Bucyrus International, Inc.

182M-AC Electric Mining Shovel

Manual No. 10954 Sept. 2010

 Bucyrus International, Inc.

182M-AC Electric Mining Shovel

DANGER:

THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND
OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE
SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO
WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES.
FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.

DANGER:

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.

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.

DANGER:

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.

Sept. 2010 Manual No. 10954

Bucyrus International, Inc.

182M-AC Electric Mining Shovel

Manual No. 10954 Sept. 2010

 Bucyrus International, Inc.

182M-AC Electric Mining Shovel

182M-AC Mining Shovel

Maintenance and Operation Manual
Manual No. 10954

This manual is divided into major sections covering the various serviceable
components and systems of the 182M-AC Mining Shovel. These sections and
their contents are organized as shown below.

–Table of Contents–

Section 1- MACHINE SPECIFICATIONS

Section 2- OPERATION

Section 3- LUBRICATION

Section 4- PREVENTIVE MAINTENANCE

Section 5- SERVICE PROCEDURES

Section 6- BRAKES AND COUPLINGS

Section 7- COMPRESSED AIR SYSTEM

Section 8 - AIR CONDITIONER

Section 9 - ENGINEERING DATA

Section 10 - SCHEMATICS

IMPORTANT NOTE
This document is protected under applicable copyright laws to the extent available. Any
unauthorized and unlawful reproduction, distribution or other use shall be subject to liability.
© 2010 Bucyrus International, Inc. All Rights Reserved.

Sept. 2010 Manual No. 10954

Bucyrus International, Inc.

182M-AC Electric Mining Shovel

Manual No. 10954 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 1
Machine Specifications
Table of Contents

GENERAL INFORMATION ............................................................................................................ 3

GENERAL SAFETY ....................................................................................................................... 4
SAFETY PRECAUTIONS .............................................................................................................. 5
FIRE PREVENTION ...................................................................................................................... 8
MACHINE OVERVIEW ................................................................................................................... 9
TRUCK FRAME AND CRAWLERS .............................................................................................. 10
PROPEL MACHINERY ................................................................................................................ 11
CROWD MACHINERY ................................................................................................................. 12
MACHINERY HOUSE .................................................................................................................. 13
OPERATOR’S CAB ..................................................................................................................... 14
BOARDING STAIRS .................................................................................................................... 15
VERTICAL BOARDING LADDER ................................................................................................. 17
HOIST MACHINERY.................................................................................................................... 18
SWING MACHINERY................................................................................................................... 19
FRONT END EQUIPMENT ......................................................................................................... 20
BOOM ......................................................................................................................................... 21
GANTRY ..................................................................................................................................... 22
BOOM SUPPORT ROPES .......................................................................................................... 23
DIPPER ASSEMBLY .................................................................................................................... 24
COMPONENT WEIGHTS ........................................................................................................... 25
TYPICAL MACHINE SPECIFICATIONS ....................................................................................... 27

DECK PLAN - COLOR .......................................... LOCATED AT THE END OF THE MANUAL

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182M-AC Electric Mining Shovel

Manual No. 10954 1-2 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 1
Machine Specifications

GENERAL INFORMATION

This manual is designed to assist the owner in the operation and preventive maintenance of this
machine. By following easy to understand step-by-step procedures the operators and maintenance
personnel can perform all tasks in a safe manner. It is important to remember that when a systematic
and thorough maintenance/service procedure is used for this machine, a minimum of unplanned
downtime and more reliable operation will result.

THIS MANUAL IS NOT THE PARTS BOOK and cannot be used as reference material to order
parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in
it. All parts are listed by group and/or product code numbers with the associated item/part numbers
for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed. RIGHT and LEFT refer
to machine locations as viewed by the operator sitting in the operator’s seat in the cab. Please
state the correct machine SERIAL NUMBER when corresponding or contacting the factory service
or parts departments. Records on each machine are filed by serial number and when given this
number, the machine’s specific design and original equipment is accessed quickly by the Bucyrus
International parts representative.

Periodic additions or revisions may be made to this manual. Should you require additional information
or factory service assistance contact your regional service representative or:

Bucyrus International, Inc.

1100 Milwaukee Avenue
P.O. Box 500
South Milwaukee, Wisconsin 53172-0500, USA
Telephone (414)-768-4000 Fax: (414) 768-4210

It is Bucyrus International’s policy to improve its products whenever possible and practical to do
so. The company reserves the right to make changes or add improvements to it’s machines at any
time. This will be without incurred obligation 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.

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182M-AC Electric Mining Shovel

GENERAL SAFETY

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 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 Bucyrus service representative or the factory.

The following defines distinctions between safety instructions. In all these definitions the safety
alert signal is used.

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.

CAUTION: This signal word serves as a reminder of safety practices, or directs

attention to specific safety practices which could prevent possible
injury if precautions are not adhered to.

DANGER! 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.

DANGER! This signal word denotes an imminently dangerous electrical hazard

which will result in death, serious bodily injury, or serious damage to
equipment if not acknowledged and appropriate action taken.

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 eyesight, hearing or reactions.

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

SAFETY PRECAUTIONS

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 man 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.
• Use extreme caution when working around drilled holes.

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182M-AC Electric Mining Shovel

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 blow guns, do
not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding to
protect everyone in the work area.
• 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.

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182M-AC Electric Mining Shovel

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, 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.
• 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.

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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. See Chapter 4 of this manual for the Scheduled Maintenance recommendations and
the Daily Inspection procedure.

• 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.

• 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.

Manual No. 10954 1-8 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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.

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182M-AC Electric Mining Shovel

TRUCK FRAME AND CRAWLERS

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182M-AC Electric Mining Shovel

PROPEL MACHINERY

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182M-AC Electric Mining Shovel

CROWD MACHINERY

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182M-AC Electric Mining Shovel

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 Gantry. 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 and/or ladders permit easy access onto
the machine.

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182M-AC Electric Mining Shovel

OPERATOR’S CAB

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182M-AC Electric Mining Shovel

BOARDING STAIRS

The boarding stairs are located on the left side of the machine at the rear of the walkway. The stairs
are counter weighted to remain in the up position when the machine is in operation or down when
boarding the machine. When the stairs are pulled down 3 to 4 inches a limit switch will trip and drop
out line Excitation (LE) which will stop the machine. Refer to the figure on the following page.

To board when the machine is in operation:

1. Pull one of the two signal chords at the rear of the ballast bar and wait for the operator to bring
the machine to a halt.

2. Lower the stairway.

WARNING: DO NOT ATTEMPT TO LOWER THE STAIRS WITHOUT SIGNALING THE

OPERATOR FIRST. When the ladder is pulled down 3 to 4 inches, all
brakes will set on the machine. FAILURE TO HEED THIS WARNING
COULD RESULT IN DAMAGE TO THE MACHINE AND/OR RESULT IN
PERSONAL INJURY.

3. After boarding the machine, raise the stairs to their full UP position. The machine will not be
operable until the stairs are completely in the UP position.

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182M-AC Electric Mining Shovel

Manual No. 10954 1 - 16 Sept. 2010

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182M-AC Electric Mining Shovel

VERTICAL BOARDING LADDER

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

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182M-AC Electric Mining Shovel

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 an anti-friction bearings supported by side frames which are bolted to the rotating
deck.

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182M-AC Electric Mining Shovel

SWING MACHINERY

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182M-AC Electric Mining Shovel

FRONT END EQUIPMENT

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182M-AC Electric Mining Shovel

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 Gantry. 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.

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182M-AC Electric Mining Shovel

GANTRY

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182M-AC Electric Mining Shovel

BOOM SUPPORT ROPES

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182M-AC Electric Mining Shovel

DIPPER ASSEMBLY

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

COMPONENT WEIGHTS
Quantity Weight Each
(U.S. Pounds)
Shoe with Pins ................................................................ 102 ............... 490

Crawler Assembly .............................................................. 2 .......... 68,110

Front Idler ...................................................................... 2 ............ 2,500
Front Idler Shaft ............................................................ 2 ............... 330
Load Roller ................................................................. 16 ............... 720
Load Roller Shaft ........................................................ 16 ............... 190
Rear Idler ...................................................................... 2 ............... 980
Rear Idler Shaft ............................................................. 2 ............... 220
Sprocket ........................................................................ 2 ............ 4,500
Sprocket Shaft Assembly .............................................. 2 ............ 1,600
Propel Gearcase........................................................... 2 ............ 6,620
Propel Motor ................................................................. 2 ............ 1,770
Propel Brake ................................................................. 2 ............... 470

Truck Frame Assembly ....................................................... 1 .......... 73,620

Truck Frame Structure ................................................... 1 .......... 55,120
Rotating Gear................................................................ 1 .......... 12,440
Center Journal .............................................................. 1 ............ 4,740
Roller Circle .................................................................. 1 ............ 6,600

Rotating Frame Assembly .................................................... 1 .......... 68,760

Structure ....................................................................... 1 .......... 58,840
Drum Shaft Pedestal - Left ............................................ 1 ............ 3,210
Drum Shaft Pedestal - Right .......................................... 1 ............ 2,860
Left Deck Extension ...................................................... 1 ............ 4,710
Right Deck Extension .................................................... 1 ............ 4,330
Ballast Box .................................................................... 1 .......... 30,730

Hoist Machinery:
Hoist Drum Shaft Assembly ........................................... 1 .......... 19,620
Hoist Intermediate Shaft ................................................ 1 ............ 1,060
Hoist Motor Pinion Shaft ............................................... 1 ............... 300
Hoist Motor ................................................................... 1 ............ 7,500
Hoist Brake ................................................................... 1 ............... 600

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182M-AC Electric Mining Shovel

Quantity Weight Each

(U.S. Pounds)

Hoist Rope Winch ......................................................... 1 ............... 120

Swing Gearcase ................................................................. 2 ............ 6,210

Swing Motor .................................................................. 2 ............ 1,770
Swing Brake .................................................................. 2 ............... 390
Main Rotating Shaft ...................................................... 2 ............ 1,730
Main Rotating Pinion ..................................................... 2 ............... 165

Gantry Front Leg ................................................................. 1 ............ 5,030

Back Leg ....................................................................... 2 ............ 1,730

House Filter/Fan Unit .......................................................... 2 ............ 1,370

Operator's Cab .................................................................... 1 ............ 6,840

