Bucyrus 191-M Mining Shovel Technical Manual BI624248
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Bucyrus 191-M Mining Shovel Technical Manual BI624248 - Image 5

Bucyrus 191-M Mining Shovel Technical Manual BI624248

$30.00

  • Type Of Manual: Technical Manual
  • Manual ID: BI624248
  • Number of Pages: 435
  • Size: 34.4MB
  • Format: PDF
Category:

Product details

  • Model List:

    • 191-M Mining Shovel
  • 1. Maint Man.pdf
  • 1.1. INTRODUCTION
  • 1.1.1. GENERAL INFORMATION
  • 1.1.2. SAFETY PRECAUTIONS
  • 1.1.3. TRAINING
  • 1.1.4. WARRANTY
  • 1.2. MACHINE SPECIFICATION
  • 1.2.1. M NOMENCLATURE
  • 1.2.2. MODEL 191-M FEATURES
  • 1.2.3. DRAWINGS
  • 1.2.3.1. DECK PLAN
  • 1.2.3.2. LOWER FRAME ASSEMBLY
  • 1.2.3.3. ROTATINGFRAME – BALLAST BOX – FRONT END COMPONENTS
  • 1.2.3.4. HOIST MACHINERY
  • 1.2.3.5. ROTATING GEARCASE ASSEMBLY
  • 1.2.3.6. BOOM ASSEMBLY
  • 1.2.4. APPROXIMATE COMPONENT WEIGHTS (TABLE)
  • 1.2.5. SPECIFICATION
  • 1.3. OPERATION
  • 1.3.1. OPERATING CONTROLS – GENERAL CONFIGURATION
  • 1.3.2. OPERATORS CAB (DRAWING)
  • 1.3.3. OPERATORS CONTROLS (DRAWING)
  • 1.3.4. LEFT CONTROLLER AND CONTROLS
  • 1.3.4.1. EMERGENCY STOP PUSHBUTTON
  • 1.3.4.2. GROUND MONITOR TRIP
  • 1.3.4.3. PROPEL BRAKES SET/RELEASED LIGHTS
  • 1.3.4.4. DIG MODE AND PROPEL MODE
  • 1.3.4.5. CONTROL TRANSFER SWITCH (DIG-BRAKES SET-PROPEL)
  • 1.3.4.6. EXCITATION START/STOP PUSHBUTTONS
  • 1.3.4.7. SWING BRAKE SWITCH
  • 1.3.4.8. HOIST BRAKE SWITCH
  • 1.3.4.9. CROWD BRAKE SWITCH
  • 1.3.4.10. WINDSHIELD WIPER
  • 1.3.5. RIGHT CONTROLLER AND CONTROLS
  • 1.3.5.1. ANNUNCIATOR SILENCE PUSHBUTTON
  • 1.3.5.2. ANNUNCIATOR TEST PUSHBUTTON
  • 1.3.5.3. PROPEL BRAKE FAULT
  • 1.3.5.4. LADDER DOWN
  • 1.3.5.5. BOARDING SIGNAL
  • 1.3.5.6. AUTO-LUBE FAULT
  • 1.3.5.7. MASTER SWITCH FAULT
  • 1.3.5.8. PROGRAMMABLE CONTROLLER FAULT
  • 1.3.5.9. SWING MOTOR OVER TEMPERATURE
  • 1.3.5.10. CROWD MOTOR OVER TEMPERATURE
  • 1.3.5.11. HOIST MOTOR OVER TEMPERATURE
  • 1.3.5.12. PROPEL MOTOR OVER TEMPERATURE
  • 1.3.5.13. MOTOR FIELD LOSS
  • 1.3.5.14. MOTOR BLOWERS FAULT
  • 1.3.5.15. COMPRESSOR AIR PRESSURE
  • 1.3.5.16. PCM AIR PRESSURE FAULT
  • 1.3.5.17. PCM XFMR OVER TEMPERATURE
  • 1.3.5.18. FAN LOSS
  • 1.3.5.19. GROUND FAULT
  • 1.3.5.20. LOOP GROUND
