PDF Maintenance & Operation Manual CAT Bucyrus 201M Electric Shovel - 1 MB
This comprehensive manual covers both the maintenance and operation of the CAT Bucyrus 201M electric shovel.
It is an essential guide for operators and maintenance crews, providing detailed procedures for daily checks, safe operation, and scheduled servicing.
Following the instructions in this manual is key to maximizing the shovel's uptime and ensuring a safe work environment in demanding mining applications.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
BI006268
© Bucyrus
All Rights Reserved
BUCYRUS R
Technical Manual
--- Page 3 ---
BI006268
SAFETY PRECAUTIONS - continued
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.
Use safety catch on all hoist hooks. Do not take a chance, the load could slip off of the
hook.
If a heavy item begins to fall, let it fall, don't try to catch it.
When disassembling machine, be sure to use safety stands and adequate cribbing to
prevent tipping or rollover of components.
Keep work area organized and clean. Wipe up oil or spills of any kind. Keep tools and
parts off of the ground. Eliminate the possibility of a fall which could result in serious
injury.
Floors, walkways and stairways must be clean and dry. After draining operations be
sure all spillage is cleaned up. Electrical cords and wet metal floors make a dangerous
combination.
Check all wire ropes for telltale signs of early wear or failure. Look for and secure any
loose bolts or locking devices.
Use extreme caution while working near any electrical lines or equipment whether it be
high or low voltage. Never attempt electrical repairs unless qualified. Check limit
switches for proper operation.
When using an 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. Do not weld or heat areas near
transformers or electrical cabinets and utilize proper shielding around lubrication lines.
Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when
applicable. Use hammers, punches and chisels only when absolutely necessary. Then,
be sure to wear safety glasses.
Be careful when using compressed air to dry parts. Use approved air blow guns, do not
exceed 207 kPa (30 psi), wear safety glasses or goggles and use proper shielding to
protect e'/eryone in the work area.
1-4
-
--- Page 4 ---
-----------------_.......'--' ......._-_..._----_•._
...
", ......._----_..._----
BI006268
--- Page 5 ---
,. ..
'J.....'.t... ......_ ......_ _ iiiIIiIaiiiiii_ _... ...
· ...... ......_ ............
• ...
$ _
~
_
-
-
~
BI006268
TELEPHONE SIGNAL - When the push button is depressed, a signal bell will ring in the
electrical compartment at rear of machine.
ALARM SI LENCE - Push button will deactivate the warning alarm when a red warning
light comes on. The lamp will remain on until condition causing alarm has been corrected.
ALARM TEST - When depressing this button all red warning lights should be on. If not
replace lamp that is out.
When any of the following red lights come on, the alarm will sound to alert the operator and
the light will indicate where the malfunction is located.
The presence of a visual and audible alarm that does not stop motion is sufficient cause to
SAFELY shut down the machine and investigate the reason for the alarm.
PCM AIR PRESS. - This light indicates air pressure is below the minimum reading in the
PCM (Power Control Module) cabinets.
PCM XFM R TEMP, (Power Control Module Transformer) - I ndicates that the operating
temperature of the transformer is above normal.
SWG (Swing) MTR TEMP., CRD (Crowd) MTR TEMP., PROP (Propel) MTR TEMP., HST
(Hoist) MTR TEMP. - These four lights will indicate if a motor is running over normal
operating temperature.
COMPRESSOR AI R PRESS - Indicates compressed air system pressure dropped below 65
psi (448.11 kPa). Check gauge reading. Pressure switch in circuit set to turn light "ON" at
65 psi (558.11 kPa) and "OF F" at 95 psi (654.93 kPa).
NOTE: Full brake release requires 100 psi (689.4 kPa).
AUTO LUBE FAILURE - Indicates a malfunction in the auto-lube system.
MINE SIGNAL - An alert from personnel on mine floor, usually for "Boarding" request.
MTR F LD. LOSS (Motor Field Loss) -- This lamp will come on to indicate current loss in
the field of a D.C. motor. The motion at which the loss has occurred will shut down and
that brake will set.
PCM FAU LT - Indicates a trip of one or more of the power converter modules.