Air Compressor ............................................................. 1 ............... 500

Boom Assembly .................................................................. 1 .......... 53,900

Boom Structure ............................................................. 1 .......... 33,870
Boom Point Sheave Assy. ............................................. 1 ............ 6,070

Shipper Shaft Assembly ...................................................... 1 ............ 8,160

Yoke Block .................................................................... 4 ............... 640
Shipper Shaft Gear ....................................................... 1 ............ 1,550
Shipper Shaft Pinion ..................................................... 2 ............... 380
Shipper Shaft ................................................................ 1 ............ 1,720
Intermediate Crowd Gear ............................................. 1 ............... 920
Intermediate Crowd Shaft ............................................. 1 ............... 450
Crowd Motor ................................................................. 1 ............ 1,770
Crowd Brake ................................................................. 1 ............... 470
Crowd Clutch ................................................................ 1 ............... 560

Dipper Handle ..................................................................... 1 .......... 26,880

Dipper Assembly ................................................................. 1 .......... 32,090

Dipper Structure ............................................................ 1 .......... 20,900
Dipper Bail .................................................................... 1 ............ 2,250
Equalizer Sheave .......................................................... 1 ............ 1,150
Dipper Door Assembly ................................................... 1 ............ 7,780
Pitch Brace, each .......................................................... 1 ............... 330

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 2
Operation
Table of Contents

GENERAL INFORMATION ............................................................................................................ 3

Nomenclature .............................................................................................................................. 3
OPERATION NEAR ELECTRICAL LINES ............................................................................... 4
OPERATOR’S CAB ...................................................................................................................... 5
Operator’s Cab ............................................................................................................................ 5
OPERATOR'S SEAT ............................................................................................................... 5
OPERATOR'S SEAT ADJUSTMENT ................................................................................ 6
OPERATING CONTROLS ............................................................................................................ 8
PRIMARY OPERATING CONTROLS ..................................................................................... 8
CONTROLS ON THE LEFT CONSOLE ........................................................................... 9
LEFT JOYSTICK ......................................................................................................... 9
DIPPER TRIP .............................................................................................................. 9
SIGNAL HORN ............................................................................................................. 9
RADIO ......................................................................................................................... 9
HOIST BRAKE .......................................................................................................... 10
CROWD BRAKE ...................................................................................................... 10
SWING BRAKE ......................................................................................................... 10
PROPEL BRAKE ...................................................................................................... 10
Left Control Console .................................................................................................................. 10
CLIMATE CONTROL PANEL ..................................................................................... 10
WINDSHIELD WIPER SWITCH ................................................................................ 10
WINDSHIELD WASHER SWITCH ............................................................................ 10
CONTROLS ON THE RIGHT CONSOLE ....................................................................... 11
RIGHT JOYSTICK ..................................................................................................... 11
CONTROL STOP PUSHBUTTON ............................................................................ 12
CONTROL RESET PUSHBUTTON .......................................................................... 12
Right Control Console ................................................................................................................ 12
DIG/PROPEL TRANSFER SWITCH ............................................................................... 13
EMERGENCY STOP PUSHBUTTON ....................................................................... 13
MAIN POWER OFF PUSHBUTTON ......................................................................... 13
EARTH CONTINUITY LOCKOUT PUSHBUTTON .................................................... 14
TELEPHONE ............................................................................................................. 14
DISPLAY SCREENS ............................................................................................................. 15
Title Screen ............................................................................................................................... 15
Icon Screen ............................................................................................................................... 16
Active Alarm .............................................................................................................................. 17
Lube Settings ............................................................................................................................ 18
CDA Filter .................................................................................................................................. 18
Joystick Calibration ................................................................................................................... 19
Fault Counters/Operating Hours ................................................................................................. 20
Deck Plan Screen ...................................................................................................................... 20

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MCC Rack Screen ..................................................................................................................... 21

Operator’s Screen ...................................................................................................................... 21
AUXILIARY CONTROLS ............................................................................................................. 22
REMOTE START CONSOLE ............................................................................................... 22
AIR PANEL ............................................................................................................................ 24
PRE-START CHECKS ................................................................................................................ 25
WALKAROUND GROUND LEVEL INSPECTION ................................................................. 25
ON-BOARD INSPECTION .................................................................................................... 26
MACHINE START-UP, OPERATION AND SHUTDOWN ............................................................. 27
START-UP ............................................................................................................................. 27
Start-Up Control Locations ......................................................................................................... 27
RESTARTING AFTER AN ELECTRICAL FAULT ................................................................... 29
OPERATION ......................................................................................................................... 30
STOPPING THE MACHINE ................................................................................................... 31
MACHINE SHUTDOWN ........................................................................................................ 31
GROUND PREPARATION .......................................................................................................... 32
MACHINERY MOTIONS ........................................................................................................ 33
HOIST MOTION ............................................................................................................... 33
CROWD MOTION ........................................................................................................... 34
PROPEL MOTION ........................................................................................................... 35
Propel - Straight Forward/Reverse .............................................................................................. 35
SWING MOTION ............................................................................................................. 36
PROPER SWING MOTION ............................................................................................. 37
STEERING ...................................................................................................................... 38
COUNTER-ROTATION TURNS ...................................................................................... 40
POSITIONING THE MACHINE .................................................................................................... 41
BACK-UP METHOD .............................................................................................................. 41
DRIVE-BY METHOD ............................................................................................................. 42
START OF THE DIG CYCLE .......................................................................................... 43
Force the Dipper Lip into the Bank .............................................................................................43
Variations on Dipper Penetration ................................................................................................ 44
Dig with the Dipper Beneath the Boom Point .............................................................................. 45
ENGAGING THE BANK ................................................................................................... 45

Manual No. 10954 2-2 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 2
Operation

GENERAL INFORMATION

This section of the manual will assist in the operation of this machine. It provides the operator with
the location and explanation of the controls, instructions for machine operation and certain
maneuvering techniques. Throughout this section and the remainder of the manual, the use of 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.

Safe operation of the machine minimizes production delays and costly damage to equipment. Carefully
study and follow all recommended procedures in this manual. Safety guidelines are intended to
prevent accidents from occurring and are provided in the interest of all mine personnel. Overall
safety depends upon the use of good judgment and the alertness of the entire mining crew. Refer to
Section 1 in this manual for specific safety precautions.

Nomenclature

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

OPERATION NEAR ELECTRICAL LINES

DANGER! HIGH VOLTAGE! The following precautions shall be complied with

whenever operating around or near electrical distribution and
transmission lines.

Working in the vicinity of electrical power lines presents a very serious hazard and special precautions
must be taken. For purposes of this manual we are considering the entire machine or its load, in
any position, that can reach to within the minimum distance specified by local, state and federal
regulations.

Safe operating practices require that you maintain the maximum possible distance from the lines
and never violate the minimum clearances.

Before working in the vicinity of power lines, always take the following precautions:

• Always contact the owners of the power lines or the nearest electric utility before beginning
work.
• You and the electrical utility representative must jointly determine what specific precautions
must be taken to insure safety.
• It is the responsibility of the user and the electric utility to see that necessary precautions are
taken.
• Consider all lines to be power lines and treat all power lines as energized even though it is
known that the power is shut off and the line is visibly grounded.
• Slow down the operating cycle. Reaction time may be too slow and distances may be
misjudged.
• Caution all ground personnel to stand clear of the machine at all times.
• Use a signal person to guide the machine into close quarters. The sole responsibility of the
signal person is to observe the approach of the machine to the power line. The signal person
must be in direct communication with the operator and the operator must pay close attention
to the signals.

DANGER! HIGH VOLTAGE! Death or injury could result should any part of the
machine come within the minimum distance of an energized power
line specified by local, state and federal regulations.

Manual No. 10954 2-4 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

OPERATOR’S CAB

Operator’s Cab
OPERATOR'S SEAT

The operator's seat has adjustments for positioning it in the best location to suit individual operators.
It swivels into and out of operating position to provide easier entry/exit for the operator. Lift the
spring loaded T-handle lock beside the seat pivot to swing it into and out of operating position. To
raise or lower the seat, turn the hand wheel under it, clockwise (CW) to raise and counterclockwise
(CCW) to lower. An adjustable foot rest is provided for operator comfort. Refer to the following
page for more information on seat adjustment.

The operator should always adjust the seat to suit before taking over the controls.

DANGER! Do not attempt to operate this machine unless you understand all the
machine controls. Never leave the operator's seat without first setting
all motion brakes and de-energizing line excitation (LE) by pushing
the EXCITATION STOP pushbutton.

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

OPERATOR'S SEAT ADJUSTMENT

The operator’s seat has been selected to provide a maximum of operator comfort along with easy
control access for increased productivity. The seat has numerous adjustments allowing it to be
tailored to meet the individual needs of each operator.

Weight Adjustment
The seat should be adjusted for the operator’s weight by pulling the actuator lever of the automatic
weight and height adjuster while the operator is sitting in the seat and the machine is stationary.

Height Adjustment
The seat height is adjusted pneumatically by pulling or pressing the adjustment lever as required to
obtain the position required. DO NOT operate the compressor unit for more than 1 minute continuously.

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Seat Cushion Angle Adjustment

The angle of the seat cushion can be adjusted individually from the back. Lift the handle and exert
pressure in the desired direction while seated. Release handle once the required position is achieved.

Seat Depth Adjustment

The depth of the seat pan can be individually adjusted. Lift the handle and slide the seat pan
forward or backwards to position. Release the handle when the desired position is obtained.

Armrest Adjustment
The armrests can be adjusted to fit the individual needs of each operator or folded up and placed
out of the way.
To adjust the armrest height loosen the manual friction knobs on the outboard side of the armrest
allowing the armrests to pivot. Move the armrest to any desired position within its range and re-
tighten when desired.
To raise the arm rests; lift at front and stow vertically.

Headrest Adjustment
The headrest can easily be adjusted by lifting, or tilting, headrest to the desired position.

Lumbar Support
The curvature of the backrest can be adjusted pneumatically by pressing the switches on the lower
left rear of the backrest.

Backrest Adjustment
The backrest is adjusted by lifting the lever and then releasing once the desired position is obtained.

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

OPERATING CONTROLS

The operator must become familiar with the machine and its operating controls. The preceding
figure depicts the general location of controls on the machine.

