SUBJECT: Electric Shovel Motor Lubrication

BULLETIN: SB-ES-112
Recommendations
MODELS AFFECTED: All VERSION: 01
APPLICABLE TO ASSEMBLIES: DATE: 12 September, 2008
PRODUCT CODE: 1075,
SPECIAL NOTE:
1080, 1196, 1141

1.0 Introduction

Service Bulletin SB-ES-112, Version 00 was released in 06/98. This bulletin provides a procedure for
lubricating the bearings on all main motion AC and DC motors manufactured by P&H for mining
shovels. This Version 01 will update this Service Bulletin.

2.0 Purpose

The purpose of this Service Bulletin is to provide information on lubricating the main motion motors
on P&H mining shovels.

3.0 Discussion

Motors for most P&H Mining Shovels are equipped with a combination of a spherical roller bearing
on the drive end and a cylindrical roller bearing on the opposite drive end. Exceptions to this are
motors that have a ball bearing and a cylindrical roller bearing on the opposite end from the ball
bearing. Shaft end play is controlled by the mounted bearing internal clearance plus the axial space
between the outer race and the bearing caps.

Because of the severe shock encountered in mining service, extra heavy press fits between inner
races and shafts are used. In addition, all inner races of the locked bearings are secured by
locknuts.

3.1 General Lubrication

Bearings of all motors are lubricated with grease prior to leaving the factory or P&H rebuild
facilities.

Motors are designed to have specific lubricant inlet and outlet (drain) fittings and the grease can
only be properly applied in one way. For this reason, the inlets are fitted with a grease fitting and
the outlet is equipped with a pipe plug or a relief fitting.

Never attempt to pump grease into the bearings through the outlet.

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Very few grease inlets and outlets on motor bearings have the grease fitting or the plug located
right at the end head of the motor. For reasons of accessibility, most inlet and outlet points are
fitted with a short length of pipe and the grease fitting or the plug is installed at the end of the
pipe. These short pipes are filled with grease at the factory or rebuild facility. However, in some
cases, such as with swing motors, a length of hose is substituted for the pipe and these hoses
might not be filled with grease.

Ensure that flexible hose extensions to the grease inlet are filled with a compatible grease
before putting the machine into operation. Also ensure that all grease lines are attached
correctly (see section 3.5). Figure 1 shows a swing motor lubrication line that was found
disconnected while doing a machine inspection.

Figure 1: Disconnected Motor Lubrication Line

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3.2 Lubrication Interval and Amount

Each motor is equipped with a metal tag similar to the one shown in Figure 2. The motor tag
contains general information, refer to this Service Bulletin for specific information as to quantity of
grease and interval. This Service Bulletin will supercede all information in Maintenance Manuals
until such time as they are updated to the latest information contained within this Bulletin.

Figure 2: Existing Motor Lubrication Tag

Generally, adding a little grease at more frequent intervals is preferred to a larger amount of grease
at infrequent intervals. For this reason, it is the recommendation of P&H Mining Equipment that
main motion electric motors be lubricated every 500 hours of machine operation.

Do not use the individual motion hour meters to determine lubrication intervals. Machine
operation hours should be used for all main motion electric motors to indicate the interval
that they should be lubricated. Example if the shovel has 500 hours of machine operation
and 50 propel hours, the propel motors should be lubricated.

The amount of grease applied to each bearing on hoist, swing, and propel motors should be ½
ounce at each 500 hour interval. The bearings of the crowd motor should receive 1 ounce of grease
at each 500 hour interval. More grease is recommended for the crowd motor due to the loading
that the crowd drive belt places on the motor bearings.

The amount of grease produced by a particular grease gun should be verified to make sure
that the amount is measured as the motor is being lubricated. Verify the output of the
grease gun being used and be consistent when lubricating the motors. As an example: a
common, cartridge-type grease gun was tested and found to expel approximately 0.05 cu in
of grease per stroke. Whether the “oz.” (ounce) unit of measure is considered to be volume

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or weight, the amount of grease expelled by a “standard” grease gun in 10 strokes was
found to be about equal to 1/2 oz. This may not be consistent for all grease guns and
should be verified to ensure the motor receives the correct amount of grease. Add grease
slowly until either the motor receives the correct measured amount of grease or grease is
expelled from the drain line, whichever happens first.

3.3 Lubrication Procedures

Failure to exercise care while working around rotating equipment can result in injury
or death. Shutdown the shovel and perform lockout/tagout before accessing the
motors for any maintenance function. Establish positive communications with the
operator’s station and notify all personnel working inside and outside of the machine
while work is being performed. Ensure that guards are in place when finished.

Prior to greasing each bearing, wipe the grease fittings using a clean dry cloth and thoroughly clean
the grease gun fitting. Remove the drain plug and remove any hardened grease. Remove hardened
grease inside grease tubes with a long drill bit or a suitable cleaning device if necessary. Choose
something that will not break off inside the tube while cleaning.

