Bumper
Regularly check the condition of the boom bumper and make repairs as required. Inspections
should be conducted at minimum of once per operating shift. Additional inspections may be
required. Operator’s style will affect bumper life. Repair of the boom bumpers consists of
replacing common hardware and cushion material.

STORED ENERGY! Removal of bolts and pins requires that the attached items be
properly supported to release their load. Failure to comply could result in death, severe

June 2012
Service Procedures
4.4.5 Saddle Block

The saddle block should be inspected daily for signs of excessive wear. Make certain that it is
being adequately lubricated and that the injectors are functioning properly. Also check the
condition of the shipper shaft sheaves for signs of unusual wear. The lubrication lines which run
up the boom should be checked for any signs of damage or crimping which could impede the
flow of lubricant to the saddle block.
Figure 4-69 Saddle Block Bushing Arrangement

June 2012
Service Procedures
4.4.5.1 Saddle Block Repair
The saddle block liners should be replaced when the chamfer has been worn off the inner
bushings, or when the measured distance from one side of the handle to the lining is 0.12 inch or
less - with the handle pushed to the same side of the liner. Measure the liners at 4 equally
spaced points about its circumference. It may be possible to remove the liner capscrews and

rotate the liner for additional wear. Replace the liners as follows:
1. Remove the dipper handle per the procedures in DIPPER HANDLE REMOVAL.
2. Secure the rear liner with a crane and remove the liner mounting bolts. Remove the liner
from the saddle block.
NOTE: The liner was installed with Loctite. It may be necessary to heat the saddle block or to
cut the liner in order to remove it. Discard after removal.
3. When installing new rear liners, uniformly coat the saddle block I.D. with retaining
compound, part number 82833871, immediately before installation. Use retaining
compound, part number 82833862, on the liner bolts.
4. Replace the front liners using the same procedures as above.

June 2012
Service Procedures
4.4.5.2 Saddle Block Removal

For any work to be done on the saddle block other than replacement of liners, the saddle block
must be removed from the machine. Remove the saddle block as follows:
1. Remove the crowd and retract ropes as described under CROWD & RETRACT ROPE
REMOVAL.
2. Remove the dipper handle as described under DIPPER HANDLE REMOVAL.
3. Two cranes are required to remove the saddle block. One crane is used to support and
remove the saddle block. The other crane is used to remove the shipper shaft.
4. Separate and plug the lube lines to the saddle block.
5. With a crane supporting the saddle block, remove the shipper shaft clamp collars and slide
the shipper shaft to either side to remove it from the saddle block and boom. Lower the
saddle block to the ground.
6. Check the shipper shaft bushings in the boom and replace if required. Consult manufacturer
service department prior to starting repair.

June 2012
Service Procedures

Figure 4-70 Saddle Block Sheave
7. Inspect and replace any worn sheave bearings and seals or saddle block bushings.
Bearing retainer shimming instructions:
a. Install the spacer and the bearing on the saddle block. Install the seals and the seal
retainers. Press the bearing tight against the spacer.
NOTE: Do not install the saddle block retainer.
b. Install the bearing retainer. Tighten just until snug, the socket head cap screws that
hold the bearing retainer in place.
c. Keeping the bearing tight against the spacer, measure the depth along the outer edge
of the bearing retainer using the depth micrometer as shown. Remove the bearing
retainer and measure the retainer thickness.
d. Subtract the measured retainer thickness from the measured depth to calculate the
gap and assemble the shim with the thickness equal to the gap thickness -0.002 to -
0.005.
e. Re-install the bearing retainer and snug-tighten the cap screws. All cap screws require
retaining compound, part number 82833859. Tighten in a sequence 180° apart in 3
steps adding 1/3 torque value each time.
NOTE: All cap screws should be tightened to 146 Ft-Lbs.
8. Reinstall the saddle block in the boom. Reconnect the lube lines. Reinstall the dipper
handle. Reeve the crowd and retract ropes on to the machine.

June 2012
Service Procedures
4.4.6 Dipper Handle Assembly

The dipper handle assembly should be checked regularly for bending or structural cracks. If any
cracks or bending are apparent, remove the handle and repair as required. For instructions and/
or assistance, please refer to the manufacturer.
Check the handle for proper lubrication in the area that passes through the saddle block. Make
sure that the automatic lubrication system is working properly.
Check the condition of the crowd rope screw rod adjustment mechanism:
1. Make sure that all fasteners are tight.
2. Check for evidence of leakage, spills or over-lubrication from the auto-lube system, or from
the OGL applied manually to crowd rope adjusting assembly. Replace damaged seals, if
required, or re-adjust lube system settings.
NOTE: OGL lubricant should be added to the crowd rope adjusting mechanism whenever the
dipper handle is positioned to re-tension the crowd rope. Refer to LUBRICATION
section - CROWD ROPE TAKE-UP MECHANISM LUBRICATION.

June 2012
Service Procedures

June 2012
Service Procedures
4.4.6.1 Dipper Handle Removal

1. Crowd the handle out until the saddle block is a slight distance from the crowd cushion.
(This is to prevent undo tension on the worm gear housing capscrews.) Lower the dipper to
the ground, resting it with the heel on the ground. Set all machine brakes, but do not lock
out the power.
2. Remove the crowd and retract ropes. Refer to ROPE REMOVAL AND REPLACEMENT for
proper instructions.
3. Support the crowd screw half-sheave assembly with a crane, both at the half-sheave and at
the take-up guide. (Weight is approximately 11,500 Lbs.) Be sure not to damage the
bellows. Note the location of the lifting lug on the top of the take-up guide housing.
4. Remove the 42 - 0.75 inch capscrews, on the half-sheave end of the handle, that attach the
worm gear housing and take-up guide to the handle. At this time do not remove the 7
capscrews toward the inside of the worm gear housing, nor the 12 nuts and capscrews
holding the cushion in place.
NOTE: The 7 capscrews toward the inside of the worm gear housing attach the housing to the
take-up guide. These screws must remain in place when removing the crowd rope take-
up mechanism as a unit.
5. The crowd rope adjusting mechanism consists of the crowd half-sheave, screw rod,
bellows, worm gear housing, crowd take-up guide and crowd cushion. With the capscrews
mentioned in Step 4 removed, carefully slide the take-up mechanism out of the handle then
lift it away from the handle and rest it on cribbing.
6. Secure a crane to the dipper handle, between the saddle block and the dipper. Ensure that
the crane will support the free end of the handle. (Weight of the complete dipper handle field
assembly is approximately 64,000 Lbs.) Apply additional rigging to prevent the crane cable
from sliding away from the dipper end of the handle. Support the saddle block to prevent it
from rotating in either direction once the handle has been removed.
THE SADDLE BLOCK MAY ROTATE SUDDENLY ONCE THE HANDLE IS REMOVED. Be
sure the saddle block is supported to prevent its rotation once the handle has been
removed.

June 2012
Service Procedures
The rigging from the crane must be securely fastened with additional rigging to prevent
the crane cable from sliding away from the dipper end of the handle, and also to support
the free end of the handle once it is removed from the saddle block.

7. While supporting the dipper handle with a crane, SLOWLY propel the machine in a straight
line to the rear. The dipper handle will slide from the saddle block.
THE DIPPER HANDLE WILL FALL ONCE REMOVED FROM THE SADDLE BLOCK IF IT IS
NOT FULLY SUPPORTED.
8. Set the free end of the dipper handle on blocking and perform the required maintenance.
While the handle is on the ground, the crowd and retract half-sheaves should be inspected
and repaired if required.
Dipper handle installation is the reverse of removal. Note the following:
• Carefully align the free end of the dipper handle and the saddle block before propelling
the machine forward.
• Refill the crowd rope worm gear housing with OGL, if required. (Total capacity is
approximately 3.0 gallons.) Add, at the least, a small amount of OGL through all of the
lube fittings in the crowd rope worm gear housing assembly to lubricate friction surfaces
adjacent to those fittings. Add a small amount of OGL through the fitting on the half-
sheave clevis pin.
• BE SURE THAT THE WORM GEAR HOUSING AND CROWD HALF-SHEAVE ARE
PERFECTLY LEVEL WITH THE DIPPER-TO-HANDLE PINS AND ALSO WITH THE
RETRACT ROPE SPREADER AND HALF-SHEAVE.
• Install the crowd and retract ropes using the proper procedures in this section of the
manual.
• Before returning the machine to normal service, re-check and/or re-set the crowd and
retract motion stop end limits, and slowdown/stop limits.

June 2012
Service Procedures
4.4.6.2 Crowd Rope Take-Up Mechanism


June 2012
Service Procedures
4.4.6.2.1 Crowd Rope Take-Up Mechanism Disassembly
With the take-up mechanism off the machine proceed as follows to disassemble it:
1. Support the crowd rope take-up mechanism. (Weight is approximately 10,000 Lbs.)
2. Remove the 12 - 0.5 inch capscrews that fasten the crowd cushion to the forward side of the
take-up guide. Then remove the crowd cushion.
3. Remove the crowd rope roller supports from the half-sheave.
4. Remove the 2 setscrews on the pin keeper for the sheave pin. Also remove the sheave pin
t-bolt and cotter pin. Pull out the pin and slide the half-sheave away from the screw rod
clevis.

June 2012
Service Procedures
5. Remove the worm shaft anti-rotation retainer, the bearing retainer and their hardware from
the drive end of the worm gear housing. Remove the oil seal.
NOTE: Refer to the graphic on the preceding page to identify ‘drive end’ and ‘non-drive’ end.
6. Remove the bearing retainer and its hardware and the shimpack from the non-drive end of
the worm gear housing. Record the number and thickness of shims used.
7. Insert a 0.5 x 8 inch bolt or threaded rod through the open bore of the non-drive end of the
take-up guide.
8. Turn the worm shaft counter-clockwise to remove it from the worm gear housing. Both of
the press-fit roller bearings will come out of the bore with the worm shaft.
9. Inspect the bearings on the worm shaft. Replace if required.

10. Remove the stop plate from the square end of the screw rod.
11. Remove the 7 - 0.75 inch capscrews that attach the worm gear housing to the crowd take-
up guide. Remove the crowd take-up guide.
12. Remove the bushing from behind the worm gear wheel.
13. Remove the worm gear wheel, worm gear housing and then the bellows.

June 2012
Service Procedures
4.4.6.2.2 Crowd Rope Take-Up Mechanism Assembly
NOTE: Before re-assembling the take-up mechanism, clean all friction surfaces of the
assembly with a cleaner that does not leave residue or deposits. Open Gear Lubricant
(OGL) can be used to pre-lube individual parts for re-assembly.
Assemble the take-up mechanism in the following order:

1. Position the screw rod so it is vertical, with the square end on top.
2. Slide the bellows over the square end of the screw rod, down toward the clevis end of the
rod. (Or, if the bellows will fit over the clevis, the bellows can be installed from that end of
the screw rod, just before the half-sheave is pinned to the clevis.)
3. Slide the worm gear housing onto the screw rod until it mates with the bellows.
4. Slide the worm gear wheel onto the screw rod and spin it onto the threaded portion of the
screw rod.
5. Slide the worm gear thrust washer onto the screw rod.
6. Slide the crowd take-up guide onto the screw rod.
7. Note the orientation of the lifting lug on the take-up guide. Position the worm gear housing
so that the worm shaft housing is opposite to the lifting lug on the take-up guide. Check that
the bolt holes on the housing and crowd take-up guide are aligned for the capscrews.
8. Install the 7 - 0.5 inch capscrews that fasten the worm gear housing to the take-up guide
and tighten.
9. Bolt the screw rod stop plate to the end of the screw rod using the 4 - 0.75 inch capscrews.
Tighten the clamps on the bellows.
10. Pre-assemble the roller bearings onto the worm gear shaft, using a press or other
appropriate tool.
11. Install a 0.50 inch bolt or threaded rod (at least eight inches in length) into the non-drive end
of the worm shaft, opposite the drive end, for assembly purposes.
12. Insert the worm shaft (with both roller bearings) into its housing. Spin the worm shaft
clockwise until it is fully inserted.

June 2012
Service Procedures
13. Install the non-drive end bearing retainer with its mounting hardware and tighten.
14. Measure the worm shaft end play. Add or remove shims to obtain 0.001 inch to 0.003 inch
end float clearance and re-install the retainer.
15. Remove the threaded rod or bolt used for assembly from the worm shaft.
16. Install the oil seal into the drive end bearing retainer. Install the drive end retainer and its
mounting hardware into the worm gear housing and tighten the retainer capscrews.
17. Install the worm shaft anti-rotation retainer and its hardware into the drive end retainer and
tighten.
18. Insert the pin bushing into the crowd half-sheave and assemble the half-sheave (weight is
approximately 2,000 Lbs.) to the screw rod with the half-sheave pin. Install the t-bolt and
cotter pin. Attach the pin locking plate and capscrews.
19. Install the roller support plates to the half-sheave. Leave the rollers off until the crowd rope
has been installed.
20. Pump OGL into the worm shaft housing until the lubricant comes out from the lube relief
valve. This will require about 3.0 gallons.
21. Attach the crowd cushion halves to the take-up guide with the 12 - 0.5 inch capscrews.

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Service Procedures
4.4.7 Dipper Assembly
The dipper should be inspected before the start of each shift. The side and front surfaces provide
critical reinforcement for the dipper. Consequently, they should be checked regularly for cracks
and component wear. When wear spots develop in the side and front surfaces, the metal contour

can be restored by building up the affected area. Contact the manufacturer for a specified
welding repair solution.
THE DIPPER HANDLE WILL FALL ONCE REMOVED FROM THE SADDLE BLOCK IF IT IS
NOT FULLY SUPPORTED. Removal of bolts and pins requires the attached items to have

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Service Procedures
NOTE: Do not apply hard-surfacing to steel side and front surfaces. This could promote the
development of cracks. Where wear is excessive, mild steel plates can be welded in
place and hard-surfacing applied to these additional plates with excellent results.
All lubrication points should be inspected and lubricated each shift. The dipper should be
checked for missing or broken teeth, and for missing wedges. Replace these items as required
before placing the dipper back into operation. Check the latch bar and the latch bar keeper insert,
if applicable, for wear and replace if required.
Figure 4-71 Dipper Door Latch Bar and Lever

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Service Procedures
4.4.7.1 Latch Bar Adjusting
Check the latch bar and latch lever for proper adjustment. The latch bar should be adjusted to
overlap the latch keeper insert by 1 inch.

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Service Procedures
4.4.7.2 Dipper Door Bumpers

1. Position the door to the rear (toward boom) as far as possible in order to obtain the
maximum possible gap between the door and the dipper body with the latch bar engaged.
2. Measure and record the gaps on both sides of the dipper between the bumper housing and
the rear face of the dipper body.
3. Assemble the bumpers so that they extend out of the housings equal to or slightly less than
the gaps recorded in step 2. Use the shims as necessary to achieve this dimension.
4. Save the excess shims for use in future adjustments.
5. Check and re-adjust the bumpers after one week of operation.
Figure 4-72 Dipper Door Bumper Adjustment

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Service Procedures
4.4.7.3 Dipper Door Snubbers
The dipper door snubbers provide tension on the dipper door to prevent excessive speed and
movement of the dipper door during closing. Check the door snubber periodically for proper
tension.

STORED ENERGY! The snubber pads are under compression. Care must be taken when
removing the adjusting nut in order to avoid injury.

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Service Procedures
4.4.7.3.1 Snubber Adjustment

These adjustment procedures apply to the following snubber assemblies using urethane snubber
pads:
E016896-01 &- 02, E017485-01 & -02,

E017992-01 & -02, E019671-01 & -02,

E020438-01 & -02, E020930-01 & -02,
E020940-01 & -02
NOTE: Refer to the Parts Book for the proper part numbers.
DO NOT use these procedures for snubber assemblies that use belleville washers.
To adjust the dipper door snubbers:

1. Using a torque wrench, tighten both snubber adjusting nuts to 650 Ft-Lbs (882 N•m).
(Approximately 30,000 Lbs. bolt tension). Both snubbers must be adjusted EQUALLY!
2. Observe the door closing during the machine dig cycles. Further tighten or loosen the
adjusting nut to allow the dipper door to gently contact the dipper body.
3. Repeat the above steps as necessary to minimize dipper-to-door contact.
4. After all adjustments are complete, rotate the adjusting nut just enough to reinstall the
adjusting nut cover. Record the final torque for future snubber adjustments.
5. After two full days of operation (40 hours), re-tighten snubbers to the final torque setting.
6. Periodically check snubbers and re-tighten to the final torque setting as needed (usually 2
months or more).
4.4.7.3.2 Allowable Wear

The snubber total allowable face wear is 1.94 inches. At that point no additional force can be
applied to the brake surfaces.
Wear components:
• 4 disc linings at 0.38 inch thick (new) and 0.12 inch thick completely worn out. (1.00 max.
wear)
• 8 steel plate surfaces which contact the discs (approximately 0.12 inch each)
NOTE: Total wear is a combination of disc and steel plate wear. The combination of the two
can not exceed 1.94 inch thickness. If the discs are discarded before they get to
0.12 inch thick minimum, then there is more wear allowance for the steel plate surfaces.

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Service Procedures
4.4.7.4 Dipper Pitch Brace

Figure 4-73 Adjustable Pitch Brace
To adjust the length of the pitch brace:

1. Remove the 12 bolts.
•
To lengthen, add the desired thickness of main shims and remove the same thickness of
bolt shims.
• To shorten, remove the desired thickness of main shims and add the same thickness of
bolt shims.
2. Install the12 bolts and tighten to 2,500 Ft-Lbs (lubricated).
NOTE: Removing one main and adding one bolt shim will raise the heel of the dipper approx.
3 inches (76 mm).

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Service Procedures
4.4.7.5 Dipper Padlock

The padlock should be checked every shift to see that all pin mounting hardware is not loose or
missing. Daily check for excessive movement at the pin joints which indicate bushing wear.
Replace worn bushings and pins. Check for cracking in the frames and links and make repairs
when required.
STORED ENERGY! Removal of bolts and pins requires the attached items to have

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Service Procedures
To repair the dipper padlock:

1. Place the dipper on the ground. Remove enough tension from the hoist ropes to remove the
weight from the dipper lug pin, but not allowing enough slack to permit the weight of the
padlock to rest on the pin.
2. Remove the clamp collars from the lug pin, as shown in Section C-C. Remove the lug pin
(approximately 450 Lbs.) with a suitable pulling device.

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Service Procedures
NOTE: The sheave pins and the lug pins are the same size but have different attaching
hardware. Ensure they are replaced in the proper location during assembly.
3. Using the hoist ropes, lift the padlock from the dipper padlock lug and lower the padlock to
the ground. Remove the thrust washers and the dowels from the lug.
4. Remove the clamp collar from the link pin, as shown in Section B-B. Strike the clamp collar
end with enough force to expose enough of the link pin head to secure a suitable pulling
device. Remove the link pin (approximately 267 Lbs.) from the padlock frame and the link.
5. Remove the bushings from the link and from the lower padlock frame. The bushings have
an interference fit.
6. Support the padlock frame and the sheave. Remove the T-bolts retaining the padlock
sheave pin, as shown in Section A-A. Remove the sheave pin (approximately 366 Lbs.) with
a suitable pulling device.
7. Using a suitable lifting device, lift the padlock sheave from the padlock frame. Remove the
thrust washers and the dowels from the sheave.
8. Remove the hoist rope from the sheave. Remove the sheave pin bushings from the sheave
and the frame. The bushings have an interference fit.
9. Clean and inspect all parts. Repair or replace all damaged or worn parts.
10. Reassemble in reverse of disassembly. Be sure all the dowels are flush with, or below, the
surface of the thrust washers.
NOTE: When installing new thrust washers, line up 0.484 inch diameter holes with 0.484 inch
diameter holes in sheave. Using these holes as a pilot, ream to 0.50 inch diameter for
proper fit with 0.50 inch diameter dowel pin.

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Service Procedures
NOTE: Assemble thrust washer with countersink facing away from sheave.
NOTE: To retain thrust washer, peen end of dowel pin into countersink.
4.4.8 Dipper Removal & Installation

Before performing this procedure, ensure that the proper lifting devices are available and
that you have a complete understanding of the removal process. DO NOT continue this
procedure until you have read and fully understand the removal process.
Follow the procedure closely. As each set of pins are removed, specific dangers as well as
changes in the dipper handle’s C.G. (center of gravity) can occur. Ensure that the components
being removed are securely supported and the spotter (rigging crew) is in direct radio
communication with the crane operator.
STORED ENERGY! Removal of dipper pins requires the attached items to have proper
support to release the load. Failure to comply could result in death, severe personal
injury, or damage to the machine.
To remove the dipper:

1. Park the machine on a firm, level work surface. Position the revolving frame parallel with the
crawlers, with the dipper over the front idlers. Allow approximately 75 feet of additional level
work surface area behind the crawlers.
2. Position the dipper with the floor flat on level ground. Ensure the base of the dipper is fully
supported and level.

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Service Procedures
STORED ENERGY! If the dipper base is not fully supported and level, movement may
result when the dipper is disconnected from the handle. Failure to comply could result in
death, severe personal injury, or damage to the machine.
3. Clear the area of all personnel not directly involved in the process. Establish direct radio
communication with the crane operator.
4. Disconnect the dipper trip rope from the dipper door.
5. Lower the hoist ropes slightly to allow for pin removal.
6. Remove the padlocks one at a time using the following procedure:
STORED ENERGY! Removal of dipper pins requires the attached items to have proper
support to release the load. Failure to comply could result in death, severe personal
injury, or damage to the machine.
a. Using a suitable lifting device, raise the padlock (approximately 5,250 lbs) just enough
to minimize the load placed on the dipper lug pin.
b. Remove the T-bolts securing the dipper lug pin in place. See View A-A.
NOTE: An alternate; pin & collar clamp assembly may replace the T-bolts as a retaining
mechanism. If so, remove the collar clamps and attaching hardware.
c. With a second lifting device, position a strap type sling under the dipper lug pin
(approximately 400 lbs) to support the pin during removal. Remove the pin. Do not
lower the pin at this time, it will be reinstalled.
Figure 4-74 View A-A
7. Raise the padlock from the dipper lug and reposition the padlock directly above the lifting
lug of the dipper handle as shown in View B.

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Service Procedures
8. Using the second lifting device, reinstall the dipper lug pin in the padlock link and secure the
pin in place.

Figure 4-75 View B
9. Attach a shackle (35-ton capacity) to the dipper handle lifting lug. Lock the shackle pin in
place.
10. Using a suitable wire rope sling, tie the padlock and shackle together.
11. Repeat steps 6 through 10 for the opposite padlock. Ensure both slings (used to connect
the padlock and shackle) are identical in length.
12. Slowly raise the hoist ropes just enough to support the dipper handle and remove the load
placed on the pitch brace pins. Ensure the load is evenly distributed between the two lifting
points.
13. Using the hoist ropes to support the dipper handle, disconnect the pitch braces from the
dipper handle using the following procedure:
a. Using a suitable lifting device with a sling-type strap, support the pitch brace
(approximately 950 lbs) from falling forward when the upper pin is removed. Remove
the collar clamp from the upper pin. Refer to Section C-C. Using a second lifting
device, remove the upper pitch brace pin (approximately 400 lbs).
b. Lower the pitch brace so it rests on the dipper. See Section C-C.
c. Repeat steps A and B for the opposite pitch brace.

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Service Procedures
Figure 4-76 Section C-C
14. Raise or lower the hoist ropes just enough to support the weight of the handle and remove
the load placed on the dipper handle pins. Remove the collar clamps holding the dipper
handle pins in place. Remove the dipper handle pins (approximately 450 lbs. each).
15. Use the hoist ropes to raise the dipper handle just high enough to clear the dipper body as
shown in Section D-D.

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Service Procedures

Figure 4-77 Section D-D
16. Carefully move the machine away from the dipper by backing up.
17. When replacing dippers, ensure that the replacement dipper is resting on flat, level ground.
Carefully reposition the machine so the revolving frame is parallel with the crawlers and the
dipper handle lined up with the dipper lugs.
Installation of the dipper is the reverse of removal.

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Service Procedures
4.4.9 Dipper Trip Assembly

The dipper trip can be disassembled in place on the machine or removed as a complete unit. In
either case, the disassembly procedure is the same.

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Service Procedures
AVOID ANY METHODS WHICH ALLOW THE ROPE TO BECOME UNCONTROLLED AT ANY
TIME DURING THE REEVING OPERATION. Death, serious injury, or damage to the
machine will result should a rope become uncontrolled.

1. Remove the drum guard and trip rope from the drum.
2. Open the gear and pinion guard.
3. Remove the drum retainer and drum.
4. Remove the bearing retainer and spacer on the drum side. Then remove the cover and
bearing retainer at the other end of this shaft.
5. Support the gear and slide the shaft from the gear and base on the drum side of the base.
Remove the gear, bearings, spacers and seals.
6. Repair or replace all worn or damaged parts and reassemble in reverse order of
disassembly. Lubricate the bearings.
7. If the pinion was removed from the motor, when it is reinstalled, the motor shaft should be
recessed inside of the pinion 1/16 inch.

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Service Procedures
4.4.10 Crowd Rope Take-up Hydraulic Unit

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Service Procedures
This hydraulic unit is used to apply torque to the worm shaft at the end of the dipper handle when
adjusting the tension in the crowd rope.
The hydraulic unit is a self-contained unit, including a reservoir of hydraulic fluid, a stationary
pump and electric drive motor, and a removable hydraulic motor (with handles) connected to the
pump through a length of hydraulic hoses. To operate the unit, withdraw the hydraulic motor from
its storage on the unit and install the motor on the dipper handle. Refer to the instructions in

CROWD ROPE ADJUSTMENT in this section of the manual for the proper procedures. Press
the start pump button on the control panel then use the hand held pendant station to control the
pump.
Be sure the reservoir is filled with hydraulic fluid. Check for leaks in the piping. Replace the filter
cartridge when indicated.
Figure 4-78 Hydraulic Schematic – Crowd Screw Hydraulic Unit

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Service Procedures
4.4.11 A-Frame
Periodically inspect the A-frame for signs of cracking or other damage. This check should include
the mounting lugs and pins, the ladders or stairs and platforms, the equalizer links holding the
boom structural strands and the leg shrouds on the machinery house roof. Make certain there
are good seals around the leg shrouds.
If any repair welding is required, contact the manufacturer for a specialized repair process. For
any other unusual problems consult the manufacturer.
Carefully inspect the mounting lugs and pins for cracks or other signs of wear or deterioration.
Lubricate these areas occasionally to prevent rusting. Check the leg shrouds both from the inside
and on the top of the machinery house to see that a tight seal is maintained and there are no
leaks. If there are any signs of leaking, reseal around the shrouds with a suitable caulking
compound.
Make certain the ladders or stairs are securely mounted and in good condition. Repair any
cracks as soon as they are noticed.
Check the condition of the platforms to see that they are secure and safe. At the same time
inspect the equalizer links and connections of the boom structural strands.
STORED ENERGY! Removal of equalizer pins requires the attached items to have
Under normal circumstances the A-Frame of the machine will most likely not be removed until
disassembly of the machine is required. Please contact the manufacturer’s service
representative should any unusual circumstances arise.

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Service Procedures

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Service Procedures
4.4.12 Auxiliary Winch

The auxiliary winch is attached to the A-frame rear legs and used to raise and lower the ropes
during hoist machinery maintenance and change-out of hoist ropes. The winch consists of a
drum and rope mounted to an electric gear motor. The winch can be single or double
arrangement. The double arrangement is shown.

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Service Procedures
4.4.13 Hoist Rope Support Roller
The hoist rope support rollers are used to guide the hoist ropes as they leave the hoist drum and
exit the machinery house.
The rollers should be inspected daily for wear. The roller bushings should be lubricated once
every shift. Repair of the rope rollers will consist mainly of replacement of worn bushing and/or
rollers.

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Service Procedures
4.4.14 Boom Support Ropes

Periodically inspect the outer layer of wires immediately adjacent to the sockets. If it is found that
30% of the outer wires are broken, or 10% of the total wires are broken, the strand must be
replaced. Lubricate the suspension rope sockets every quarter or 1250 hours of machine
operation.
STORED ENERGY! Removal of equalizer pins requires the attached items to have
Additional, detailed information can be found in WIRE ROPE CARE AND MAINTENANCE in

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Service Procedures
The structural strands on the UPPER lugs of the equalizers MUST connect to the OUTER
lugs at the boom point. The painted strip on the structural stands must be in a straight
line.

4.4.15 Wire Ropes
The proper wire rope has been determined for satisfactory performance on this machine. To
maintain the machine at its highest level of efficiency, purchase new ropes which conform to
manufacturer’s specifications, and thereby obtain the wire rope best suited for the particular
application. Here are a few pointers relative to the proper inspection, lubrication and replacement
of wire ropes on the machine.