The operating controls will be grouped as primary and secondary controls, depending upon their
location. The primary controls are the controls located in the operator’s cab and the secondary
controls are the controls located in the machinery house.

The descriptions listed should familiarize the operator with each control’s location and functional
use. The terms left, right, forward and reverse indicate directions with the operator seated in the
cab, facing forward, with the boom extending over the take-up axle of the crawlers.

PRIMARY OPERATING CONTROLS

Manual No. 10954 2-8 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CONTROLS ON THE LEFT CONSOLE

LEFT JOYSTICK

The Left Joystick controls the crowd/horn/dipper trip and propel. It is the vertical handle mounted on
the left console of the operator’s seat. This joystick will spring return to neutral when released.

During normal operation, pushing the joystick forward will

extend the dipper handle and dipper into the bank. Pulling
the joystick rearward will retract the dipper handle and
dipper toward the machine. The neutral position between
the crowd and retract functions is defined by a detent that
is easily felt. The rate of motion is controlled by varying
the distance the joystick is moved from the neutral (center)
position. Full forward or full rearward position provides
maximum speed to the handle. Moving the joystick to
neutral will cause a braking action slowing the crowding
or retracting handle. Reversing the joystick will cause the
motion to stop and if the joystick is held in this position, it
will change the direction of the motion.

With the propel transfer switch in the PROPEL position, pushing the joystick forward will cause the
left crawler to move forward. Pulling the joystick to the rear will cause the left crawler to move in the
reverse direction. The crowd/retract motion is locked out electrically when the machine is in the
propel mode.

Refer to JOYSTICK CONFIGURATION in this section of the manual to view the standard and
alternate configurations for the Right and Left Joysticks.

DIPPER TRIP

The dipper trip is part of the left joystick function in the standard configuration. Moving the joystick
to the right will activate the dipper trip mechanism which releases the dipper door latch. The dipper
trip is operational throughout the entire range of the crowd motion.

SIGNAL HORN

Moving the Left Joystick (in the standard configuration) to the left will activate the signal horn. The
signal horn is operational throughout the entire movement range of the crowd motion.

RADIO

The radio supplied with your machine is an AM/FM Stereo radio with the capability to play cassette
tapes in the player incorporated. This is a quality piece of sound equipment and will provide long
term operation.

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HOIST BRAKE

A selector switch used to set or release

the Hoist Brake.

CROWD BRAKE

A selector switch used to set or release

the Crowd Brake.

SWING BRAKE

A selector switch used to set or release

the Swing Brake.

PROPEL BRAKE

A selector switch used to set or release

the Propel Brake.

Left Control Console

CLIMATE CONTROL PANEL

The Climate Control Panel contains a rheostat controller on the top portion of the panel which is
used to tailor the temperature of the air delivered to the operator’s cab within the selected mode of
operation.
The Mode switch is provided to set the basic mode of operation for the roof mounted air conditioning/
heater unit.
The Blower Speed switch controls the volume of air being moved by the unit.

WINDSHIELD WIPER SWITCH

The windshield wiper switch controls the speed of the wipers, as well as the starting and stopping of
the wipers.

WINDSHIELD WASHER SWITCH

The windshield washer pushbutton controls the supply to the washer reservoir which powers the
washers.

Manual No. 10954 2 - 10 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CONTROLS ON THE RIGHT CONSOLE

RIGHT JOYSTICK
The Right Joystick controls the hoist/swing and propel. It is a joystick mounted on the right console
of the operator’s seat. The joystick is used to control the hoist, swing and right crawler motions of
the machine. The position of the propel transfer switch will determine whether this joystick controls
the hoist motion or the crawler motion.

With the propel transfer switch in the dig position, and

during normal operation, pushing the joystick forward will
lower the dipper. Pulling the joystick to the rear will hoist
the dipper. The neutral position between the hoist and
lower functions is defined by a detent that is easily felt.
The speed of moving the dipper is controlled by varying
the distance the joystick is moved from the neutral (center)
position. The full forward or full rearward position provides
maximum speed to the dipper. Moving the joystick to
neutral will cause a braking action slowing the hoisting or
lowering motion. Reversing the joystick will cause the
motion to stop and if the joystick is held in this position, it
will change the direction of the motion.
NOTE: When the right joystick is used in the hoist/lower mode it is a spring returned switch.
That is, it will return to the neutral position when it is released.
Moving the joystick to the left from the neutral position will cause the machine to swing to the left.
Moving the joystick to the right will cause the machine to rotate to the right. The swing motion is
operational throughout the entire movement range of hoisting or lowering the dipper. The swing
rate of acceleration is controlled by varying the distance the joystick is moved from the neutral
position. Moving the joystick to the neutral position will not stop the swing motion but will allow the
machine to coast. To stop or change direction the control joystick is moved past the neutral point in
the opposite direction. The rate of deceleration is controlled by varying the distance the joystick is
moved from the neutral position in the opposite direction.
Refer to JOYSTICK CONFIGURATION in this section of the manual to view the alternate
configurations for the Right and Left Joysticks.

With the propel transfer switch in the propel position, pushing the joystick forward will cause the
right crawler to move forward. Pulling the joystick to the rear will cause the right crawler to move in
the reverse direction. The hoist motion is locked out electrically when the machine is in the propel
mode.

NOTE: When the JOYSTICK is used in the swing mode the switch is a spring returned switch.
That is, it will return to the neutral position when it is released.

• DIG - activates the hoist, crowd, and swing drives; deactivates the propel drive; and
automatically sets the propel brakes.

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CONTROL STOP PUSHBUTTON

The control stop pushbutton is located on the right operator’s console. Normally it is used to de-
energize controls after the machine has been safely stopped by placing motion controls in neutral.

Actuation of this pushbutton when motions are running

will cause all motions to automatically electrically brake
to a stop and, when the motion speed has reached
less than 5% speed, set all mechanical brakes. If the
motions are already stopped, the brakes will be set
and power is removed immediately. A similar switch is
located on the front panel of the PLC control cabinet
that can be used during testing of the machine.

DANGER: THE OPERATOR SHOULD

NEVER LEAVE THE
OPERATOR’S SEAT
BEFORE PRESSING THE
CONTROL STOP
PUSHBUTTON. Setting only
the mechanical brakes with
individual switches is not a
sufficient safeguard to
prevent machine damage
and/or personnel hazards.

CONTROL RESET PUSHBUTTON

CAUTION: This is not an automatic reset

system. All controls must be
returned to neutral before the
control reset button is pushed.

Right Control Console

The control reset pushbutton is located on the right operator’s console. The reset pushbutton
restores control to all motions if no additional faults exist. This pushbutton is inoperative until the
main power start control has been actuated.

If a control fault occurs that shuts down a motion, all motions will automatically be shut down together.
At this time the operator should set all brakes. If the fault clears, the motion may be reset by
pressing this pushbutton. If the fault does not clear, the unfaulted motions can be restarted by
pressing this pushbutton to enable these motions to re-position themselves.

Manual No. 10954 2 - 12 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

DIG/PROPEL TRANSFER SWITCH

The Dig/Propel Transfer Switch is used to switch between the two primary operating modes of the
machine. The current mode of operation will be indicated on the Operator’s screen on the Operator’s
Display.

IMPORTANT:
• WHILE IN THE DIG MODE, THE PROPEL CONTROLS ARE DISABLED.
• WHILE IN THE PROPEL MODE, THE DIG CONTROLS ARE DISABLED.

The recommended procedure to transfer from dig to propel is to bring all motions to a controlled stop
by the operator. Turn the hoist brake switch to the SET position and then press the control stop
pushbutton. Turn the transfer switch from DIG to PROPEL. When the indicator on the Operator
Display screen indicates that the transfer has been completed, turn the propel brake switch to
release.

EMERGENCY STOP PUSHBUTTON

The machine stop/emergency stop pushbutton is located on the right operator’s console. It is used
to remove power from the machine motions after the motions have been stopped in the normal
manner. A second purpose of the pushbutton is to stop the machine under operational emergency
conditions. Pushing this button will provide electrical and immediate mechanical braking
simultaneously. Therefore, this button should only be used if the operator intends the harshest
braking of all motions. If the machine is in motion, power will remain on the motions in order to
provide electrical braking for a few seconds. If the machine is in motion or stopped, this button will
power the DC bus to approximately zero voltage quickly after the time delay.

CAUTION: PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY

RESULT IN COMPONENT DAMAGE.

A second pushbutton that also provides the functions as described above is located in the remote
start console and is labeled “machine stop.”

MAIN POWER OFF PUSHBUTTON

The main power off pushbutton is located on the right operator’s console. It is used only to immediately
remove power from the drives in case of an electrical emergency involving component failure or fire.

CAUTION: PUSHING THE “POWER OFF” PUSHBUTTON WHILE IN MOTION WILL

IMMEDIATELY SET THE MECHANICAL BRAKES AND REMOVE
INCOMING HIGH VOLTAGE FROM THE DRIVES. THIS ACTION MAY
RESULT IN COMPONENT DAMAGE. It will also result in the inability
to power the DC bus voltage down to a low value. This voltage will
decay slowly, taking several minutes.

Sept. 2010 2 - 13 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

EARTH CONTINUITY LOCKOUT PUSHBUTTON

The earth continuity lockout pushbutton is used to trip the breaker that supplies power to the machine.
When the machine is operating, this pushbutton should be used to shutdown the machine only
when removal of power to the machine is required.

TELEPHONE

A telephone is located at the rear of the right control console. This telephone is connected to other
phone stations throughout the machine.

Manual No. 10954 2 - 14 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

These icons and buttons will react by activating the screen, switch activation or display information
relevant to the icon.

All the machine controls can be found on the Operator’s Display Panel touch sensitive screen or the
left and right Control Consoles of the operator’s seat.

DISPLAY SCREENS

The Title Screen display appears when the machine is initially started.

Title Screen

The information provided in the central area of the screen is machine specific.

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182M-AC Electric Mining Shovel

Icon Screen

This screen displays the icons used throughout all the screens in the system.

Manual No. 10954 2 - 16 Sept. 2010

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182M-AC Electric Mining Shovel

Active Alarm

The Active Alarm screen will provide a list of all active alarms and faults that have been initiated on
the machine and have not been RESET. Once an alarm or fault has been sensed, these messages
will remain visible and WILL NOT be removed from this screen until it is RESET.