MOTOR BLOWERS - A warning that indicates one (or more) of the motor blowers has
malfunctioned. The blower at fault will have to be determined.
LOOP GROUND -- Indicates a ground condition exists in hoist or swing or crowd or propel
armatu re circu its.
LADDER DOWN - Indicates the access ladder IS in the down position and the Primary
Controls are deactivated.
FILTER FANS - Indicates a malfunction at one (or more) of the filter fan(s) located on
the house roof.
2-6
--- Page 6 ---
------_ _---_ _-------,---_ _---_ ~ ~ ~ _-_ _----_ _--_ _-_ _-_ _-------
BI006268
--- Page 7 ---
BI006268
CODE NAME DESCRIPTION
continued...
GL Enclosed Gear Case 3. Inside machinery house, where oil is not
pumped, use G L-200 except where freezing
temperatures rarely or never occur, use G L-
250.
On new machines, oil should be drained after first
60 days of operation and replaced with new oil.
Thereafter, change oil once a year, or when deter-
mined necessary by oil supplier. Oil should be
checked for contamination every 30 days.
PO Pneumatic Oil Petroleum oil especially compounded for use in
air lines oilers or built in lubricators having the
correct viscosity, low pour point, emulsifying
ability, film strength and free of deposit forming
tendencies. It should not cause swelling or dete-
-
rioration of rubber or leather seals and gaskets.
EMG Electric Motor Grease Electric motor bearing grease meeting the require-
ments of G.E. Specification D6A2C5 or Westing-
house equivalent.
3-8
--- Page 8 ---
BI006268
Adjusting Nut
Lock Nut
Piston
Packing Washer
Fitting Assembly
o o o
o o o
Inlet Disc
Packi ng
INasher
Adaptor Gasket
3"
8 N.P.T.
ACaptor Bolt
Gasket
LUBE INJECTOR· ASSEMBLY
3-18
--- Page 9 ---
"",""'. *..
, ......... .. *........_.. . ._ _
@$...... ··~ ...
···e
. ..
t _ _. . . . . . ~s
... ............ _
BI006268
4. Attach crane sling to lift hoist ropes off sheaves and support them on the bearing
boss between the sheaves.
5. Remove one sheave at a time. Run wire rope or sling thru sheave and take up
slack. Remove lock pins securing sheave shafts to boom, then pull out shaft far
enough to release sheave and sleeve assembly. Lift sheave at right angle to boom.
Sheave weight is approximately 3200 pounds. Shaft weight is 788 pounds.
6. Remove other sheave in same manner.
7. Lower sheave to ground and sUPiJ0rt with axis vertical to remove bearings. Loosen
bolts and remove lock bar from split nut and sleeve. Remove nut from sleeve.
Remove spacers and grease retainer. I nvert sheave and remove second grease
retainer, sleeve, bearings and spacer. Check bearing cones and cups for pitting,
scoring and wear.. Check for evidence of inadequate lubrication.
8. Replace damaged bearings. To install new bearings: thoroughly clean sheave hub
bore. Press bearing cups in each side, making sure cups seat against shoulder in
bore. Assemble and lightly lubricate bearing cones and insert in bearing bore
without spacer. Clamp cones with tool J-14077 until bearing binds slightly when
rotated. Use inside micrometer to measure between cones at three points 120
degrees apart. Calculate average dimension and machine spacer to this dimension
+.001, -.000. Remove clamp and bearing cones.
9. Pack cones with multi-purpose grease (MPG). Insert sleeve with bearing cone in
bore and carefu Ily install grease retainer. I nvert sheave and install mach ined
spacer, second bearing cone, grease retainer and external spacer. Place split nut
on sleeve. Tighten nut with spanner wrench until bearings are firmly seated. With
assembly tight, remove one nut bolt and insert lock bar in nearest slot, then
replace bolt.
10. To install sheave, use crane to lift sheave to point. Position sheave and drive shaft
into place. Secure shaft with lock pin. Use crane to lift hoist ropes into position
on sheave. Make sure rope towards center of drum is in inside groove of sheave.