  • 1.3.5.21. TELEPHONE SIGNAL PUSHBUTTON
  • 1.3.6. AIR PANEL STAND
  • 1.3.7. DECK PLAN
  • 1.3.8. CONTROLS IN MACHINERY HOUSE
  • 1.3.8.1. AIR COMPRESSOR SWITCH
  • 1.3.8.2. FILTER FANS START/STOP PUSHBUTTONS
  • 1.3.8.3. HOIST MOTOR BLOWER START/STOP PUSHBUTTONS
  • 1.3.8.4. AC VOLTMETER
  • 1.3.8.5. DC VOLTMETER
  • 1.3.8.6. MACHINE HOUR METER
  • 1.3.8.7. PHASE SEQUENCE LIGHT
  • 1.3.8.8. T1-OL (HOIST PCM XFMR OVERLOAD)
  • 1.3.8.9. REST PUSHBUTTON (FOR PCM XFMR OVERLOAD)
  • 1.3.8.10. T2-OL ( SWING/CROWD PCM XFMR OVERLOAD)
  • 1.3.8.11. CROWD AND SWING MOTOR BLOWERS LIGHT
  • 1.3.8.12. MOTOR FIELD EXCITER FEEDER START PUSHBUTTON AND INDICATOR LIGHT
  • 1.3.8.13. AC AMMETER
  • 1.3.8.14. AC VOLTMETER
  • 1.3.8.15. PCM START / STOP PUSHBUTTONS
  • 1.3.9. BOARDING MACHINE
  • 1.3.10. OPERATORS SEAT ADJUSTMENT
  • 1.3.11. PRE-STARTUP INSPECTION
  • 1.3.11.1. GENERAL DESCRIPTION
  • 1.3.11.2. VISUAL INSPECTION ROUTINE
  • 1.3.12. MACHINE STATUP AND SHUTDOWN
  • 1.3.12.1. TYPICAL START-UP
  • 1.3.12.2. PARTIAL SHUTDOWN
  • 1.3.12.3. COMPLETE SHUTDOWN
  • 1.3.13. OPERATING CONTROLS (DRAWING)
  • 1.3.14. MACHINE OPERATION
  • 1.3.14.1. DIGGING
  • 1.3.14.2. PROPEL
  • 1.3.15. OPERATING TECHNIQUES
  • 1.3.15.1. GENERAL
  • 1.3.15.2. DIG CYCLE
  • 1.3.15.3. PRODUCTION EFFICIENCY
  • 1.4. LUBRICATION
  • 1.4.1. GENERAL
  • 1.4.1.1. LUBRICATION FITTINGS
  • 1.4.1.2. ANTI-FRICTION BEARINGS
  • 1.4.1.3. OPEN GEARS
  • 1.4.1.4. ENCLOSED GEAR CASES
  • 1.4.1.5. EXTREME TEMPERATURE OPERATION
  • 1.4.1.6. WIRE ROPE PENDANT LUBRICATION
  • 1.4.2. LUBRICATION SPECIFICATIONS
  • 1.4.2.1. GL – GEAR LUBRICANTS (OIL TYPE)
  • 1.4.2.2. HGL – GEAR LUBRICANTS (OIL TYPE)
  • 1.4.2.3. OIL AND GREASE CLASSIFICATION
  • 1.4.2.4. SPECIAL LUBRICANTS
  • 1.4.3. SAFETY CHECK LIST FOR INSPECTION, LUBRICATION, MAINTENANCE
  • 1.4.4. LUBRICATION POINTS
  • 1.4.4.1. POINTS ON AUTO LUBE USING MPG
  • 1.4.4.2. POINTS ON AUTO LUBE USING OGL
  • 1.4.4.3. MANUAL LUBE POINTS
  • 1.4.5. LUBING ELECTRIC MOTOR BEARINGS WITH EMG LUBRICANT
  • 1.4.6. LUBE DRAINAGE AND VENTING SYSTEM
  • 1.4.7. AUTOMATIC LUBRICATION SYSTEM
  • 1.4.7.1. AUTO LUBE CENTER
  • 1.4.7.2. AUTO LUBE PANEL
  • 1.4.7.3. OPERATION
  • 1.4.7.4. SYSTEM FAULT
  • 1.4.7.5. TIMERS
  • 1.4.7.6. MANUAL ACTIVATION OF A LUBE CYCLE