When a new alarm occurs, it shows up in a separate window on the top of any screen. It is cleared
when there are no active alarms, the user goes to one of the other alarm screens, or the user
presses the X next to the line.

NOTE: It is important to remember that messages will appear in this screen that are no longer
active alarm messages. All messages will appear since the time of the last reset.

Sept. 2010 2 - 17 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Lube Settings
This screen will provide clarifying information on the lubrication settings.

CDA Filter

Manual No. 10954 2 - 18 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Joystick Calibration

This screen will provide information on the joystick calibration process.

Sept. 2010 2 - 19 Manual No. 10954

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182M-AC Electric Mining Shovel

Fault Counters/Operating Hours

The Fault Counter/Operating Hours screen provides the operator with information on the number
of faults that have occurred since last RESET. It also provides the total operating hours.

Deck Plan Screen

This screen will activate further screens which are used to monitor various racks within the PLC
cabinets.

Manual No. 10954 2 - 20 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

MCC Rack Screen

Operator’s Screen

The Operator’s Screen is the primary operational information tool to be visible to the machine
operator during daily use of this machine. The controls available on this screen will provide the
operator with the information needed to view “at a glance” the status of items required for digging
and make changes in control settings.

Sept. 2010 2 - 21 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

AUXILIARY CONTROLS

REMOTE START CONSOLE

The remote start panel contains the following

switches and indicator lights used to initially
start the machine.

Phase Sequence Light

This green indicator light, when lit, indicates

that incoming power sequence is correct. If
the light is OFF, have electrical maintenance
change the trail cable phase sequence.

Drive Cabinets Temperature Light

This green indicator light, when lit, indicates that the

drive electronic cabinets are at the correct operating
temperature. Too low or too high cabinet temperatures
will not allow the machine to start.

PLC Power On Light

This green indicator light, when lit, indicates that PLC and drive control power is on.

System Ready Light

This green indicator light, when lit, indicates the system is ready to start. When the system run
pushbutton is pressed and the system successfully started, this light will go out.

Auxiliary Ground Fault Light

This green indicator light, when lit, indicates that no auxiliary power ground fault exists. If the light is
OFF, alert an electrician as soon as possible.

Manual No. 10954 2 - 22 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Incomplete Sequence Light

This red indicator light, when lit, indicates the automatic start-up sequence did not complete in a
preset time period. Have an electrician troubleshoot the sequence. If this indicator does not light
up, the start-up sequence is progressing properly and machine start-up can continue.

System Run Pushbutton

This pushbutton will energize the drive system when pressed if the system ready light is on.

Ladder Down Horn

When the boarding ladder is not latched in place, the operator's controls are deactivated.

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

AIR PANEL

1. The upper air pressure gauge indicates the air

system operating pressure of 120 PSI (689
Kpa).

CAUTION: IF THE SYSTEM PRESSURE

IS BELOW 100 PSI, OR
ABOVE 120PSI, SHUT THE
MACHINE DOWN AND
CORRECT THE PROBLEM.
Failure to heed this caution
could result in machine
damage.

2. Crowd Clutch Regulator - The crowd machinery

is fitted with a clutch which will slip and protect
the machinery from impact loads that may occur
when digging.

3. Adjust the air regulator to obtain an air pressure

of 80 PSI in the lower gauge. Further
adjustment may be required due to digging
conditions and friction material. Once set, no
additional adjustment is required.

NOTE: The air supply line at the crowd clutch is equipped with a check valve that permits air
flow into the clutch but not out. This check valve is there to prevent inadvertent loss of
clutch action by accidentally exhausting air and possibly letting the dipper handle
move in the boom yoke blocks without motor or brake control. This check valve is
located inside the guard over the clutch. To exhaust air from the crowd clutch, the air
supply line must be closed, the clutch guard removed and the air line to the clutch
loosened to reduce the air pressure.

DANGER! RELEASE THE AIR LINE PRESSURE BEFORE REDUCING AIR

PRESSURE TO THE CLUTCH. DO NOT ATTEMPT TO REMOVE ANY
FITTINGS UNTIL THE AIR PRESSURE HAS COMPLETELY BLED OFF.
FAILURE TO USE CAUTION COULD RESULT IN PERSONAL INJURY.

Manual No. 10954 2 - 24 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

PRE-START CHECKS

Before starting, inspect the machine to ensure it is ready to be put into operation. Failure to make
such a routine check could result in unnecessary downtime. For example: an undetected oil leak
could result in a dry gearcase, eventually leading to excessive gear wear or destruction, seized
bearings or other mechanical problems. Broken strands in the hoist ropes, suspension rope or
structural strands could, if undetected, result in serious injury or damage to the machine or haulage
unit. A few minutes spent inspecting the machine often results in considerable savings in time and
machine efficiency. Section 4 of this manual contains checklists to assist in record keeping and
ensure that adequate inspection standards are met.

WALKAROUND GROUND LEVEL INSPECTION

Check the following areas daily during a general walkaround inspection:

1. 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 make a note of it on the log
sheet. If pooling of oil is noticed, determine the source and take corrective action 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. Inspect the crawler belts for missing links or lock pins, excessive belt sag, cracked shoes or
other deterioration. Check the oil level in the propel planetary gearcase. Add oil as required.

3. Check the swing rack 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.

DANGER: 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.

4. Visually inspect the trail cable for cuts, abrasions and other damage.

5. Visually inspect exterior of machinery house for damage or evidence of internal leakage.

6. Inspect the dipper trip mechanism, rope, latch bar and associated hardware for damage,
adjustment and wear.

7. Inspect the dipper door, hardware and bumpers for damage and excessive wear.

8. Inspect fulcrum attachment points, slide blocks and spacers, and dipper handle for damage,
excessive wear and evidence of adequate lubrication.

9. Inspect the dipper and tooth adapters for tightness and excessive wear.

10. Inspect Dipper Bail Assembly for damage, wear and evidence of adequate lubrication.

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11. Check both the running ropes and the boom structural strands for broken strands and loose
sockets.

ON-BOARD INSPECTION

Check the following areas daily on board the machine:

1. Visually inspect the swing and hoist gearcases for oil levels and leaks. Repair or service as
required.

2. Visually inspect all machinery for loose bolts, nuts, clamps or unusual deterioration. Repair as
required.

3. 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.

4. Check the oil level in the air compressor. Add oil if required.

5. Inspect the automatic lubrication central pumping stations for any signs of malfunctioning.
Check the lubricant supply and refill tanks if required.

6. Visually inspect swing, crowd and hoist brake assemblies for damage, wear and evidence of
an overheated condition.

7. Check the operator’s cab for cleanliness and visual condition of controls and location of special
equipment that may be required by the mine site. Check all operating controls for freedom of
movement. Controls should move freely without binding.

8. Clean windows of operator’s cab.

9. Inspect all walkways and stairways to ensure there are no obstructions or fluids creating a
safety hazard.

10. Ensure ladder(s), steps and/or man basket are raised and properly stowed.

11. Perform the manual lubrication points detailed in Sections 3 and 4 of this manual.

Manual No. 10954 2 - 26 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

MACHINE START-UP, OPERATION AND SHUTDOWN

START-UP

Whether starting the machine for the first time, or starting after the machine has been in service for
some time, the procedures are essentially the same.

1. Perform all pre-start checks listed in PRE-START CHECKS in this section of the manual.

2. Raise the LH boarding stair and RH boarding ladder, making sure they are secured in the
raised position. The limit switch at the top of the ladder and the back of the stair will not
activate and the controls will not energize if the stair and ladder are not in the fully-raised
position.

Start-Up Control Locations

3. In the operator’s cab check that all brake switches are in the SET position and that the
joysticks are in the neutral position. Then go to the electrical area at the rear of the machinery
house.

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4. At the AC control cabinet verify that the uninterruptable breaker is in the ON position. At the
motor control cabinet, verify that all breakers are in the ON position.

5. At the remote starting console in the operator’s cab, use the following sequence to start the
machine:

a. Verify that the green AUXILIARY GROUND FAULT light is lit.

CAUTION: IF THE AUXILIARY GROUND FAULT LIGHT IS OFF, ALERT AN

ELECTRICIAN AS SOON AS POSSIBLE. The machine may be
operated with one fault but a second fault could cause damage to the
machine and/or become a safety hazard. The fault should be cleared
as soon as possible.

b. Verify that the green PHASE SEQUENCE light is lit. This indicates that the incoming
power sequence is correct. If not, the light will be out and the machine will not start.
Electrical maintenance personnel must correct the problem.

NOTE: This PHASE SEQUENCE light also indicates auxiliary power phase unbalance, phase
loss or under-voltage. Any of these faults occurring while the machine is running will
produce an alarm. In the event of such an alarm an electrician should be notified,
however the machine may be operated.

c. Verify that the PLC and drive cabinets’ green temperature lights are lit. If the cabinet
temperature is too low or too high, the machine cannot be started.

d. Verify that the green PLC POWER ON light is lit. This light should be on about 20
seconds after the UPS motor is started.

e. Turn the AIR COMPRESSOR RUN switch to the run position. It is located on the air
compressor.

f. Verify that the green SYSTEM READY light is lit on the start console.

g. Press the SYSTEM RUN pushbutton. When this button is pressed, the system ready
light will go out and the drive system will automatically power up.

h. Verify that the red INCOMPLETE SEQUENCE light is out. If lit, call the electrician to
troubleshoot the sequence.

6. In the operator’s cab, verify that the air pressure displayed on the operator’s display is correct.
The machine cannot be operated until the air pressure is at the specified rating.

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7. Verify that the brake switches are in the set position and the joysticks are in the neutral
position. Sound the signal horn and be sure all personnel are clear of machine.

8. Turn the propel transfer switch to the DIG position. When the Operator Display lights indicate
that the process is complete, press the control reset pushbutton to activate the controls.

9. Turn the hoist, crowd, swing and propel brake switches to their RELEASED position.

10. Briefly actuate swing, hoist and propel controls to make sure each motion is operational.

RESTARTING AFTER AN ELECTRICAL FAULT

To restart the machine after the electrical control system has gone into a fault condition, proceed as
follows:

NOTE: Before any or all motions can be reset, the following conditions must be met:

a. No operator’s monitor special screens should be activated.

b. For hoist/propel motion the hoist/propel transfer switch is in the position called for by the
operator’s mode selector switch.
c. The joystick for the motion being reset must be in the neutral position.
d. The motion mechanical brake selector switch must be in the released position.