NOTES:
4-2
--- Page 10 ---
~~]fJ'
BI006268
LATCH BAR AND/OR WEAR PLATE REPLACEMENT - Position dipper so that door
hangs free and high enough to allow removal of latch bar from door bottom. Support latch
bar weight enough to permit removal of trip lever pin. Lower the latch bar out of door
when support is removed.
A CAUTION: Use care to avoid injury from heavy latch bar.
Remove worn wear plates. install new wear plates and tack weld them to hold while as-
sembling latch. Reassemble latch bar, trip lever and pin.
Maintain good film of lube on latch bar. Most operators pour used motor oil on latch bar
frequently to keep it lubed.
DIPPER TRIP motor and the gear-driven rope drum are located on the boom top plate. The
trip rope is reeved from the drum thru a boom-mounted fairlead to the trip lever mounted
on right side of dipper handle. This lever is connected by trip chain to trip lever on dipper
door.
The trip motor is constantly energized by a low voltage current which is just strong enough
to apply a slight torque to reel, keeping the rope taut. The rope unreels as the dipper
crowds out. As the dipper retracts, motor torque rewinds the rope. When the operator
-
actuates the dipper trip switCh, additional voltage is applied to pull the dipper latch bar.
The combined weight of the dipper trip lever and latch bar returns the bar to the latch
position when the trip switch is released. Weight of the dipper door swings the door shut
as the dipper is lowered.
No mechanical adjustments are required. The only electrical adjustment is the controlled
low voltage to the trip motor. Adjustment is made by an electrici2n only if control circuit
components are replaced.
NOTES:
~'
4-12
--- Page 11 ---
_ _ _ _ _ _ _ _ _ _ _ _.._ ....
'$ • ... ........ t
......
.
_
i
I
l
l
I
I
I
i
!
i
~
,
i
l
l
i
i
i
~
,
~
l
t
i
~
~
m
.
_
·
·
·
l
f
_
4
~
l
?
BI006268
DIPPER HANDLE
YOKE BLOCK
(WEIGHT - 24,500 LBS.)
THRUST WASHER
(WEIGHT - 130 LaS.)
~
PIN (WEIGHT - 90 L8S.)
JI
.' ~PlNHETAINER
BEARING HOUSING
~EIGHT - 2,000 Li3S~
BUSHING
(WEIGHT - 290 LBS.)
YOKE BLOCK AND BEARING HOUSING DETAILS
4-22
--- Page 12 ---
.. t
c--'.'C.....
:"MO{
.. "...
" ............
_.-......
'......_ _....
_........
_ ~, _ _...
*Mi.•.................... .. "_(;_
......, ti-...
·_
BI006268
TO INSTALL INTERMEDIATE SHAFT:
1. Preassemble shaft, outer bearing, spacer and cone of inner bearing. See Section 7 for
information on bearing installation.. Attach shaft lifting tool.
2. IMPORTANT: Install inner bearing cup and bearing cage in boom housing. Do not
install on shaft.
3. Pack shaft housing with MPG multi-purpose grease.
4. Insert shaft assembly into boom housing and inner bearing. Start outer bearing into
housing, then remove lifting tool and complete shaft installation.
5. Install eight capscrews thru split retainer to secure outer bearing.
6. Install spacer over shaft splines and against cone of inner bearing.
7. Install inner bearing retainer with eight capscrews. Torque to specification (see Section
7).
8. Install intermediate gear on shaft splines and against spacer. Install gear retainer with
three capscrews. Torque to specification (see Section 7). -
9. Install shipper shaft gear and guard.
CROWD MOTOR REMOVAL - Disconnect electrical power from machine. Disconnect
electrical wiring from crowd motor. Identify wires and cover connectors. Disconnect air
line to crowd motor brake.
Remove gear and pinion guard. Remove motor as a unit with brake and pinion installed.
Weight of unit is approximately 3,140 pounds. Weight of motor with blower is 2,755
pounds. Weight of brake is approximately 385 pounds.
L1.. CAUTION: Carefully loosen and work motor from mounting to avoid damage to
~ motor pinion.
Lower motor onto cribbing at ground level and protect it from weather and dirt.
4-32
--- Page 13 ---
BI006268
Weight of Motor and
Crowd Motor
Blower is 2755 Lbs.