  • 1.4.7.7. SPECIAL FEATURES IN SYSTEM
  • 1.4.7.8. SYSTEM SETTINGS
  • 1.4.7.9. SYSTEM SCHEMATIC
  • 1.4.7.10. LINCOLN TYPE SL-1 LUBRICANT INJECTORS
  • 1.4.7.11. LUBE CIRCUIT PRESSURE SWITCHES
  • 1.4.7.12. SYSTEM MAINTENANCE
  • 1.4.7.13. REPLACEMENT OF AUTO LUBE COMPONENTS
  • 1.5. MECHANICAL MAINTENANCE
  • 1.5.1. DECK PLAN
  • 1.5.2. FRONT END EQUIPMENT
  • 1.5.3. BOOM ASSEMBLY
  • 1.5.3.1. MAINTENANCE
  • 1.5.3.2. BOOM LOWERING/RAISING
  • 1.5.3.3. BOOM REMOVAL
  • 1.5.4. BOOM POINT
  • 1.5.4.1. BOOM POINT SHEAVE REMOVAL
  • 1.5.4.2. BOOM SHEAVE DISASSEMBLY AND ASSEMBLY
  • 1.5.5. GANTRY
  • 1.5.5.1. MAINTENANCE
  • 1.5.5.2. GANTRY DISASSEMBLY/REMOVAL
  • 1.5.6. BOOM SUPPORT PENDANTS
  • 1.5.6.1. REMOVAL OF PENDANTS FROM SERVICE
  • 1.5.6.2. TO REPLACE BOOM SUPPORT PENDANTS
  • 1.5.7. DIPPER/HANDLE ASSEMBLY
  • 1.5.7.1. MAINTENANCE
  • 1.5.8. DIPPER TRIP
  • 1.5.9. DIPPER DOOR
  • 1.5.9.1. MAINTENANCE
  • 1.5.9.2. LATCH BAR ENGAGEMENT
  • 1.5.9.3. LATCH BAR AND / OR WEAR INSERT REPLACEMENT
  • 1.5.9.4. DIPPER DOOR REMOVAL
  • 1.5.10. DIPPER DOOR SNUBBER
  • 1.5.10.1. REPLACEMENT OF SNUBBER FRICTION DISCS
  • 1.5.11. DIPPER REMOVAL
  • 1.5.11.1. PITCH BRACE REMOVAL
  • 1.5.12. DIPPER TEETH AND BASES
  • 1.5.13. DIPPER HANDLE REMOVAL FROM BOOM
  • 1.5.14. HANDLE RACK WELDMENT (ILLUSTRATION ONLY)
  • 1.5.15. YOKE BLOCK WEAR PADS (ILLUSTRATION ONLY )
  • 1.5.16. YOKE/HANDLE CLEARANCE
  • 1.5.17. BOOM LIMIT
  • 1.5.18. CROWD MACHINERY
  • 1.5.18.1. CROWD MOTOR
  • 1.5.18.2. CROWD MOTOR REMOVAL
  • 1.5.18.3. CROWD MOTOR INSTALLATION
  • 1.5.18.4. CROWD MACHINERY
  • 1.5.18.5. CROWD MACHINERY INTERMEDIATE SHAFT
  • 1.5.18.6. INTERMEDIATE GEAR REMOVAL
  • 1.5.18.7. INTERMEDIATE SHAFT REMOVAL DIASSEMBLY
  • 1.5.18.8. INTERMEDIATE SHAFT ASSEMBLY
  • 1.5.18.9. CROWD CLUTCH
  • 1.5.18.10. SHIPPER SHAFT ASSEMBLY
  • 1.5.18.11. SHIPPER SHAFT DISASSEMBLY
  • 1.5.18.12. SHIPPER SHAFT PINION ALIGNMENT
  • 1.5.19. DIPPER / HANDLE / BOOM REASSEMBLY
  • 1.5.20. CROWD LIMIT
  • 1.5.20.1. CROWD LIMIT SWITCH INSTALLATION (ILLUSTRATION)
  • 1.5.20.2. CROWD LIMIT SWITCH
  • 1.5.20.3. ELECTRICAL RATINGS
  • 1.5.20.4. CAM SETTING
  • 1.5.20.5. OPERATION AND ADJUSTMENT OF CAMS
  • 1.5.20.6. VERNIER ADJUSTMENT
  • 1.5.20.7. MAINTENANCE