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Service Procedures
4.4.15.1 Wire Rope Inspection

1. It is the operator’s responsibility to maintain drums and sheaves in good condition. Use
ropes of proper size and construction. Examine ropes for signs of deterioration or damage
in service, replace them when necessary.
2. It is customary to work the running ropes almost to destruction in order to reduce the
machine operating cost and downtime for replacement. When loading trucks, hoppers and
the like, which would be damaged by a falling dipper, ropes should be inspected for signs of
deterioration.
3. Outer wires of the hoist ropes may be damaged or broken by falling rocks, by chafing over
sharp rocks in the bank and by the presence of stones in sheave grooves. Rope life may be
prolonged if broken wires are trimmed so that they do not cross over and cause additional
damage to adjacent unbroken wires.
4. The operator should always observe safety precautions.
5. For more information refer to the WIRE ROPE CARE AND MAINTENANCE in
4.4.16 Hoist Rope Reeving & Replacement
NOTE: The procedure outlined in this manual assumes that the old hoist ropes are not broken
or severely frayed, that the machine is equipped with an auxiliary rope winch and that
all of the tools and supplies specified are on hand. THE HOIST ROPE MUST BE KEPT
UNDER COMPLETE CONTROL AT ALL TIMES.

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Service Procedures
AVOID ANY METHODS WHICH ALLOW THE ROPE TO BECOME UNCONTROLLED AT ANY
TIME DURING THE REEVING OPERATION. Death, serious injury, or damage to the
machine will result should a rope become uncontrolled.

To replace the hoist ropes:
1. The machine should be in a clear, flat area with sufficient room in front of the machine to
work. All applicable safety regulations should be followed. Only personnel directly
connected with replacing the ropes should be allowed on or near the machine.
ROPE END(S) WILL FORCEFULLY UNCOIL IN RELEASE OF ENERGY WHEN SHIPPING

RESTRAINTS ARE REMOVED.
The condition of the ropes may make it necessary to modify the procedures outlined,
especially if the rope is broken or severely damaged. Be sure to always follow safety
precautions when burning or climbing. Always keep the ropes under complete control.
2. Lower the dipper to the ground. Position the dipper so that the padlocks are directly beneath
the point sheaves. The hoist ropes will be vertical and the heel of the dipper will be on the
ground.
3. Position a person in the machinery house in a position to observe the hoist drum and ropes.
Slowly rotate the drum in a lowering direction until all of the rope is spooled off of the drum
and the rope sockets are in the bottom rear quadrant of the hoist drum.
Throughout this operation drum or rope positions must be communicated to the operator.
Make sure that a system of signals is worked out in advance and that the line of
communication is unbroken.
NOTES:
• Each hoist rope is a continuous length of rope.
• The “LEAD ROPE” is the portion of rope from the hoist drum, over the outer groove of the
point sheaves, and down to the back of the padlock. The socket on the hoist drum for this
rope “LEADS” the socket for the “FOLLOW” rope.
• The “FOLLOW ROPE” is the portion of rope from the front of the padlock, over the inner
groove of the point sheaves, and back to the hoist drum.

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Service Procedures
4. Attach an auxiliary winch line to each follow rope becket. Remove the keeper that attaches
the follow ropes to the hoist drum.
5. Pull the ferrules out of the becket receivers. Lower the auxiliary winch line until the hoist
rope can be tied off. Tie-off the follow ropes.
6. Carefully rotate the drum 180° in the lower direction to unwrap the remainder of the lead
ropes from the drum.
7. With the lead rope sockets in the lower rear quadrant of the drum, stop the drum.
8. Attach the auxiliary winch line to each lead rope becket. Remove the lead rope keeper.
Payout the winch line until the lead rope can be tied off then tie it off.
9. Attach the follow ropes to the winch line.
10. Attach a sling to the follow rope near the front of the padlock. Attach this sling to a ground
vehicle.
11. Slowly and carefully payout the auxiliary winch while pulling the hoist rope away from the
front of the machine with the ground vehicle. Lower the hoist ropes until the winch line can
be disconnected.

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Service Procedures

NOTE: The ground vehicle is required to pull the weight of the hoist ropes over the boom point
sheaves, and also help bend the ropes through the padlock sheaves.
12. Rotate the hoist drum in the lower direction until the lead rope keeper in is the lower rear
quadrant.
13. Attach a winch and lower the lead ropes in the same manner as that used for the follow
ropes. When the ends of the lead ropes approach the padlocks, one rope must be removed
from the winch line, the remaining lead rope lowered through the padlock, and then
removed from the winch rope.
To install a new pair of hoist ropes:
1. Place the new hoist ropes approximately 10 feet in from of the dipper. If the ropes are on
reels, they should be located so that the ropes unreel from the bottom of the reel.
ROPE END(S) WILL FORCEFULLY UNCOIL WHEN SHIPPING CONSTRAINTS ARE

REMOVED.
NOTE: Drum grooves are not painted to ensure a good rope grip. Some rust may be present;
remove excess rust.
2. Be sure a winch line runs through each padlock.
3. Attach a winch line to one end of each new rope, making them the new lead ropes.
4. Hoist the winch until the lead ropes have cleared the padlock. Attach the free end of each
hoist rope to the winch line that its lead end is attached to.
5. Pull both ropes over the point sheave, being careful to keep the lead rope (rear rope in
padlock) on the outside groove of the point sheave.
6. Continue pulling the ropes into the machinery house. When the ends of the ropes reach a
point where the follow rope can be tied off, stop pulling, detach the follow rope from the
winch line and tie it off.
7. Pull the lead ropes until they are in a position to be placed in their becket resolvers. Place
the lead rope ferrules in the resolvers, install the lead rope keeper and detach the winch
line.
8. Slowly rotate the drum 180° in the hoist direction so that the follow ropes can be attached.

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Service Procedures
9. Hoist the winch attached to the follow ropes until the ropes can be attached to the drum.
10. Place the follow rope ferrules in the resolvers, install the lead rope keeper and detach the
winch line.
11. Slowly rotate the drum in the hoist direction until the hoist ropes are tight. Make sure the
ropes stay in the proper grooves.
12. Hoist the dipper approximately 1 foot off of the ground. Check to make sure the dipper
hangs straight. If not, place shims between the ferrule and the ferrule socket on either the
lead or the follow ropes on the side that the dipper hangs lower. If necessary, locally
manufactured shims may be placed under both ferrules.
13. Hoist and lower the dipper several times to seat the ropes. Make sure the dipper hangs
straight. If not, shim as above. Reset the hoist and crowd limit switches.
Figure 4-79 Shim for Hoist Rope Socket
NOTE: The above steps are used to remove and replace 1 pair of hoist ropes. When replacing
a single hoist rope, be sure to check the alignment of the dipper and shim of the old
rope if required to level the dipper.
4.4.17 Crowd Rope Reeving & Replacement

NOTE: To use the procedure below the old crowd rope must not be broken or severely frayed,
the new crowd rope should be wound on a shipping reel with one ferrule button-end in
and one ferrule button-end out, and all tools and equipment specified must be on hand.
AVOID ANY METHODS WHICH ALLOW THE ROPE TO UNWIND OR FALL

UNCONTROLLED. An uncontrolled rope could cause death or serious injury.
NOTE: Should it be necessary to replace both the crowd and retract ropes, the crowd rope
should be replaced first. The crowd rope has ferrules swagged onto the ends of the
rope to the drum. These ferrules limit the amount of rope on the crowd drum in
relationship to the handle position. Failure to install the crowd rope first may cause the
ropes to be “out of time” and cause operating difficulties. Replacing both ropes
simultaneously should not be attempted.

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Service Procedures
To replace the crowd rope:
1. Check the new rope for the correct length. Measure to the inner ends of the ferrule buttons.
2. The machine should be in a clear flat area with sufficient room to allow all of the steps in the
procedure to be carried out. All applicable safety regulations should be followed. Only
personnel directly connected with replacing the rope should be allowed on or near the
machine.

The condition of the rope may make it necessary to modify the procedure described here,
especially if the rope is broken or severely damaged. Be sure to always follow all safety
precautions when burning. Always maintain complete control over the rope and over any
burned sections of rope.
3. Position the dipper handle horizontal and retract the handle until the crowd screw retract
mechanism is within reach of the hydraulic unit on the machinery house roof.
4. Use the hydraulic unit to retract the crowd rope retract mechanism. Refer to CROWD AND
RETRACT ROPE TIGHTENING in this section of the manual.
NOTE: The dipper handle must be extended next. Use caution when crowding to carefully take
up any slack just developed in the crowd rope.
5. Carefully crowd and lower the dipper simultaneously until the rear stop (cushion) of the
dipper handle contacts the saddle block and the dipper heel is resting on the ground as
shown in the figure.
6. Set all brakes, shut the machine down and tag and lock all controls.
7. While using an auxiliary line to control the becketed end of the retract rope, remove the
clamp and disconnect retract rope from left side of the crowd drum.
8. Use an auxiliary line to pull the ferrule button-end of the retract rope sufficiently to permit the
removal of the ferrule button from the ferrule socket on the right side of the crowd drum.
9. Secure both ends of the retract rope away from the crowd drum to allow rotation of the
crowd drum.
10. Remove locks and tags from the controls. Using the crowd motor, rotate the crowd drum in
the retract direction to unwind the crowd rope from the drum. When the crowd rope ferrule
buttons are in position for easy removal from the sockets, stop rotating the crowd drum. Set
the brakes and replace the tags and locks to the controls.

June 2012
Service Procedures
Figure 4-80 Crowd Rope Reeving
11. Remove the crowd rope ferrule buttons from the ferrule sockets and allow the rope ends to
hang vertically from the saddle block sheaves. Inspect the drum grooves for sharp edges
and grind them as necessary.
12. Position the reel of new crowd rope under the saddle block and in-line with the left saddle
block sheave.

• If the old crowd rope IS NOT broken, attach the end of the new crowd rope to the end of
the old crowd rope at the left side. Secure the end of the old crowd rope on the right side
to a ground vehicle. - OR -
• If the old crowd rope IS broken and has to be removed in sections:
a. Inspect rope grooves and repair/weld as required.
b. Reeve an auxiliary line up to and over the inner groove of the right side saddle block
sheave, around the crowd half-sheave, back over the inner groove of the left saddle
block sheave, and down to the new reel of rope. Attach the auxiliary line to the becket
loop of the new rope and the other end of the line to a ground vehicle as shown.
NOTE: The becketed ends of the crowd rope should pass through the rollers on the crowd half-
sheave. If this becomes difficult, the rollers (2 places) can be removed during rope
replacement. However, these rollers must be reinstalled before the machine is put into
operation.

June 2012
Service Procedures
13. With the ground vehicle, pull the new crowd rope onto the machine until an equal amount of
crowd rope hangs from each saddle block sheave. Secure the crowd rope and disconnect
the auxiliary line.
NOTE: Liberally lubricate the grooves of the crowd drum to help prevent damage to the new
crowd rope as it is pulled into position on the crowd drum.

Figure 4-81 Crowd Rope Termination Details
14. Bring the auxiliary line over the top of the crowd drum, through the crowd rope socket,
around the rear of the drum and forward from the bottom of the drum to the corresponding
end of the new crowd rope. Connect the auxiliary line to the corresponding end of the crowd
rope. Release the corresponding end of the crowd rope from (step 12) securing means, and
with the ground vehicle still attached to the other end of the auxiliary line, pull the crowd
rope onto the rope ferrule socket on the drum. Secure the crowd ferrule button into the drum
ferrule socket. Release the auxiliary line from the crowd rope.
15. Connect the other end of the crowd rope to the other corresponding crowd drum ferrule
socket in the same way as described in the previous step.
16. Remove the locks and tags from the controls, and using the crowd motor, rewind the new
crowd rope onto the crowd drum by rotating the drum in the crowd direction. Make sure rope
is seating properly in the drum grooves and the inner grooves of the saddle block sheaves.
Stop rotating drum when the crowd rope is tight. Set the brakes and replace the tags and
locks on the controls.
17. With the ferrule button-end of the retract rope controlled by an auxiliary line to start with,
reinstall the retract rope to the crowd drum by following steps 6 through 13 of the Retract
Rope Reeving Procedure.
18. Refer to CROWD AND RETRACT ROPE TIGHTENING to tighten the crowd and retract
ropes.

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Service Procedures
4.4.18 Retract Rope Reeving & Replacement

NOTE: To use the procedure below the old retract rope must not be broken or severely frayed,
the new retract rope should be wound on a shipping reel, and all tools and equipment
specified must be on hand.
AVOID ANY METHODS WHICH ALLOW THE ROPE TO UNWIND OR FALL

UNCONTROLLED. An uncontrolled rope could cause death or serious injury.
NOTE: Should it be necessary to replace both the crowd and retract ropes, the crowd rope
should be replaced first. The crowd rope has ferrules swagged onto the ends of the
rope to the drum. These ferrules limit the amount of rope on the crowd drum in
relationship to the handle position. Failure to install the crowd rope first may cause the
ropes to be “out of time” and cause operating difficulties. Replacing both ropes
simultaneously should not be attempted.
To replace the retract rope:
1. The machine should be in a clear, flat area with sufficient room to allow all of the steps in
the procedure to be carried out. All applicable safety regulations should be followed. Only
personnel directly connected with replacing the rope should be allowed on or near the
machine.
The condition of the rope may make it necessary to modify the procedure described here,
especially if the rope is broken or severely damaged. Be sure to always follow safety
precautions when burning. Always maintain complete control over the rope and any
burned section of rope.
2. Position the dipper handle horizontal and retract the handle until the crowd screw retract
mechanism is within reach of the hydraulic unit on the machinery house roof.
3. Use the hydraulic unit to retract the crowd rope retract mechanism. Refer to CROWD AND
RETRACT ROPE TIGHTENING in this section of the manual.
NOTE: The dipper handle must be extended next. Use caution when crowding to carefully take
up any slack just developed in the crowd rope.
4. Carefully crowd and lower the dipper simultaneously until the rear stop (cushion) of the
dipper handle contacts the saddle block and the dipper heel is resting on the ground as
shown in the figure.
5. Set all brakes, shut the machine down and tag and lock all controls.
6. Remove the rope retaining bolts on the retract half-sheave and the rope retainers on the
front spreader.
7. Remove the retract rope from the drum.
8. Remove the old retract rope from the machine.
9. Position the reel of new retract rope directly under the saddle block.

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Service Procedures


Figure 4-82 Retract Rope Reeving

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Service Procedures
10. Reeve an auxiliary line under then over the crowd drum, up and over the outer groove of the
saddle block sheave, through the rope guide on the front stop and around the retract half-
sheave. Reeve it through the rope guide on the front stop on the opposite side of the
handle, over the outer groove of the other shipper shaft sheave, down and over then under
the crowd drum and secure the other end of the auxiliary line to the ground vehicle.
NOTE: Liberally lubricate the grooves of the crowd drum and the retract half-sheave to help
prevent damage to the new retract rope as it is pulled onto the machine.
11. With the ground vehicle pull the new rope onto the machine until an equal amount of the
retract rope is on each side of the machine. Disconnect the auxiliary line from the retract
rope.
12. Reeve the auxiliary line, still attached to the ground vehicle, under the crowd drum up
through the rope socket, down under then over the drum and secure it to the retract rope
becket loop. With the ground vehicle, pull the retract rope onto the drum and into the rope
socket. Seat the becket within the drum receptacle.
13. Install the other end of the retract rope in the crowd drum in the same way.
14. Be sure the retract rope is seated in the outer groove of the shipper shaft sheaves and the
rope grooves of the front stops. Re-install the rope retaining bolts on the retract half-sheave
and front stop rope retainers.
15. Take up any slack in the retract rope with the crowd take-up mechanism. Refer to CROWD
AND RETRACT ROPE TIGHTENING.
16. Re-index the crowd limit switch.

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Service Procedures
4.4.19 Crowd and Retract Rope Tightening
NOTES:
•The constructional stretch may be out of the crowd and retract ropes when it becomes
necessary to adjust the ropes for about the third time. Therefore, after the third rope

adjustment or after replacement, back off the take-up mechanism 1/2 inch after obtaining
a tight rope to prevent working with an overly tight rope.
• Do not overtighten the ropes. The ropes are properly adjusted when a very slight
curvature is noticeable on the retract rope (a 3 to 5 inch sag) with a tight crowd rope.
1. Hoist the dipper until the dipper handle is horizontal, parallel to the ground. Retract the
handle until the crowd half-sheave is within reach of the hydraulic unit on the machinery
house roof, behind the operator’s cab. (With the hoist ropes supporting the dipper and the
handle just retracted, any slack that exists should be in the crowd rope.)
2. Remove the worm shaft retainer from the end of the worm shaft.
3. Retrieve the hydraulic motor from the hydraulic unit on the machinery house roof. Install the
socket adapter (part number B008078-01, supplied with a key and set screw) and a
standard 1.50 inch impact socket on the drive end of the motor.
4. Install the motor onto the worm shaft as shown in the illustration. Use 4 - 0.625 inch
capscrews to attach the motor to the Drive Unit Adapter (S051069).

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Service Procedures
Figure 4-83 Worm Drive During Crowd Rope Adjustment
5. Using the hand-held pendant on the hydraulic unit, extend the crowd screw rod until the
crowd rope is tight. Back off the crowd screw rod one-half inch to allow for proper slack in
the ropes.
NOTE: The half-sheave assembly is pinned to the crowd screw rod. It is the part of the
assembly that is nearest the machinery house roof, so the back end of the half-sheave
is the easiest reference point for gauging the one-half inch clearance dimension.
6. After adjusting the ropes, remove the hydraulic motor, socket adapter, key, set screw and
socket from the motor mount adapter and return them to the storage position on the
machinery house roof.
7. Replace the anti-rotation retainer on the worm shaft and tighten its hardware.
Figure 4-84 Worm Drive During Normal Machine Operation

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Service Procedures
4.4.20 Dipper Trip Rope Reeving & Replacement
1. Use steps one and two from Hoist Rope Reeving. In this procedure the on-board auxiliary
winch is not used.
2. Trip and lock the DTB breaker in the MCC cabinet.
3. Crowd the dipper handle to unwind the trip rope from the reel. Lower the dipper to the

ground and retract it slightly to get some slack in the trip rope. Remove worn rope from
dipper door.
4. Open the drum guard on the dipper trip and remove the rope and wedge from the drum.
Attach a work line to the trip rope. Pull the trip rope over and off of the trip rope guide
sheave and lower to ground. The work rope will remain on the guide sheave and will be
used to pull the new trip rope on.
NOTE: Do not use new trip rope which is longer than specified. Increasing length adds layers of
rope on the drum which decreases trip torque.
5. Reeve one end of the new trip rope under the guide roller, around the latch lever sheave
and secure it to the rope socket with the rope socket wedge on the dipper door.
6. Attach the other end of the new trip rope to the work line still in place on the guide sheave.
With the work line, pull the trip rope onto the guide sheave and up to the dipper trip. Secure
the trip rope to the drum with the rope wedge. Close the drum guard.
7. Remove the lock that was previously placed on the DTB breaker in the MCC cabinet and
reset the breaker.
4.4.21 Hoist and Crowd Limit Systems

All electric rope shovels incorporate a PLC-based limit position system that permits the setting of
the Hoist/Lower and Crowd/Retract operational limits. Hoist and crowd encoders send digital
signals to the PLC relative to the hoist crowd motor positions. The setup of the hoist and crowd
limits is accomplished through the operator’s display terminal by following the instructions
provided here in this manual along with those on the operator’s display. When encoder
calibration and hoist/crowd positional limits have been properly set the system will prevent the
dipper handle from hitting its end stops and will prevent the padlocks from being pulled into the
boom point sheaves.
Hoist/Crowd encoder calibration provides the limit system a reference point for tracking both the
hoist and crowd positions. Performing the encoder calibration sets all the hoist and crowd limits
to their previously set values in order that the actual limits do not require reset after initial
commissioning.

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Service Procedures
4.4.21.1 Setting Limits In The Hoist & Crowd System

The hoist and crowd limits may be changed as often as desired without encoder recalibration
providing the ropes have not been replaced. The individual limits may be set in any order.
Suggested slowdown and stop points are shown as a guide only, and must be adjusted to suit
local operation.
NOTES:
• Hoist and crowd limits should be set with care, as the limits will affect the digging range of
the machine. After the motion limits have been set initially, it is necessary to calibrate the
encoder if the ropes have been replaced, or if the encoder has been replaced. Performing
the encoder calibration will reset the motion limits to their previous positions.
• The slowdown limits reduce handle speed to 20% of maximum prior to reaching the stop
limit. Because the drive requires a discrete distance to stop that is different at all
positions, it is recommended that the slowdown limit be tried several times. Increase
speeds from minimum to maximum to determine if sufficient distance is available in the
limits as set to stop without impacting the mechanical stops.

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Service Procedures
To calibrate the encoder:

1. Go to the Limits screen on the operator display shown in Figure 4-85.

limD1439
Figure 4-85 View A - Calibration Limits Screen
2. Raise the dipper to the maximum point (just touching boom point sheaves).
3. Extend the handle to its crowd end stop.
4. Press the CALIBRATE button on the operator display. This calibrates the rope lengths prior
to setting limits. This is required only after changing the ropes, or if the encoder has been
replaced.

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Service Procedures
4.4.21.1.1 Crowd Slowdown/Stop Limits
To set the crowd slowdown and stop limits:

1. With the handle horizontal, position the handle approximately one foot from the rear end of
the saddle block.
2. Press the CROWD STOP LIMIT button on the operator display.
3. Retract the handle until the crowd stops are approximately 2 feet from the saddle block.
4. Press the CROWD SLOWDOWN LIMIT button on the operator display.

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Service Procedures
4.4.21.1.2 Retract Slowdown/Stop Limits
To set the retract slowdown and stop limits:
1. Position the handle horizontally. Retract the handle until the retract stops are approximately
18 inches from the front end of the saddle block.
2. Press the RETRACT SLOWDOWN LIMIT button on the operator display.

3. Position the handle with the retract stops approximately 6 inches from the saddle block and
press the RETRACT STOP LIMIT button on the operator display.

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Service Procedures
4.4.21.1.3 Lower Slowdown/Stop Limits

To set the lower slowdown and stop limits:
1. Position the handle vertically with the dipper teeth just touching pit floor and the hoist ropes
tight. Press the LOWER SLOWDOWN LIMIT button on the operator display.
2. Keeping the handle vertical, let the padlocks fall forward until the padlocks contact the
dipper.
3. Press the LOWER STOP LIMIT button on the operator display. The lower stop limit helps
prevent rope from spooling off the hoist drum.

June 2012
Service Procedures
4.4.21.1.4 Hoist Slowdown/Stop Limits
To set the hoist slowdown and stop limits:
1. With the handle at full crowd extension, hoist the dipper so the padlocks are approximately
one foot from the boom point sheaves.

2. Press the HOIST STOP LIMIT button on the operator display.
3. Lower dipper until the padlocks are three feet from the boom point sheaves. Press the
HOIST SLOWDOWN LIMIT button on the operator display.

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Service Procedures

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5 Brakes and Couplings
Brakes and Couplings
5.1 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table 5-1 - Machine Motion Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1.1 Disc Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1.2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.1.3 Brake Adjustment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Table 5-2 - Brake Adjustment Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.1.4 Hoist Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Figure 5-1 Hoist Brake and Motor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Figure 5-2 Section View A-A (Hoist Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.1.4.1 Hoist Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.1.4.2 Hoist Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.1.4.3 Hoist Brake Wear & Release Switches . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.1.5 Crowd Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Figure 5-3 Crowd Brake and Motor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Figure 5-4 Section View B-B – Crowd Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.1.5.1 Crowd Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.1.5.2 Crowd Brake Wear & Release Switches . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.1.6 Propel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Figure 5-5 Propel Brake and Motor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Figure 5-6 Section View C-C – Propel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.1.6.1 Propel Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.1.6.2 Propel Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

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5.1.6.3 Tachometer Mounting & Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Figure 5-7 Tachometer Mounting & Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.1.7 Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Figure 5-8 Location of Swing Brakes and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Figure 5-9 Section View D-D – Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.1.7.1 Swing Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.1.7.2 Swing Brake Wear & Release Switches. . . . . . . . . . . . . . . . . . . . . . . 5-26

5.1.7.3 Swing Brake Burnishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.1.8 Spring Replacement — All Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5.1.9 Friction Disc Replacement — All Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.1.10 O-Ring Replacement — All Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5.1.11 Brake Wear & Release Switches — Single Disc Brakes . . . . . . . . . . . . . 5-33
5.1.12 Brake Wear & Release Switches — Multiple Disc Brakes . . . . . . . . . . . . 5-34
5.2 Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5.2.1 Grid Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5.2.1.1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5.2.1.2 Coupling Disassembly and Grid Removal . . . . . . . . . . . . . . . . . . . . . 5-36
5.2.1.3 Grid Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
5.2.1.4 Seal Replacement without Hub Removal . . . . . . . . . . . . . . . . . . . . . . 5-40
5.2.1.5 Grid Coupling Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Table 5-3 - Grid Coupling Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5.2.2 Gear Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.2.2.1 Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.2.2.2 Gear Coupling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Table 5-4 - Gear Coupling Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5.2.2.3 Hoist Coupling Shaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

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BI010311 Brakes
5.1 Brakes
This machine uses spring-set, air-released disc brakes on the HOIST, CROWD, PROPEL and
SWING motions.

In the event of a power failure or loss of air pressure, the brakes will automatically set to stop the
machinery motion. Pressure switches located near each brake control valve monitor air pressure
at the brake. The brakes cannot be released for operation until the air pressure reaches the
operating pressure.
Each brake is fitted with a proximity sensor to monitor lining wear and a limit switch to monitor the
brake set or released position. When the lining wear limit is reached, it is announced on the
operator’s display terminal. The brake position is announced in the operator’s control screen.
x
Table 5-1 - Machine Motion Brakes
Hoist Crowd Propel Swing

Quantity 1 1 2 2
Friction Disc per Brake 3 1 2 1
Weight of Brake 1,346 lbs. 490 lbs. 650 lbs. 490 lbs.
Quantity 12 12 12 12
Mounting Size 0.75 inch 0.75 inch 0.75 inch 0.75 inch
Screws Torque 200-220 Ft-Lbs 200-220 Ft-Lbs 200-220 Ft-Lbs 200-220 Ft-Lbs
(271-298 Nm) (271-298 Nm) (271-298 Nm) (271-298 Nm)
5.1.1 Disc Brake Operation

When air is exhausted, the spring force “clamps” the rotor between the friction discs or the
mounting flange and pressure plate. To disengage the brake, air enters through the end plate
into the diaphragm cavity. As air pressure increases, the end plate moves away from the
stationary spring housing. The pressure plate is bolted to the end plate and travels in the same
direction compressing the springs and releasing the brake.
PRIOR TO INSTALLATION OR MAINTENANCE ON A BRAKE, MAKE SURE THAT

MACHINE OR MACHINERY IS BLOCKED TO PREVENT MOVEMENT. Failure to do so could
result in serious personal injury or machine damage.

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Brakes BI010311
Protective means must be used to prevent oil or grease from coming into contact with the
disc(s) or the friction discs. Oil or grease will significantly reduce the torque capacity of
the brake and decrease its ability to hold the machinery in a safe position. DO NOT RISK
INJURY!
DO NOT OPERATE THE MACHINE WITHOUT ALL BRAKE GUARDS INSTALLED.
5.1.2 Maintenance
• No lubrication is required.
• Replace friction disc(s) when worn to the step on the friction disc O.D.
5.1.3 Brake Adjustment Specifications

Table 5-2 - Brake Adjustment Chart
Adjustable Shims Stroke Stroke

(New) (Worn)
Hoist Brake Yes Yes 0.27 inch 0.40 inch
Crowd Brake No No 0.10 inch 0.20 inch
Propel Brake Yes Yes 0.22 inch 0.32 inch
Swing Brake No No 0.10 inch 0.20 inch

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5.1.4 Hoist Brake

Figure 5-1 Hoist Brake and Motor Location
The hoist brake is located on the right side of the hoist motor. An internal tachometer is located
between the brake and the motor (inside the brake adapter). The hoist brake is spring set, air
released and contains three friction discs. Refer to Section View A-A. Visual inspection of the
brake’s internal components can be made after removing the brake guard. Periodically inspect
the brake friction disc, wear plate, pressure plate and center plates for signs of uneven or
excessive wear. If found, disassemble brake to determine the extent of damage. The friction
discs must be replaced if they become contaminated with oil/grease or are worn out.
PRIOR TO INSPECTION OR MAINTENANCE ON A BRAKE, MAKE SURE THAT MACHINE

OR MACHINERY IS BLOCKED TO PREVENT MOVEMENT. Failure to do so could result in
serious personal injury or machine damage.