1. For hoist or crowd travel limit faults, the motion will first slow down and then will stop, but the
controls will remain active. Reversing the joystick will remove the fault and allow continued
operation.

2. For a boom jacking fault, the crowd motion will stop but the controls will remain active. Put
both joysticks in neutral. Reversing the left joystick will remove the fault and allow continued
operation.

3. If the RH boarding ladder or LH stairs are pulled down while the machine is in operation, an
alarm message will be sent to the operator and swing and propel motions will be shut down.
The hoist and crowd motions will remain active.

Once the ladder is back in position, the motions may be restarted by pressing the control reset
pushbutton.

4. For most other faults, the machine will be shut down and the brakes set. In these situations,
the controls cannot be reset until the fault has been corrected by an electrician.

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OPERATION

Efficient operation is essentially the result of understanding and applying the basic techniques
related to each machine motion, to achieve fast, smooth and safe load cycles. The interrelated
coordination of the hoist, swing and crowd motions results in efficient machine operation.

Each motion is described in the following paragraphs. The operator should thoroughly learn each
motion, its purpose and how this knowledge can be applied in becoming a better operator.

When learning to handle the operator controls, be sure that all personnel are clear of the machine
and that there is ample clearance with no danger spots around the machine, such as culverts,
ditches or embankments and that the machine is not too close to the digging face or overhanging
ledges and large rocks.

Use the Operator Display panel, in the operator’s cab, to assist in the operation of the machine.
The monitor allows a large number of messages to be sent to the operator from all portions of the
control system. These messages fit into four basic categories:

1. Normal routine operational messages.

2. Alarm only.
3. Delayed shutdown messages.
4. Immediate faults and shutdowns.

This monitor also allows the setting of certain operating parameters for the machine. Refer to
OPERATOR’S DISPLAY in this section of the manual for detailed descriptions of the Operator
Display monitor screens and how they relate to the proper operation of the machine.

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STOPPING THE MACHINE

1. Return left and right joysticks to their center positions and set all brake switches.

2. After all motions are stopped and brakes are set, press the CONTROL STOP pushbutton.
This action will remove power to the control units and set the brakes. The controls will become
inoperative.

3. To stop the machine completely and remove power from the drives, press the MACHINE
STOP Pushbutton on the right operator’s console.

MACHINE SHUTDOWN

When shutting down the machine at the end of a shift proceed as follows:

1. Park the machine on firm ground in a position where it cannot be damaged by a slide, falling
rocks or flooding.

2. Place the dipper firmly on the ground.

3. Make sure left and right joysticks are in their center positions.

4. Make sure all brake switches are in their SET positions.

5. Press the CONTROL STOP pushbutton. All primary controls should be de-energized.

6. To de-energize the DC bus, press the MACHINE STOP pushbutton on the remote start console
or the MACHINE STOP/EMERGENCY STOP pushbutton on the operator’s console.

7. Close all windows in the cab and lock all cab doors.

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GROUND PREPARATION

Ground preparation is very important. The mining shovel requires a properly prepared ground base
for operation. The crawler shoes must have full contact with the ground when the machine is digging.
With the machine weight distributed over the crawler shoes minimum ground bearing pressure is
obtained and the machine components are less stressed.

For optimum operation, the ground supporting a mining shovel must be as near level as possible
and firm. Sharp rocks and boulders cause point loading which will damage the propel machinery
and crawler structures and should be removed if possible. Where this is impractical, cover the
working area with fill dirt to a sufficient depth that will eliminate the effects of the rocks.

The mining shovel design incorporates a calculated balance between boom length, boom angle,
allowable dipper load, machine weight, and ballast used. During normal digging cycles, the center
of gravity shifts from the front to the rear within a specific distance. If, for any reason, the digging
radius or load increases to cause the center of gravity to extend beyond this specific distance the
machine will become unstable.

CAUTION: OPERATION OF AN UNSTABLE MACHINE COULD RESULT IN

DAMAGE TO THE SHOVEL, TRUCKS OR SUPPORT EQUIPMENT.

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MACHINERY MOTIONS

HOIST MOTION

In standard configuration, Hoist motion is controlled by the operator’s right joystick. Set the propel
transfer switch in the DIG mode. The crawlers should be positioned so that the digging is done over
the front of the crawlers. Move the joystick between hoist and lower until a “feel” is developed for the
height, depth range and speed at which the dipper moves. Practice the hoist function until movement
can be stopped smoothly.

CAUTION: This joystick also controls the swing motion through left and right
motions.

NOTE: The following represents the standard configuration.

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CROWD MOTION

In standard configuration, Crowd motion is controlled by the operator’s left joystick. Move the
joystick to crowd and retract the dipper handle until a “feel” is developed for the limits and speed of
the motion.

CAUTION: This joystick also controls the signal horn and dipper trip.

NOTE: The following represents the standard configuration.

Practice the crowd and retract functions until the movement can be stopped smoothly. Combine the
crowd and hoist functions and practice until smooth coordinated motions and subsequent machine
effectiveness are achieved.

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182M-AC Electric Mining Shovel

PROPEL MOTION

Propel motion is controlled by placing the propel transfer switch in the propel mode and actuating
the left or right joystick. To propel in a straight forward direction, push forward on both the left and
right joysticks at the same time. The speed is increased as the levers are displaced farther from
neutral. To propel straight in reverse, pull equally both joysticks to the rear.

NOTE: The control stop pushbutton must be pressed before the propel transfer switch can be
activated.

DANGER: THE HOIST BRAKE MUST BE SET WHENEVER IN THE PROPEL

MODE.

Propel - Straight Forward/Reverse

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SWING MOTION

In standard configuration, Swing motion is controlled by the operator’s right joystick. To swing in
either direction, move the joystick lever in the direction of swing. Practice swinging in each direction
until a “feel” is developed for start-up and stopping.

NOTE: The joy stick also controls the hoisting and lowering of the dipper through forward and
backward motions.

DANGER: Each motion - hoist or swing - is fully operational throughout the

complete movement of the other motion.

NOTE: When this joystick is used for propelling the machine, the hoist and swing motions are
electrically locked out.

NOTE: The following represents the standard configuration.

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PROPER SWING MOTION

Proper swing motion means smooth control and an efficient swing cycle. The swing motion is begun
toward the haulage unit when the dipper is filled and is clear of the bank.

DANGER: EXTENSIVE DAMAGE TO THE DIPPER HANDLE AND DIPPER CAN

OCCUR IF THE MACHINE IS ROTATED BEFORE THE DIPPER CLEARS
THE BANK.

The swing motion begins with acceleration to an optimum point at which the excavator is brought to
a stop over the haulage unit. Maximum efficiency and minimum swing machinery wear are direct
results of mastering the swing motion.

NOTE: Improper swing motion results in erratic control and an inefficient swing cycle.

DANGER: THE DIPPER SHOULD NEVER BE POSITIONED OVER PERSONNEL,

TRAIL CABLES, RELATED ELECTRICAL EQUIPMENT OR OTHER
EQUIPMENT. When the dipper is loaded, accidental tripping of the
dipper door could result in death or serious injury to personnel and
extensive damage to equipment. Empty dippers may contain small
fragments of material that can be extremely dangerous when
dropped from a considerable height. On long moves open the door
on an empty dipper and lower the dipper to a point that permits
moving without striking the ground.

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182M-AC Electric Mining Shovel

Time is required to accelerate any motion from zero to working speed and also to decelerate from
working speed back to zero. THE TIME EXPENDED FOR ACCELERATING AND DECELERATING
THE SWING REPRESENTS THE MAJOR PART OF THE ENTIRE DIG CYCLE. Therefore, the
swing arcs must be kept to a minimum to obtain maximum operating efficiency. As an example:
assuming that a 90° swing results in 100 percent of the maximum output, increasing the swing arc to
180° reduces output to 70 percent, while decreasing the swing arc to 45° increased the output to
126 percent. Therefore, a swing arc of 90° or less should usually be used.

Haul units should be positioned so their center line is approximately under or not more than slightly
outside the swing path of the boom point. This substantially reduces the amount of dipper
maneuvering required of the operator when positioning the dipper for dumping. Positioning of the
haulage unit inside or outside the boom point makes it necessary to retract or crowd the dipper
handle and dipper, which breaks the operator’s natural rhythm.

A clean, level pit floor must be maintained. A good operator will always clean the floor before moving
into the bank. A clean and level floor grade is a requisite to safe and stable machine operation and
reduces damage to crawler links and related components.

DANGER: “SWEEPING” SHOULD NEVER BE ATTEMPTED WITH THE MACHINE.

Sweeping consists of lowering the dipper to the ground and using the
swing motion of the machine to move the dipper from side-to-side
and “sweep” the pit floor. THE DIPPER, DIPPER HANDLE AND BOOM
STRUCTURES CAN BE DAMAGED BY SWEEPING. A bulldozer or
loader should be used to help the machine operator maintain a clean
pit floor in conjunction with the shovel.

STEERING

To make a gradual forward right turn, move the

LEFT joystick (crowd) forward and leave the right
joystick (hoist) in neutral.

To make a gradual forward left turn, move the

RIGHT joystick (hoist) forward and leave the left
joystick (crowd) in neutral.

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182M-AC Electric Mining Shovel

Whenever possible, gradual turns should be made in short increments of 15° to 20° maximum.
Propel straight for a short distance (usually 1/2 the length of the crawler belts) to clear the crawler
belts of stone and other debris; then make another 15° to 20° turn. Continue until the turn is
completed.

NOTE: When steering in soft material such as sand, clay, etc., increments of less than 15° to
20° should be used to minimize material build up on the crawler belt roller path.