  • 1.5.21. HOIST MACHINERY
  • 1.5.22. HOIST DRUM SHAFT ASSEMBLY
  • 1.5.22.1. TO REMOVE DRUM AND HOIST DRUM GEAR
  • 1.5.22.2. HOIST DRUM SHAFT BEARING ASSEMBLY (ILLUSTRATION)
  • 1.5.22.3. TO REMOVE HOIST DRUM BEARINGS
  • 1.5.22.4. INSTALLATION OF DRUM SHAFT ASSEMBLY
  • 1.5.23. INTERMEDIATE HOIST SHAFT ASSEMBLY (ILLUSTRATION)
  • 1.5.23.1. TO REMOVE AND DISASSEMBLE INTERMEDIATE SHAFT ASSEMBLY
  • 1.5.23.2. TO REASSEMBLE AND REINSTALL INTERMEDIATE SHAFT ASSEMBLY
  • 1.5.24. HOIST MOTOR EXTENSION SHAFT
  • 1.5.24.1. TO REMOVE MOTOR EXTENSION SHAFT
  • 1.5.24.2. TO INSTALL MOTOR EXTENSION SHAFT
  • 1.5.25. HOIST LIMIT SWITCH
  • 1.5.25.1. LIMIT ADJUSTMENT
  • 1.5.26. SWING MACHINERY (ILLUSTRATED)
  • 1.5.26.1. MAINTENANCE
  • 1.5.26.2. GEARCASE AND MOTOR (ILLUSTRATION)
  • 1.5.26.3. MOTOR REMOVAL
  • 1.5.26.4. MAIN ROTATING SHAFT (ILLUSTRATION)
  • 1.5.26.5. MAIN ROTATING SHAFT REMOVAL
  • 1.5.26.6. MAIN ROTATING SHAFT INSTALLATION
  • 1.5.26.7. MAIN ROTATING SHAFT BEARING INSTALLATION
  • 1.5.26.8. MAIN ROTATING SHAFT PINION INSTALLATION (ILLUSTRATION)
  • 1.5.26.9. MOTOR INSTALLATION
  • 1.5.26.10. GEARCASE REMOVAL AND DISASSEMBLY (ILLUSTRATION)
  • 1.5.26.11. GEARCASE REMOVAL AND DISASSEMBLY
  • 1.5.26.12. GEARCASE ASSEMBLY
  • 1.5.26.13. ROTATING GEARCASE HOLD DOWN DETAILS (ILLUSTRATION)
  • 1.5.27. RING GEAR AND ROLLER RAILS (ILLUSTRATION)
  • 1.5.27.1. UPPER ROLLER CIRCLE RAIL
  • 1.5.27.2. MAIN ROTATING GEAR ASSEMBLY
  • 1.5.27.3. LOWER ROLLER CIRCLE RAIL
  • 1.5.27.4. RING GEAR REPLACEMENT
  • 1.5.27.5. ROTATING GEAR TO LOWER FRAME TORQUING PROCEDURE
  • 1.5.28. ROLLER CIRCLE
  • 1.5.28.1. ROLLER CIRCLE ADJUSTMENT
  • 1.5.28.2. ROLLER CIRCLE COMPONENT(S) REPLACEMENT
  • 1.5.29. CENTER JOURNAL
  • 1.5.29.1. CENTER JOURNAL ADJUSTMENT
  • 1.5.29.2. CENTER JOURNAL NUT ADJUSTMENT
  • 1.5.29.3. CENTER JOURNAL REMOVAL
  • 1.5.29.4. THRUST WASHER REPLACEMENT
  • 1.5.29.5. CENTER JOURNAL BUSHING REPLACEMENT
  • 1.5.30. AUXILIARY COLLECTOR RINGS AND ROTOSEAL
  • 1.5.31. MAIN COLLECTOR RINGS
  • 1.5.31.1. MAINTENANCE
  • 1.5.32. LOWER FRAME ASSEMBLY (ILLUSTRATED)
  • 1.5.32.1. LOWER FRAME ASSEMBLY
  • 1.5.33. CRAWLER SIDE FRAME ASSEMBLY (ILLUSTRATED)
  • 1.5.33.1. MAINTENANCE
  • 1.5.33.2. LOWER FRAME TO CRWLER CONNECTING RODS
  • 1.5.34. CRAWLER SHOES/BELTS