June 2012
Brakes BI010311
Brake wear can be extended with proper adjustment. Once the piston stroke has reached a
specified point, an adjustment shim can be removed to bring the piston stroke into the safe
operating limits. Refer to the Brake Adjustment Chart in BRAKE ADJUSTMENT
SPECIFICATIONS. A friction disc must be replaced if it has become contaminated with grease,
oil or foreign material. Refer to the FRICTION DISC REPLACEMENT procedure in this section of
the manual.
Figure 5-2 Section View A-A (Hoist Brake)

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BI010311 Brakes
5.1.4.1 Hoist Brake Adjustment
The hoist brake is equipped with 2 adjustment shims to compensate for lining wear. This brake
should be checked daily for lining wear and proper piston travel. If out of adjustment it will not be
able to support a fully loaded dipper.
To inspect for excessive disc wear, use a depth micrometer as shown in View A. The reading

must be taken from the same location with the brake engaged and released.
NOTE: The brake will be fully released once air pressure exceeds 60 PSI on a properly
functioning brake. However, air pressure in excess of 125 PSI could damage the
internal seals of the piston.
Due to the tapered surface of the pressure plate, care must be taken to duplicate the position and
process as closely as possible. Friction disc adjustment must be performed when the wear
reaches 0.40 inch.
NOTE: Adjustment shims are split for ease of removal and installation. DO NOT DISCARD
shims after removal during brake adjustment. These shims will be required when
reassembling the brake following a friction disc replacement.
Adjusting the hoist brake:
1. When wear has reached 0.40 inch, remove a single shim. Loosen the “X” stud nuts enough
to slide the assembly back approximately 0.06 inch. Do not completely remove the stud
nuts.

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Brakes BI010311
2. Spread one shim at the split line and remove it from the brake, taking care not to bend or
spring the shim. For ease of removal, the shims are split radially.
3. Tighten outer cylinder nuts to 110-120 Ft-Lbs.
Tighten the stud nuts as per the instructions on the brake drive ring to a maximum of 120
Ft-Lbs. Excessive or improper tightness can cause the drive ring to become deformed and
seriously reduce the effectiveness and life of the brake assembly.
4. Re-check the piston stroke. If the piston stroke is greater than 0.27 inch, place the unit back
into service.
If the brake has already had a single shim removed, a second adjustment is possible. If the brake
movement is greater than 0.40 inch the second shim may be removed.
NOTE: If friction disc(s) show signs of uneven wear, move the inner friction disc to outer
location and the outer disc to the inner location to equalize wear. Ensure the side of the
disc with the machined step “Z” faces the motor.

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BI010311 Brakes
5.1.4.2 Hoist Brake Installation
The tachometer, furnished with the electric motor, must be installed before installing the brake
assembly.
1. Install the drive hub and keyway on the motor. Refer to PINION & HUB INSTALLATION in

2. Install motor shaft nut and secure to shaft with Loctite.
3. Install brake adapter onto the motor and secure with hardware. Use care to align the access
slots in the adapter for future tachometer inspections.
4. Lubricate the hub and friction disc splines with a light coat of Teflon grease or anti-seize
compound.
5. Install the friction discs and center plates onto the shaft adapter in the required order before
sliding on the brake assembly. Tighten the drive ring hardware and install the brake guard.
5.1.4.3 Hoist Brake Wear & Release Switches

The hoist brake is equipped with two switches mounted to the outer edge of the brake housing.
For more information, refer to BRAKE WEAR & RELEASE SWITCHES - MULTIPLE DISC
BRAKES in this section of the manual.

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5.1.5 Crowd Brake

Figure 5-3 Crowd Brake and Motor Location
The crowd brake is located on the left side of the crowd motor. An internal tachometer is located
between the brake and the motor (inside the brake adapter). The crowd brake contains a single
friction disc and is non adjustable, refer to Section View B-B. Once the stroke reaches 0.20 inch,
the friction disc must be replaced. Visual inspection of the brake’s internal components can be
made after removing the brake guard. Periodically inspect the brake friction disc, wear plate,
pressure plate and center plates for signs of uneven or excessive wear. If found, disassemble
brake to determine the extent of damage.


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Figure 5-4 Section View B-B – Crowd Brake
The crowd brake is non-adjustable. Once the piston stroke has reached a specified point, the
friction disc must be replaced. Refer to the Brake Adjustment Chart in BRAKE ADJUSTMENT
the manual.

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5.1.5.1 Crowd Brake Installation

Installation of the tachometer, furnished with the electric motor, is required prior to brake
installation. Install the tachometer and the torque arm as shown in View BA. Reposition if
necessary.
the ENGINEERING DATA section.
2. Install the motor shaft nut and secure to the shaft with the lockwasher by bending the tabs
over the flats.
3. Install the brake adapter onto the motor and secure with hardware. Use care to align the
access slots in the adapter for future tachometer inspections. Refer to View BE.
4. Lightly coat the splines of the drive hub with a Teflon grease allowing only a thin film of
lubricant to remain on the splines. Excess grease will be thrown outward by centrifugal force
and have a degrading effect on the brake.

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5. Using a lifting device and the holes provided in the outer portion of the drive ring, place the
brake assembly onto the drive hub and lower while aligning the splines in the drive hub with
those in the brake disc.
6. Apply at least 46 PSI compressed air to release the brake. Verify piston stroke.
7. Release the air pressure from the brake piston to relax the internal springs.
8. Tighten the drive ring for final installation.
9. Apply at least 46 PSI compressed air to release the brake. Verify that the proper gap
remains between the pressure plate and friction surface of the disc.
10. Install safety guard around the brake assembly.

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5.1.5.2 Crowd Brake Wear & Release Switches

The crowd brake is equipped with two switches mounted to the outer edge of the brake housing.
For more information, refer to BRAKE WEAR & RELEASE SWITCHES - SINGLE DISC BRAKES
in this section of the manual.

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5.1.6 Propel Brake

Figure 5-5 Propel Brake and Motor Location
The two propel brakes are located at the rear of the machine, installed in front of each propel
motor. Each propel motor has an externally mounted tachometer as shown in View X. Each
propel brake is spring set, air released and contains two friction discs. Refer to Section View C-C.
Visual inspection of the brake’s internal components can be made after removing the brake
guard. Periodically inspect the brake’s friction disc, wear plate, pressure plate and center plates
for signs of uneven or excessive wear. If found, disassemble brake to determine the extent of
damage. The friction discs must be replaced if they become contaminated with oil/grease or are
worn out.
Brake wear can be extended with proper adjustment, refer to the PROPEL BRAKE
ADJUSTMENT procedure in this section of the manual.


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Figure 5-6 Section View C-C – Propel Brake

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5.1.6.1 Propel Brake Adjustment
The propel brake is equipped with three shims located between the drive ring and the cylinder.
Two of the shims compensate for disc lining wear and one shim is to remain in place. After the
two shims have been removed and the piston stroke reaches 0.31 inch, the friction discs must be
replaced. DO NOT remove the third shim! Refer to the FRICTION DISC REPLACEMENT

procedure in this section of the manual.
NEVER ALLOW THE BRAKE TO OPERATE WITH PISTON TRAVEL OF LESS THAN
0.22 inch. Removal of shims prior to normal wear adjustment requirements will not
increase brake holding capacity. Premature shim removal will reduce running clearances,
causing premature wear and heat damage to linings and brake.
THE THIRD SHIM MUST NEVER BE REMOVED FOR ADJUSTMENT PURPOSES AS

DAMAGE CAN OCCUR TO PRESSURE AND WEAR PLATES.
To inspect and adjust the propel brake:

1. With the machine parked on flat level surface, with dipper heel resting on the ground,
remove the tachometer, tach supports and the brake guard.
2. Determine the piston stroke (amount of piston travel) between the brake’s SET position and
it’s RELEASED position. To determine piston stroke:
a. Using a depth micrometer, measure the brake in it’s SET position. Refer to View C.
b. Apply at least 43 PSI compressed air to release the brake. Do not use excessive air
pressure. Pressures above 125 PSI could damage the internal seals of the piston.
c. Using a depth micrometer, measure the brake in it’s RELEASED position.
d. Calculate the piston stroke.
3. If the brake stroke is between 0.22 and 0.30 inches, no brake adjustment is required at this
time. If the piston stroke has reached 0.31 inches, continue to Step 4.

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NOTES:
• Use a depth micrometer to measure the change in the stroke. Due to the sloped surface
of the pressure plate, measurement must be taken at the same spot for both the set and
the released positions.
• If friction disc(s) show signs of uneven wear, move the inner friction disc to outer location
and the outer disc to the inner location to equalize wear. Ensure the side of the disc with
the machined step “Z” faces the motor.
4. When the piston stroke reaches 0.31 inch, one shim can be removed provided one shim
remains in place. DO NOT remove the third shim!
5. To remove one shim, loosen the “X” stud nuts enough to slide the assembly back
approximately 0.06 inch. Do not completely remove the stud nuts.
NOTE: Do not remove the heat treated “Y” socket head capscrews by the bore of the piston
when removing shims.
6. Spread one shim at the split line and remove it from the brake, taking care not to bend or
spring the shim. For ease of removal, the shims are split radially.
Store shims for later use. Shims will be needed when installing replacement friction discs.
7. Retighten the “X” stud nuts in a star tightening pattern to 90-100 Ft-Lbs and check piston
stroke. Depressurize brake.

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Do not overtighten the stud nuts as this will cause drive ring distortion and lead to
excessive wear on brake disc and mating surfaces.
8. Reinstall the brake guard, tach supports and tachometer.

NOTE: If opposing plate surfaces (center, wear and pressure plates) show 0.03 inches per
surface wear, they must be replaced.
5.1.6.2 Propel Brake Installation

the ENGINEERING DATA section.
2. Assemble the tach drive shaft onto the propel motor shaft using retaining compound.
Tighten to 300 Ft-Lbs.
3. Install the brake adapter to the motor.

4. Install brake adapter (approximately 365 lbs.) onto the motor and secure with hardware.
Use care to align the access slots in the adapter for future tachometer inspections.
5. Lubricate the hub and friction disc splines with a light coat of Teflon grease or anti-seize
compound.
6. Install the friction discs and center plates onto the shaft adapter in the required order before
sliding on the brake assembly (approximately 365 lbs.). Tighten the drive ring hardware.
7. Install tach supports, tachometer and tach coupling. Refer to TACHOMETER MOUNTING
& ALIGNMENT procedure in this section of the manual.
8. Install the brake guard.

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5.1.6.3 Tachometer Mounting & Alignment

1. Assemble the tach drive shaft into propel motor shaft using retaining compound. Tighten to
300 Ft-Lbs.
2. Assemble tach shaft extension onto the tach drive shaft using the socket cap set screws,
tach shaft extension should protrude beyond tach drive shaft by 1.31(+.13/-.00) as shown in
View E.
3. Release the propel motor brake. The motor shaft can be rotated back and forth for tach
alignment without breaking the motor coupling.

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:

Figure 5-7 Tachometer Mounting & Alignment
4. While rotating the motor shaft, center the tach shaft extension using the socket cap set
screws. Check the alignment using a single dial indicator at two locations. Align the shaft to
within 0.005 T.I.R. at both locations.
5. Install the tach supports.

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6. Install the tach shaft and key in the tachometer.

7. Attach the tachometer to the front tach support using M6 capscrews provided with
tachometer. Do not tighten completely.
8. Install the coupling hubs to the tachometer shafts, center as shown in Tachometer Mounting
& Alignment.
9. Using a dial indicator, align the hubs of the coupling to within 0.005 T.I.R. by using the
shims between the tach supports.
10. Complete assembly of the coupling. Add flex element.
11. After the final alignment, tighten fasteners of tachometer assembly.
12. When shaft alignment is acceptable, remove one setscrew at a time and reinstall with
retaining compound. With the indicator still mounted on shaft, make sure the alignment
stays within allowable range.
13. When completed, all eight setscrews should be tight, secured with retaining compound, and
shaft in alignment.

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5.1.7 Swing Brake

Figure 5-8 Location of Swing Brakes and Motors
A swing brake is located on top of each of the two swing motors. An internal tachometer is
installed on one of the two swing motors (inside the brake adapter). Due to the mechanical
coupling of the motors and the gearcases, both motors will operate at the same speed. Each
swing brake contains a single friction disc and is non adjustable, refer to Section View D-D. Once
the stroke reaches 0.20 inch, the friction disc must be replaced. Visual inspection of the brake’s
internal components can be made after removing the brake guard. Periodically inspect the brake
friction disc, wear plate, pressure plate and center plates for signs of uneven or excessive wear.
If found, disassemble brake to determine the extent of damage.

Swing brakes are unique because of its horizontal operation which requires an additional
burnishing procedure when new or relined brake discs are installed. For additional information,
refer to the SWING BRAKE BURNISHING procedure in this section of the manual.

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The swing brakes are non-adjustable. Once the piston stroke has reached a specified point, the
friction disc must be replaced. Refer to the Brake Adjustment Chart in BRAKE ADJUSTMENT
the manual.
Figure 5-9 Section View D-D – Swing Brake

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5.1.7.1 Swing Brake Installation
The tachometer, furnished with the electric motor, must be installed before installing the swing
brake assembly.
NOTE: Tachometer will only be installed on one of the two swing motors. Due to mechanical
coupling the 2 swing motors and gearcases will operate at identical speeds.

1. The tachometer is to be oriented as shown in View G. Reposition if necessary.
3. Install motor shaft nut and secure to shaft with the lockwasher by bending tabs over flats.
4. Install brake adapter onto the motor and secure with hardware. Use care to align the access
slots in the adapter for future tachometer inspections.
5. Lightly coat the splines of the drive hub with a Teflon grease allowing only a thin film of
lubricant to remain on the splines. Excess grease will be thrown outward by centrifugal force
and have a degrading effect on the brake.
6. Using a lifting device and the holes provided in the outer portion of the drive ring, place the
brake assembly (approximately 500 lbs.) onto the drive hub and lower while aligning the
splines in the drive hub with those in the brake disc.
7. Apply at least 46 PSI compressed air to release the brake.
8. Install shims, as required, to achieve a gap of 0.015 - 0.030 inch between the brake disc
and the pressure plate. Refer to View D.

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A minimum of 46 PSI must remain applied to the brake while this dimension is
determined. The brake must remain fully disengaged!
9. Release the air pressure from the brake piston to relax the internal springs.
10. Tighten the drive ring for final installation.

11. Apply at least 46 PSI compressed air to release the brake. Verify that the proper gap
remains between the pressure plate and friction surface of the disc.
12. Install brake guard.
13. If previously removed, install the wear/release switches and brackets for the wear and
release indicators.
5.1.7.2 Swing Brake Wear & Release Switches

Each swing brake is equipped with two switches mounted to the outer edge of the brake housing.
For more information, refer to SINGLE DISC BRAKE WEAR & RELEASE SWITCHES in this

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5.1.7.3 Swing Brake Burnishing
The swing brake on this machine is a “single disc assembly” consisting of a ductile iron disc to
which multiple metallic lining segments are riveted. The burnishing-in procedure for a new or
relined disc brake initiates a controlled wear process to develop the maximum contact area
between braking surfaces. The burnish-in process will also start the formation of an oxide layer

on the surface of the linings to stabilize and to establish the coefficient of friction.
Prior to beginning the burnishing procedure check and record the brake pressure plate
temperature with a hand held temperature measuring device. Between each stop, continue
monitoring the pressure plate temperature. Do not allow the pressure plate temperature to
exceed 300° Fahrenheit (149°C).
NOTE: Check the temperature of each brake on the machine. If the temperature exceeds
300°F (149°C) stop the burnishing procedure and allow the brakes to cool to 200°F
(93°C). If overheated or malfunctioning brakes are found, check if the brake is releasing
properly. It is normal for a small amount of disc particles to be ejected from the brake
and for sparking to occur during this operation. Large amounts of either situation may
indicate overheating or improper release and should always be corrected prior to
continuing.
To burnish the brakes, perform a series of machine swing stops and starts as shown below:
Burnish-In Procedure (dipper empty)

# of Stops at Speed Time Between Stops
4 stops/1/4 speed 1 minute minimum
8 stops/1/2 speed 2 minutes minimum
Perform one additional full load, 3/4-speed stop with the dipper handle in the horizontal position
and the hoist rope vertical on the swing motion. This will ensure that the brakes are functional.
Record the swing stopping times and angles. Forward these recorded readings to the
manufacturer.

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5.1.8 Spring Replacement — All Brakes

To replace the brake springs, disassemble the brake as follows:
1. Follow steps one through five of the Replacement of Friction Discs procedure.
2. Remove the cylinder stud nuts.
NOTE: It is recommended that the piston cylinder, pressure plate and drive ring be marked so
that the same studs pass through the same bolt holes at reassembly.
3. Remove the piston with cylinder and pressure plate as a complete assembly from the studs
and place on a clean level working area.
4. Slowly open the temporary shut-off valve and release pressure from the piston with cylinder
and pressure plate assembly.
The brake springs are under compression. Care must be taken when removing piston
bolts in order to avoid injury.
5. Remove all piston bolts except for four located at 90° from one another.
NOTE: Reinstall one piston bolt to the right of each of the four remaining piston bolts, turning
each of the reinstalled piston bolts two turns. These bolts act as a safety stop during the
removal of the four remaining piston bolts 90° from each other.
6. Carefully loosen each of the four remaining piston bolts two turns each in a pattern 180°
opposite each other until all four piston bolts have been loosened two turns. Repeat
loosening each of the four piston bolts in the above manner until the brake spring
compression has been fully released at all four remaining piston bolts.
Tap the piston to make sure it has not bound against the cylinder. Care must be taken
when loosening piston bolts so that the piston does not bind against the cylinder.
7. Remove the four remaining piston bolts and the safety stop bolts and lift the cylinder with
piston off the pressure plate and brake springs.
8. Remove all brake springs and insulating washers.
NOTE: The springs are equipped with insulated fiber washers. Be sure the washers are in
place at reassembly.
9. Place new insulating washers, then new springs into the counterbores of the pressure plate.
Reposition the cylinder with piston onto the springs taking care that each spring end
properly seats into each counterbore of the brake cylinder.
10. Using piston bolts, assemble the cylinder with piston to the pressure plate and springs by
reversing step 3 above. Tighten all piston bolts to 200-220 Ft-Lbs in a pattern 180° apart.
11. Close the temporary shut-off valve. Reconnect the auxiliary airline to the temporary shut-off
valve and follow steps 4 and 5 of the Replacement of Friction Discs procedure.

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12. Slide the pressurized piston with cylinder and pressure plate assembly onto the cylinder
studs. (When applicable, make sure cylinder shimming is in place between the cylinder and
drive ring.) Secure the assembly in place with the stud nuts. Tighten the nuts in a
diametrical pattern to 90-100 Ft-Lbs.

Do not overtighten the stud nuts as this will cause drive ring distortion leading to
excessive wear on brake disc and mating surfaces.
NOTE: Observe the temporary regulator pressure gauge. If the pressure has dropped, the
piston O-Rings may need replacement.
13. Open the temporary shut-off valve and release the brake pressure. Remove the temporary
regulator with gauge and the shut-off valve from the brake inlet and reconnect the brake
airline to the brake inlet.
14. Reinstall the brake guard, the tach supports, the tach and the tach cover.
5.1.9 Friction Disc Replacement — All Brakes

The friction disc(s) will require replacement when excessively worn or when contaminated by
grease, oil or other foreign materials.
Major damage will occur to the components of the brake assembly if the friction disc is
not replaced when worn. The result of “pushing” will result in metal-to-metal contact that
will cause extremely expensive repairs and a seriously degraded braking system.
Do not remove the socket head capscrews near the bore of the piston as this will release
the spring pressure within the brake assembly and make re-assembly much more difficult.
1. Remove the brake guard as required.

2. Release air pressure and remove the air line from the air INLET to the brake.
3. Install a ball or gate valve into the air INLET. This valve will be used to capture pressure
within the piston during removal.
4. Reconnect the air source and pressurize the brake to the full released position. Close the
valve, and then remove the air lines. At this point the brake is disengaged and not
connected to an air source.
NOTE: The cylinder, piston and pressure plate may be removed as a single unit.
5. Remove the outer cylinder stud nuts at this time and the lift the entire brake assembly off
the top of the studs as a unit. Once removed from the motor the pressure may be removed
from the cylinder.

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6. Slide the friction disc(s) and center plate (for multiple disc brakes) up and off of the hub
adapter splines and free it from the assembly. Do not remove the studs and collars retaining
the separating springs, they will lift out with the plates.
7. Clean the area where the friction disc resides and coat the splines with fresh Teflon
lubricant lightly.
8. Install the replacement friction disc ensuring that the machined step “Z”, near the center, is
facing downward – toward the motor.
9. Carefully align the splines between the hub and the disc and allow the new disc to rest.
Install brake specific spacer or shims. Refer to specific BRAKE ADJUSTMENT procedure.
10. Reinstall the piston and pressure plate onto the top of the friction disc and align the
pneumatic fitting, access holes and studs accordingly. Pressurize the piston once more to
minimum pressure allowing complete disengagement of the components.
11. Replace the stud nuts and tighten to 90–100 Ft-Lbs.
Tighten the stud nuts as per the instructions on the brake drive ring. Excessive, or
improper, torque application can cause the drive ring to become deformed and seriously
reduce the effectiveness and life of the brake assembly.
12. Ensure the air line and wear/release switches are properly reconnected. Refer to BRAKE
WEAR & RELEASE SWITCHES in this section of the manual.

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5.1.10 O-Ring Replacement — All Brakes
NOTE: On machines using hydraulic crowd in place of rope crowd, the crowd brake does not
exist.
With machine parked on flat level surface, with dipper heel resting on the ground, the O-Rings

may be replaced by disassembling the brake as follows:
1. For the propel brake, remove the tachometer, tach supports and the brake guard as
required.
2. For hoist, crowd or swing brakes, remove the wear and release switches along with the
mounting bracket and hardware. Remove the brake guard.
3. Release air pressure to the brake. Disconnect the air line to the brake inlet. Install a
temporary pressure regulator with gauge and a closed shutoff valve to the brake inlet.
NOTE: The pressure regulator with gauge should be located between the brake and the shutoff
valve.
4. Remove the capscrews attaching the piston to the pressure plate. Remove the piston.
Do not remove cylinder stud nuts securing cylinder to pressure plate as this will release
the brake springs and make reassembly difficult.
NOTE: It is recommended that piston and cylinder be marked so that the piston bolts pass
through the same piston and pressure plate bolt holes at reassembly.
5. Inspect O-Rings for cleanliness, wear, deterioration, or cracks. Clean each as required and
replace old or damaged O-Rings. Dress out any nicks or grooves in the cylinder wall with a
fine stone and finish with a fine emery cloth prior to installing the new O-Ring seals.

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6. Lubricate the O-Rings and grooves generously before assembly. Install the O-Rings in
grooves as they would lay naturally. Do not nick, pinch, or twist O-Rings.
NOTE: It is a good practice to coat the inner surfaces of the piston and cylinder with a Teflon
type lubricant. This coating of lubricant acts as a final filter to remove air system dust
particles which could damage the O-Rings.
7. Reassemble the piston to the pressure plate with 12 capscrews. Tighten in a star tightening
pattern to 200–220 Ft-Lbs.

8. Pressurize the piston to disengage the brake. Close the valve, and then remove the airlines.
At this point the brake is disengaged and not connected to an air source.
9. Observe the pressure gauge. If no pressure drop is observed, continue to Step 10. If
pressure drops, the seals are not properly seated. Release any remaining air pressure and
go to Step 4.
10. Release the brake pressure by opening the temporary shutoff valve. Remove the temporary
regulator and shutoff valve from the brake inlet. Reconnect the brake air line to the brake
inlet.
11. For the propel brake, reinstall the tach supports and the tachometer.
12. For hoist, crowd or swing brakes, reinstall the wear and release switches along with the
mounting bracket and hardware. Refer to BRAKE WEAR & RELEASE SWITCHES in this
13. Reinstall the brake guard.

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5.1.11 Brake Wear & Release Switches — Single Disc
Brakes
exist.

The crowd and swing brakes are single disc brakes equipped with two switches mounted to the
outer edge of the brake housing as shown in View T.
For identification purposes, the loose end of the release switch is tagged yellow and the loose
end of the wear switch is tagged red. Both switches are preset by the manufacturer and do not
require adjustment unless they are being removed or replaced.
Note the location of the two shims for proper assembly. When replacing switches, set switch trip
point dimension “Y” to brake shim thickness when brake is engaged. Reference “X” to brake
stroke new + brake shim thickness when brake is released.

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5.1.12 Brake Wear & Release Switches — Multiple Disc

Brakes
The brake is equipped with two switches mounted to the outer edge of the brake housing as
shown in View S.
For identification purposes, the loose end of the release switch is tagged yellow and the loose
end of the wear switch is tagged red. Both switches are preset by the manufacturer and do not
require adjustment unless they are being removed or replaced.
Note the location of the two shims for proper assembly. When replacing switches, set switch trip
point dimension “Y” to brake shim thickness when brake is engaged. Reference “X” to brake
stroke new + brake shim thickness when brake is released.

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5.2 Couplings
5.2.1 Grid Couplings

These instructions apply to tapered grid couplings. They are designed to operate in either the
horizontal or vertical position without modification. However, for vertical applications, the match
mark shown above, must be up. The performance and life of the couplings depend largely upon
how they are installed and serviced. Carefully follow these instructions for optimum performance
and trouble-free service.
All coupling parts have identifying part numbers. When ordering parts, always SPECIFY SIZE
and TYPE. Cover halves have 1/8 NPT lube holes. Use a standard grease gun and lube fitting.
For Long Term Grease (LTG) use part number MP295148.
5.2.1.1 Lubrication
Adequate lubrication is essential for proper operation of the coupling. Refer to the table for the
amount of lubricant required. It is recommended that the coupling be checked once a year and
lubricant added if required. For extreme or unusual operating conditions, check more frequently.
Grid couplings initially lubricated with LTG will not require re-lubrication until the connected
equipment is stopped for servicing.

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5.2.1.2 Coupling Disassembly and Grid Removal
STORED ENERGY! Once grid is removed, machinery is free to rotate and brake will no
longer hold. Equipment must be blocked prior to doing any maintenance to prevent
unwanted movement. Death, serious injury, or damage to the machine can result from
failure to take proper measures to prevent movement due to release of energy.
Whenever it is necessary to disconnect the coupling, remove the cover halves and grid. A round
rod or screwdriver that will conveniently fit into the open loop ends of the grid is required. Begin at
the open end of the grid section and insert the rod or screwdriver into the loop ends. Use the
teeth adjacent to each loop as a fulcrum and pry the grid out radially in even, gradual stages,
proceeding alternately from side to side.

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5.2.1.3 Grid Coupling Installation
Only standard mechanics tools, wrenches, a straight edge and feeler gauges are required for
installation. For instructions on mounting to a drive motor, refer to the appropriate motor shaft
installation instructions in this manual.
1. Mount seals and hubs

Clean all parts. Heat hubs in an oven or use suitable dry heat. DO NOT rest gear teeth on
container bottom or apply flame directly to gear teeth. DO NOT heat hubs over 275°F (135°C) for
mounting. Lightly coat seals with grease and place them on shafts BEFORE mounting hubs.
Mount hubs on their respective shafts so the hub face is flush with the end of its shaft.
2. Gap and angular alignment

Use a spacer bar equal in thickness to the gap specified. Insert the bar, as shown here, to the
same depth at 90° intervals and measure clearance between bar and hub face with feelers. The
difference in minimum and maximum measurements must not exceed the ANGULAR limit
specified.
NOTE: The motor shaft must be at the mid-point of its end play when measuring the gap.
3. Offset alignment
Align hubs so that a straight edge rests squarely (or within the limit specified) on both hubs as
shown here. Check at 90° intervals with feelers. The clearance must not exceed the OFFSET
limit specified. Tighten all foundation bolts and repeat Steps 2 and 3. Realign coupling if
necessary.

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NOTE: Use a dial indicator for more accurate alignment.

4. Insert grids
Pack gap and grooves with specified lubricant before inserting grids. Install grid segments so that
all cut ends extend in the same direction; this will assure correct grid contact with non-rotating pin
in cover halves. Spread grid segments slightly to pass over the coupling teeth and seat with a
soft mallet.

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5. Pack with grease and assemble covers
Pack the spaces between and around the grid with as much lubricant as possible and wipe off
excess flush with top of grid. Position seals on hubs to line up with grooves in cover. Position
gaskets on flange of lower cover half and assemble covers so that the match marks are on the
same side as shown above. If shafts are not level (horizontal) or coupling is to be used vertically;
assemble cover halves with the lug and match mark up, or on the high side. Secure covers
halves with fasteners and tighten to torque specified in the coupling data table. MAKE SURE
LUBE PLUGS ARE INSTALLED BEFORE OPERATING!
6. Periodic Lubrication
Remove both lube plugs and insert a lube fitting. Fill with recommended lubricant until excess
appears at hole opposite; then insert plug. Lubricate couplings at least once ever year. Lubricate
more frequently when exposed to excessive-moisture, extreme temperatures, rapid reversing or
shock loads or excessive misalignment. It is not necessary to re-lube couplings filled with Long
Term Grease (LTG) until disassembled for service to attached components.
NOTE: For Long Term Grease (LTG) use part number MP295148.