The grease should be added as soon as possible after the motors were in operation, so that the
motors are still warm. Pump the grease into the bearing slowly and gradually with a hand operated
grease gun (see section 3.2 for the amount of grease and the frequency). Leave the outlet (drain)
holes open and run the motor to relieve pressure and until no more grease is expelled (20 minutes
or longer). Then replace the drain plugs.

Over greasing the bearings in vertical applications may cause premature bearing
failure and physical injury if grease should drip on the commutator and flashover
occur (see Figure 3). To avoid over-greasing when re-packing bearings, fill the cavity
1/3 to 1/2 full.

While it is important not to over-grease any bearing, it is especially important that the top bearing
on vertical applications not be over-greased. Over-greasing the bearings can cause bearing failure.

In addition to causing premature bearing failure, excess grease can drip onto the commutator and
adjacent parts and cause a flashover. Avoid contaminating the commutator and windings with
grease during assembly and maintenance.

When re-packing the bearings, only fill the cavity about 1/3 to 1/2 full. Do not pack the cavity
completely full.

Make no attempt to ‘purge’ motor bearings by pumping large volumes of grease into the bearings.
There are labyrinth passages within the motor end heads that will pass grease internally without
forcing it out of the drain. Purging will result in over greasing the bearing which will lead to failure
and can lead to flashing as noted in the CAUTION above.

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LEGEND 03. Bearing

01. Bearing 04. Drain Plug
02. Drain Plug 05. Grease Fitting

Figure 3: Vertical Motor Bearing Lubrication

3.4 Grease Selection

The grease must be compatible with that used at manufacture. The grease required is an extreme
pressure (EP) grease with an NLGI specification of 0, 1, or 2 conforming to P&H spec 472A, 472B,
or 472C, respectively. Ensure that the correct NLGI grade of grease is used for the ambient
temperature. Refer to Service Bulletin 84 for P&H lube specifications.

Under no circumstances should greases containing molybdenum disulfide (MOS2) or graphite be

used in electric motor applications because of the electrical conductivity of these solids.
Contamination of the commutator and adjacent parts with conductive greases will promote
flashovers.

If the wrong grease is used or if the grease is suspected of being contaminated, both the bearing
and the bearing cavity should be completely cleaned of all greases using a suitable solvent.

3.5 Installing a Replacement Motor

Although all the bearings in the motors on new machines are packed with grease at the factory or
rebuild center, it is still necessary to check all of the flexible hoses connected to the inlets during
the machine build or Encore unit installation, especially on the swing (see Figure 1).

The supply hose must be disconnected from the fitting on the end head of the motor. Grease must
be pumped through the grease fitting until the lube comes out of the end of the hose. Then

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reconnect the hose. This procedure is necessary because there is not a sure way to tell when the
hose has been filled and to continue to pump grease into the fitting while waiting for it to come out
of the drain will only result in over greasing.

Follow the lubrication procedures outlined in paragraph 3.3 above. Best practices suggest that all of
the main motion motors should be set up on the machine build site so that they can be run at no
load for a few hours. A welding machine can be used to do this.

Consideration must be given to the NLGI grade of grease to use at the machine build and the
builder must be cognizant of the fact that the standard grade of lubricant used in the factory and
most repair facilities is NLGI 2. NLGI 2 might be totally inappropriate for machines in cold climates.
At the build site it might be necessary to move the motors indoors and to perform the no load runs
and lubrication procedure in a warmer environment. Follow instructions on all tags or decals
attached to the motor.

3.6 Lubrication After Extended Storage

The grease used as a bearing lubricant will gradually deteriorate when the motor is idle for
extended periods. The bearing grease could become contaminated during storage in dirty
environments but the separation of the oil from the soap matrix of the grease is the most likely
form of deterioration. The oil separation leaves only the soap matrix which is not, in itself, an
effective lubricant. Therefore, if the motor has been stored in a protected area for a period of 8
months or more, the old grease must be removed from the bearings and capsules and the bearings
relubricated with fresh, clean grease meeting the applicable specification described in 3.4 above.

Relubrication is also recommended following storage outdoors or in a contaminated environment

for a period of 5 months or longer.

P&H Mining Equipment recommends that motors never be stored outdoors.

Bearings are greased completely at the factory. If the bearing and capsule has been cleaned out,
each bearing should be packed between 1/2 and 2/3 full of grease upon installation. A layer of
grease should be added to both inner and outer bearing capsules by the labyrinth seals to seal out
dirt and grime during shipping and storage. Do not over grease. Operate the motor at a lower rpm
and light loads for a few minutes after installation.

3.7 Lubrication of Remanufactured Motors

Follow the procedures outlined in section 3.3 above when installing ENCORE or rebuilt motors.

4.0 Conclusion

Lubrication of P&H main motion electric motors should follow P&H’s recommendations.

5.0 Actions

Follow the recommendations in this Service Bulletin regarding lubrication of all P&H main motion
electric motors.

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