  • 1.5.34.1. MAINTENANCE
  • 1.5.34.2. CRAWLER BELT ADJUSTMENT
  • 1.5.34.3. CRAWLER BELT / SHOE REPLACEMENT
  • 1.5.34.4. SIDE BAR REBUILD
  • 1.5.35. LOAD AND REAR ROLLERS
  • 1.5.35.1. ROLLER REMOVAL
  • 1.5.35.2. ROLLER INSTALATION
  • 1.5.36. FRONT IDLER ROLLER
  • 1.5.37. PROPEL MACHINERY
  • 1.5.37.1. MAINTENANCE
  • 1.5.37.2. PROPEL GEARCASE REMOVAL
  • 1.5.37.3. PROPEL GEARCASE
  • 1.5.37.4. PROPEL GEARCASE INSTALLATION
  • 1.5.38. PROPEL MOTORS
  • 1.5.38.1. MAINTENANCE
  • 1.5.38.2. PROPEL MOTOR REMOVAL
  • 1.5.38.3. PROPEL MOTOR INSTALLATION
  • 1.5.39. MAIN PROPEL SHAFT/SPROCKET
  • 1.5.39.1. MAIN PROPEL SHAFT REMOVAL
  • 1.5.39.2. MAIN PROPEL SHAFT ASSEMBLY
  • 1.5.39.3. MAIN PROPEL SHAFT/SPROCKET INSTALLATION
  • 1.5.39.4. SPROCKET REBUILD PROCEDURE
  • 1.5.40. DISC BRAKES – SWING, CROWD, HOIST PROPEL
  • 1.6. COMPRESSED AIR SYSTEMS
  • 1.6.1. COMPRESSED AIR SYSTEM SCHEMATIC
  • 1.6.2. COMPRESSED AIR SYSTEM
  • 1.6.3. AIR COMPRESSOR
  • 1.6.4. AIR COMPRESSOR MAINTENANCE
  • 1.6.5. AIR LINE FILTERS
  • 1.6.6. DE-ICER
  • 1.6.7. AIR LINE LUBRICATORS
  • 1.6.8. PRESSURE REGULATORS
  • 1.6.9. AIR FLOW CONTROL VALVES
  • 1.6.10. FLOW RATE CONTROL VALVES
  • 1.6.11. AIR PRESSURE SWITCHES
  • 1.6.12. HOUSE AIR FILTRATION SYSTEM
  • 1.6.13. AIR WINCH FOR HOIST ROPE REEVING
  • 1.7. ELECTRICAL MAINTENANCE
  • 1.7.1. ELECTRICAL MAINTENANCE
  • 1.7.1.1. CARE OF D.C. MOTORS AND GENERATORS
  • 1.7.1.2. BRUSH INSTALLATION
  • 1.7.1.3. COMMUTATORS
  • 1.7.1.4. PROPER LUBRICATION
  • 1.7.2. ELECTRICAL TROUBLESHOOTING
  • 1.7.2.1. PREPARATION
  • 1.7.2.2. INVESTIGATION
  • 1.7.2.3. PERFORMANCE
  • 1.7.2.4. TYPES OF FAILURE
  • 1.7.2.5. SHORT CIRCUITS
  • 1.7.2.6. INTERMITTENT FAILURES
  • 1.7.2.7. SIMULATED TROUBLESHOOTING
  • 1.7.3. ELEMENTS OF A MAINTENANCE PROGRAM
  • 1.7.4. OTHER REFERENCE PUBLICATIONS
  • 1.8. ENGINEERING DATA
  • 1.8.1. BUSHINGS
  • 1.8.2. SEALING GEAR CASES
  • 1.8.3. SEALING GEAR CASE BEARING RETAINERS
  • 1.8.4. SPLINES
  • 1.8.5. ANTI-FRICTION BEARINGS
  • 1.8.6. GEAR BACKLASH
  • 1.8.7. GEAR CONTACT PATTERN
  • 1.8.8. BRACK INSTALLATION AND MAINTENANCE
  • 1.8.9. SHRINK FIT COMPONENTS
  • 1.8.10. CAPSCREW (BOLT) GRADES
  • 1.8.11. TORQUE METHOD AND CHART
  • 1.8.12. WIRE-LOCKING CAPSCREWS