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5.2.1.4 Seal Replacement without Hub Removal

The instructions below offer additional procedures that may be useful when replacing seals on an
existing installation.
Replacement seals are continuous, one piece members. Unless the connected machines are
being moved from their foundation for some other reason you need not disturb the existing
mountings to get the new seals in place. The following cut and cement procedures offer a simple
way to install new seals without moving machines or pulling coupling hubs.
Falk Steelflex and gear couplings are lubricated shaft connectors. In both designs, a metallic
cover and elastomer seals contain the lubricant. Refer to the applicable Installation, Maintenance
and Lubrication Instructions furnished with each coupling when replacing worn or damaged
seals.
To install a new coupling seal without hub removal:
1. Cut the coupling seal using a clean, sharp utility knife.
NOTE: The following illustrations show O-Ring seals. The same procedures apply when
replacing U-shaped or trapezoidal-shaped seals.
2. Lightly dress both cut surfaces on a grinding wheel. The resultant square evenly roughened
seal ends provide excellent bonding surfaces. Thoroughly clean and degrease the cut ends.
3. Apply adhesive to the seal ends as instructed by the adhesive manufacturer.

• Use Masterbond EP21TDC-7, Loctite Superbond or Loctite 414 Superbond for Viton
Seals.

June 2012
BI010311 Couplings
4. Place the split seal around the shaft and carefully align the two seal ends.
5. Carefully press and hold the joint together. Do not attempt to stretch the joint seal over the
hub for several additional minutes. Refer to the adhesive manufacturer’s instructions for
procedure and drying time.

6. Carefully position the fused seal in place on the coupling hub.

June 2012
Couplings BI010311
5.2.1.5 Grid Coupling Alignment

Table 5-3 - Grid Coupling Data
Coupling Crowd
*Part No. C113194-01
Type Grid
Motor Frame 812
# Bolts 14
Dia. (inch) 0.5
Torque (In-Lbs) 650
Torque (Ft-Lbs) 54
Max. Parallel Offset (in.) 0.022
Max. Angular Limit (in.) 0.04
Min. End Gap Limit (in.) 0.556
Grease Wt. (lbs.) 1.6
NOTES:
• Bolts are NOT Standard Fasteners. Values indicated are for clean, dry threads.
• *Use Parts Book to verify part number.
DO NOT SUBSTITUTE STANDARD FASTENERS FOR COUPLING BOLTS.

June 2012
BI010311 Couplings
5.2.2 Gear Couplings
5.2.2.1 Coupling Installation

1. Clean all parts. Heat hubs in an oven or use suitable dry heat. DO NOT rest gear teeth on
container bottom or apply a flame directly to gear teeth. DO NOT heat hubs over 275°F
(135°C) for mounting. Refer to motor shaft installation for hubs mounted on drive motors.
Pack sleeve teeth with grease and lightly coat seals with grease BEFORE assembly. DO NOT
DAMAGE THE SEALS.
Use a dial indicator to align dynamically balanced couplings and assembly parts with mating
match marks aligned. Mount the indicator on one hub and take readings for the OFFSET check
on the O.D. of the other hub. The difference between the minimum and maximum readings
DIVIDED by two should not exceed the values in the table. For ANGULAR check, take readings
on either face of other hub. The difference between the minimum and maximum readings should
not exceed the values in the gear coupling data table.
2. Mount the flanged sleeves, seal and hubs. Place the flanged sleeves WITH the seal rings
on the shafts before mounting the hubs.

June 2012
Couplings BI010311
DO NOT DAMAGE THE SEALS. Mount the hubs on their respective shafts, as shown, so
that each hub is flush with its shaft end. Position the equipment in approximate alignment
with the approximate gap specified in the table.
3. Gap and angular alignment - Use a spacer bar equal in thickness to gap specified in Table.
Insert bar, as shown, to same depth at 90° intervals and measure clearance between bar
and hub face with feelers. The difference in minimum and maximum measurements should
NOT exceed the ANGULAR limit specified in the table.
4. Clamp a dial indicator to the rigid hub as shown and rotate the rigid hub one complete turn.
The total indicator reading DIVIDED by two must not exceed the OFFSET limit specified.
Tighten all foundation bolts and repeat Steps 3 and 4. Realign coupling if necessary.
Grease the hub teeth.
5. Insert gasket, DO NOT DAMAGE the GASKET, between flanges. Position flanged covers
with lube holes at 90° and draw flanged cover into position. Use bolts, nuts and lockwashers
furnished with couplings.

June 2012
BI010311 Couplings

Tighten the flange bolts and nuts to the torque specified in the table.
6. For TYPE G couplings, fill with recommended grease until excess appears at the open hole;
then insert plug. For TYPE GV couplings, proceed as outlined above. IN ADDITION, when
flex hub is on TOP, vent by inserting a 0.010 thick SMOOTH feeler gauge between seal and
hub. Fill until excess appears at feeler. Repeat at 90° intervals.
Make certain all plugs are inserted after lubricating.

June 2012
Couplings BI010311
5.2.2.2 Gear Coupling Alignment

Table 5-4 - Gear Coupling Data
Coupling Swing Hoist Propel Motor Propel Gearcase

End End
*Part Number C111720-01 S070512 1561739 S101595
Type Gear Gear Gear Gear
Motor Frame 812 820 812 812
# Bolts 8 14 8 8
Dia. (inch) 0.625 0.875 0.75 0.75
Torque (In-Lbs) 1500 3756 2520 2520
Torque (Ft-Lbs) 125 313 210 210
Max. Parallel Offset (in.) 0.005 0.005 0.007 0.007
Max. Angular Limit (in.) 0.013 0.005 0.018 0.018
Designed End Gap (in.) 1.69 37.88 4.20 4.20
Grease Wt. (lbs.) 0.54 1.6 1.080 1.080
• Bolts are NOT Standard Fasteners. Values indicated are for clean, dry threads.
• *Use Parts Book to Verify Part Number.
DO NOT SUBSTITUTE STANDARD FASTENERS FOR COUPLING BOLTS.

June 2012
BI010311 Couplings
5.2.2.3 Hoist Coupling Shaft Alignment
To perform the hoist shaft alignment procedure, the center shaft must be removed and the
coupling hubs must be properly installed on the hoist motor and gearbox. All steps to be
performed using a laser alignment process.
1. Check center gap between the coupling parting face on the motor and gearbox. Measure at
four places 90° apart, approximately at the bolt circle centerline of the rigid coupling.
Average of the four measurements is to be 37.88 inches, +0.00/-0.12.
2. Check angular alignment. Refer to Table 5-4.
3. Check parallel offset alignment. Refer to Table 5-4.

June 2012
Couplings BI010311

June 2012
BI010312
PRELIMINARY SAMPLE USE FOR REFERENCE ONLY July 11, 2012

6 Compressed Air System
Compressed Air System
6.1 Air Compressor - Dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.1.1 Compressor Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.1.2 Compressor Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.1.3 Compressor Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.1.4 Recommended Lubrication Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.1.5 General Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.1.5.1 Fluid & Fluid Filter Change Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.1.5.2 Air Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.1.5.3 Air/fluid Separator Element Change . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.2 Air Dryer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.3 Lockout Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Figure 6-1 Lockout Valve Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Figure 6-2 Lube Room Lockout Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.4 Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

July 2012
BI010312

July 2012
BI010312 Air Compressor - Dual
6.1 Air Compressor - Dual

This machine uses dual air compressors mounted in a welded frame assembly on the left side of
the machine inside the machinery house. High pressure air is used to operate machinery brakes,

lubrication and various other functions.
Each of the rotary screw compressors is driven by a 10HP electric, air cooled motor. Each unit
has a control box containing a motor start and manual reset switch and two gauges to monitor air
system pressure and discharge pressure. Check fluid level visually using the sight glass.
Complete replacement of the fluid, fluid filter and separator element are recommended every
8,000 hours of operation. Replace the primary air filter as needed.
STORED ENERGY! Air under pressure will cause severe personal injury or death. Shut
down compressor and relieve system of all pressure before removing components such
as valves, plugs, fittings and bolts.

July 2012
Air Compressor - Dual BI010312

July 2012
6.1.1 Compressor Start-up Procedure
NOTE: Prior to start-up, check the compressors fluid level in the sight glass located on the
compressor’s bell housing. The fluid should cover 3/4 of the sight glass when not in
operation.

1. Open the shut-off valve to the service line.
2. Start the compressor motor by turning the selector switch to MANUAL START or
AUTOMATIC START/STOP.
3. When the compressor is running, observe the instrumentation. Discharge temperature
should never exceed 200° F (93°C).

July 2012
6.1.2 Compressor Shutdown Procedure

1. Turn the selector switch located on the control box to OFF/RESET position.
2. Close the shut-off valve to the service line.

NOTE: Allow the unit to cool and ensure that the line pressure gauge on the control panel
indicates “zero” pressure prior to performing any maintenance.

July 2012
6.1.3 Compressor Fluid Level Check

A sight glass is located on the bell housing.
• WHEN NOT IN OPERATION, the fluid should cover 3/4 of the sight glass.
• DURING OPERATION, the fluid should cover 1/4 to 1/2 of the sight glass.
If the fluid level is low, shutdown the compressor. Add fluid as necessary to bring the fluid level in
the sight glass cover 1/4 to 1/2 of the sight glass during operation. DO NOT OVERFILL. DO NOT
mix other fluids within the compressor!

July 2012
6.1.4 Recommended Lubrication Guide

For longest uninterrupted service, the compressor is factory filled with Sullube, a long life
lubricant.
For light-duty high humidity service where condensed moisture and emulsification may occur, the
fluid change interval must be reduced to 300 hours maximum. A non-detergent fluid with rust,
oxidation and foam inhibitors and good water separation characteristics should be used.
DO NOT mix other fluids within the compressor. Contamination of non-detergent mineral fluids
with traces of ATF or detergent motor fluids may lead to operational problems such as foaming,
filter plugging, orifice or line plugging. Complete flushing is required if changing to a different
lubricant.
Lubricant Fluid Change Fluid Filter Change Separator Change
Sullube A, E G, C A, D
SRF 1/4000 B, E G, C B, D
24KT F, E G, C A, D
A - 8,000 Hours or once a year.
B - 4,000 Hours or once a year.
C - When measured pressure loss exceeds 20 psig (1.3 bar).
D - When measured pressure loss exceeds 10 psig (0.7 bar).
E - When required by fluid analysis or known containation.
F - Does not require replacement during normal service conditions.
G - Every 1,000 hours.

July 2012
6.1.5 General Compressor Maintenance
STORED ENERGY! Air under pressure will cause severe personal injury or death. Shut

down compressor and relieve system of all pressure before removing components such
as valves, plugs, fittings and bolts.
6.1.5.1 Fluid & Fluid Filter Change Procedure

When the compressor fluid is ready to be changed, the compressor needs to be shutdown with
the power to the compressor disconnected.
NOTE: For long uninterrupted service, the compressor is factory filled with Sullube, a long life
lubricant. Under normal service conditions the fluid should be changed every 8,000
hours of operation or once a year. Compressors using SRF 1/4000 fluid should be
changed every 4,000 hours. Anytime measured pressure loss exceeds 20 psig (1.3 bar)
the fluid should be changed.
1. Drain the fluid from the compressor using the fluid drain cap located at the bottom of the
compressor.
NOTE: Complete flushing is required if the fluid has been contaminated, or when changing to a
different lubricant.
2. Remove the old fluid filter and gasket. Clean the gasket seating surface. Apply a thin coat of
fluid to the new gasket and hand tighten new fluid filter until gasket is seated. Continue
tightening an additional 1/2 to 3/4 turn.

July 2012
3. Remove the fill plug on the bell housing and fill with clean Sullair fluid. Sump capacity is 4.6
quarts (4.35 liters).
4. Check the fluid level in the sump. When not in operation, the fluid should cover 3/4 of the
sight glass. DO NOT OVERFILL.
5. Tighten the fill plug. Restart the compressor and check for leaks.
6.1.5.2 Air Filter Maintenance

NOTE: Under normal service conditions air filter maintenance should be performed every six
months, more frequently when operating in extreme conditions. Care should be taken
so no dirt or debris is allowed to enter the intake housing during the procedure below.
1. Clean the exterior of the filter cover, removing any loose dirt or debris.
2. Remove the wing nut holding the air filter cover in place.
3. Remove the element and base. Clean the base and cover with a damp cloth.
4. Reposition the base to the compressor. Place a new air filter element onto the base.
Replace the pre-filter and cover. Tighten wing nut securely in place.

July 2012
6.1.5.3 Air/fluid Separator Element Change
NOTE: Under normal service conditions the air/fluid separator element should be changed
every 8,000 hours of operation or once a year. Compressors using SRF 1/4000 fluid
should be changed every 4,000 hours. Anytime measured pressure loss exceeds 10
psig (0.7 bar) the air/fluid separator element should be changed.

1. Insert a 1/4" diameter pin through the hole in the separator cap. Remove the cap.
2. Using channel lock pliers, remove the old separator element. Remove old o-ring from the
separator cap.
3. Clean separator cap and install new o-ring. Install new o-ring to new separator element.
Lightly lubricate to make installation easier.
4. Insert and push the new element in place.
5. Reinstall the cap using the 1/4" diameter pin inserted in the separator cap. Remove the pin
and store for later use.

July 2012
Air Dryer Assembly BI010312
6.2 Air Dryer Assembly

The twin-tower air dryer system is mounted to the machinery house wall above the dual
compressor unit. The dryer delivers dry, oil-free and clean air to all components in the
compressed air system. The air dryer system is engineered as both a filtration and continuous
drying package in one. A high efficiency coalescing filter removes liquids, sub-micron aerosols
and solid contaminants 10 micron and greater. Simultaneously, two towers filled with high
absorbent desiccant reduce the relative humidity of the compressed air.
During proper operation, you should feel a slight continuous flow of air from the purge valve at
the bottom of only one of the two drying towers. The unit should cycle every 60 seconds. Each
time this occurs there should be a momentary high volume rush of air from one of the purge
valves. Also at each cycle there should be a momentary high volume rush of air from the filtration
tower drain valve. A pressure check valve prevents cycling until a minimum system pressure is
obtained.
Standard operating pressure should never exceed 150 PSIG. Ideally, the system is designed to
provide 125 CFM maximum air flow at 125 PSI continuous duty cycle.
STORED ENERGY! Compressed air systems contain high levels of stored energy! Any
attempt to connect or service these components with a system that is under pressure can
lead to death or serious personal injury. Before servicing, be sure to vent all pressure and
cut off electrical power to the system.

July 2012
BI010312 Lockout Valves
6.3 Lockout Valves

A series of lockout valves are provided to enable maintenance personnel to isolate and remove
compressed air from the swing, crowd, hoist and propel brakes should they require maintenance.
This permits airflow to continue to the other brakes and features of the machine.

exist.
Isolating only one feature of the machine will not eliminate the danger of machine motion
while maintenance is being performed. The user is responsible to ensure that all proper
precautions, including lock-out/tag-out, bracing and any other necessary precautions
have been taken, so that no unanticipated machine motions will occur.

July 2012
Lockout Valves BI010312
Figure 6-1 Lockout Valve Locations

July 2012
BI010312 Lockout Valves
Figure 6-2 Lube Room Lockout Valves

July 2012
Safety Warnings BI010312
6.4 Safety Warnings

Ensure that all personnel are aware of, and adhere to the instructions below, which may or may
not appear as warnings on the compressor. In addition, refer to all instructions and warnings
contained in the manufacturer's catalog for the compressor.

July 2012
BI010313

7 Air Filtration
Air Filtration
7.1 House Filter Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.1.1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.1.2 Dynavane Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Figure 7-1 Filter Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2 Air Filtration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Figure 7-2 Right SideView of Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Figure 7-3 Left SideView of Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.2.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.2.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Figure 7-4 Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.2.2.1 Operational Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.2.3 Compressed Air Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.2.4 Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.2.5 Solid-State Timer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.2.5.1 Solenoid Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.2.5.2 Timer and Solenoid Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.2.6 Delta P Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.2.6.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.2.6.2 Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.2.7 Setpoint Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.2.7.1 Quick Start Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

June 2012
Air Filtration
BI010313
7.2.7.2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7.2.7.3 Password Protected Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.2.7.4 Delta P Plus Control Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Figure 7-5 Delta P Plus Control Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Figure 7-6 Delta P Plus Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.2.7.5 Preliminary Start-Up Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.2.7.6 Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Figure 7-7 Solid-State Timer Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.3 Air Conditioner/Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7.3.1 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.3.2 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.3.3 Pressurizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.3.3.1 Cleaning The Washable Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.3.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

June 2012
Air Filtration
BI010313 House Filter Fans
Air Filtration
7.1 House Filter Fans

Check the blades for grease and/or dirt accumulation. Clean if necessary. Blades should rotate
freely without binding.
If vibration is detected, check the following:
1. Bearing and drive alignment
2. Shaft straightness
3. Wheel or sheaves loose on shaft
4. Loose or worn bearings
5. Loose mounting bolts
6. Motor out-of-balance
7. Sheaves out-of-balance
8. Nose cap loose on wheel
9. Worn or corroded wheel
10. Accumulation of material on the wheel
11. Cracks on blades and/or at the hub
12. Worn fan blades and hubs

June 2012
Air Filtration
House Filter Fans BI010313
7.1.1 Lubrication
All bearings are pre-lubricated and sealed at the factory. Under normal temperature conditions
(-20° to +150°F / -29° to +66°C), when the fans are circulating clean air, the bearings are
considered lubricated for life and additional lubrication is unnecessary.
If the fans are circulating contaminated air, or operating at elevated temperatures, periodic
lubrication is required. For normal temperatures, a high quality, light, neutral mineral grease is
used. It is free of abrasive fillers and highly resistant to oxidation. When fans are operating at
elevated temperatures (166°F / 74°C or higher), silicone or lithium soap base grease should be
used. This high temperature grease should have a breakdown point above 350°F (177°C).
Use a low pressure grease gun for fan bearings. Either the gun or the fitting should be vented. To
prevent overfilling apply a small amount of grease. This is especially important when extended
lubrication piping is used and the bearing cannot be observed.
7.1.2 Dynavane Air Cleaner

Dynavane air cleaners are self-cleaning and do not require the routine service typical of air filters
which collect and hold the dirt removed from the air. There are a few maintenance procedures
which should be observed.
• The air entering the side of the cells should be kept free of rags, leaves and papers to assure
free airflow. Applications exposed to this type of material should have intakes covered with a
course mesh (5 mesh) screen to prevent entry of material larger than the bleed slot.
Figure 7-1 Filter Components Overview

June 2012
Air Filtration
BI010313 House Filter Fans
• Check the bleed system to make sure nothing has impaired bleed airflow.
• The cells should be examined for buildup of deposits on the blades. A light coating of dust is
normal and will not impair the operation or efficiency of the cell. Occasionally, due to the
presence of oil mist or similar vapors in the air, heavier surface accumulations will occur and
the cell will require cleaning. Cleaning the cells can be accomplished by brushing the surface
of the blades or blowing down with compressed air.

• Another method of cleaning the Dynavane filters is to reverse the direction of fan rotation.
This creates reverse air pressure which helps free up the dirt. The units can be removed for a
more thorough cleaning.

June 2012
Air Filtration
Air Filtration System BI010313
7.2 Air Filtration System

This machine is equipped with a Donaldson Torit air filtration system mounted on top of the
electrical room.
The collector housing contains 36, 27 inch, replaceable filter cartridges. Dual 4" screw conveyors
are powered by 1.5 HP motors. An integral hood inlet contains a precipitation baffle with a bug
screen. All hardware on the system is to be shock and vibration proof.
A more detailed break down of the air filtration system can be found in the parts book.
Figure 7-2 Right SideView of Filter Assembly

June 2012
Air Filtration
BI010313 Air Filtration System

Figure 7-3 Left SideView of Filter Assembly
7.2.1 Description
The Pure Aire collector is a continuous-duty, modular collector with cartridge-style filters. The
downward airflow design delivers high filtration efficiency while using less energy. Continuous-
duty means no downtime. The filters are pulse-cleaned in sequence, one set at a time, without
turning the unit off. Each standard module is three filter rows wide by three rows high by two
filters deep.

June 2012
Air Filtration
7.2.2 Operation
During normal operation, dust-laden air enters the unit through the baffled-air inlet. Airflow is
directed downward through the collector and heavier particulate falls directly into the hopper. The
cartridges remove fine particulate and clean, filtered air passes through the cartridge to the
clean-air plenum and discharges through the fans.
Filter cleaning is completed using pulse-jet technology. A solenoid and diaphragm valve aligned
to each row of filters provides the pulse cleaning. The cleaning sequence starts at the top filter
row and continues down through each module. Remove, inspect, or change the cartridges from
outside the unit by removing the filter access cover and sliding the filters out.
Figure 7-4 Unit Operation
7.2.2.1 Operational Checklist

1. Monitor the physical condition of the collector and repair or replace any damaged
components. Routine inspections will minimize downtime and maintain optimum system
performance. This is particularly important on continuous-duty applications. Periodically
check the compressed air components and replace compressed air filters. Drain moisture
following the manufacturer's instructions. With the compressed air supply ON, check the
cleaning valves, solenoid valves, and tubing for leaks. Replace as necessary.
2. Monitor pressure drop across filters.
3. Abnormal changes in pressure drop indicate a change in operating conditions and possibly
a fault to be corrected. For example, prolonged lack of compressed air will cause an excess
build-up of dust on the filters resulting in increased pressure drop. Cleaning off-line with no
flow usually restores the filters to normal pressure drop.
4. Monitor exhaust.
5. Monitor dust disposal.

June 2012
Air Filtration
7.2.3 Compressed Air Installation
Turn compressed-air supply OFF and bleed lines before performing service or

maintenance work. A safety exhaust valve should be used to isolate the compressed air
supply. The safety exhaust valve should completely exhaust downstream pressure when
closed and include provisions to allow closed-position locking.
NOTE: Do not set compressed-air pressure above 100-psi. Component damage can occur.
All compressed air components must be sized to meet the maximum system requirements of 90-
psi supply pressure.
The compressed-air supply must be oil and moisture free. Contamination in the compressed air
used to clean filters will result in poor cleaning, cleaning valve failure or poor collector
performance.
Purge compressed-air lines to remove debris before connecting to the unit's compressed-air
manifold.
1. Remove the plastic pipe plug from the unit's air manifold and connect the compressed-air
supply line. Use thread-sealing tape or pipe sealant on all compressed-air connections.
2. Install a customer-supplied shut-off valve, bleed-type regulator with gauge, filter, and
automatic condensate valve in the compressed-air supply line.
7.2.4 Filter Removal

1. Turn power to unit OFF.
2. Start at the top access port.
3. Remove access cover. If the access cover clamp fails to operate smoothly, apply WD-40®
or silicon spray to the riveted pivot points and to the clamp rod where it passes through the
outside of the cover. Wipe off overspray.
4. Break the seal between the filter cartridge and the sealing surface.
5. Slowly rotate the cartridge 1/2-turn to remove dust that may have accumulated on the top of
the filter.
6. Slide the filter out the access port along the suspension yoke and dispose of properly.
7. Clean the sealing surface with damp cloth.
NOTE: Clean dust from gasket sealing area to ensure a positive filter gasket seal.

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7.2.5 Solid-State Timer Installation
Electrical installation must be performed by a qualified electrician and comply with all
applicable national and local codes. Turn power off and lock out electrical power sources
before performing installation, service, or maintenance work. Do not install in classified
hazardous atmospheres without an enclosure rated for the application.
The solid-state timer is an electronic timer used to control the filter cleaning system.
1. Using the wiring diagram supplied, wire the fan motor, fan-motor starter, solid-state timer,
and solenoid valves. Use appropriate wire gauge for rated amp load as specified by local
codes.
2. Plug the program lug into the pin that corresponds with the number of solenoid valves
controlled (set at factory).
3. With power supply ON, check the operation of the solenoid valves. The valves should open
and close sequentially at factory set 10-second intervals.
4. A Delta P Plus is used to control the solid-state timer. The solenoid valves pulse only when
the differential pressure reaches the high-pressure setpoint. The valves continue to pulse
until the low-pressure setpoint is reached.
NOTE: The solid-state timer requires a 105 to 135-Volt customer-supplied power supply. Do
not mount the solid-state timer directly to the unit. Mechanical vibration can damage the
control.
7.2.5.1 Solenoid Connection

The unit is equipped with 115-V solenoid valves that control the pulse-cleaning valves, which
clean the filters.
The weatherproof NEMA 4 with 3D2 solenoids, is mounted near or on the unit's compressed-air
manifold.
Wire the solenoids to the solid-state timer following the wiring diagram supplied with the unit.
Filter life and cleaning operation will be affected if not wired correctly.
7.2.5.2 Timer and Solenoid Specifications

Power to the solid-state timer is supplied to Terminals L1 and L2, which operate in parallel with
the fan starter's low-voltage coil. On fan start-up, power is supplied to the timer and the preset
OFF time is initiated. At the end of the OFF time, the timer energizes the corresponding solenoid
valve to provide the ON time cleaning pulse for one diaphragm valve and then steps to the next
until all filters have been cleaned.
To pulse when the fan is OFF, install a toggle switch as shown on the Solid-State Timer Wiring
Diagram. When the toggle switch is ON, the timer receives power and energizes the solenoid
valves' pulse-cleaning operation even though the fan is turned OFF.

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Input
105-135V/50-60Hz/1Ph or 24 DC
Output Solenoids
The load is carried and turned ON and OFF by the 200 watt maximum-load-per-output solid-state
switch.

Pulse ON Time
Factory set at 100-milliseconds, or 1/10-second.
NOTE: Do not adjust pulse ON time unless the proper test equipment is available. Too much
or too little ON time can cause shortened filter life.
Pulse OFF Time
Factory set at 10-seconds, adjustable from 1 to 1.5-second minimum to maximum 60 to 66-
second.
Operating Temperature Range
-20° F to 130° F
Transient Voltage Protection
50 kW transient volts for 20-millisecond duration once every 20 seconds, 1% duty cycle.
Solenoid Valves
115-V at 19.7 watts each
Compressed-Air
Set compressed-air supply at 90-psig. The timer is factory set to clean one filter or set of filters
every 10-seconds.
NOTE: Do not set compressed-air pressure above 100-psi. Component damage will occur.

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7.2.6 Delta P Plus

The Delta P Plus controller continuously monitors and displays differential pressure drop in
inches of water or decaPascals on the panel face. When combined with a pulse timer, it can
control the collector cleaning mechanism to maintain the differential pressure drop between
chosen limits. Three cleaning modes are available along with an alarm function and a 4 - 20 mA
signal output.
7.2.6.1 Operation
Three cleaning modes, Differential Pressure Cleaning (DFF), Downtime Cleaning (DTC), and
Combined Differential and Downtime Cleaning (ALL) are available with this controller and can be
individually chosen by the user.
• Differential Pressure Cleaning (DFF) - When the differential pressure drop reaches the
controller's HIGH setpoint, the controller closes an output relay initiating the cleaning cycle.
When the differential pressure drop reaches the LOW setpoint, the relay opens and the
cleaning cycle stops. This sequence continues as long as the collector is running,
maintaining the differential pressure drop within a specified range.
• Downtime Cleaning (DTC) - The Delta P Plus controller monitors for the differential pressure
drop to exceed the LOW setpoint. (Indicates the blower has been started). When the
differential pressure drop later approaches zero (indicating the blower has been shut down),
the Delta P Plus engages the cleaning cycle for a pre-selected time. A delay timer allows the
blower to come to a stop before the cleaning cycle starts. The delay timer and cleaning cycle
durations are both user adjustable but password protected.
• Combined Differential and Downtime Cleaning (ALL) -The ALL mode combines the two
functions described above, maintaining the differential pressure drop in a specified range,
then initiating a down-time cleaning cycle when the differential pressure drop approaches
zero. The downtime cleaning function can be toggled on or off from the keyboard.

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NOTE: The DTC and ALL cleaning modes incorporate compressed air cleaning of the filters
when the main collector fan is not running. This may result in collected material
"drifting" out the inlet duct of the collector. An isolation valve in the inlet duct of the
collector can reduce or eliminate that drifting.
NOTE: Consideration should be made on the use of the DTC or ALL cleaning mode on small
collectors where the relatively low volume of the collector may produce pressure spikes

with each pulse of the cleaning cycle. Such pressure spikes may accelerate the
fatigue, or damage of ancillary items such as pressure sensors or explosion relief
panels.
7.2.6.2 Alarm
The alarm is used to indicate that the differential pressure drop has exceeded a preset value.
The alarm setpoint is set to a value exceeding the HIGH setpoint used to start the filter cleaning
cycle. The purpose of the alarm is to notify the user, via a light on the panel or dry contact
output, that the cleaning system cannot reduce the pressure drop possibly due to a cleaning
system failure, lack of compressed air, or the end of the filter's useful life. It can also be used to
notify the user that the pressure drop has reached a certain value (process related). There is a
time delay prior to activating the alarm to prevent nuisance trips of the alarm. The Delta P Plus
Control also provides an input connection for a remote alarm reset/disable.
NOTE: Once the differential pressure drop reaches the Alarm value, the relay and LED remain
activated until the pressure drop falls below the value set for the HIGH set point or until
you deactivate the alarm using a remote reset/disable.
7.2.7 Setpoint Adjustments

7.2.7.1 Quick Start Instructions
1. Press the MENU key, Lo appears. Press the SET key and the current value appears in the
display. Use the arrow keys to change this value. Press SET again, and the display will blink
twice, indicating that the new set point has been accepted. The Lo setting selects the
differential pressure drop value used to stop the pulse cleaning cycle, 2.0” w.g. is a typical
initial value.
2. Press the MENU key twice, Hi appears. Press the SET key and the current value appears in
the display. Use the arrow keys to change this value. Press SET again, and the display will
blink twice, indicating that the new set point has been accepted. The Hi setting selects the
differential pressure drop value used to start the pulse cleaning cycle, 4.0” w.g. is a typical
initial value.
3. Press the MENU key three times, AL appears. Press the set key and the current value
appears in the display. Use the arrow keys to change this value. Press SET again, and the
display will blink twice, indicating that the new setpoint has been accepted. The AL setting
selects the differential pressure drop value used to close the Alarm relay and turn on the
Alarm pilot light on the display.
4. Press the DOWNTIME CLEAN key, and the display will read either On or Off. Pressing the
same key again will toggle the reading [On to Off or Off to On]. Press the SET key to lock in
your choice.