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182M-AC Electric Mining Shovel

Manual No. 10954 2 - 40 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 3
Lubrication
Table of Contents

LUBRICATION PRINCIPLES ......................................................................................................... 3

GREASING MAIN A.C. DRIVE MOTORS ...................................................................................... 5
1. TYPE OF GREASE ............................................................................................................. 5
2. INITIAL COMMISSIONING .................................................................................................... 5
3. MAINTENANCE ................................................................................................................... 5
4. REGREASING INTERVALS ................................................................................................. 6
AUTOMATIC LUBRICATION SYSTEM .......................................................................................... 7
AUTO LUBE CONTROL ......................................................................................................... 8
182M Auto Lube Control Center ................................................................................................. 8
AUTO LUBE ~MPG AND OGL ................................................................................................ 9
Auto Lube Control Panel ............................................................................................................. 9
Vent Valve .................................................................................................................................. 9
AUTO LUBE CONTROL PANEL (ELECTRIC) ...................................................................... 10
OPERATION ................................................................................................................... 11
IMPORTANT NOTES ON SYSTEM OPERATION ........................................................... 12
MPG PRESSURE SWITCHES ....................................................................................... 13
OGL PRESSURE SWITCH ............................................................................................. 13
SAFETY UNLOADER VALVES ........................................................................................ 14
LUBE CIRCUIT PRESSURE SWITCHES ...................................................................... 14
AIR OPERATED LUBE PUMPS ............................................................................................ 15
GUIDELINES FOR TROUBLESHOOTING AN AUTO LUBE ALARM .................................... 18
LINCOLN TYPE SL-1 LUBRICANT INJECTORS ........................................................................ 21
LUBRICANT INJECTOR OPERATION.................................................................................. 22
SL-1 INJECTOR ADVANTAGES ............................................................................................ 23
LUBE DRAINAGE SYSTEMS ...................................................................................................... 24
Lube Drainage System on the Rotating Frame ........................................................................... 25
Hoist Gearing and Center Journal Lube ...................................................................................... 25
Lube Drainage System on the Lower Frame ............................................................................... 26
LUBRICATION STANDARDS ...................................................................................................... 27
DESCRIPTION OF OIL AND GREASE CLASSIFICATION.................................................... 28
SPECIAL LUBRICANTS .................................................................................................. 30

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LUBRICATION SPECIFICATIONS ......................................................................................... 31

GREASE SPECIFICATIONS ........................................................................................... 31
OIL SPECIFICATIONS ..................................................................................................... 31
GEAR LUBRICANTS - GL (OIL TYPE) ............................................................................ 32
TEMPERATURE CHART ~ GL OILS ......................................................................... 33
GEAR LUBRICANTS ~ HGL (OIL TYPE) ......................................................................... 34
TEMPERATURE CHART ~ HGL OILS ...................................................................... 35
LUBE POINTS ............................................................................................................................. 36
POINTS ON AUTO LUBE SYSTEM USING "MPG" ............................................................... 37
POINTS ON AUTO LUBE SYSTEM USING "OGL" ............................................................... 38
MANUAL LUBE POINTS ........................................................................................................ 39
CRAWLERS .......................................................................................................................... 39
ROLLER CIRCLE ................................................................................................................. 39
AUXILIARY COLLECTOR RING/ROTOSEAL ASSEMBLY .................................................... 39
ROTATING FRAME ............................................................................................................... 40
BOARDING STAIRWAY ......................................................................................................... 41
OPERATOR'S CAB .............................................................................................................. 41
SWING MACHINERY ............................................................................................................. 41
HOIST MACHINERY .............................................................................................................. 42
BOOM ................................................................................................................................... 42
DIPPER/HANDLE ................................................................................................................. 43
CABLE REEL ........................................................................................................................ 44
LUBRICANT SPECIFICATIONS ............................................................................................ 45

ADDITIONAL LUBRICATION BENCHMARKS

SPECIFICATION FOR ENCLOSED GEARCASE LUBRICANT - SD4722 ................... (insert)

(For Propel gearcases)

SPECIFICATION FOR ENCLOSED GEARCASE LUBRICANT - SD4721 ................... (insert)

(For Non-Planetary Swing gearcases)

SPECIFICATION FOR OGL - OPEN GEAR LUBRICANT - SD4713............................. (insert)

(For Non-Planetary Hoist and Crowd gearcases)

SPECIFICATION FOR MPG - MULTIPURPOSE GREASE - SD4711 ........................... (insert)

CERTIFIED LUBRICANT LISTING FOR OGL, MPG & EGL LUBRICANTS .................. (insert)

Manual No. 10954 3-2 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 3
Lubrication

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 that will
make your mining operation profitable. Proper lubrication will provide better component service life
and reduce repairs and downtime. When not properly lubricated, moving parts wear quicker and
fail sooner.

The major portion of this machine is 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 auto lube system that
you become familiar with it and understand its operation so you can maintain and service it and
keep it operable. It is also necessary that you periodically inspect on a regular basis the lubed
points for lubricant application to insure the system is performing its job.

Some components, due to their location and function, can not be readily covered by the auto lube
system. A listing of these manually lubed areas that shows the lube application frequency is given
in this section. 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 also included.

Per Bucyrus standard, the 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 lubed 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 lubing anti-friction
bearings, especially those that are sealed such as in electric motors, remove the pressure fitting,
or the relief plug when provided, and allow 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 coat of a good grade of lubricant acceptable for
operation. Inspect all open gear sets at least once daily (every 24 hours) to insure they are coated
with OGL.

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The automatic lubrication system is not designed to provide INITIAL COVERAGE. New parts
installed or those cleaned during maintenance procedures must be fully lubed before commencing
machine operation. Anti-friction bearings and bushings bust 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 cause you to do a repair job!

ENCLOSED GEARCASES must have their recommended lubricant level maintained. 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 gearcases at their recommended
intervals, 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 OF. DO NOT POLLUTE
THE ENVIRONMENT!

Bucyrus recommends that scheduled oil samplings from the enclosed gearcases and air compressor
crankcase(s) on this machine be taken and tested by an authorized and 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 they are good representative samples. This preventive maintenance
procedure will permit you to determine the best time to change the oil, thus obtaining its best
service life, and will simultaneously allow you to monitor the condition of the components. This
program will pay you dividends in the long run.

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 application, such as the hoist rope, it is at the sheaves or
drum 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.

LUBRICANT SERVICE LIFE is adversely affected by unusually dusty or dirty environments and an
atmosphere where high humidity or extreme 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.

IMPORTANT: For AIR and HYDRAULIC QUALITY RECOMMENDATIONS and QUALITY

MAINTENANCE PROCEDURES, refer to Section 9 - ENGINEERING DATA in
this manual.

Filter all lubricants, especially oil, before adding them to the system or using
them on the machine. Store lubricant drums on their side with the opening UP.
Use only clean, uncontaminated lubricants!

CAUTION: Automatic lubrication systems operate under pressure. Before

opening any lube supply line, relieve the system, and that line in
particular, of any residual pressure. CONTACT WITH OR INGESTING
PETROLEUM PRODUCTS CAN BE HARMFUL.

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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 for Bucyrus International machines 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.

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 @ 40C.
Caution: Do not mix greases with different thickeners since the greases may
not mix properly and bearing failure may result.

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.

3. MAINTENANCE

This procedure should be used for regular maintenance regreasing. Refer to the following table,
REGREASING INTERVALS, 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.

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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.
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.

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.

Drive End Non-Drive End

Motor Regreasing Grease Amount Grease Amount
Interval Grams (oz.) Grams (oz.)
Hoist motor 3000 operating hours 88 (3.1) 140 (5.0)
or every 6 months
Propel motor 3000 operating hours 54 (1.9) 94 (3.3)
or every 6 months
Crowd motor 3000 operating hours 54 (1.9) 94 (3.3)
or every 6 months
Swing motor 1500 operating hours 54 (1.9) 80 (2.8)
or every 4 months
NOTES:

1. It is critical that the drain pipe not be allowed to become plugged with caked or
contaminated grease. If it does, then the pipe must be cleared.

2. 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.

3. Bucyrus part number 59100651 is a 14 ounce cartridge of Mobilith SHC100 grease.

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182M-AC Electric Mining Shovel

AUTOMATIC LUBRICATION SYSTEM

This system automatically dispenses measured amounts of open gear lubricant (OGL) and
multipurpose grease (MPG) at preset intervals through 3 circuits to the open gearing and selected
bearings and bushings on this machine. These 3 circuits are:

• Open Gears (OGL) .......................................................... 26 points

• Rotating Frame (MPG) ..................................................... 35 points

• Lower Frame & Crawlers (MPG) ...................................... 24 points

This system serves a total of 85 Lube Points: 26 OGL and 59 MPG.

The operation of each of these 3 circuits is controlled electrically to start and stop the air-operated
pump that delivers lubricant to the injectors. The injectors (Lincoln type SL-1) cycle during pump
operation to meter the lubricant to the designated points. Each circuit is monitored for operating
faults. If any are detected, they are indicated at the OIU light and the warning horn on the front of
the affected control panel.

This system consists of:

- OGL reservoir (16 gal. drum) fitted with an air-operated lube pump (50:1 ratio).
- 2 MPG drum reservoirs (16 gal. drum each) fitted with an air-operated lube pump (50:1 ratio)
One for the lower frame lube circuit and one for the upper frame circuit.
- Air supply from the compressed air system to each circuit's piping panel above the air pump.
Each panel has a pressure regulator for limiting the operating air pressure to the lube pump.

CAUTION: All air line shutoff valves must be open during machine operation.

- A solenoid controlled, 3-way, air operated valve on each panel controls air to the pump and vent
valve.
- An air operated vent valve on each panel permits lubricant to be pressurized in the circuit during
the pumping cycle, and vents off pressure from the circuit when the pump is off.
- Lincoln SL-1 high-pressure lubricant injectors.
- Air and hydraulic pressure gauges located at strategic points for visually monitoring the system
operation.
- High pressure switches in each circuit which shutdown the pumps, terminating the lube cycles at
2500 PSI (17.2 MPa).
- Safety unloaders (factory set at 3750-4250 PSI and nonadjustable) in each lube pump delivery
line to protect the lube system from excessive pressure.
- Operator's Interface Unit in the Operator's Cab to program and control the lube systems.

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182M-AC Electric Mining Shovel

AUTO LUBE CONTROL

182M Auto Lube Control Center

NOTE: The safety unloaders are preset at a nominal 4000 PSI. Cycle time intervals given are for
average conditions. The rotating frame MPG & Hoist/Boom OGL system pressure
switches are located on the shipper shaft gear guard. The lower frame MPG system
has 2 pressure switches, one on each crawler.

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182M-AC Electric Mining Shovel

AUTO LUBE ~MPG AND OGL

These 3 systems use identical valve panels. Refer to the end of this section of the manual for the
lube points and lube schematic.