  • 1.8.13. TORQUE VALUES – METRIC FASTENERS
  • 1.8.14. WIRE ROPE CARE
  • 1.8.15. REPAIR WELDING PROCEDURES
  • 1.8.16. O-RING GUIDE
  • 1.8.17. DECIMAL EQUIVALENTS
  • 1.8.18. COUPLINGS (FOR PROPEL)
  • 1.8.19. COUPLINGS (FOR HOIST)
  • 1.8.20. M-G SETS – GEARLESS COUPLINGS
  • 1.9. PREVENTIVE MAINTENANCE
  • 1.9.1. PREVENTIVE MAINTENANCE
  • 1.9.1.1. SCHEDULED PREVENTIVE MAINTENANCE PROGRAM
  • 1.9.1.2. ELEMENTS OF A MAINTENANCE PROGRAM
  • 1.9.2. TYPICAL PREVENTIVE MAINTENANCE PROGRAM
  • 1.9.2.1. DAILY INSPECTION
  • 1.9.2.2. HOUR INSPECTION / SERVICE
  • 1.9.2.3. HOUR INSPECTION / SERVICE
  • 1.9.2.4. HOUR INSPECTION / SERVICE
  • 1.9.3. PREVENTIVE MAINTENANCE CHECKLIST
  • 1.9.4. PROJECTED MAINTENANCE SCHEDULE FOR REPLACEMENT OR REBUILD
  • 1.9.5. INSPECTION FORM (EXAMPLE)
  • 1.10. AIR CONDITIONING
  • 1.10.1. DESCRIPTION -MECHANICAL
  • 1.10.1.1. OPERATION
  • 1.10.1.2. REFRIGERANT SYSTEM
  • 1.10.1.3. SYSTEM SPECIFICATION
  • 1.10.1.4. CONDENSING UNIT
  • 1.10.1.5. COOLING (EVAPORATING) UNIT
  • 1.10.1.6. FRESH AIR, PRESSURIZATION PACK (OPTIONAL)
  • 1.10.2. INSTALLATION, OPERATING MAINTENANCE INSTRUCTIONS
  • 1.10.2.1. START-UP INSTRUCTIONS
  • 1.10.2.2. MAINTENANCE SCHEDULE
  • 1.10.2.3. LEAK TESTING – GENERAL INSTRUCTIONS
  • 1.10.2.4. NITROGEN LEAK TESTING
  • 1.10.2.5. VACUUM DRYING
  • 1.10.2.6. FIELD CHARGING PROCEDURE
  • 1.10.2.7. REPLENISHING REFRIGERANT
  • 1.10.2.8. ADDING OIL
  • 1.10.2.9. COMPONENT MAINTENANCE
  • 1.10.2.10. COMPRESSOR – GENERAL
  • 1.10.2.11. COMPRESSOR – REMOVAL FROM SYSTEM
  • 1.10.2.12. COMPRESSOR – REPLACEMENT
  • 1.10.2.13. AIR COOLED CONDENSER
  • 1.10.3. ELECTRIC AND CONTROLS
  • 1.10.3.1. OPERATION
  • 1.10.3.2. PRESSURE SWITCHES
  • 1.10.3.3. MAINTENANCE SCHEDULE
  • 1.10.3.4. MAINTENANCE
  • 1.10.3.5. COMPRESSOR PRESSURE SWITCH – ADJUSTMENT
  • 1.10.4. OPERATING DATA AND FAULT DIAGNOSIS
  • 1.10.4.1. OPERATING DATA
  • 1.10.4.2. FAULT DIAGNOSIS / TROUBLE ANALYSIS
  • 1.10.4.3. COMPRESSOR FAILS TO START
  • 1.10.4.4. COMPRESSOR SHORT CYCLE
  • 1.10.4.5. COMPRESSOR RUNS CONTINUOUSLY
  • 1.10.4.6. COMPRESSOR LOSES OIL
  • 1.10.4.7. COMPRESSOR IS NOISY
  • 1.10.4.8. SYSTEM SHORT OF CAPACITY
  • 1.10.4.9. HEAD PRESSURE TOO HIGH
  • 1.10.4.10. HEAD PRESSURE TOO LOW
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