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7.2.7.2 Adjustments
1. Pressing the MENU key repeatedly scrolls through the following programming choices:
• Lo — Low set point
• Hi — High set point
• AL — Alarm set point

• rtn — Return to reading current conditions
• PAS — Password (for access to secured functions)
2. The SET key shows current value and locks in values after adjustments.
3. The DOWNTIME Clean button toggles the function on and off when available.
4. Not pressing any buttons for 10 seconds allows the control to return to monitoring the filter
system.
7.2.7.3 Password Protected Settings

To reach the password protected settings, press the MENU key 5 times, the display will show
PAS.
Press the SET key, use the up arrow key to set the value to “4”, press set again.
When the display blinks twice, press the MENU key repeatedly until you reach the parameter you
wish to change.
Once you have selected a parameter, use the arrow keys to change the value within the setting
range as shown in the table below.
Press the SET key to lock in the value.
Parameters Description Setting Factory Units Function

Range Default
All ALL - Combines differential

pressure (Delta P) based cleaning
with downtime cleaning ON/OFF
selectable from keypad.
P6 Mode Select DTC All -- DTC - Filters downtime cleaned

only, not based on filter Delta P.
DFF DFF - Filter cleaning based on

Delta P with downtime cleaning not
available.

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Parameters Description Setting Factory Units Function

Range Default
P7 Display Units 0 -1 0 -- Selects units of measure for the

0 = in. w.g. digital display.
1 = daPa

P8 Downtime Start 30 - 99 30 Seconds Adjustable time lag between the
Relay pressure dropping below the value
set in parameter P 11 and the start
of downtime cleaning.
P9 Downtime 30 - 99 30 Seconds Adjustable time required to be

Pressure Enable above the value set as the Low Set
Relay Point (Lo) before the downtime
feature is enabled.
P 10 Downtime 1 - 999 10 Minutes The amount of time the downtime

Cleaning Time cleaning will continue once the time
set in P 9 expires.*
P 11 Downtime Start 0 - 9.6(2245) 0.3(13) In. Water The falling pressure that triggers the
Pressure (daPa) downtime cleaning sequence. **
P 12 Pressure Sensor 0-2 1 -- Sets the time used for Delta P value
Input Filtering averaging (0 = 250 ms, 1 = 2.5 sec,
2 = 10 sec).
P 13 Reset to Factory 0-1 0 -- 0 = No Reset

Defaults 1 = Reset
P 14 Zero Offset 0-1 0 -- 0 = No Operations

1 = Offset and Displayed Zero
P 15 Software Version -- -- --
P 16 Password -- -- -- Factory password, no user

adjustable items in subsequent
parameters.
* If the downtime cleaning sequence is in progress and the pressure drop indicates a fan restart,
the cleaning sequence will end.
** If P 11 is set as equal to or greater than the Lo value, the Lo value will automatically increase
0.2” above the P 11 value.

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7.2.7.4 Delta P Plus Control Calibration

The only user calibration is the zero adjustment of the display. Due to slight changes in electronic
components over time or pressure within the plant environment, the display may read something
other than 0.0 while at rest. Use the following procedure to recalibrate the operating system.
1. Turn power to the Delta P Plus Control ON for a minimum of 30-minutes to stabilize the
operating temperature.
2. Disconnect the pressure tubing, either leaving it to atmosphere, or connecting the two
barbed fittings together with a short length of tubing.
3. Use the Menu key to select PAS.
4. Press SET, then use the arrow keys to display "4", press SET again.
5. Press the MENU key repeatedly until you reach P 14.
6. Press SET, then use the arrow keys to display "1", press SET again.
7. After 10 seconds with no further button action, the display will return to reading the
pressure.
Figure 7-5 Delta P Plus Control Display Panel

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Figure 7-6 Delta P Plus Control Installation

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7.2.7.5 Preliminary Start-Up Check
Electrical work during installation must be performed by a qualified electrician and

comply with all applicable national and local codes.
Turn power off and lock out electrical power sources before performing service or maintenance
work.
Turn compressed air supply OFF and bleed lines before performing service or maintenance
work.
Check that the collector is clear and free of all debris before starting.
Do not install in classified hazardous atmospheres without an enclosure rated for the application.
Optional fans over 600 lbs must be independently supported.
1. Check all electrical connections for tightness and contact.
2. Check for and remove all loose items in or near the inlet and outlet of the unit.
3. Check that all remote controls are wired into the control system, and all service switches are
in the OFF position.
4. Turn power ON at source.
5. Turn the compressed-air supply ON. Adjust pressure regulator for 90 to 100-psig.
7.2.7.6 Maintenance Information

Instruct all personnel on safe use and maintenance procedures.
Electrical work during installation must be performed by a qualified electrician and

comply with all applicable national and local codes.
Turn power off and lock out electrical power sources before performing service or maintenance
work.
Do not install in classified hazardous atmospheres without an enclosure rated for the application.
Turn compressed air supply OFF and bleed lines before performing service or maintenance
work.
NOTE: Do not set compressed-air pressure above 100-psi. Component damage can occur.
All compressed air components must be sized to meet the maximum system requirements of 90-
100 psi supply pressure.
The compressed-air supply must be oil and moisture free. Contamination in the compressed air
used to clean filters will result in poor cleaning, cleaning valve failure, or poor collector
performance.

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Purge compressed air lines to remove debris before connecting to the unit's compressed air
manifold.
Figure 7-7 Solid-State Timer Wiring Diagram

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Air Conditioner/Heater BI010313
7.3 Air Conditioner/Heater

The BES3800 HVAC is a split system consisting of two major units. The system contains of an
evaporator unit containing the air handling components and is installed on top of the cab. The
main control panel is mounted on the top portion of the evaporator for ease of service. A unit
containing the compressor and condenser is mounted outside the cab. A pressurizer unit is
mounted on the outer left side wall of the cab.
7.3.1 Evaporator
Air is drawn from under the unit, passes over the heat exchange coil and heating elements into
the double inlet wheel fan deck and is discharged through the base into the operator's cab.
Refrigerant flow is metered by an externally equalized TX valve, and is cut off by a liquid line
solenoid valve. The heat exchange coil is large with heavy gauge tubing and coarse fin pitch to
reduce clogging. The fan motor has a single shaft and is totally enclosed. The "V" design drain
pan is large and easy to clean.

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BI010313 Air Conditioner/Heater
7.3.2 Condenser
The compressor is a heavy duty, fully sealed scroll device. The assembly is mounted to heavy
flexible mounts to reduce noise transmission to the structure and provides some damping of
shock. Connections are either soldered, 'O' ring or Rotolock. A large filter drier is mounted in the
liquid line to filter and remove moisture from the refrigerant. Isolation valves are installed on

either side to enable refrigerant to be "pumped down" and thus enabling core to be replaced
without total loss of refrigerant. The condenser fan only operates at a single speed.
7.3.3 Pressurizer
The pressurizer unit is located on the outside of the operator's cab. It is mounted on the left side
wall of the cab under the awning. The BESP100 is designed to pressurize the cab enclosure and
filter the incoming air. Every few hours, the unit will go through a purge cycle, back flushing the
air filter with compressed air. When the purge cycle is complete, the fans will resume operation
automatically. A manual purge button is located on the right side of the unit.
The pressurizer unit requires only minimum routine maintenance. The main air filter is washable
and should be cleaned after 6 months (2000 hours) of operation. Refer to CLEANING THE
WASHABLE FILTER for more information. The main air filter should be replaced annually, the
compressed air filter should be replaced every 2 years. The manufacturer recommends replacing
the two motors annually along with the main relay. Every 6 months, the motor brushes should be
changed and the motors blown out (cleaned) with compressed air.
7.3.3.1 Cleaning The Washable Filter

The main air filter inside the pressurizer should be washed after 2,000 hours of operation.
Although the filter material is durable, it should never be cleaned with pressurized air or a
pressure washer!
To wash the main air filter:
1. Disconnect power to the pressurizer.

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Air Conditioner/Heater BI010313
NOTE: The power is supplied to the pressurizer through the electric control panel located
inside the evaporator unit on top of the cab. To isolate power to the pressurizer you
would have to isolate power to the entire HVAC unit. The other way to disconnect power
is to open the 30 amp breaker located on the electrical panel of the pressurizer unit.
2. Remove the air filter.
3. Brush with a soft brush to remove any large particles.
4. Continue cleaning the filter with water, brushing down the filter as the water is applied. DO
NOT use a pressure washer!
5. Allow the filter to dry completely before re-installing the filter.
6. Restore power to the pressurizer unit.
7. Close up unit and manually purge the system.
NOTE: Every time the power is restored, the purge cycle timing module will be reset to zero.
Therefore the unit should be manually purged after filter cleaning or replacement.
7.3.4 Specifications
Nominal Cooling Capacity 37,500 Btu/hr@380V/460V50Hz
Heating Capacity 14 kw @380V/50Hz
17 kw @415V/50Hz
Power requirements 380V/415V/3ph/50Hz
30.0 Amps
Control Voltage 24 VDC power supply within the unit
Refrigerant Total system charge: 30 pounds of HFC 134 refrigerant
Oil POE Variety Mobil Arctic EAL22CC or ICI Emcarate RL32CF
Compressor Fully sealed, scroll type
Condenser Coil 5 row, 3/8 inch copper tube with 8 aluminum fins/inch
Evaporator Coil 4 row, 3/8 inch copper tube with 10 aluminum fins/inch
Condenser Fan 17.5 inch, 10 blades, provides 3000 cfm
High Fan: 1300 cfm @ 50Hz Low Fan: 870 cfm @ 50Hz
Thermostat 5 stage electronic with adjustable thermostat bands
Detailed information on the BES3800 can be found in the vendor’s documentation that
accompanied the machine and the General Arrangement drawings provided by the machine
manufacturer.

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BI010314

8 Engineering Data
Engineering Data
8.1 Capscrew (Bolt) Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.1.1 Bolt Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.1.1.1 Torque Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Table 8-1 - Lubricated or Plated Threads or with Hardened Washers . . . . . . . . . . . . 8-6
Table 8-2 - Dry Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.1.1.2 Turn-of-Nut Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Table 8-3 - Snug Tight Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.2 Measurement Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8.2.1 Linear Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Table 8-4 - Length Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Table 8-5 - Length Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.2.2 Area Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Table 8-6 - Area Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Table 8-7 - Area Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.2.3 Volume Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Table 8-8 - Volume Standards - Cubic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Table 8-9 - Volume Conversions - Cubic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Table 8-10 - Volume Standards - Wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Table 8-11 - Apothecaries' Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Table 8-12 - Volume Conversions - English to Metric . . . . . . . . . . . . . . . . . . . . . . . 8-11
Table 8-13 - Volume Conversions - Apothecaries' Measure to English . . . . . . . . . 8-12
Table 8-14 - Volume Conversions - Apothecaries' Measure to Metric . . . . . . . . . . 8-12

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BI010314
8.2.4 Torque Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Table 8-15 - Torque Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Table 8-16 - Torque Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.2.5 Weight Measurements - Conventional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Table 8-17 - Weight Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Table 8-18 - Weight Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Table 8-19 - Weight Conversions - Metric to English (Avoirdupois) . . . . . . . . . . . . 8-14
8.3 Split Flange Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Table 8-20 - Torque Table for Split Flange Assembly . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.4 Wire Locking Capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

Figure 8-1 Patterns for Wirelocking Capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.5 Torque Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

Table 8-21 - Torque Nut Location Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.6 Expansion Bolt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

Table 8-22 - Expansion Bolt Location Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.6.1 Tightening Procedure for 1.25-Inch Torque Nut . . . . . . . . . . . . . . . . . . . . . 8-19
8.6.2 Tightening Procedure for 2-Inch Torque Nut . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.6.5 Tightening Procedure for 2.5-Inch Torque Nut . . . . . . . . . . . . . . . . . . . . . . 8-23
8.6.7 Tightening Procedure for 3.5-Inch Torque Nut . . . . . . . . . . . . . . . . . . . . . . 8-25
8.6.8 Procedure For Use Of Mechanical Tensioner On 3.5 Inch Crawler Rods . 8-26
8.6.8.1 Initial Tensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.6.8.2 Final Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Figure 8-2 Connecting Rods - Crawlers to Truck Frame . . . . . . . . . . . . . . . . . . . . . 8-27
8.6.9 Tightening Procedures - Expansion Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.6.9.1 Rack & Roller Torque Rod, Tapered Sleeve & 1.0 Inch Torque Nut . 8-28
8.6.9.2 Hoist Torque Rod, Tapered Sleeve & 1.62 Inch Torque Nut . . . . . . . 8-30
8.6.9.3 Swing Torque Rod & Tapered Sleeve & 3.25 Inch Torque Nut . . . . . 8-32
8.7 Torque Nut Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8.7.1 Thread Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8.8 Torque Nut Helpful Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
8.9 Locking Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
8.9.1 Locking Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.10 Pinion and Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
8.10.1 Removal from a Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

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Engineering Data
BI010314
8.10.2 Mounting a Pinion or Hub on a Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

8.10.3 Pre-heat Advance Requirements - Pinions and Hubs . . . . . . . . . . . . . . . . 8-42
8.10.4 Motor Coupling Pre-Heat Advance Requirements . . . . . . . . . . . . . . . . . . 8-43
8.11 Open Gear Contact Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Figure 8-3 Contact Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45

8.12 Open Gear Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
8.13 Maintenance Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
8.13.1 Welding Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
8.13.2 Repair Welding of Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Figure 8-4 Joint Preparation for Repair of Cracks. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
8.13.2.1 Preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
8.13.2.2 Welding Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
8.13.3 Repair Welding of Broken Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
8.13.4 Repair Welding Swing Rack Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
8.13.4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
8.13.4.2 Swing Rack Welding Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
8.13.4.3 Preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
8.13.4.4 Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
8.13.5 Welding and Cutting Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59
8.13.6 Stress Relieving & Temperature Measuring Equipment . . . . . . . . . . . . . . 8-59
8.14 Wire Rope Care and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61
8.14.1 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61
8.14.2 Checking Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61
Figure 8-5 Correct Method for Checking Wire Rope Diameter . . . . . . . . . . . . . . . . . 8-61
8.14.3 Handling Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62
Figure 8-6 Improper Methods for Uncoiling Wire Rope. . . . . . . . . . . . . . . . . . . . . . . 8-63
8.14.4 Seizing Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64
8.14.5 End Preparations/Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66
8.14.6 Wire Rope Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67
8.14.6.1 Wire Rope Clip Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-67
8.14.6.2 Wedge Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-69
8.14.7 Inspection of Sheaves and Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70
Figure 8-7 Examples of Sheave Groove Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 8-70
Figure 8-8 Groove Gauge for New or Re-Worked Sheaves . . . . . . . . . . . . . . . . . . . 8-71
Figure 8-9 Inspecting for Worn Sheave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71
8.14.8 Breaking In a New Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72
8.14.9 Inspection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72
8.14.10 Guideline to Inspections and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73
8.14.10.1 Wire Rope Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74

June 2012
Engineering Data
BI010314
8.14.10.1.1 Reduction in Rope Diameter . . . . . . . . . . . . . . . . . . . . . . . . . 8-74

8.14.10.1.2 Rope Stretch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
Figure 8-10 Wire Rope Stretch vs. Rope Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
8.14.10.1.3 Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
8.14.10.1.4 Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
8.14.10.1.5 Kinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
8.14.10.1.6 Bird Caging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76

8.14.10.1.7 Localized Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
8.14.10.1.8 Heat Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
8.14.10.1.9 Protruding Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
8.14.10.1.10 Damaged End Attachments . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
8.14.10.1.11 Peening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
8.14.10.1.12 Scrubbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
8.14.10.1.13 Fatigue Fracture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
8.14.10.1.14 Broken Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
Figure 8-11 Examples of Broken Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78
8.14.10.1.15 Electric Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78
8.15 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79
8.15.1 Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79
Figure 8-12 Split Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-80
8.15.2 Gearcase Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-81

June 2012
Engineering Data
BI010314 Capscrew (Bolt) Grade
Engineering Data
8.1 Capscrew (Bolt) Grade

The grade classification of a capscrew (bolt) is identified by the marks on the head as shown
below:

Use the SAME GRADE washer and nut as the capscrew. NEVER SUBSTITUTE A LESSER GRADE
CAPSCREW IN PLACE OF THAT WHICH IS SPECIFIED.
8.1.1 Bolt Tightening
8.1.1.1 Torque Wrench Method

The following tables show torque values for bolt grades 5 and 8 with UNC threads only. Table 8-
1 lists torque values for lubricated or plated threads and for using hardened washers. Table 8-2
lists those for dry threads. The bolts should be tightened to the specified total value in
increments, alternating from bolt to bolt to assure gradual, even pull-up of mating parts.
Tightening should progress systematically from the most rigid part of a joint to its free edges.
Circular bolt patterns should be tightened in a diametric crosshatch pattern while applying torque
in increasing values to ensure proper pull-up of parts.

June 2012
Engineering Data
Capscrew (Bolt) Grade BI010314
Table 8-1 - Lubricated or Plated Threads or with Hardened Washers
Diameter Grade 5 Grade 8

Inch Cm Ft-Lbs. Nm Ft-Lbs. Nm
.250 .63 6.3 8 8 12
.375 .95 23 31 35 47
.500 1.27 55 74 80 108

.625 1.58 110 149 170 230
.750 1.90 200 270 280 379
.875 2.22 320 433 460 623
1.00 2.54 480 650 680 921
1.25 3.17 840 1,138 1,360 1,843
1.50 3.81 1,460 1,979 2,360 3,199
1.75 4.44 1,700 2,304 3,740 5,070
2.00 5.08 2,600 3,525 5,625 7,626
2.25 5.71 3,780 5,124 8,240 11,171
2.50 6.35 5,160 6,995 11,250 15,252
2.75 6.98 7,000 9,491 15,300 20,743
3.00 7.62 9,250 12,541 20,150 27,319
Table 8-2 - Dry Threads
Diameter Grade 5 Grade 8

Inch Cm Ft-Lbs. Nm Ft-Lbs. Nm
.250 .63 8.3 10 12 16
.375 .95 30 40 46 62
.500 1.27 73 98 106 143
.625 1.58 146 197 226 306
.750 1.90 266 360 373 505
.875 2.22 426 577 613 831
1.00 2.54 639 866 906 1,228
1.25 3.17 1,120 1,518 1,810 2,454
1.50 3.81 1,950 2,643 3,150 4,270
1.75 4.44 2,270 3,077 4,980 6,751
2.00 5.08 3,740 4,704 7,500 10,168
2.25 5.71 5,040 6,833 11,000 14,913
2.50 6.35 6,880 9,327 15,000 20,337
2.75 6.98 9,330 12,649 20,400 27,658
3.00 7.62 12,300 16,676 26,800 36,335

June 2012
Engineering Data
BI010314 Capscrew (Bolt) Grade
8.1.1.2 Turn-of-Nut Method
THIS TIGHTENING PROCEDURE IS ONLY APPLICABLE FOR BOLT GRADES 5 AND 8

WITH UNC THREADS. For bolts with other than UNC threads, contact the manufacturer.

NOTE: When using this procedure the bolt threads and the surfaces under the bolt head and
nut must be lubricated. This procedure is applicable only if the joint and under head
surfaces for bolt and nut are machined for parallelism.
1. The bolts should be brought to a “snug tight” condition to ensure that the parts of the joint
have good contact with each other. “Snug Tight” is defined as the tightness attained by
torquing a bolt to the value specified in the table on the following page. Snug tightening
should progress systematically from the most rigid part of the joint to its free edges while
alternating from bolt to bolt to assure gradual even pull up of the mating parts. After all bolts
have been snugged, the first bolts tightened at the most rigid part of the joint should be
rechecked for proper torque retention. If these bolts are loose due to pull up of the joint, the
snug tightening sequence should be repeated for all bolts in the connection. This
rechecking and re-torquing procedure should be repeated as many times as is required until
the joint is completely pulled up and all bolts are at the specified “snug tight” torque.
Tightness of the mating surfaces of the joint should then be verified by using feeler gauges.
Table 8-3 - Snug Tight Torque Values
Bolt Diameter Torque Values (1)

Inches Cm Ft-Lbs Nm Part No. Nut Rotation Bolt Length (2)
.500 1.27 15 20 74773-01 1/3 Turn of +/- 10% Up to and including 4
.625 1.58 30 40 diameters
.750 1.90 53 71 74773-02 1/2 Turn of +/- 10% Over 4 diameters but
.875 2.22 86 116 not exceeding 8
diameters
1.000 2.54 128 173
1.250 3.17 224 303
1.500 3.81 390 523 74773-03 2/3 Turn of +/- 10% Over 8 diameters but
1.750 4.44 457 619 not exceeding 12
diameters
2.000 5.05 688 932
2.250 5.71 1005 1362
2.500 6.35 1375 1804
2.750 6.98 1664 2627
3.000 7.52 2462 3337
(1) Tighten to values listed +10%. The torque values listed are calculated for 20% x proof load with
lubricated threads and under the head surfaces of the bolt and nut.
(2) In case part number or nut rotation designation is not given, the nut rotation can be determined by the
bolt length (grip length + 1/2 bolt diameter). For bolt lengths exceeding 12 diameters contact the
manufacturer.

June 2012
Engineering Data
Measurement Systems BI010314
2. The nuts and bolts should then be matched marked by center punching the bolt end and
nut. On rod bolts match mark both rod ends and nuts. The bolts and nuts should then be
tightened additionally by the applicable amount of nut rotation as specified in chart above. It
is not necessary to follow any particular bolt to bolt sequence during this portion of the “turn
of the nut” tightening.
NOTE: Nut rotation is read between the punch mark on the bolt and the punch mark on the nut.
For rod bolts, nut rotation is the cumulative total rotational movement between punch
marks on both ends of the rod bolt.
8.2 Measurement Systems

The following describes differing measuring systems and the conversion factors used to change
them from one type to another. Where possible, these have been generalized to limit the defined
systems to the most conventional and frequently referenced formats. Additional resources are
available including both reference documentation and software applications readily available for
use on personal computers.
Intermediate Metric Weights including Hectograms, Decagrams, Decigrams, Centigrams and
Milligrams are not generally used in our applications and are not discussed here.

June 2012
Engineering Data
BI010314 Measurement Systems
8.2.1 Linear Measurements
Table 8-4 - Length Standards
Metric English

1 Kilometer = 1000 Meters 1 Mile = 1,760 Yards
1 Meter = 10 Decimeters 1 Mile = 5,280 Feet
1 Decimeter = 10 Centimeters 1 Yard = 3 Feet
1 Centimeter = 10 Millimeters 1 Foot = 12 Inches
Table 8-5 - Length Conversions
Metric to English English to Metric

1 Kilometer = 0.6214 Miles 1 Mile = 1.609 Kilometers
1 Meter = 1.0936 Yards 1 Yard = 0.9144 Meters
1 Meter = 3.2808 Feet 1 Foot = 0.3048 Meters
1 Meter = 39.37 Inches 1 Foot = 304.8 Millimeters
1 Centimeter = 0.3937 Inches 1 Inch = 2.54 Centimeters
1 Millimeter = 0.03937 Inches 1 Inch = 25.4 Millimeters
8.2.2 Area Measurements

Table 8-6 - Area Standards
Metric English
1 sq. Kilometer = 1,000,000 Meters 1 sq. Mile = 640 Acres
1 sq. Meter = 100 sq. Decimeters 1 sq. Mile = 3,098,000 sq. Yards
1 sq. Decimeter = 100 sq. Centimeters 1 sq. Mile = 27,880,000 sq. Feet
1 sq. Centimeter = Millimeters 1 Acre = 4,840 sq. Yards
1 Acre = 43,560 sq. Feet
1 sq. Yard = 9 sq. Feet
1 sq. Yard = 1,296 sq. Inches
1 sq. Foot = 144 sq. Inches
NOTE: One Acre is equal to a square measuring 208.7 Feet (63.61 Meters) per side.

June 2012
Engineering Data
Table 8-7 - Area Conversions

1 sq. Kilometer = 0.3861 sq. Miles 1 sq. Mile = 2.590 sq. Kilometers
1 sq. Kilometer = 247.1 Acres 1 Acre = 0.004047 sq. Kilometers
1 sq. Meter = 1.196 sq. Yards 1 Acre = 4047 sq. Meters

1 sq. Meter = 10.76 sq. Feet 1 sq. Yard = 0.8361 sq. Meter
1 sq. Meter = 1550 sq. Inches 1 sq. Foot = 0.0929 sq. Meter
1 sq. Centimeter = 0.1550 sq. Inch 1 sq. Foot = 929.0 sq. Centimeters
1 sq. Millimeter = 0.001500 sq. Inch 1 sq. Inch = 6.452 sq. Centimeters
1 sq. Inch = 645.2 sq. Millimeters

June 2012
Engineering Data
8.2.3 Volume Measurements
Table 8-8 - Volume Standards - Cubic
Metric English

1 cu. Meter = 1,000,000 cu. Centimeters 1 cu. Yard = 27 cu. Feet
1 Liter = 1,000 cu. Centimeters 1 cu. Foot = 1728 cu. Inches
Table 8-9 - Volume Conversions - Cubic

1 cu. Meter = 1.308 cu. Yards 1 cu. Yard = 0.7646 cu. Meter
1 cu. Meter = 35.31 cu. Feet 1 cu. Foot = 0.02832 cu. Meter
1 cu. Meter = 61,020 cu. Inches 1 cu. Inch = 16.39 cu Centimeters
1 cu. Centimeter = 0.06102 cu. Inch 1 cu. Foot = 28.32 Liters
1 Liter = 0.03531 cu. Foot 1 cu. Inch = 0.01639 Liter
1 Liter = 61.02 cu. Inches
Table 8-10 - Volume Standards - Wet
Metric English
1 Hectoliter = 100 Liters 1 Gallon = 4 Quarts
1 Liter = 10 Decimeters 1 Quart = 2 Pints
1 Decimeter = 10 Centiliters 1 Pint = 4 Gills
1 Centiliter = 10 Milliliters
Table 8-11 - Apothecaries' Measure
Apothecaries' Measure
1 UK Gallon = 4 UK Quarts
1 UK Quart = 2 UK Pints
1 UK Pint = 4 UK Gills
Table 8-12 - Volume Conversions - English to Metric
English Metric
1 US Gallon = 3.785 Liters 1 Liter = 0.2642 Gallon
1 Quart = 0.9464 Liter 1 Liter = 1.057 Quarts
1 Pint = 0.4732 Liter 1 Liter = 2.113 Pints

June 2012
Engineering Data
Table 8-13 - Volume Conversions - Apothecaries' Measure to English
English Apothecaries' Measure

1 US Gallon = 0.8327 UK Gallon 1 UK Gallon = 1.201 US Gallons
1 US Pint = 0.8327 UK Pint 1 UK Pint = 1.201 US Pints
1 US Fld Oz = 1.041 UK Fld Oz 1 UK Fld Oz = 0.9608 US Fld Oz
Table 8-14 - Volume Conversions - Apothecaries' Measure to Metric
Apothecaries' Measure Metric

1 UK Gallon = 4.546 Liters 1 Liter = 0.2200 UK Gallon
1 UK Quart = 1.137 Liters 1 Liter = 0.8799 UK Quart
1 UK Pint = 0.5683 Liters 1 Liter = 1.760 UK Pints
The Apothecaries Measure was established in England in 1824. Originally set up to be similar to
the Apothecaries Weight System, parts of it were abandoned in 1963 and banned from use in
1971. The only remnants still in limited use are the UK (Imperial) Gallon, Pint and Fluid Ounce
measurements.