CAUTION: Inadequate lubricant to machine components can result in serious

damage and costly repairs.

Auto Lube Control Panel

~3 Places

Vent Valve

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

AUTO LUBE CONTROL PANEL (ELECTRIC)

The following items are on the

electrical Auto Lube Control Panel:

1. POWER ON - A green light that indicates

the power is on to the control panel and
the lube system.

2. MACHINE OPERATING - A green light

which indicates that Line Excitation (L.E.)
is energized and the machine is operable.

3. PROPEL MODE - An orange light which

indicates the lower frame lube system is
in operation.

4. SILENCE - A white pushbutton used to silence the fault alarm. The fault light(s) will remain
active until the fault is corrected.

5. AUDIBLE SIGNAL - Signals a lube system fault. Can be silenced by pressing the silence
pushbutton.

6. OGL - A red indicating light which turns on when the pump reaches peak pressure during a
lube cycle. The light will remain on until the pressure switch resets. When flashing, a fault is
indicated. The problem must be corrected and the system successfully cycled manually to
clear the fault.

7. UPPER FRAME PRESSURE SWITCH - A red indicating light which turns on when the pump
reaches peak pressure during a lube cycle. The light will remain on until the pressure switch
resets. When flashing, a fault is indicated. The problem must be corrected and the system
successfully cycled manually to clear the fault.

8. LOWER FRAME PRESSURE SWITCH - A red indicating light which turns on when the
pump reaches peak pressure during a lube cycle. The light will remain on until the pressure
switch resets. When flashing, a fault is indicated. The problem must be corrected and the
system successfully cycled manually to clear the fault.

9. LAMP TEST - A white pushbutton to test the control panel indicator lights. Replace any light
which does not turn on when the button is pushed.

10. OGL CYCLE - An amber pushbutton to manually cycle the OGL system. The light will remain
on while the system is cycling.

Manual No. 10954 3 - 10 Sept. 2010

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182M-AC Electric Mining Shovel

11. UPPER FRAME CYCLE - An amber pushbutton to manually cycle the upper frame MPG lube
system. The light will remain on while the system is cycling.

12. LOWER FRAME CYCLE - An amber pushbutton to manually cycle the lower frame MPG lube
system. The light will remain on while the system is cycling.

13. STOP - A pushbutton (Push / Pull) to stop the lube systems in an emergency. When pushed,
the red light will be on. The button must be pulled out for the lube systems to operate.

OPERATION

When L.E. is activated, the Upper Frame MPG, OGL and Lower Frame MPG will cycle once in the
order stated. The lube cycle timers will initiate succeeding lube cycles.

A lube cycle can be initiated by L.E. activation, the cycle timer or the manual pushbutton on the
lube control panel. The selected 3-way air solenoid valve is energized, air is directed to the lube
pump and the vent valve is closed. Lube is pumped to the injectors which inject a metered amount
of lubricant to the bearings or gears. When the lube pressure reaches the preset level, the pressure
switch will close. The air solenoid valve is de-energized which stops the pump and opens the vent
valve. With the vent valve open, the system pressure will drop to zero and the injectors will recharge
for the next cycle.

Sept. 2010 3 - 11 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

IMPORTANT NOTES ON SYSTEM OPERATION

1. A lube cycle is the interval between the initiation of lube cycles. The cycles will continue as
long as L.E. is energized and NO fault is detected in the lube supply circuit.

2. The lube system is programmed to operate one lube system at a time. No 2 systems will
operate simultaneously.

3. The Lower Frame Lube system has 2 cycle times. The cycle time selected is dependent on
the machine operating mode. When in the PROPEL mode the number of lube cycles is
increased to provide additional lube to the crawlers.

4. The Lower Frame lube system has two pressure switches to insure lubricant dispersal. (Refer
to the system schematic.) Both pressure switches must open to terminate a lube cycle.

5. When L.E. is energized, one of the 3 systems will cycle. The timers in the other 2 systems
will reset to zero. The program will cycle a different system each time L.E. is energized.

6. If any automatic lubrication supply system is operating at the time the machine's drive system
control is changed from DIG to PROPEL, DIG to BRAKES SET, etc., the system operating
will be interrupted to allow the Lower Frame system to operate.

7. The alarm time must be greater than the cycle duration and less than the preset cycle time.

Any of the lubricant supply circuits can be cycled manually when power is ON the control panel,
regardless of the machine operating mode. There are pushbuttons on the front of the control panel
used for manual operation. Manual operation of a lube circuit is useful for purging the lube lines,
supplying additional lubricant to components or investigating a fault. The circuits must be manually
cycled to clear a fault.

For manual operation, select the circuit desired by pressing one of the 3 pushbuttons provided on
the auto lube control cabinet. Push the Manual Cycle START button to start the lube cycle. Only
one lube supply system can be operated at a time.

Once activated, a lube cycle will run until one of the following occurs:

a. The contacts in the pressure switch(es) in the operating circuit opens.

b. The alarm time for that system is exceeded and a fault is indicated.

c. The Manual Cycle STOP button is pushed.

Manual No. 10954 3 - 12 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

MPG PRESSURE SWITCHES

• Rotating Frame, Gantry and Boom - The pressure switch on the shipper shaft gear guard
must close to terminate the lube cycle.

• Crawlers - The pressure switch inside the lube injector cabinet on both crawlers must close
to terminate the lube cycle.

OGL PRESSURE SWITCH

• Hoist, Swing and Crowd Machinery - The pressure switch on the shipper shaft Gear guard
must close to terminate the lube cycle.

NOTE: The pressure switch located in each lube system normally terminates the lube cycle
when the operating pressure is reached. The switch must be activated before the cycle
time is exceeded or a malfunction will be indicated. Normal operating pressure is 2500
PSI. The pressure may vary with conditions. Since the lube cycle time will vary with
lubricant viscosity, temperature, pump capacity and air pressure, cycle the system
manually several times and record the normal cycle time. Set the cycle time to the
longest cycle, plus 30 seconds.

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

SAFETY UNLOADER VALVES

A Safety Unloader valve is provided at each pump to protect against excess lubricant pressure that
could damage the system components. The unloader valve vents the lubricant directly to atmosphere
when the circuit pressure exceeds 3750 PSI.

LUBE CIRCUIT PRESSURE SWITCHES

These high pressure switches are used to signal the controller (PC) that the lubricant pressure in
a circuit has attained the level sufficient for pump shutdown and cycle termination. There are 4 of
these switches used on the machine in this automatic lubrication system. They are located at
various points around the machine that best insure lube distribution has been made throughout
the 3 circuits. The Lower Frame lube system circuit contains 2 pressure switches.

These switches are all double make, double break

units that have snap action switching elements.
They automatically reset by a snap action of the
switch. DO NOT PLUG THE DRAIN PORT ON
THE SWITCH. Each switch is adjustable
externally within the ranges listed on it. In this auto
lube system, each switch is to be adjusted to
switch at 2500 PSI and reset at 1900 PSI. Check
these settings with a gauge installed in the circuit
as close as possible to the switch while manually
cycling the lube circuit.

NOTE: All lube pressure switches are wired

NORMALLY OPEN.

Manual No. 10954 3 - 14 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

AIR OPERATED LUBE PUMPS

NOTE: The AIR PRESSURE REGULATOR and AIR SOLENOID VALVES used in this automatic
lubrication system are covered in Section 7 - COMPRESSED AIR SYSTEM in this
manual. REFER TO IT FOR MORE DETAILED INFORMATION.

The following air pumps are used in the lube system on this machine:

The pump assemblies consist of a reciprocating pump powered by an air motor and are equipped
with mufflers. These pumps are durable and will give adequate service life. When a pump will not
stall with its lube discharge port blocked (plugged), then the pump should be rebuilt. Kits are
available to rebuild the pumps. Refer to the Parts Book for parts information.

Sept. 2010 3 - 15 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

OPERATING PRECAUTIONS:

• The pump service life and efficiency will be reduced if the pump strokes per minute exceed
75.

• Add an air line restriction to limit the strokes if required.

• Before servicing or cleaning the pump, disconnect the air lines and bleed off the system
pressure.

• To prime the pump, open the output line and slowly cycle the pump until all air is pushed out
of the lines and lube fills the pump tube. Check that the pump will stall at operating pressure.

IMPORTANT:

• When assembling the air valve components, make sure that the power slide valve, the pilot
slide valve and the valve actuator are in their "down" positions. The valve actuator should
bridge the slide valves without interference.

• If the acorn nuts are tightened with the valve parts misaligned, the valve actuator will be bent
and the valve body will be ruined.

Manual No. 10954 3 - 16 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Power Master 2

When replacing the air motor or pump tube on this pump, connect the pump piston rod to the pump
tube plunger rod and bolt the motor to the pump tube flange. Install the 4 capscrews hand-tight.
Cycle the pump several times to correct any misalignment. Stop the pump on the up-stroke and
tighten the 4 capscrews.

To Lubricate the Air Valve Mechanism:

a. Disconnect the air to the pump. Remove the 4 cover screws, the cover plate and the cover
plate gasket. Grease should be packed behind the toggle plate. Use approximately 1-1/2
ounces of N.L.G.I. grade No.1 water repellant grease.

b. If the toggle plate has been removed from the air valve casting, pack the cavity with grease
before replacing the toggle plate.

c. Replace the cover plate gasket, the cover plate and cover screws. Tighten to avoid air leaks.

d. Periodic inspection of all parts at least once a year is advisable.

Sept. 2010 3 - 17 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

GUIDELINES FOR TROUBLESHOOTING AN AUTO LUBE ALARM

The first time a fault is announced in the cab, reset it by pressing the SILENCE pushbutton on the
operator's console. This permits the control to cycle the system again normally per its cycle time
setting. If the same fault is annunciated again during its succeeding cycle, then a fault must exist
and needs to be investigated.

(continued on next page.)

Manual No. 10954 3 - 18 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

(continued from previous page.)

NOTE: If a fault persists without a solution, contact Bucyrus for assistance.

Sept. 2010 3 - 19 Manual No. 10954

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182M-AC Electric Mining Shovel

When troubleshooting the auto lube system, alarms can be caused by one or more of the following:

• Any main line-to-injectors break or disconnection.

• A problem in the air supply system (pressure too low).

• The supply line from the pump to the pressure switch blocked or open.

• The lube unable to reach the pump inlet.