Weight of Brake
is 470 Lbs.
Gear
Nut and Lockwasher
Supplied with Mo~or
Shield
CROWD BR.AKE INSTALLATION
4-42
--- Page 14 ---
BI006268
Inspection of the cam·follower roller assembly can be made by removing the two forward
bolts holding the cam-follower bracket, then swinging the entire bracket assembly back
to provide access to the cam-follower parts.
The following procedures should be
followed when replacing bearings or
camshaft or reversing the camshaft
extension (see figure 5).
Remove the cast cover. Remove both
seal plates (1) (2), the cam follower
bracket (3), and the four bolts which
secure the internal switch to the cast
box. Remove the internal switch
from the box.
Remove three bolts holding flangette
on shaft extension side of switch.
After removing the filler strips (5),
loosen the tf1rust collers on each end
of the shaft and slide them inward
along the shah. Lift entire cam shah
assembly up and out of the switch FIGURE 4. CAM FOLLOWER ROLLER
frame. ASSEMBLY AND INTERIOR OF SWITCH
After replacing parts as required, reassemble the filler strips (5) and the three bolts holding
the flangette.
Reinstall the internal switch into the cast box with the shah extension protruding from the
desired side and tighten the four mounting bolts (4) which secure the switch to the box.
Reinstall the seal plates (1) (2).
Visually center the shah in the seal plate hole and tighten the internal flangette. Re-
assemble and tighten the cam follower bracket. Measure for proper shaft-extension length
and position, and tighten the thrust collars.
The final step in the reassembly procedure is to reset the desired contact se~uence by
adjusting the cam and vernier adjustment.
4-52
--- Page 15 ---
_ "··'. .iIiIIV @_t , _ _...... ..._ ....... _
~
~
~
i
i
I
l
I
i
l
l
o
l
i
i
i
i
i
,
BI006268
heads tight against the flange and the lockwashers loose. Attach choker slings to the drum
and place it in position on the base frame. Drive the four lock pins in place and secure
them with pin retainers and wire lock. Tighten gear bolts in accordance with the following
-
procedure:
BOLTING PROCEDURE FOR HOIST GEAR:
Keep drum shaft frre to turn with ropes slack and brake released.
Loosen all bolts, one or two turns.
Tighten all nuts by hand.
Use air wrench; tighten the two topmost, center bolts ON LY.
Rotate drum 180 0 ; tighten two topmost, center nuts.
Rotate drum 90°; tighten two topmost, center nuts.
Rotate gear 180°; tighten two topmost, center nuts.
Rotate gear 45 0 ; tighten two topmost, center nuts.
Rotate gear 180 0 ; tighten two topmost, center nuts.
Rotate gear 90 0 ; tighten two topmost, center nuts.
Rotate gear 180 0 ; tighten two topmost nuts.
Tighten ALL remaining nuts.
RETIGHTEN ALL nuts, advancing one nut each time. Rotate drum so each nut
to be tightened is at top of drum in turn.
Operate machine 30 minutes under load and RETIGHTEN.
NOTE: Due to dead weight, it is possible that ALL bolts seem tight (nuts do not turn
anymore) and still a gap exists at bottom of gear as gear rotates. The changing position
under load causes the bolts to loosen with additional bending stress. RETIGHTENING IS
IMPORTANT.
The HOIST INTERMEDIATE GEAR runs in an oil-tight gear case containing 60 gallons of
GL type oil. This double helical gear is splined to the intermediate shaft and driven by the
hoist motor pinion.
The HOIST INTERMEDIATE SHAFT ASSEMBLY consists of the intermediate gear, the
intermediate shaft with integral pinion, and two sets of double row tapered roller bearings.
4-62
--- Page 16 ---
BI006268
The HOIST LIM IT SWITCH is mounted on the right side of the boom in a position where it
will be tripped by the yoke block when the handle reaches a predetermined angle above
horizontal. This angle is 21 degrees on a 51 foot,6 inch long boom set at 45 degrees, This
limit is adjustable,
Front of "':- --------:7\,
)_;::1:\ 7V~:::f e
~
'I L'
Swli';:;~
\
.
" ~
13.3 (ref.)
Actuating