June 2012
Engineering Data
8.2.4 Torque Measurements
Table 8-15 - Torque Standards
Metric English

1 N·m = 1000 mN·m 1 ft-lb = 12 in-lb
1 ft-lb = 192 oz-in
Table 8-16 - Torque Conversions

1 N·m = 0.7376 ft-lb 1 ft-lb = 1.356 N·m
1 N·m = 8.851 in-lb 1 in-lb = 0.1130 N·m
1 mN·m = 0.1416 oz-in 1 oz-in = 7.062 mN·m
8.2.5 Weight Measurements - Conventional

Table 8-17 - Weight Standards
Metric English (Avoirdupois)

Tonne (Metric) = 1000 Kilograms Long Ton = 2240 Pounds
Kilogram = 10 Hectograms Short Ton = 2000 Pounds
Hectogram = 10 Decagrams Pound (lb) = 16 Ounces
Decagram = 10 Grams Ounce = 437.5 Grains
Gram = 10 Decigrams
Decigram = 10 Centigrams
Centigram = 10 Milligrams
Table 8-18 - Weight Standards
Troy Apothecaries' Weight

Pound (Troy) = 12 Ounces (Troy) 1 Pound = 12 Ounces = 5760 Grains
Ounce (Troy) = 20 Pennyweights 1 Ounce = 8 Drachms = 480 Grains
Ounce (Troy) = 480 Grains (Troy) 1 Drachm = 3 Scruples = 60 Grains
Pennyweight = 24 Grains (Troy) 1 Scruple = 20 Grains
Carat = 3.086 Grains (Troy)

June 2012
Engineering Data
NOTE: Troy Weight is used for measuring precious materials such as gold, silver and
crystalline minerals such as diamonds, emeralds and rubies. Apothecaries’ Weight, set
up by U.S. Pharmacists, is seldom used. These are included for comparative purposes
only.
NOTE: The English System of weights is also known as Avoirdupois weights and is based
upon a standard whereby 16 ounces equal 1 pound. Avoirdupois is a French term for
“goods of weight”.
Table 8-19 - Weight Conversions - Metric to English (Avoirdupois)

1 Tonne = 0.9842 Long Ton 1 Long Ton = 1.016 Tonne
1 Tonne = 1.1023 Short Tons 1 Short Ton = 0.9072 Tonne
1 Tonne = 2204.6 Pounds 1 Pound = 0.0004536 Tonne
Kilogram = 2.2046 Pounds 1 Pound = 0.4536 Kilogram
Gram = 0.03527 Ounce 1 Ounce = 28.35 Grams
NOTE: Intermediate Metric Weights including Hectograms, Decagrams, Decigrams,

Centigrams and Milligrams are not generally used in our applications and are not
discussed here.

June 2012
Engineering Data
BI010314 Split Flange Assembly Procedure
8.3 Split Flange Assembly Procedure

The 4 bolt split flange connection consists of four main components.
• Body of flange head (part of hose or tube)
• O-Ring
• Pair of split flange clamps
• Bolts and lockwashers
To assemble split flange connection:
1. Ensure that all sealing surfaces are free of burrs, nicks, scratches or any foreign particles.
2. Lubricate the o-ring with light grease or oil and insert into groove.
3. Position flange head and clamp halves.
4. Apply retaining compound to the bolt threads. Place lock washers on bolts and insert
through clamp halves.
5. Hand tighten bolts.
NOTE: Refer to the TORQUE TABLE for proper torque values. All torque values apply to
Grade 5 (Metric Grade 8.9) hardware or above with lubricated threads.

June 2012
Engineering Data
Split Flange Assembly Procedure BI010314
6. Tighten all bolts in a diagonal sequence in three incremental steps. Use the appropriate
torque value specified in the TORQUE TABLE.
7. Clean components before marking, then apply a legible mark with a permanent marker or
paint across each bolt and clamp.
Table 8-20 - Torque Table for Split Flange Assembly
Port Code 61 Bolt Size Torque Code 62 Bolt Size Torque

Inch Size Inch Ft-Lbs Inch Ft-Lbs
(Dash Size) (mm) (mm)
.50 .31-18 17 +/-2.0 .31-18 17 +/-2.0
(-8) (M8) (M8)
.75 .38-16 25 +/-4.5 .38-16 30 +/-4.5
(-12) (M10) (M10)
1.00 .38-16 31 +/-4.5 .44-14 46 +/-4.5
(-16) (M10) (M12)
1.25 .44-14 41 +/-5 .50-13 69 +/-6
(-20) (M10) (M14)
1.50 .50-13 52 +/-6 .63-11 125 +/-8
(-24) (M12) (M16)
2.00 .50-13 60 +/-6 .75-10 208 +/-20
(-32) (M12) (M20)
2.50 .50-13 85 +/-9 .88-9 330 +/-25
(-40) (M12) (M22)
3.00 .63-11 144 +/-15 1.13-7 640+/-30
(-48) (M16) (M27)
3.50 .63-11 125 +/-8 N/A N/A
(-56) (M16)
4.00 ..63-11 125 +/-8 N/A N/A
(-64) (M16)
5.00 .63-11 125 +/-8 N/A N/A
(-80) (M16)

June 2012
Engineering Data
BI010314 Wire Locking Capscrews
8.4 Wire Locking Capscrews

Wire locking of capscrews is used when maximum lock assurance is required when periodic
visual inspection is not possible.
The illustrations below show the recommended wire locking methods for various right hand

thread capscrew patterns. For patterns not shown, wire lock the screws “in pairs”. For odd
numbered patterns, wire lock the screws in pairs except the remaining 3 capscrews wire lock
together.
Figure 8-1 Patterns for Wirelocking Capscrews
Use 14 gauge soft annealed lock wire. Thread the wire through the capscrew head so that
tightening stress on the wire will exert a tightening torque on the direction of capscrew thread.
(The illustrations show lock wire threading for right hand threaded capscrews. Reverse the lock
wire patterns shown for left hand capscrews.)

June 2012
Engineering Data
Torque Nut Installation BI010314
8.5 Torque Nut Installation

Table 8-21 - Torque Nut Location Chart
Assembly Assembly Description P/N Supernut Size Jackbolt Qty.

K380509 Boom Point Sheaves MP263241 1.25 8
S070569-VG04 Hoist Motor 82637920 2.00 8
S006761 Hoist Pedestal Hardware 82637924 2.00 12
E020743-01 Crowd 2nd Intermediate Shaft 82637931 2.00 8
E022328-01 Crowd Drum Bearing/Cap 82637942 2.50 8
E022328-01 Crowd Drum Bearing/Cap 82637943 3.00 12
S106508 Crawler 82637955 3.50 16
8.6 Expansion Bolt Installation

Table 8-22 - Expansion Bolt Location Chart
Assembly Assembly Description P/N Supernut Size Jackbolt Qty.

S064280 Rack & Rollers 82637952 1.00 6
S006761 Hoist Pedestal Hardware 82637950 1.62 8
S006969 Hoist Pedestal Hardware, LH 82637950 1.62 8
1563167 Swing Drive 82637949 3.25 16

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Engineering Data
BI010314 Expansion Bolt Installation
8.6.1 Tightening Procedure for 1.25-Inch Torque Nut

1. Ensure that a special steel washer, supplied with the torque nut, is placed beneath the
torque nut. DO NOT USE STANDARD COMMERCIAL WASHERS.
2. The jackbolt threads and faces are prelubricated with graphite lube. Ensure that this lube is
present. Apply additional lube (part number MP390331) as needed.
3. Check the base of the torque nut to ensure that all jackbolts are flush with the bottom.
4. Spin the torque nut onto the rod or bolt by hand.
5. Tighten the jackbolts to 27 Ft-Lbs (37 N•m) as follows:
a. Snug all jackbolts to 3 Ft-Lbs (4 N•m) each.
b. Using the STAR pattern shown, tighten all jackbolts to 15 Ft-Lbs (21 N•m).
c. Switch to the CIRCULAR pattern shown and tighten all jackbolts to 20 Ft-Lbs (28
N•m).
d. Continue with the CIRCULAR pattern and tighten all jackbolts to 30 Ft-Lbs. (41 N•m)
NOTES:
• With longer rods and bolts, stretch in the rod or bolt occurs during tightening of the
jackbolts. Therefore, after tightening with the CIRCULAR pattern in step 5-d above, the
first jackbolt may have loosened. The higher torque value is used in this step only to
speed the tightening process. After performing the above steps, use a torque wrench for
the final torque values and continue tightening the jackbolts in a CIRCULAR pattern until
all jackbolts are tightened to a value of 27 Ft-Lbs (37 N•m).
• An impact wrench can be used for the initial tightening sequences, however a torque
wrench must be used to achieve the final torque values.
• Repeat the above steps for all remaining torque nuts.

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Expansion Bolt Installation BI010314
8.6.2 Tightening Procedure for 2-Inch Torque Nut

N•m).
d. Continue with the CIRCULAR pattern and tighten all jackbolts to 125 Ft-Lbs (170
N•m).
NOTES:

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Engineering Data

present. Apply additional lube (part number, MP390331) as needed.
N•m).
d. Continue with the CIRCULAR pattern and tighten all jackbolts to 125 Ft-Lbs. (170
N•m)
NOTES:
jackbolts. Therefore, after tightening with the circular pattern in step 5-d above, the first
jackbolt may have loosened. The higher torque value is used in this step only to speed
the tightening process. After performing the above steps, use a torque wrench for the final
torque values and continue tightening the jackbolts in a circular pattern until all jackbolts
are tightened to a value of 114 Ft-Lbs (155 N•m).

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Engineering Data

present. Apply additional lube (part number, MP390331) as needed.
5. Tighten the jackbolts to 100 Ft-Lbs as follows:
a. Snug all jackbolts to 10 Ft-Lbs each.
b. Using the STAR pattern shown, tighten all jackbolts to 50 Ft-Lbs.
c. Switch to the CIRCULAR pattern shown and tighten all jackbolts to 75 Ft-Lbs.
d. Continue with the CIRCULAR pattern and tighten all jackbolts to 110 Ft-Lbs.
NOTES:
jackbolts. Therefore, after tightening with the circular pattern in step 5-d above, the first
jackbolt may have loosened. The higher torque value is used in this step only to speed
the tightening process. After performing the above steps, use a torque wrench for the final
torque values and continue tightening the jackbolts in a circular pattern until all jackbolts
are tightened to a value of 100 Ft-Lbs.

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Engineering Data

NOTES:
all jackbolts are tightened to a value of 233 Ft-Lbs.

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Engineering Data

NOTES:
all jackbolts are tightened to a value of 233 Ft-Lbs.

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Engineering Data

N•m).
d. Continue with the CIRCULAR pattern and tighten all jackbolts to 193 Ft-Lbs (262
N•m).
NOTES:

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8.6.8 Procedure For Use Of Mechanical Tensioner On

3.5 Inch Crawler Rods
NOTES:
• Assemble all rods to the 0.50 inch STANDOUT DIMENSION as shown before tightening
jackbolts.
DO NOT tighten jackbolts to the stamped preload value on the torque nut!
• Tighten the jackbolts to a final torque value of 175 Ft-Lbs (211 N•m).
• The rod threads should be clean and the fit of the tensioners and nuts on the rods should
be very free. This is to allow for stretch of the rod during tensioning.
• Perform all steps completely for each Mechanical Tensioner — using the tightening
sequence indicated in the overall view in the figure.
• Due to stretching of long bolts and rods, the final tensioning steps may have to be
repeated to obtain the final preload.
• After 20 hours of machine operation, repeat the final tensioning step #1 for all the rods, in
the sequence indicated.
• Annually, repeat the final tension step #1 for all the rods, in the sequence indicated.
8.6.8.1 Initial Tensioning

1. To seat the threads and eliminate clearances, use a small wrench to tighten the jackbolts on
the mechanical tensioner to 10% of the final torque required [approximately 18 Ft-Lbs (25
N•m)]. Tighten the jackbolts in the tightening sequence indicated in Sequence 1.
2. Switch to a torque wrench and tighten the jackbolts to 50% of the final torque required
[approximately 88 Ft-Lbs (120 N•m)], again using the tightening Sequence 1.
3. Re-tighten the jackbolts to 75% of the final torque required [approximately 132 Ft-Lbs (179
N•m)] — however, use tightening Sequence 2.
8.6.8.2 Final Tensioning

1. Tighten the jackbolts to 110% of the final torque required [approximately 193 Ft-Lbs (262
N•m)] using the tightening Sequence 2.
2. Tighten all the jackbolts to the final torque value of 175 Ft-Lbs (211 N•m) using the
tightening Sequence 2.

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Figure 8-2 Connecting Rods - Crawlers to Truck Frame

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Engineering Data
8.6.9 Tightening Procedures - Expansion Bolts
8.6.9.1 Rack & Roller Torque Rod, Tapered Sleeve & 1.0 Inch
Torque Nut
1. The jackbolt threads, tapered portion of the rod bolt and the expansion sleeve ID are
prelubricated with graphite lube. Ensure that this lube is present. Apply additional lube
(part number MP390331) as needed. Also apply a thin film of lube to the OD of the
expansion sleeve, the revolving frame and swing girder bores, and the jack bolt end faces
and threads.
3. Insert the expansion sleeve from the top of the structure.
4. Insert the tapered stud into the sleeve. Note the direction of the taper on the rod.
5. Slip the special washer (spacer) over the lower threaded end of the stud.
6. Spin the lower torque nut onto the stud by hand.
7. Tighten the lower nut jackbolts to 27 Ft-Lbs (37 N•m) as follows:
a. Using the STAR pattern shown, snug all jackbolts to approximately 15 Ft-Lbs (21 N•m)
each.
b. Switch to the CIRCULAR pattern shown and tighten all jackbolts to 27 Ft-Lbs (37
N•m).
upper torque nut. DO NOT USE STANDARD COMMERCIAL WASHERS.
9. Spin the upper torque nut onto the stud by hand.
10. Finalize the preload of the upper torque nut by tightening the upper torque nut jack bolts to
27 Ft-Lbs (37 N•m) as follows:
a. Using the STAR pattern shown, snug all jack bolts (1 round only) to approximately 15
Ft-Lbs (21 N•m).

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Engineering Data
b. Set the torque wrench to 27 Ft-Lbs (37 N•m). Working in the CIRCULAR pattern,
continue tightening the jack bolts of the upper torque nut until they are stabilized at full
torque. This may take several rounds. (Stabilized is when the torque wrench is moving
less than 1/8 turn.)
11. Finalize the preload of the lower torque nut by tightening the lower torque nut jackbolts to 27
Ft-Lbs (37 N•m) as follows:

• Set the torque wrench to 27 Ft-Lbs (37 N•m). Working in the CIRCULAR pattern, continue
tightening the jack bolts of the lower torque nut until they are stabilized at full torque. This
may take several rounds.
NOTES:

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8.6.9.2 Hoist Torque Rod, Tapered Sleeve & 1.62 Inch Torque
Nut
prelubricated with graphite lube. Ensure that this lube is present. Apply additional lube
(part number MP390331) as needed. Also apply a thin film of lube to the OD of the
expansion sleeve, the revolving frame and swing girder bores, and the jack bolt end faces
and threads.
7. Tighten the lower nut jackbolts to 57 Ft-Lbs as follows:
a. Using the STAR pattern shown, snug all jackbolts to approximately 30 Ft-Lbs each.
b. Switch to the CIRCULAR pattern shown and tighten all jackbolts to 57 Ft-Lbs.
10. Finalize the preload of the upper torque nut by tightening the upper torque nut jack bolts to
57 Ft-Lbs as follows:
a. Using the STAR pattern shown, snug all jack bolts (1 round only) to approximately
30 Ft-Lbs.
b. Set the torque wrench to 57 Ft-Lbs. Working in the CIRCULAR pattern, continue
tightening the jack bolts of the upper torque nut until they are stabilized at full torque.
This may take several rounds. (Stabilized is when the torque wrench is moving less
than 1/8 turn.)
11. Finalize the preload of the lower torque nut by tightening the lower torque nut jackbolts to 57
Ft-Lbs as follows:
• Set the torque wrench to 57 Ft-Lbs. Working in the CIRCULAR pattern, continue
tightening the jack bolts of the lower torque nut until they are stabilized at full torque. This
may take several rounds.

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NOTES:

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8.6.9.3 Swing Torque Rod & Tapered Sleeve & 3.25 Inch
Torque Nut
prelubricated with graphite lube. Ensure that this lube is present. Apply additional lube (part
number MP390331) as needed. Also apply a thin film of lube to the OD of the expansion
sleeve, the revolving frame and swing girder bores, and the jack bolt end faces and threads.
7. Tighten the lower nut jackbolts to 182 Ft-Lbs (247 N•m) as follows:
a. Using the star pattern shown, snug all jackbolts (one round only) to approximately 30
Ft-Lbs (41 N•m) each.
b. Continue using the STAR pattern shown, tighten all jackbolts (one round only) to
approximately 90 Ft-Lbs (123 N•m).
c. Switch to the circular pattern shown and tighten all jackbolts (one round only) to 182
Ft-Lbs (247 N•m).
d. Inside the revolving frame, measure the protrusion of the rod bolt beyond the face of
the expansion sleeve flange. Refer to View - A. It must be within the acceptable range
shown.

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Engineering Data

10. Finalize the preload of the inner torque nut by tightening the upper torque nut jack bolts to
182 Ft-Lbs (247 N•m) as follows:
a. Using the STAR pattern shown, snug all jack bolts (1 round only) to approximately 90
Ft-Lbs (123 N•m).
b. Set the torque wrench to 182 Ft-Lbs (247 N•m). Working in the CIRCULAR pattern,
continue tightening the jack bolts of the upper torque nut until they are stabilized at full
torque. This may take several rounds. (Stabilized is when the torque wrench is moving
less than 1/8 turn.)
11. Finalize the preload of the outer torque nut by tightening the lower torque nut jackbolts to
182 Ft-Lbs as follows:
• Set the torque wrench to 182 Ft-Lbs (247 N•m). Working in the CIRCULAR pattern,
continue tightening the jack bolts of the outer torque nut until they are stabilized at full
torque. This may take several rounds.
NOTES:

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Engineering Data
Torque Nut Removal Procedure BI010314
8.7 Torque Nut Removal Procedure
THE PROPER REMOVAL OF TORQUE NUTS REQUIRES FOLLOWING STRICT

PROCEDURES. LONGER ANCHOR BOLTS AND RODS REQUIRE GREATER CARE. If

some jackbolts are completely unloaded prematurely, the remaining jackbolts will carry
the entire load of the fastener. This may cause the jackbolts to become extremely hard to
turn or even deformed.
NOTE: It is a good practice to spray the entire fastener and jackbolts with a penetrating type
lubricant prior to attempting removal. This step will be critical if rust exists on the
components.
1. Turn the first jackbolt counter-clockwise until it feels loose, but no more than 1/2 turn.
2. Repeat the loosening with the rest of the jackbolts. Use the reverse of the star pattern used
to tighten the jackbolts. This will minimize loading on the last few jackbolts.
3. Repeat the entire loosening pattern, turning each jackbolt no more than 1/2 turn at a time,
until the torque nut can be spun off the rod or bolt by hand.
After removal of the torque nut:
• Remove all jackbolts from the torque nut. Clean, inspect and lubricate the toque nut,
hardened washer and the jackbolts for later reassembly.
NOTE: On smaller torque nut fasteners it may be possible to utilize impact tools to speed
removal after performing step 2 above. However, DO NOT USE IMPACT TOOLS FOR
THE INITIAL LOOSENING PROCEDURE. Longer anchor bolts may require several
repetitions of the initial loosening process prior to switching to impact tools for
assistance.
8.7.1 Thread Lubrication

For the main studs of torque nut fasteners any standard anti-seize compound may be used. A
thin, brush-on type application, or aerosol spray lubricant is acceptable.
Jackbolts are pre-lubricated from the factory with either moly or graphite lubricants depending on
the intended use. Ensure lube is present on these surfaces and apply additional lube
(part number MP390331) as needed. Similar lubricants may be used on the jackbolt tips and
hardened washer during installation.

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Engineering Data
BI010314 Torque Nut Helpful Hints
8.8 Torque Nut Helpful Hints

Prior to Tightening
1. Threads: Check all threads of the main stud to verify that the torque nut will spin on freely
prior to installation. If a restriction is found, use a lapping compound on the main threads or

chase the threads in either the torque nut or the main stud using a good die or tap. THE
UNRESTRICTED MOVEMENT OF THE torque nut ON THE MAIN STUD IS CRITICAL IN
THE INSTALLATION PROCESS.
2. Spacers: The torque nut should be positioned at the end of the main stud when installation
is complete in order to minimize exposed threads which could be damaged. This will also
serve to minimize any difficulty in reaching the jackbolts and avoid the need for thinwall, or
deepwell sockets. A spacer or stacked washers can be used beneath the hardened washer
to accomplish this. The spacer will also allow a step-over of a damaged area on stud from
repeated installations.
3. Gaps: Back off the torque nut to provide a gap of 1/16 to 1/8 inch between the torque nut
and the hardened washer prior to beginning the torque application process. This will allow
additional jackbolt extension which provides easy access for jackbolt tip lubrication prior to
removal. When closing a gap between flanges, or where long fasteners are used, there may
be insufficient jackbolt stroke to allow this step.
4. Sockets: Use only six-point quality sockets in good condition. Worn sockets will eventually
round out the corners of the jackbolts possibly causing damage or injury.
While Tightening
5. Do not tighten a jackbolt completely prior to moving on to the next jackbolt. As the torque
nut is tightened, the first jackbolt that was tightened in that sequence will have a tendency to
loosen. It will be faster to make multiple passes by moving quickly between jackbolts.
6. Overshoot the Target Torque as indicated PRIOR to the final tightening. This will quicken
the tightening sequence by stabilizing previously tightened jackbolts sooner. BE CERTAIN
NOT TO “STABILIZE” THE JACKBOLTS AT THIS HIGHER TORQUE VALUE!
While Removing
7. Removing the jackbolts too quickly during disassembly may increase the removal torque of
the remaining jackbolts. If a jackbolt should become jammed, re-tighten several jackbolts to
either side to even the tension on the torque nut.
8. If a jackbolt tip “mushrooms” its tip must be cut off with a cutoff wheel or abrasive disc, then
the jackbolt removed.

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Locking Assemblies BI010314
8.9 Locking Assemblies

To install a locking assembly:
1. Clean and lightly oil all parts of the locking assembly, the shaft or pin and the housing bores.
Be sure the bores to be connected are properly aligned.
2. Loosen all socket head capscrews on the locking assembly.
3. Install the locking assembly and the shaft or pin into the housing. Carefully note any
measurements required to align the locking assembly.

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BI010314 Locking Assemblies
4. Tighten the capscrews of the locking assembly evenly. Do not tighten each screw all at
once. Instead, gradually tighten each one and proceed with the entire set, using a
crisscross pattern, and repeat until all screws are tight. Refer to the proper section of the
maintenance manual for the specific torque required.
Where pilot bushings are used:
1. Insert the locking assembly as stated above - except remove all socket head capscrews.

2. Insert 3 pilot bushings, equally spaced. Insert the longer capscrews supplied with the pilot
bushings.
3. Tighten the capscrews using the same procedure required for the locking assembly
capscrews.
4. Once the pilot bushing is has been properly tightened, remove the longer socket head
capscrews and the pilot bushings. Replace the capscrews in the locking assembly with the
socket head capscrews that came with the locking assembly.
5. Tighten all capscrews using the procedure above. Retain the pilot bushings and longer
capscrews for future use.

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Locking Assemblies BI010314
8.9.1 Locking Assembly Removal

For series 1015 assemblies with a center collar:

1. Loosen all capscrews on the locking assembly by at least 2 turns in 1/4 turn increments.
2. Transfer all the capscrews to the push-off threads provided in the clamp collar and in the
center collar.
3. Progressively tighten all screws in a diametrical pattern - except the screws adjacent to the
slit in the clamp collar - these should be tightened one after the other.
For series 4000 assemblies with NO center collar:
1. Loosen all capscrews on the locking assembly by at least 2 turns in 1/4 turn increments.
2. The locking assembly incorporates a self-releasing taper, which should allow the assembly
to be removed. However if the thrust rings jam, tap on the heads of 3 equally spaced
capscrews to positively release the connection.
3. Insert pullout screws in the threads under the cadmium plated locking screws to remove the
assembly.

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BI010314 Pinion and Hub Installation
8.10 Pinion and Hub Installation
8.10.1 Removal from a Shaft

A properly mounted pinion, brake drum or coupling will have an interference fit with the
shaft causing it to release suddenly and violently when broken loose. Loosen the shaft
nut just enough to allow the pinion, brake drum or coupling to free itself. The shaft nut will
stop the pinion or coupling and avoid injury to personnel.
NOTE: When removing the pinion, brake drum or coupling from a motor shaft, always use a
suitable puller to avoid causing damage to either the pinion, coupling, motor frame,
bearings or shaft. Do not heat the pinion, brake drum or coupling before pulling and do
not use wedges between them and the bearing cap. To prevent damage to the anti-
friction bearings, avoid the use of a sledge hammer on the puller.
8.10.2 Mounting a Pinion or Hub on a Shaft

NOTE: Mounting pinions, brake drums or coupling by heating them in boiling water and driving
them on the shaft with a blow from a heavy sledge hammer is not recommended. This
results in uncontrolled advance of the pinion or coupling on the shaft. Too great an
advance can cause breakage of the pinion, brake drum or coupling core, while
insufficient advance can cause slippage and wear in spite of the presence of the key. In
addition, hammer blows can injure the finished surface of the anti-friction bearings.
Successful operation of the gearing largely depends on the proper mounting of the pinion, brake
drum or coupling on the shaft.
Pinions, brake drums or couplings must be mounted to a definite advance on the shaft, without
hammer blows. This requires heating them to a higher temperature than is obtainable with boiling
water, and is based on a difference in temperature between them and the shaft. The following is
the recommended method for mounting pinions, brake drums or couplings:
1. Thoroughly clean the pinion, brake drum or coupling seating surface on the shaft and the
bore of the pinion, brake drum or couplings. Use toluol or percholoethylene; do not use
kerosene. Remove any scoring from either part. Spot the cold pinion, brake drum or
coupling on the shaft by hand to obtain at least a 75% fit. Check the fit with bluing. Remove
the pinion, brake drum or coupling.
Solvents may be toxic or flammable. Adequate ventilation must be provided to minimize

fire and health hazards. Use away from sparks, heat or flame to prevent fire or explosion.
Follow the manufacturer’s instructions.

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Pinion and Hub Installation BI010314
2. Break all sharp edges of the key and the keyway with a fine file, so there will be a radius of
about 1/64 inch at each edge. Fit the key to the shaft, taking care to avoid upsetting the
metal of the shaft adjacent to the key. If previously upset, file lightly, checking the fit with
bluing until a 75% fit results. Try the pinion, brake drum or coupling on the shaft to make
certain it does not bind on the key.
3. Mount the pinion, brake drum or coupling cold by placing it on the shaft and snapping it into
position by hand. Measure the “cold” position of the pinion, brake drum or coupling using a
micrometer depth gauge. The following figure illustrates the method of using the depth
gauge.
Mark the places where the depth gauge was resting so measurements can be made from
the same position after the pinion, brake drum or coupling has been mounted.
4. Remove the pinion, brake drum or coupling from the shaft and heat it in a suitable oven to
the temperature specified. If the pinion, brake drum or coupling is heated in oil, the bore
must be thoroughly cleaned before mounting. To avoid the cleaning, the use of an oven is
recommended.
Use suitable protective equipment when handling hot items.
The pinion, brake drum or coupling temperature is indicated as a temperature difference

between the shaft and pinion; this temperature difference is estimated only and can be
adjusted to maintain the specified advance. Heat the pinion, brake drum or coupling in the
oven until the temperature is uniform at the required number of degrees above the shaft
temperature. For example, if the shaft temperature is 25°C (77°F) and the estimated
difference is 125°C (225°F), heat the pinion, brake drum or coupling to 150°C (320°F) for
mounting.
Pinion, brake drum or coupling temperature must never exceed 190°C (374°F).

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Some accurate method must be provided for quickly measuring the temperatures of the
pinion, brake drum or coupling and shaft before mounting them. This is best done with a
hand pyrometer (refer to the figure). When a hand pyrometer is not available, a centigrade
thermometer can be used by placing putty over the bulb to hold it against the pinion or
coupling. Heat the pinion, brake drum or coupling a few degrees above the desired
temperature before removing it from the oven. Wait until it has cooled to the temperature
desired, remove the thermometer and quickly mount the pinion, brake drum or coupling as
described below.
5. After making sure the bore is clean, quickly mount the hot pinion, brake drum or coupling on
the shaft. When it is nearly engaged with the taper fit (but not actually in contact), snap it
forcible into place with a quick push. It is important that the hot pinion, brake drum or
coupling be instantly snapped into position before it has cooled appreciably; otherwise it will
immediately “freeze” to the shaft and cannot be adjusted further.
6. Check the “hot” or shrunk-on position of the pinion, brake drum or coupling on the shaft,
using the micrometer depth gauge. The actual advance is the difference between depth
gauge readings at the hot and cold positions. To control the stresses in the pinion, brake
drum or coupling, the advance must be within the limits specified in the table below.
If the advance is not within the limits given, the pinion, brake drum or coupling should be
pulled and remounted.
7. Assemble the lockwasher and nut, tighten firmly and lock. Where a lockwasher is not used,
retaining compound must be used to keep the nut tight during operation.
When a lockwasher is used, the nut must be firmly tightened against it, then the tab on the
lockwasher must be bent against the flat of the nut. This is required to keep the nut tight
during operation.

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Pinion and Hub Installation BI010314
8.10.3 Pre-heat Advance Requirements - Pinions and

Hubs
Motor Shaft Advance Estimated Temperature
Difference
Size (inches per 1.25 in/foot (Celsius / Fahrenheit)

taper)
Use chart for: 2.000 0.013 to 0.018 70° / 126°
all Drive 2.500 0.017 to 0.022 70° / 126°
Motors 3.000 0.020 to 0.025 70° / 126°
3.250 0.020 to 0.032 80° / 144°
3.625 0.037 to 0.045 95° / 171°
4.250 0.045 to 0.055 100° / 180°
4.525 0.055 to 0.065 115° / 207°
5.000 0.065 to 0.075 125° / 225°
5.875 0.080 to 0.090 130° / 234°
6.250 0.085 to 0.095 135° / 243°
7.000 0.095 to 0.105 140° / 252°

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8.10.4 Motor Coupling Pre-Heat Advance
Requirements
Difference

Size (inches per 1.25 in/foot taper) (Centigrade/Farenheit)
2.000 0.011 to 0.016 63° / 113°
2.500 0.013 to 0.018 54° / 97°
Use chart for: 3.000 0.015 to 0.020 49° / 88°
all Drive 3.250 0.016 to 0.021 46° / 83°
Motors Except 3.625 0.017 to 0.025 42° / 76°
Propel 4.250 0.019 to 0.027 38° / 68°
4.525 0.021 to 0.029 38° / 68°
5.000 0.022 to 0.030 37° / 67°
5.875 0.027 to 0.037 37° / 67°
6.250 0.028 to 0.038 35° / 63°
7.000 0.031 to 0.041 35° / 63°

Difference
Size (inches per 1.25 in/foot taper) (Centigrade/Farenheit)
1.750 .019 to .029 128° / 230°
2.000 .023 to .033 128° / 230°
2.500 .028 to .038 119° / 214°
Use chart for: 3.000 .028 to .038 106° / 191°
Propel Drive 3.250 .033 to .043 106° / 191°
Motors 3.625 .033 to .043 94° / 169°
4.250 .038 to .048 92° / 166°
4.625 .038 to .048 86° / 155°
5.000 .043 to .053 86° / 155°
5.885 .043 to .053 75° / 135°
6.250 .047 to .057 75° / 135°
7.000 .047 to .057 67° / 121°
7.846 .047 to .057 61° / 110°
8.500 .052 to .062 61° / 110°

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Open Gear Contact Check BI010314
8.11 Open Gear Contact Check
STORED ENERGY! Equipment must be blocked prior to open gear/pinion contact pattern
check or inspection to prevent unwanted rotational movement. Failure to comply could

result in death or severe personal injury.
NOTE: It is recommended that the remote drum control be used whenever possible. If remote
drum control is not available, establish uninterrupted radio contact with the machine
operator. Constant radio contact with the operator helps prevent accidents.
Maintain a safe distance from any open gears when the machinery is in motion. Failure to
comply with this warning could result in death or serious injury.
TOOLS:
Duct Tape
Solvent
Shop Rags
Digital Camera
1. Prepare for dynamic contact check by cleaning all upper and lower pinion teeth using a
solvent. Follow the solvent manufacturer's safety procedures.
Solvent & Shop Rag
2. Paint all pinion teeth with a hardening layout fluid dye. Allow sufficient time for the dye to dry
completely. After the dye has dried completely apply open gear lubricant on the teeth over
the dye.
Layout Dye PN: 1544229
3. With a dry rag wipe the open gear lube from the dyed pinion teeth. Do not use solvent as it
might remove the layout dye.
4. Record the dynamic contact pattern on the pinion. This is shown by the dye which has been
removed. Record by photograph, or sketch if camera is not available. After completion of
contact check, apply open gear lubricant by coating all pinion teeth.

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Engineering Data
BI010314 Open Gear Contact Check
NOTE: Contact checks should resemble the figures below. Dynamic contact check is to cover
75% of the face width, and 75% of the tooth height measured in the center of the face
width.

Figure 8-3 Contact Patterns
NOTE: The pattern may be spotty due to surface roughness. The contact area is considered to
be the total length or depth and not a summation of the individual contact points. Refer
to Figure 8-3.

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Engineering Data
Open Gear Break-In BI010314
8.12 Open Gear Break-In

When a machine is new, is returned to service after a long period of storage or is returned to
service after major repairs, a "break-in" period should be used to burnish the gear teeth, bearing
and bearing seals. The burnishing process is vitally important in obtaining long service life of
open gears.
TOOLS:
Dial Indicator
Duct Tape
Solvent
Shop Rags
Digital Camera
Ensure that the pinion teeth have been coated with a dye checking compound. For more
information, refer to OPEN GEAR CONTACT CHECK in the ENGINEERING DATA section of
this manual.
During break-in, the open gearing should be manually covered with OGL lubricant. For OGL
specifications, refer to OGL - OPEN GEAR LUBRICANT in the LUBRICATION section of this
manual. The lubricant injectors should be set to full open. During break-in, the recommended
time intervals for the shovel lubrication injectors are:
A1 Circuit Time Interval 5 Minutes
A2 Circuit Time Interval (Dig Mode) 5 Minutes
A2 Circuit Time Interval (Propel Mode) 3 Minutes
B1 Circuit Time Interval 6 Minutes
B2 Circuit Time Interval 5 Minutes
C1 Circuit Time Interval 5 Minutes
C2 Circuit Time Interval 4 Minutes
Lubrication intervals should be observed for the first two weeks of operation, and then can be
adjusted as required.
NOTE: As described in the LUBRICATION section, OGL grease based products inherently
provide marginal film thicknesses. This requires stringent break in procedures and
increased lubricant intervals.
The break-in process is started at no-load, and over a period of time the speeds and loads are
gradually increased. The following process is recommended:
1. Hoist Motion:
a. Raise and lower the dipper at 20% to 30% of full motor speed for one hour. Monitor the
gear lubrication constantly during this period of time to insure adequate lubricant film
on all teeth.
b. After 1 hour, inspect the hoist gear and pinions closely for signs of marking or any
distress. Be sure to inspect the entire circumference of the gear and pinions.
2. Crowd Motion: (Not Necessary for HydraCrowd®)

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Engineering Data
BI010314 Open Gear Break-In
a. Raise and lower the dipper at 20% to 30% of full motor speed for one hour. Monitor the
gear lubrication constantly during this period of time to insure adequate lubricant film
on all teeth.
b. After 1 hour, inspect the hoist gear and pinions closely for signs of marking or any
distress. Be sure to inspect the entire circumference of the gear and pinions.
3. Swing Motion:

a. Simultaneously operate the hoist and crowd motions as outlined in Steps 1 and 2 as
well as swinging the machine slowly. Be sure to rotate the machine at least 400° in
each direction to assure full swing rack circumference is burnished.
NOTE: Speed control on the swing is a function of judgment by the operator or electrical
adjustment to limit speed.
b. Repeat Step 3a for a period of one operating shift. Periodic inspections (approximately
every hour) of the gearing should be made during the break-in period.
NOTE: During the break-in period maintain close observation for unusual vibration, noise, hot
operating bearings and to assure adequate lubrication of gearing. This is a good
opportunity to establish temperature and vibration baseline data.
4. Stop the machine and fully inspect all gearing for signs of any distress, along with any
lubrication contamination.
STORED ENERGY! Equipment must be blocked prior to hoist gear/ hoist pinion
inspection to prevent unwanted rotational movement. Failure to comply could result in
death or severe personal injury.
NOTE: It is recommended that the remote hoist control be used whenever possible. If remote
hoist control is not available, establish uninterrupted radio contact with the machine
operator. Several of the steps in the procedure involve engaging the hoist machinery.
Constant radio contact with the operator helps prevent accidents.
Maintain a safe distance from any open gears when the hoist machinery is in motion.
Failure to comply with this warning could result in death or serious injury.
5. Repeat Step 3 using a higher speed. Initial break-in period should exceed 10 hours with an
empty dipper.
6. Propelling:
a. During the first 4 days (100 hours) of operation, the operator must restrict machine
propel speed to 50% of maximum controller while propelling.
b. Steer in 15° increments, propelling straight for approximately 1/2 the length of the
crawlers in between each turn.
c. Ensure that the crawler links are properly tensioned.
d. Always propel forward and backwards to assure break-in in both directions.
7. Digging Operation for first 4 days (or 100 actual digging hours):

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Engineering Data
Open Gear Break-In BI010314
a. Ensure that the digging material is properly blasted and loose. For this process do not
fill the dipper more than half full. Do not stall the hoist motion in the bank.
b. Close observation of gear teeth must be done throughout the period of break-in. This
is a good time also to monitor the automatic lube system and fine tune injector output
to obtain complete gear face coverage. Seek support from a lubrication engineer as
necessary.
c. After completing the break-in period, a close inspection of the gear teeth wear pattern
should be made and recorded on the hoist, crowd and swing open gear sets.
Documenting the wear pattern is very important. Use layout dye (PN: 1544229) to
record wear patterns. For more information, refer to OPEN GEAR CONTACT CHECK
on page 0-2 of this manual.
Upon completion of the final inspection place the machine into service using normal operation
parameters. If there are questions concerning this procedure contact the manufacturer.

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Engineering Data
BI010314 Maintenance Welding
8.13 Maintenance Welding

These recommendations for repair welding apply to the major structural members of the
machine. The high cyclic loading characteristics of the machine are considered in the design and
material selected for the construction of the machine. However, due to unusual operational
conditions that may be encountered and to the great number of cyclic loadings that may be

applied to the machine, fatigue cracks or other abnormalities may occur. Early detection of these
conditions through regular machine inspection helps to avoid problems or emergency
breakdowns.
Maintenance welding is applied to the repair of cracked or broken structural components.
Reconditioning of broken parts by the application of heating, cutting and welding processes
requires attention to a number of details, careful adherence to the repair procedure and
observance of federal, state and local safety regulations.
WELDING AND THERMAL-CUTTING OF METALS INVOLVE THE GENERATION OF

TEMPERATURES UP TO THOUSANDS OF DEGREES AT WHICH METALS MELT AND
VAPORIZE. When proper precautions are taken to protect personnel and property against
the heat, evolved gases and fumes, electric shock and radiation, no harm will result either
to personnel or property. In gas heating and cutting, the handling and storage of
compressed gases present other hazards that also must be protected against to provide a
safe working environment.
Safety precautions should conform to the latest edition of ANSI standard Z49.1, Safety in
Welding and Cutting, published by the American Welding Society.
Reconditioning of failed members requires attention to a number of details and careful

application of the repair procedure. Only in certain cases is it necessary to strengthen members
by added reinforcement.
REINFORCING STRUCTURAL MEMBERS SHOULD BE MADE ONLY UPON

RECOMMENDATION BY THE MANUFACTURER. IMPROPERLY APPLIED
REINFORCEMENTS CAN HAVE AN ADVERSE EFFECT ON THE PERFORMANCE AND
LIFE OF THE STRUCTURE.
A broken member is best repaired by making a complete penetration weld, preferably by welding
from both sides, using the correct welding electrode and observing all precautions such as
preheat, back-gouging, etc. The complete penetration groove weld should be ground flush with
the base metal on both sides to remove all surface irregularities. An alternate procedure
incorporates backup bars to ensure sound, complete penetration welds in the repair area. Be
sure to follow all applicable safety measures and federal, state and local regulations.

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Engineering Data
Maintenance Welding BI010314
A complete penetration weld repair conditioned by grinding instead of adding reinforcement is

favored to maintain the original pattern of stress flow designed into the structural members.
Addition of reinforcement which is not part of the design can reduce fatigue strength because of
the change in geometry from the original structure.
Effective repair welding of cracked, broken or bent structural members of the machine involves
knowledge of the types of steel used, proper welding electrodes and recognized good welding
practice. The chemical composition, mechanical properties and thickness of the steel determine
the welding electrode to be used and the preheat temperature required.
8.13.1 Welding Electrodes

With the exception of the boom, weld repairs on the various structures of the machine can be
made with two basic classifications of shielded metal arc electrodes: E7018 and E8018-C1. Both
are low hydrogen electrodes which deposit weld metal having excellent properties at strength
levels with 70,000 to 80,000 PSI, and impact properties from -20° to -75°F (-29° to -59°C). These
are all-position electrodes which produce high quality welds for repairing the structural
components of heavy machinery.
NOTE: Although these electrodes are of superior quality, care must be exercised in their
application. Low hydrogen electrodes are highly susceptible to moisture pickup after
removal from sealed containers. To maintain low hydrogen, crack-resistant properties,
they must be stored in electrode ovens at 250°F (121°C) up to the time of use. Small
portable rod ovens at the welder’s side are ideal. Use of dry low hydrogen electrodes
cannot be over-emphasized.
Cracks caused by hydrogen are extremely fine and occur invisibly below the surface in the base
metal heat affected zone, as shown. Therefore, they are not detectable at the time of welding.
These cracks can propagate in service and lead to ultimate failure of the part. It is necessary to
adhere strictly to recognized good welding practice regarding the handling, storage and use of
low hydrogen electrodes. To avoid underbead cracks, remove all oil or grease or other
contaminates from the surface and be sure the steel is dry.

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Engineering Data
Preheat to the required temperature. Use only dry electrodes taken from the electrode oven.
After exposure to the air, the electrodes must be returned to the oven. Time limit outside the oven
is four hours for E7018 and two hours for E8018-C1 electrodes.
8.13.2 Repair Welding of Cracks

Figure 8-4 Joint Preparation for Repair of Cracks
Remove the entire crack by arc air-gouging or grinding. Prepare a V-groove of approximately 45-
60° included angle for rewelding. If cracked through the full thickness and if it is possible to make
the repair from both sides, a double V preparation is preferred. When welding from both sides,
back-gouging for complete penetration is always recommended.
When it is not physically possible to back-gouge and weld the second side, an alternate
approach must be taken. Sometimes it is possible to gouge through to completely remove the
crack, then fit a backup bar on the underside to facilitate making a complete penetration weld.
NOTE: The backup bar must fit tightly to the underside otherwise poor welding conditions
conducive to cracking may occur.
When it is not possible to fit a backup due to limited accessibility to the underside, it is advisable
to remove a portion of the defective plate and weld in a new piece, using back up bars on all
sides to ensure complete penetration welds.
A further alternative is to gouge through, removing the crack, and then weld small stringer beads
to close the gap and prepare a groove for a repair weld. In this case, the repair weld will be
essentially full penetration, but will be less than perfect on the under side. The other methods are
preferred in the order described, that is, welding both sides, welding against a backup bar, or
completely replacing a section of plate.

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Engineering Data
8.13.2.1 Preheat
When preheating, apply heat to a broad, general area surrounding the repair location. A soaking
heat that penetrates the material through its full thickness is preferred to high surface
temperature quickly applied. Electrical resistance or radiant heating is suggested since the heat
source can be left operating during welding to maintain the minimum preheat temperature.
Preheat temperatures up to 400°F (204°C), depending upon the steel analysis, are adequate
under most conditions for major repairs. As previously stated, preheat temperatures are
determined by the type of steel in the structure. Temperatures should be measured with
temperature indicating crayons.
8.13.2.2 Welding Technique
Maximum electrode sizes are 1/4 inch for flat position, 3/16 inch for horizontal position and 5/32
inch for vertical and overhead positions. Use a split weave as soon as bead width is large
enough to accommodate beads side by side. Throughout all welding be certain thorough fusion
with the base metal and adjacent weld beads is obtained on all weld passes. Clean off all slag
between passes and all craters before starting the next electrode.

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Engineering Data
Inspect closely for cracks, undercut or overlap of beads, and gouge out or grind flaws where they
occur before continuing. It is very important on highly loaded parts, particularly members subject
to cyclic or dynamic stresses, to obtain sound repair welds.
The presence of any stress risers on the surface of a part is detrimental to fatigue life and can
result in future cracking. Therefore, it is essential that the finished repair be smooth and well
blended into the base metal. Repair weld any undercuts, grind off overlapped weld beads and

blend out any notches or gouges. The best condition in a repair weld location is provided by
grinding the repair smooth and flush with the surface of the base metal. Final grinding direction is
to be identical with the direction of applied load on the structure. Refer to the figure.
8.13.3 Repair Welding of Broken Parts

All recommendations given for repair of cracks apply to repair of broken parts, with additional
corrections. Depending on the size and cross-section of the part, a specific sequence of welding
procedures may be required in making the repair. These techniques include back-step welding
sequence, block welding sequence, alternating from side to side, welding simultaneously on
opposite sides, etc. All of these precautionary measures are intended to minimize shrinkage
stresses and subsequent distortion or cracking during welding. The method to follow should be
determined after a careful analysis of the situation and by approaching the problem with common
sense. Generally a procedure which has proven successful in previous experience could logically
be applied in most cases.
Use of doubling plates, stiffeners or other reinforcements to strengthen a member which has
cracked in service, must be carefully considered before that repair measure is decided upon.
Additional material added for strengthening alters the configuration and geometry of the member,
possibly with a pronounced effect on the fatigue life of that structure. Many times, such attempts
at strengthening by adding plates only serves to “chase the crack someplace else.” The stress
flow in the part has been altered, creating a location for stress concentration. Attachments
requiring fillet welds across a tension member for example, are poor repair methods. A sound
repair weld, carefully made and smoothly blended into the base metal on all sides, is preferable
to additional reinforcements. Any application of reinforcements requires careful consideration
regarding total overall effect on the structure during service, and should be done only after
consulting the manufacturer.

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8.13.4 Repair Welding Swing Rack Teeth
The following is a suggested method for the repair of cracked or broken swing rack teeth. The
repair method should produce satisfactory results and provide a serviceable swing rack, provided
the procedure is carefully followed in all details. The welding procedure is essentially the same
for the three conditions shown.

8.13.4.1 Preparation
1. Clean off the swing rack in the area of the tooth to be repaired to remove all traces of
grease, oil or dirt. Wash down thoroughly with a solvent cleaner and wipe dry with clean
rags.
2. Grind to completely remove the crack and prepare a groove for welding as shown in the
figures.
3. Dye penetrant test for complete crack removal.
4. In the case of a broken tooth, grind the fracture surface on the swing rack smooth and round
off edges as shown.
8.13.4.2 Swing Rack Welding Electrodes

1. All welding is to be done using oven dry E11018-M low hydrogen electrodes. Connect an
electrode drying oven as close as possible to the work area. Set the oven temperature at
300°F (149°C). As sealed containers of electrodes are opened, place the entire contents of
the container in the oven. Remove no more electrodes than can be consumed in one-half
hour. If all electrodes are not used in 1/2 hour, return them to the oven. Discard any
electrodes which have been wet.
8.13.4.3 Preheat
1. Two levels of preheat are required for tooth repair, 250°F (121°C) minimum for butter
welding and 175°F (79°C) minimum for filling in the groove. Temperatures should be
measured with temperature indicating crayons.

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Engineering Data
2. Preheat will be difficult to maintain because of the mass of metal in the swing rack to draw
the heat away from the repair area. It is therefore recommended to apply heat to a large
section of the swing rack to offset this quench effect. A section covering at least 3 teeth on
either side of the tooth being repaired should be heated so that the minimum preheat
temperature is obtained at the repair location. It is suggested that electrical resistance
heaters be applied behind the teeth as shown, if such physical arrangement is possible. If
the repair area cannot be heated to the required minimum temperature by this arrangement,
supplementary heat must be applied from the tooth side of the swing rack. Electrical
resistance heaters can be applied, or heat provided by oxy-propane torches. Adjacent
areas of the swing rack should be covered with heavy insulation to avoid beat loss.
3. During welding, the repair area must be continually checked with temperature indicating
crayons to be sure that the minimum temperature is being maintained. Do not weld at
temperatures below the specified minimums.
NOTE: Contract services are available for field application of resistance heating equipment.
Suggested source:
Stresstech
Box 11
Red Wing, MN 55066
(651) 388-7117

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Engineering Data
8.13.4.4 Welding Procedure
1. Refer to the previous butter-welding figures. The purpose of the butter weld layer is to
provide a buffer between the weld required to fill the groove and the alloy cast steel. This
technique is essential in preventing heat affected zone cracking in the cast steel which
otherwise is likely to occur due to the shrinkage of the weld as the groove is filled. Butter

welding permits the repair weld to be made at the preheat temperatures specified. Much
higher temperature would otherwise be required for crack free welding.
2. Butter welding is done using 1/8 inch diameter E11018-M electrodes at a minimum preheat
temperature of 250°F (121°C). (See section under WELDING ELECTRODES regarding use
of the electrode drying oven.) Horizontal weld beads are applied to completely cover the
cavity or surface to be welded. The edges of the butter weld must overlap the adjacent
surface about 1/2 inch. This is to prevent subsequent welding from impinging upon the cast
steel.
3. Before starting the butter weld, position a piece of thin mild steel plate under the bottom end
of the tooth. This is to provide a shelf for starting the weld and to avoid irregular weld beads
at the bottom which would become stress risers to cause cracking when the tooth is loaded
in service.
4. Apply the butter weld, progressing with horizontal beads from bottom to top. Use care to
keep the butter weld layer as smooth and regular as possible. When finished, remove all
slag and grind any high spot which could trap slag when welding to fill the groove. In the
case of repairing a broken tooth the prepared tooth segment is butter welded separately
before positioning for final welding in place.
5. Filling the groove is done with 1/8 inch or 5/32 inch E11018-M electrodes at a minimum
preheat temperature of 175°F (79°C). (See section under WELDING ELECTRODES
regarding the use of the electrode drying oven.) Weld vertically up using a split layer
technique as soon as the groove is wide enough to accommodate 2 or more beads. Refer to
the butter-weld figures for the approximate weld bead sequence.
6. For replacing a tooth segment as shown, it will be necessary to prepare a tooth profile
template. The template must be carefully made to fit the rack teeth as accurately as
possible. Use the template to position the tooth segment prior to tack welding. When
welding the tooth segment in place alternate welding from side to side to control distortion.
Check frequently with the template.
7. When groove welding is finished check carefully for low spots and fill in as required. Grind
the weld smooth and flush with the adjacent tooth surfaces. Use the tooth profile template to
check grinding of a welded-on tooth segment. Grinding of the radius at the root of the tooth
is very important. Avoid any nicks, gouges or grinding marks in a vertical direction. Grind a
smooth radius using small diameter (peanut) grinders. Failure to achieve a smooth, notch-
free radius may result in future cracking at the root of the tooth.
8. After the swing rack has cooled to ambient temperature, dye-penetrant test the repaired
tooth for soundness.

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Engineering Data
8.13.5 Welding and Cutting Equipment
The welding and cutting equipment needed for general repair welding is listed below.
WELDING MACHINES, Arc - 600 ampere (for Welding and Air Arcing)
OXY ACETYLENE TORCHES with Gauges - 150' Long Hoses

HEATING TORCHES, Butane (for Boom Welding)
ARC AIR ATTACHMENTS (for use with 600 Ampere Welding Machines)
WELD RODS - E7018, E8018, E11018 - 1/8", 5/32". 3/16", 1/4"
C02 - Welding Grade - 45°F (7°C) Max. Dew Point
OXYGEN - Cutting, and Heating
ACETYLENE
WELD FLUX CHIPPERS - Pneumatic with Chisels and Spare Parts
BLOWERS, Ventilating (for Compartment Welding,)
GRINDERS, Wheel - Air Powered w/Wheels
TARPAULINS - Fireproof (for Boom Welding Shelters)
HIGH TEMPERATURE GLOVES
CUTTING GOGGLES, Dark
SOAPSTONE MARKERS
ANTI-SPATTER COMPOUND
TEMPILSTIKS - 200° and 400°
8.13.6 Stress Relieving & Temperature Measuring

Equipment
The equipment recommended for stress relieving, after repair welding, is listed below.
TEMPERATURE MEASURING EQUIPMENT

SPEEDOMAX, “W” Multipoint, Potentiometer Recorder
POWER REQUIREMENT - 120 Volts, 60 or 50 Hz.
RANGE - 0 to 1500°F (-18 to 816°C)
CALIBRATION - Chromel-Alumel Thermocouple Wire
ACCURACY RATING - 0.3% of Electrical Span
CHART SPEED - 2" per Hour
THERMOCOUPLE SELECTION - Six (6) Points
FLUORESCENT LIGHTING
MANUFACTURER - Leeds & Northrup Company
THERMOCOUPLE EXTENSION WIRE
DUPLEX WIRES - Chromel-Alumel - Type K - 16 AWG Stranded
LENGTH - Total External Resistance for both Wires including Thermocouple not to exceed 2500 Ohms or
410 Feet.
WIRE RESISTANCE - Nominal Resistance, Ohm per Foot at 20°C (66°F) - Chromel - Ohms - Alumel -
0.0683 Ohms.
WIRE INSULATION - each Conductor Enamel, Asbestos (Twisted Pair) Overall Asbestos Braid

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Engineering Data
WIRE CODE -Alumel, Negative Wire (Red); Chromel, Positive Wire (Yellow)
OVERALL COLOR - Yellow
CATALOG No. 16-59-17
POLARITY DISCONNECT
CHROMEL-ALUMEL COMPENSATED CONNECTION
JACK Color Code (Yellow) - Catalog No. 040419
PLUG Color Code (Yellow) - Catalog No. 040434

CABLE CLAMP - Catalog No. 072513
ADAPTER - Catalog No. 076794
THERMOCOUPLE ELEMENT
CHROMEL-ALUMEL - Type K - Swaged One (1) Inch Stripped
CHROMEL POSITIVE WIRE Color Code (None)
ALUMEL NEGATIVE WIRE Color Code (Red)
CATALOG No. 8784-K-1-3-12"-D
1. 588003 Kaopak Flex Heaters
2. 588004 Kaopak Collector Streamer Type
3. Kaopak Blankets 3, 5, or 6 Pocket Size as needed for Size Pipe being Stressed Relieved
Thermocouple Assembly, Complete
Catalog No. 8784-K-1-3-12"-Q
Temperature Indicating Pellets (Tempil° Pellets)
Indicating Temperature: 1050°F, 1100°F, 1200°F, and 1250°F. (Several of each temperature)
Mean Accuracy: +/-1%
These Tempil Pellets will begin to melt at the temperature specified.

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Engineering Data
BI010314 Wire Rope Care and Maintenance
8.14 Wire Rope Care and Maintenance

8.14.1 Storage
Reels of wire rope stock may be kept on hand for a considerable length of time. This is

particularly true of slow-moving special ropes that may not be disposed of completely for several
years. Consequently, wire rope should be stored in an are that is well-ventilated and stable with
regard to temperature and humidity.
Do not store rope in contact with the bare ground or expose it to the elements. Excessive
atmospheric vapors will condense moisture on the rope causing corrosion. If exposed to the
direct sun, next to a boiler or in similarly warm conditions, the original lubrication will dry out and
lose its preservation properties.
Similarly, storage in a dusty or chemical laden environment may coat the surface of the rope with
corrosive materials or even deteriorate the fiber core. If it should be necessary to store rope
outside, the reel should be set on blocks or raised off the ground, and covered with a waterproof
covering.
8.14.2 Checking Diameter

It is critical to check the diameter of the delivered rope BEFORE installation on the machine. This
is to ensure that the rope diameter meets the specified requirements for the given machine or
equipment. An UNDERSIZE diameter rope will bring about a condition where stresses are
exceeding design limitations. This will increase the possibility of injury or machine damage as the
chances of breaking the rope will be increased. Use of an OVERSIZE diameter rope will bring
about premature wear of that rope. The rope constantly being pinched and compressed in the
grooves of the sheaves and drum causes this.
Figure 8-5 Correct Method for Checking Wire Rope Diameter
When checking it is imperative that the actual rope diameter is measured. This is defined as the
diameter of the circumscribing circle, or its largest cross-sectional dimension. To ensure
accuracy this measurement should be made with a wire rope caliper to obtain the outside
dimension of 2 diametrically opposing strands of the rope. When measuring a rope with an odd
number of outer strands, special techniques must be employed. Refer to the manufacturer of the
product for accurate information.

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Engineering Data
Wire Rope Care and Maintenance BI010314
8.14.3 Handling Wire Rope

When re-reeling wire rope from a horizontally supported reel to a drum, keep in mind that a wire
rope has a “memory” to be considered. If at all possible, it is preferable for the rope to travel from
the top of the reel to the top of the drum during this process. The same would hold true for the
bottom of the reel to the bottom of the drum. Re-reeling in this manner will avoid putting a reverse
bend into the rope as it is being installed. If a rope is installed so that a reverse bend is induced,
it may cause the rope to become “cranky” and, consequently, more difficult to work with.
There are several methods, which can be used to uncoil rope from a spool or coil. The particular
situation, or application, will determine the method used.
One method begins by placing the coil or spool on a vertical unreeling stand. The stand consists
of a base with a fixed vertical shaft. On this shaft there is a “swift” or rotating sleeve” consisting of
a plate with inclined pins. This is positioned so that the coil or spool may be placed over them
allowing the coil or spool to rotate in the horizontal axis. The whole swift and coil then rotate as
the rope is pulled off without adding twist or the possibility of kinks. This method is particularly
effective when the rope is to be wound on a vertical drum.
The most common, and the easiest uncoiling method is merely to hold one end of the rope while
rolling the coil along the ground like a hoop.

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Engineering Data

NOTE: Avoid unreeling and uncoiling methods that are likely to provide kinks. Such
IMPROPER procedures should be strenuously avoided in order to prevent the
occurrence of loops. These loops, when pulled taut, will inevitably result in kinks. No
matter how a kink develops, it will damage strands and wires, resulting in a kinked
section that must be cut out. Proper and careful handling will keep the wire rope free
from kinks.
Figure 8-6 Improper Methods for Uncoiling Wire Rope

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Engineering Data
8.14.4 Seizing Wire Rope

While there are numerous ways to cut wire rope, in every case, certain precautions must be
observed. It is critical that before any cut is made proper seizings must be applied on both sides
of the location where the cut is to be made. Carelessly or inadequately seized, ends may become
distorted and flattened. This will also prevent the strands at the ends from loosening or fraying.
Subsequently, when the rope is installed there may be an uneven load distribution to the strands.
This will create a condition that will significantly shorten the life of the rope.
There are two widely accepted methods of applying a seizing, which are illustrated. The seizing
material itself should be soft, or an annealed wire or strand. Seizing wire diameter, and the length
of the seize, will be dependant on the diameter of the wire rope. But the length of the seize
should never be less than the diameter of the rope in use. Normally, for a preformed rope, one
seize on each side of the cut is sufficient. For ropes that are not preformed, a minimum of two
seizings on each side is recommended; and these should be spaced six rope diameters apart.
For larger wire ropes: lay one end of the seizing wire in the groove between two strands; wrap
the other end tightly in a close helix over a position of the groove using a seizing iron (a round bar
1/2" to 5/8" dia. x 18" long) as shown. Both ends of the seizing wire should be twisted together
tightly, and the completed seize should appear as shown. Seizing widths should not be less than
the rope diameter.
The procedure illustrated below is the second of the two accepted methods for placing seizing on
wire rope. This method is normally used on smaller ropes.

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8.14.5 End Preparations/Terminations

There may arise a need for special end preparations in order to compensate for certain
applications such as tight drum openings, or other complicated reeving systems. When these
situations are encountered a number of basic designs (and combinations) are available to
choose from. Whenever possible end preparations should be removed after final installation.
“Beckets” are what is referred to when we discuss a termination utilized to pull the operating rope
into place. The rope end must be fastened to a mechanism so that force and motion are
transferred efficiently without distortion of the wire rope. End terminations become items of great
importance for transferring these forces. Each basic type of termination has its own individual
characteristic. Hence, one type will usually fit the needs of a given installation better than others.
It should be noted that not all end terminations will develop the full strength of the wire rope being
utilized. To lessen the possibility of error, the wire rope industry has determined terminal
efficiencies for various types of end terminations. Four commonly used beckets are illustrated.

June 2012
Engineering Data
8.14.6 Wire Rope Clips
Wire rope clips are widely used for making end terminations. Clips are available in two basic
designs; the U-BOLT and FIST GRIP. The efficiency of both types is approximately the same.

NOTE: When using U-BOLT clips, extreme care must be exercised to make certain that they
are positioned correctly. The important factor is that the U-BOLT clip be applied in order
that the “U” section is in contact with the dead end of the rope. Also, the tightening and
re-tightening of the nuts must be accomplished as required.
8.14.6.1 Wire Rope Clip Application

The following is the recommended method of applying U-Bolt clips in order to get the maximum
holding power from the installation:
1. Turn back the specified amount of rope from the thimble. Apply the first clip a distance of
one base width from the dead end of the wire rope (U-bolt over the dead end - live end rests
in the clip saddle). Tighten nuts diametrically and evenly to recommended torque.
2. Apply the next clip as near the loop as possible. Snug down the nuts, but do not tighten.
3. Space additional clips (if required) equally between the first two. Turn on nuts evenly to take
up rope slack. Continue to tighten all nuts evenly (on all clips) until recommended torque is
reached.
NOTE: Apply the initial load to the strand of rope, and then re-tighten nuts to the recommended
torque. This is accomplished because the rope will stretch and be reduced in diameter
when loads are applied. Inspect periodically and tighten to recommended torque each
time.

June 2012
Engineering Data
A termination complying with the above instructions, using the number of clips shown, has
approximately an 80% efficiency rating. This rating is based upon the nominal strength of the
wire rope. If a pulley is used in place of a thimble where the rope turns back, add one additional
clip.
The number of clips shown is based upon using right regular or lang lay wire rope, 6 x 19 class or
6 x 37 class, fiber core or IWRC, IPS or EIP. If Seale construction is to be used for sizes 1 inch
and larger, or similar large outer wire type construction in the 6 x 19 class, add one additional
clip.
The number of clips shown also applies to right regular lay wire rope, 8 x 19 class, fiber core,
IPS, sizes 1-1/2 inch and smaller; and right regular lay wire rope, 18 x 7 class, fiber core, IPS or
EIP, size 1-3/4 inch and smaller.
For other classes of wire rope not mentioned, it may be necessary to add additional clips to the
number shown. If a greater number of clips than shown are used, the amount of rope turn-back
should be increased proportionately. THE ABOVE IS BASED ON THE USE OF CLIPS ON A
NEW ROPE.
Failure to make a termination in accordance with the aforementioned instructions, or

failure to periodically check and re-tighten to recommended torque, will cause a reduction
in the efficiency rating.
The correct spacing and number of clips is shown above.

June 2012
Engineering Data
8.14.6.2 Wedge Sockets
One of the more popular field end attachments for wire rope is the wedge socket. Attachment
and the dismantling of this device is both easy and simple.
1. Inspect the wedge and socket; remove all rough edges/ burrs that might damage the rope.

2. Welded ends of the rope should be cut off prior to assembly. This will allow the rope strands
to distort slightly as they bend sharply around the wedge. If the welded end were not
removed the minimal sliding of the strands would be restricted and evidenced further up the
rope. This may result in the development of high strands, wavy rope and uneven loading.
3. Place the socket in an upright position and bring the rope around it in a large, easy to
handle loop. Care must be taken to make certain that the live-loaded-side of the rope is in
line with the ears.
4. The dead end of the rope should extend from the socket for a distance of six to nine times
the rope diameter. The wedge is now placed in the socket.
5. Secure the socket and carefully apply a gradually increasing load to the live side of the rope
in order to pull the wedge into position. Only tension sufficiently to hold the pieces in place.
6. After checking alignment increase the load GRADUALLY until the wedge is properly seated.
Avoid sudden shock loads.
This is the recommended procedure. If variations are made to suit special conditions, they should
be carefully evaluated beforehand.

June 2012
Engineering Data
8.14.7 Inspection of Sheaves and Drums

Machines should receive periodic inspections, and the results concerning their over-all condition
recorded. Such inspections usually include the drum, sheaves, and any other parts that may
come into contact with the wire rope. These are considered high wear items. As an additional
precaution, any rope-related working parts, particularly those in the areas described below,
should be re-inspected prior to the installation of a new wire rope.
Figure 8-7 Examples of Sheave Groove Conditions
These cross-sections are illustrating three sheave-groove contact areas. “A” is correct, “B” is too
tight, and “C” is too loose.
The very first item to be checked when examining sheaves and drums is the condition of the
grooves. To accurately check the size, contour and amount of wear, a groove gauge is used. As
shown in the figure, the gauge should contact the groove for about 150 degrees of arc when in
optimal condition.
There are two types of groove gauges in general use. The two differ by their respective
percentage over nominal.

June 2012
Engineering Data

Figure 8-8 Groove Gauge for New or Re-Worked Sheaves
For new or re-machined grooves, the groove gauge is nominal plus the full oversize percentage.
The gauge carried by most wire rope representatives today is used for worn grooves and is made
nominal plus 1/2 the oversize percentage.
This latter gauge is intended to act as a sort of “no-go” gauge. Any sheave with a groove smaller
than this must be re-grooved or, in all likelihood, the existing rope will be damaged.
Figure 8-9 Inspecting for Worn Sheave
These sheave-groove cross-sections represent three wire rope seating conditions: “A” - a new
rope in a new groove; “B” - a new rope in a worn groove; and “C” - a worn rope in a worn groove.

June 2012
Engineering Data
8.14.8 Breaking In a New Wire Rope

A new wire rope requires careful installation. Adherence to the previously covered procedures is
highly recommended. After the rope has been installed, and the ends secured in the applicable
manner, the mechanisms should be started carefully and then permitted to run through a
complete cycle of operation at greatly reduced speed. During this trial operation, a very close
watch should be kept on all working parts such as sheaves, drums and rollers to ensure the rope
runs freely. Be vigilant to ensure there are no obstructions as it makes its way through the
system. If no problems are apparent, the next step should include several run-throughs of the
normal operational cycle under light load conditions at a reduced speed. This procedure allows
the component parts of the new rope to gradually adjust to the actual operating conditions.
8.14.9 Inspection Data

It is essential to maintain a well-planned program of periodic inspection. Frequently, there are
statutory and/or regulatory agencies that incur additional requirements that must be adhered to.
Refer to the suggested procedures that follow.
Abrasion - Bending and Crushing represent the ABC’s of wire rope abuse. It is the primary goal
of a good inspection practice to uncover such conditions early enough that corrections may be
made, or ropes replaced safely with minimum effort. When any sudden degradation indicates a
loss of original rope strength, a timely decision is required as to allowing the rope to remain in
service. Such a decision can only be made by an experienced inspector. His/her determination
should be based on:
1. Details of the equipment’s operation.
2. Frequency of inspection.
3. Maintenance history.
4. Consequences of failure.
5. Historical records of similar equipment.
To ensure sufficient information can be obtained, the following pages contain guidelines that
should be adhered to.

June 2012
Engineering Data
8.14.10 Guideline to Inspections and Reports
(Equipment, Wire Rope and Wire Rope Slings)
1. Maintain all inspection records and reports for the length of time deemed appropriate.
2. Prior to daily use, the following procedure should be followed.

a. Check all equipment functions.
b. Lower load blocks and check hooks for deformation or cracks.
c. During lowering procedure and the following raising cycle, observe the rope and the
reeving. Particular notice should be paid to kinking, twisting or other deformities. Drum
winding conditions should also be noted.
d. Check wire rope and slings for visual signs of any unsafe condition, including broken
wires, excessive wear, kinking or twisting, and severe corrosion. Particular attention
should be given to any new damage during operation.
3. Periodic inspections consistent with applicable standards are recommended with a signed
report by an authorized and competent inspector. These Periodic Reports should include
inspection of the following:
a. All functional operating mechanisms for excessive wear of components, brake system
parts and lubrication.
b. Limit switches.
c. Crane hooks for excessive throat opening or twisting, along with a visual for cracks.
d. Wire rope and reeving for conditions causing possible removal.
e. Wire rope slings for excessive wear, broken wires, kinking, twisting and mechanical
abuse.
f. All end connections such as hooks, shackles, turnbuckles, plate clamps, sockets, etc.
for excessive wear, and distortion.
4. At least one annual inspection with signed report must be made for the following:
a. Crane hook for cracks.
b. Hoist drum for wear or cracks.
c. Structural members for cracks, corrosion and distortion.
d. For loose structural connections such as bolts, rivets, and weldments.

June 2012
Engineering Data
8.14.10.1 Wire Rope Inspection Criteria

The following is a fairly comprehensive listing of critical inspection factors. It is not, however,
presented as a substitute for an experienced inspector. It is rather a user’s guide to the accepted
standards by which ropes must be judged.
8.14.10.1.1 Reduction in Rope Diameter

Any marked reduction in rope diameter indicates degradation. Such reduction may be attributed
to:
• Excessive external abrasion.
• Internal or external corrosion.
• Loosening or tightening of rope lay.
• Inner wire breakage.
• Ironing or milking of strands.
In the past, the determination on the continued service of a rope was largely dependent on the
rope’s diameter at the time of inspection. Recently this practice has undergone significant
modification.
Previously, a decrease in the rope’s diameter was compared with published standards of
minimum diameters. The amount of change in diameter is, of course, useful in assessing a
rope’s condition. But, comparing this figure with a fixed set of values can be misleading. These
long-accepted minimums are not, in themselves, of any serious significance since they do not
take into account such factors as:
• Variations in compressibility between IWRC and Fiber Core.
• Differences in the amount of reduction in diameter from abrasive wear, or from core
compression, or a combination of both.
• The actual original diameter of the rope rather than its nominal value.
As a matter of fact, all ropes will show a significant reduction in diameter when a load is applied.
Therefore, a rope manufactured close to its nominal size may, when it is subjected to loading, be
reduced to a smaller diameter that stipulated in the minimum diameter table. Yet, under these
circumstances, the rope would be declared unsafe although it may, in actuality, be safe.
As an example of the possible error at the other extreme, we can take the case of a rope
manufactured near the upper limits of allowable size. If the diameter has reached a reduction to
nominal or slightly below that, the tables would show this rope to be safe. But it should, perhaps,
be removed.
Evaluations of the rope diameter are first predicated on a comparison of the original diameter
when NEW and subjected to a KNOWN load with the current reading under comparable
circumstances. Periodically, throughout the life of the rope, the actual diameter should be
recorded while the rope is under equivalent loading and in the same operation section. This
procedure, if followed carefully, reveals a common rope characteristic: after an initial reduction,
the diameter soon stabilizes. Later, there will be a continuous, albeit small, decrease in diameter
throughout its life.

June 2012
Engineering Data
Core deterioration, when it occurs, is revealed by a more rapid reduction in diameter and is time
for removal.
Deciding whether or not a rope is safe is not always a simple matter. A number of different but
interrelated conditions must be evaluated. It would be dangerously unwise for an inspector to
declare a rope safe for continued service simply because its diameter had not reached the
minimum arbitrarily established in a table, while at the same time, other observations lead to an

opposite conclusion.
Because criteria for removal are varied, and because diameter in itself, is a vague criterion, the
table of minimum diameters has been deliberately omitted from this publication.
8.14.10.1.2 Rope Stretch

All ropes will stretch when loads are initially applied.
Figure 8-10 Wire Rope Stretch vs. Rope Life
As a rope degrades from wear, fatigue, etc., (excluding accidental damage), continued
application of a load of constant magnitude will produce varying amounts of rope stretch. A
“stretch” curve plotted for stretch vs. time displays three distinct phases:
• PHASE 1. - Initial stretch, during the early (beginning) period of rope service, caused by the
rope adjustments to operating conditions (constructional stretch).
• PHASE 2. - Following break-in, there is a long period-the greatest part of the rope’s service
life-during which a slight increase in stretch will take place over an extended time. This
results from normal wear, fatigue, etc. On the plotted curve stretch vs. time-this portion would
almost be a horizontal straight line inclined slightly upward from its initial level.
• PHASE 3. - Thereafter, the stretch occurs at a quicker rate. This means that the rope has
reached the point of rapid degradation, a result of prolonged subjection to abrasive wear,
fatigue, etc. This second upturn of the curve is a warning indicating that the rope should soon
be removed.

June 2012
Engineering Data
8.14.10.1.3 Abrasion
Rope abrades when it moves through an abrasive medium or over drums and sheaves. Most
standards require that rope is to be removed if the outer wire wear exceeds 1/3 of the original
outer wire diameter. This is not easy to determine and discovery relies upon the experience
gained by the inspector in measuring wire diameters of discarded ropes.
8.14.10.1.4 Corrosion
Corrosion, while difficult to evaluate, is a more serious cause of degradation than abrasion.
Usually, it signifies a lack of lubrication. Corrosion will often occur internally before there is any
visible external evidence on the rope surface. Pitting of wires is a cause for immediate rope
removal. Not only does it attack the metal wires, but also prevents the rope’s component parts
from moving smoothly as it is flexed. Usually, a slight discoloration because of rust merely
indicates a need for lubrication.
Severe rusting, on the other hand, leads to premature fatigue failures in the wires necessitating
the rope’s immediate removal from service. When a rope shows more than one wire failure
adjacent to a terminal fitting, it should be removed immediately. To retard corrosive deterioration,
the rope should be kept well lubricated. In situations where extreme corrosive action can occur, it
may be necessary to use galvanized wire rope.
8.14.10.1.5 Kinks
Kinks are permanent distortions caused by loops drawn too tightly. Ropes with kinks must be
removed from service.
8.14.10.1.6 Bird Caging

Bird caging results from torsional imbalance that comes about due to mistreatment such as
sudden stops, rope being pulled through excessively tight sheaves, or wound on too small a
drum for a given rope diameter. This is cause for rope replacement unless the affected section
can be removed.
8.14.10.1.7 Localized Conditions

Careful attention must be paid to wear at the equalizing sheaves. During normal operation this
wear is not visible. Excessive vibration, or whip can cause abrasion and/or fatigue. Drum cross-
over and flange point areas must be carefully evaluated. All end fittings, to include splices,
should be examined for worn or broken wires, loose or damaged strands, cracked fittings and
worn or distorted thimbles and tucks of strands.
8.14.10.1.8 Heat Damage

After a fire, or exposure to elevated temperatures, there may be discoloration, or an apparent
loss of internal lubrication. Fiber core ropes are particularly vulnerable. Under these
circumstances the rope should be replaced.

June 2012
Engineering Data
8.14.10.1.9 Protruding Core
If, for any cause, the rope core protrudes from an opening between the strands, the rope is unfit
for service and should be removed.
8.14.10.1.10 Damaged End Attachments

Cracked, bent, or broken end fittings must be eliminated. The cause should be sought out and
corrected. In the case of bent hooks, the throat openings must be measured at the narrowest
point and should not exceed 15% over normal. Twisting to be no greater than 10 degrees.
8.14.10.1.11 Peening
Continuous pounding is one of the causing of peening. The rope can strike against an object,
such as some structural part of the machine, or it beats against a roller, or itself. Often this can be
avoided by placing protectors between the rope and the object it is striking. Another common
cause of peening is continuous working under high loads over a sheave or drum. Where peening
action cannot be controlled it is necessary to have more frequent inspections and be prepared for
premature rope replacement.
8.14.10.1.12 Scrubbing
Scrubbing refers to the displacement of wires and strands as a result of rubbing against itself or
another object. This, in turn, causes wear and displacement of wires and strands along one side
of the rope. Corrective measures should be taken as soon as this condition is observed.
8.14.10.1.13 Fatigue Fracture

Wires that break with square ends and show little surface wear have usually failed as a result of
fatigue. Such fractures can occur on the crown of the strands, or in the valleys between the
strands where adjacent strand contact exists. In almost all cases, these failures are related to
bending stresses or vibration.
If diameter of the sheaves, rollers or drum cannot be increased, a more flexible rope should be
used. But, if the rope in use is already of maximum flexibility, the only remaining course that will
help prolong its service life is to move the rope through the system by cutting off the dead end.
By moving the rope through the system, the fatigued sections are moved to less fatiguing areas
of the reeving.
8.14.10.1.14 Broken Wires

The number of broken wires on the outside of a wire rope are an index of 1) its general condition,
and 2) whether or not it must be considered for replacement. Frequent inspection will help
determine the elapsed time between breaks.
On occasion, a single wire will break shortly after installation. However, if no other wires break at
that time, there is no need for concern. On the other hand, should more wires break, the cause
should be immediately investigated.

June 2012
Engineering Data
On any application, valley breaks (where the wire fractures between strands) should be given
serious attention. When two or more such fractures are found, the rope should be replaced
immediately.
NOTE: No valley breaks are permitted in elevator ropes.
Once broken wires appear within a rope operating under normal conditions many more will show
up within a relatively short period. Attempting to squeeze the last measure of service from a rope
that is beyond the allowable number of broken wires will create an intolerably hazardous
situation.
A wire broken under a tensile load that has exceeded its strength is recognized by the “cup and
cone” configuration at the fracture point (Rope A). The necking down of the wire at this point
shows that failure occurred while the wire retained its ductility. Shear-tensile fracture (Rope B)
occurs in wire subjected to a combination of transverse and axial loads. Fatigue breaks are
usually characterized by squared-off ends perpendicular to the wire either straight across or Z-
shaped (Ropes C and D).
Figure 8-11 Examples of Broken Wires
8.14.10.1.15 Electric Arc

Rope that has either been in contact with a live power line or been used as “ground” in an electric
welding circuit, will have wires that are fused, discolored and/or annealed, and must be removed.

June 2012
Engineering Data
BI010314 Seals
8.15 Seals
Oil and grease seals are critical to machine availability. Careless storage, handling, removal and
installation can contribute to reduced service life of machine components and higher cost of
operation.

Seals come in all sizes, shapes and materials. Wherever possible, the manufacturer has
specified the use of the most common solid molded element type seals for use on their
machines.
All types of oil and grease seals have a limited shelf life. Store seals in a cool, dry location
protected from direct sunlight. Keep in sealed containers or packaging until ready to use. Seals
keep lubricant clean and contained in their respective housings, bearings or passageways.
Always handle seals carefully to prevent exposure to nicks, bends or pinching. Do not wash them
in solvents as some solvents may destroy properties of the seal.
8.15.1 Seal Installation

Solid molded seals are installed at time of manufacture with interference fit between seal and
bore. This method of installation creates an oil tight fit. When partial disassembly of a machine
component involves removal of solid molded seal before reassembly inspect it carefully for cuts,
nicks or cracking. Replace with a split seal if complete disassembly is inconvenient or with a new
solid molded seal. Split seals, especially those made with interference fit at butt, also install with
compression at the joint. Split seals used as substitutes for solid molded seals should be
replaced at next major component overhaul.
Do not cut a solid seal and reuse for a split seal.
Check shaft for scratches, burrs or surface roughness that may cut or score the lip of seal. Be
aware of sharp threads keyways or splines over which the seal must travel. Protect seal lip by
covering these interferences with tape.
Inspect the bore area for surface roughness, dirt or burrs. Remove and clean as required. The
bore and shaft need 0.0625 in. (1.588 mm) chamfer to accommodate a leak free installation. If
shaft or bore do not have chamfer, carefully provide one by trimming inside flange of seal.
Determine the correct direction for lip installation and start the seal into the cavity by finger
pressure, then tap evenly all around until seated or flush with the housing face. (Tap only on
outer edge of seal with hammer on wood block.)
A double seal, installed back to back can be used to retain grease or oil plus be more effective in
preventing egress of contaminants.
Follow this installation procedure for split seals:
1. Remove garter spring and separate at the hook and eye.

June 2012
Engineering Data
Seals BI010314
2. Open the seal, ends sideways, for installation on shaft as shown by moving the butt ends
along the axis of the seal.
3. Lubricate spring and install around shaft. Connect ends and insert spring in lip groove with
spring ends 90° away from butt joint.
Figure 8-12 Split Seal Installation
Do not trim or cut ends of split seals or pull ends apart. This will destroy seal.
Gearcase seals used for all oil tight gearcase assemblies require surface preparation on one side
of case flanges with a 1/100 inch thick Form-a-Gasket #3 (Permatex Co.) coating. If using a
manila paper gasket always replace with a new one, never reuse. Apply Form-a-Gasket #3 to
both sides of the paper gasket. Tighten gearcase cover bolts until seal material “squeezes out” at
joint.
When surface finishes range up to 250 micro-inches, a compression type gasket seal is
recommended. This material (VELLUMOID) available in standard thickness inches (mm) 1/64
(.397), 1/32 (.794), 1/16 (.063), and 1/8 (.125) should also be installed with Permatex applied to
both sides.

June 2012
Engineering Data
BI010314 Seals
8.15.2 Gearcase Sealing
Use the information in the following image to properly seal gearcase halves and /or covers.

NOTE: Before applying any sealants or gaskets, clean all mating surfaces of all dirt, rust and
scale.

June 2012
Engineering Data
Seals BI010314

June 2012
BI010315

9 Schematics
Schematics
9.1 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.2 Side View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.3 Deck Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 OGL System A & B Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.5 Grease System C Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.6 HVAC Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.7 Air Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

June 2012
Schematics
BI010315 Schematics
Schematics
9.1 Schematics
The following pages contain the side view and deck plans of the machine as well as a series of
block diagrams depicting the schematic layout of the automatic lubrication and air systems.

June 2012
Schematics
BI010315 Side View
9.2 Side View

June 2012
Schematics
BI010315 Deck Plan
9.3 Deck Plan

C
L Rotation Lube Room
Jib Crane
Welder Receptacle
Boarding
Ladder
Front of
Machine
Auto Lube
Drive Power Pumps and
Transformer No.2 Remote Hoist Reservoirs
Air Cabinet
Auxiliary Compressor Mine Signal
Transformer
Swing
A-Frame Blower Fire
Lugs, Rear Protection
Panel Lubrication Remote
Room Auto Lube
Swing Swing Cabinet
Brake Motor, Left
Hoist Planetary
Gearcase Boom Foot Lugs
Remote Bearing
Temp. Cabinet Hoist Crowd Brake
Hoist Machinery Crowd Blower
Power Skid Coupling
Control Shaft Crowd
Center Machinery
Cabinet Crowd
Hoist Motor Pintle
Motor
C
L Machine
High Hoist
Voltage Drum
Hoist Access Shaft
Crowd Drum
Blower
A-Frame Lugs, Front
Remote Swing Lighting Transformer

Crowd/Swing Blower Swing LTT1, LTT2
Hoist Cabinet Brake
Thermostats Brake Dipper Trip Motor
High Swing Utility

Constant Remote Drum Control Panel
Voltage Emergency Motor, Right Voltage Room
Cabinet Stop Transformer Dipper Trip
Motor Control Center Transformer
(MCC)
Drive Power Auxiliary Seat
Mine Signal Switch Transformer No.1
Lighting Transformer
LTT3
Welder Operator’s Seat
Receptacle
Toilet Room
Horn, Backup Alarm Operator’s Cab

Boarding Stairs, Right
Outline
C
L Rotation
Power Step
SN: 141450

June 2012
Schematics
BI010315 OGL System A & B Schematic
9.4 OGL System A & B Schematic

June 2012
Schematics
BI010315 Grease System C Schematic
9.5 Grease System C Schematic

June 2012
Schematics
BI010315 HVAC Schematic
9.6 HVAC Schematic
82002763_sch

June 2012
Schematics
BI010315 Air Schematic
9.7 Air Schematic

June 2012

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LatchFree™ and HydraCrowd™ © 2012 Bucyrus International, Inc.

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY May 31, 2012

SECTION 3 - PREVENTIVE MAINTENANCE

SECTION 4 - SERVICE PROCEDURES

SECTION 5 - BRAKES AND COUPLINGS

SECTION 6 - COMPRESSED AIR SYSTEM

SECTION 7 - AIR FILTRATION

SECTION 8 - ENGINEERING DATA

SM141450-EN Electric Rope Shovel TOC – i

TOC – ii Electric Rope Shovel SM141450-EN

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 21, 2012

S.1 Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-iii

SM141450-EN Electric Rope Shovel S–i

S.2.5.7 Cameras. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xvii

Figure S-11 Left Side Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-xix

S – ii Electric Rope Shovel SM141450-EN

S.1 Safety Symbols

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 21, 2012

SM141450-EN Electric Rope Shovel S – iii

Safety must always be paramount!

S – iv Electric Rope Shovel SM141450-EN

S.2 Safety Precautions

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 21, 2012

Do not attempt mechanical or electrical maintenance on this machine without a full

SM141450-EN Electric Rope Shovel S–v

S.2.1 General Precautions

• Keep hands, feet and clothing away from rotating parts.

S – vi Electric Rope Shovel SM141450-EN

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 21, 2012

SM141450-EN Electric Rope Shovel S – vii

S – viii Electric Rope Shovel SM141450-EN

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 21, 2012

S.2.4 Fire Prevention

SM141450-EN Electric Rope Shovel S – ix

Figure S-1 Fire Extinguisher Locations

S–x Electric Rope Shovel SM141450-EN

S.2.5.1 Emergency Lighting

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 21, 2012

Figure S-2 Emergency Lighting Locations

SM141450-EN Electric Rope Shovel S – xi

S.2.5.2 Mine Signal

Figure S-3 Mine Signal Switch

Figure S-4 Mine Signal Horn Location

S – xii Electric Rope Shovel SM141450-EN

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 21, 2012

SM141450-EN Electric Rope Shovel S – xiii

S.2.5.4 Propel Warning Lights

Figure S-6 Right Side Warning Light

S – xiv Electric Rope Shovel SM141450-EN

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 21, 2012

SM141450-EN Electric Rope Shovel S – xv

S.2.5.6 Emergency Stop Buttons

Figure S-8 Emergency Stop Button Locations

S – xvi Electric Rope Shovel SM141450-EN

PRELIMINARY SAMPLE USE FOR REFERENCE ONLY June 21, 2012

SM141450-EN Electric Rope Shovel S – xvii

S.2.5.8 Boarding Stairs

Figure S-10 Right Side Boarding Stair