• The pump failing.

• An inoperable pressure switch.

• Air entrapped in the lube supply lines.

• Electrical control system failing.

DANGER! To avoid personal injury when working on pressurized systems,

always remove the pressure from the system and loosen all
connections slowly and carefully. This is to guard against residual
pressure conditions.

Manual No. 10954 3 - 20 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

LINCOLN TYPE SL-1 LUBRICANT INJECTORS

These pressure operative, spring reset, series installed injectors are supplied in banks mounted on
manifolds. Each injector will expel a maximum of .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
Bucyrus recommends they 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

To set an injector for maximum output:

1. Loosen locknut.
2. Turn adjusting nut until there is a small gap at the top
of the stem.
3. Orient the adjusting nut so that the opening is toward
the front of the injector.
4. Tighten the locknut.
To reduce injector output:
1. Loosen locknut.
2. Turn adjusting nut clockwise (CW) until desired
discharge rate is obtained. This will force stem into body,
retarding its movement.
3. Set the locknut.

LINCOLN INJECTOR

CAUTION: Do not turn adjusting nut down clockwise

more than 5 full turns from maximum
discharge setting. Check output flow from
injector then to insure it is still operating.
If not, back off adjusting nut until injector
does consistently operate. Inspect
adjusted injector for operation for 3 or 4
cycles after returning machine to work to
make sure it is functioning.

Sept. 2010 3 - 21 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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.

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 singly, or may be grouped in a

manifold at one location.

Manual No. 10954 3 - 22 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

SL-1 INJECTOR ADVANTAGES

Sept. 2010 3 - 23 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

LUBE DRAINAGE SYSTEMS

Special provision is made at several points around the machine to drain and/or vent lubricant from
the area of application, a catchment area, or a housing cavity. The ones on this machine are
explained here.

A lube catch basin is provided on the machinery deck of the rotating frame around the center journal
and under the hoist drum gear. Excess lube from these areas drains down through the upper frame
structure in a tube into the drainage system on the lower frame. Check this drainage system quarterly
for flow. Clean and/or flush it annually.

DANGER! HIGH VOLTAGE! The high voltage collector rings are located in
the area inside the roller circle between the upper and lower frames.
DO NOT WORK IN OR AROUND THE AREA BETWEEN THE LOWER
AND UPPER WORKS UNLESS POWER TO THE MACHINE HAS BEEN
SHUT OFF AND LOCKED OUT BY QUALIFIED ELECTRICIANS. Failure
to comply with this directive could result in personal injury or death.

Two catch basins are provided on the top of the lower frame structure. One around the center
journal and one around the roller circle area. There is one drain tube from the center journal catch
basin and 4 from the roller circle area catch basin. These drain tubes direct excess lubricant from
these areas down through the lower frame. Check that these drains are open to flow quarterly. DO
NOT INSERT RODS OR PIPES INTO THESE TUBES FROM BELOW UNLESS POWER TO
THE MACHINE IS OFF. Clean and/or flush the lower frame catch basins and drain annually.

See the accompanying sketches of these areas for further information.

Manual No. 10954 3 - 24 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Lube Drainage System on the Rotating Frame

Hoist Gearing and Center Journal Lube

Sept. 2010 3 - 25 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Lube Drainage System on the Lower Frame

Manual No. 10954 3 - 26 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

LUBRICATION STANDARDS

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 insure the consumer of an exact supply to specific requirements, regardless
of source.

We recommend you advise your petroleum supplier of the following information to assist him 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 -20oF/-29oC or above 110oF/44oC)

requires special lubrication. Note the temperature ranges on the following lubricant specification
sheets. Contact your local supplier, your Bucyrus representative, or the Service Department here
in Bucyrus for recommendations if you require additional information or advice.

• Store lubrication drums on their side, with the opening toward the top.
• FILTER ALL OIL BEFORE ADDING IT TO THE SYSTEM.
• USE ONLY CLEAN and PROPER LUBRICANTS - KEEP IT CLEAN !
• DO NOT MIX TYPES or BRANDS of LUBRICANTS.

Sept. 2010 3 - 27 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

DESCRIPTION OF OIL AND GREASE CLASSIFICATION

CODE NAME DESCRIPTION

MPG Multipurpose Grease A well manufactured extreme pressure (E.P.) grease

having good resistance to both heat and water,
possessing good mechanical stability and oxidation
resistance. It must be suitable for use in automatic
lubrication dispensing systems. It shall be free of
corrosive and harmful foreign matter. It must be
useable in ambient temperatures between -20oF to
100oF (-29oC to 44oC). Bucyrus should be consulted
regarding products intended for service outside
this temperature range.

USES - Anti-friction bearings, both packed and gun

lubricated, brass and plain bearings, and central or
automatic lubricating systems.

LTG Long Term Grease A specially formulated product of the Falk Corp. that is
designed to provide superior lubrication for flexible
shaft couplings. This lubricant is highly resistant to
separation, which allows it to be used for relatively long
periods of time.

Falk Steelflex couplings initially lubricated with this

grease will not require re-lubrication unless opened for
service work. Falk gear type couplings initially
lubricated with this grease will not require re-lubrication
for up to 3 years. If a coupling leaks grease, is exposed
to extreme temperatures or moisture levels, or
experiences frequent reversals, then more frequent
lubrication intervals may be required.

Manual No. 10954 3 - 28 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CODE NAME DESCRIPTION

OGL Open Gear Lubricants Either of two types of product may be specified. They
are intended for use on open gearing where
retention is a problem. Both must be adhesive in
nature and resist dripping from or flinging off the
exposed gearing when either idle or in motion. They
must be water and corrosion resistant and have
extreme pressure (E.P.) properties.

1. Type B must be suitable for application without

heat or diluent and should be suitable for use in
automatic lubrication dispensing systems if
required.

2. Type H is usually an asphaltic type product

requiring heat or a diluent for application.

Diluents used in solvent cutback products must

have a fast evaporation rate and be non flammable.
They must not show separation in storage or service
and should be suitable for use in automatic lubrication
dispensing systems at low ambient temperatures.

USES - Open gears.

HGL Gear Lubricant for This gear oil must have good load carrying and extreme
Surface Hardened pressure (E.P.) properties. It must be able to lubricate
and Ground Gearing extremely accurate gears and rolling element bearings
in Enclosed Gearcases including planetary gear arrangements. The gears will
be highly loaded and subjected to large shock loads.
Fast stops, starts, and reversing action will be "normal"
operation for the gears and bearings lubricated by this oil.

Three temperature ranges are defined in this oil's

specification: Arctic, Moderate, and Hot. For best
results, use the same product for all seasons of the
year; however, where extreme ambient temperature
ranges are experienced, that will not be possible and
the oil will require changing seasonally or when
determined necessary by its condition. Oil samples
should be tested every 30 days to determine
contamination levels.

HGL oil in new or rebuilt planetary gearcases should be

changed after the first 150 hours (1 week) of initial
operation. Thereafter, change the oil as stated above.

Sept. 2010 3 - 29 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CODE NAME DESCRIPTION

GL Gear Lubricant for This gear oil must have good load carrying and extreme
Enclosed Gearcases pressure (E.P.) properties. The gears will be highly
with Through-hardened loaded and subjected to large shock loads. Fast stops,
gears starts, and reversing action will be "normal" operation
for the gears and bearings lubricated by this oil.

Use as viscous a product as possible for maximum

gear life.

On new machines, oil should be drained after the first

60 days of operation and replaced with new oil.
Thereafter, change the oil once a year, or when
determined necessary by the oil supplier. The oil
should be checked for contamination every 30 days.

MO Motor Oil A rust and oxidation motor oil suitable for use in
DeVilbiss, Ingersoll Rand, and other makes of piston
type, reciprocating air compressor crankcases.

HL Hand Lubrication Use oil MO above or a general machine oil such as S-

SAE 30 or W-SAE 20W, etc.

PO Pneumatic Oil Petroleum oil especially compounded for use in air line
oilers or built-in lubricators having the correct viscosity,
low pour point, emulsifying ability, and film strength and
that is free of deposit forming tendencies. It should not
cause swelling or deterioration of rubber or leather
seals and gaskets.

SPECIAL LUBRICANTS

CODE DESCRIPTION

EMG Electric Motor Grease Electric Motor bearing grease meeting the requirements of G.E.
specification D6A2C5 for their equipment, or Westinghouse specification 1449556 for
their equipment, or an equivalent specification for other makes.

GP Grease paste meeting the requirements of Molub-Alloy 298-1. This is a specially

formulated product of Imperial Oil and Grease Company which contains a high
percentage of solid additives.

USES: To prevent fretting of splined connections and registers.

WRL Wire Rope Lubricant. May be of either solvent cutback asphaltic water resistant type
or penetrating oil type containing corrosion and rust preventatives, anti-wear, and other
suitable polar additives. The former are preferred for wire rope operating in extremely
wet environments, while the latter are preferred for normal shovel and dragline operations
where contamination of the wire with highly abrasive dust particles is the primary problem.

Manual No. 10954 3 - 30 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

LUBRICATION SPECIFICATIONS

GREASE SPECIFICATIONS

OIL SPECIFICATIONS

Sept. 2010 3 - 31 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

GEAR LUBRICANTS - GL (OIL TYPE)

CODE or ASTM
SYMBOL NO. or TEST GL-90 GL-140 GL-200 GL-250

Pour point, max.oF(oC) D-97 0(-18) 10(-12) 20(-7) 30(-1)

Flash point, min.oF(oC) D-92 410(210) 410(210) 410(210) 410(210)
Viscosity @ 100oF(38oC)SUS min. D-446 1100 2000 3500 4500
Viscosity @ 210oF(99oC)SUS D-446 80-120 120-180 180-210 210-260
Viscosity index, min. D-567 80 80 80 80
Equiv.AGMA lubricant no. -- 6 EP 7-8 EP 8 ep 8a
SAE viscosity no. -- 90 140 140/250 250
EP Timken, min.OK -- 65 65 65 65
Copper corrosion, max. D-130 2 2 2 2

Manual No. 10954 3 - 32 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

TEMPERATURE CHART ~ GL OILS

OIL TEMPERATURE
o
F o
C
Gear Lubricant Min. Max. Min. Max.
GL-90 0 105 -18 41
GL-140 10 125 -12 52
GL-200 20 140 -7 60
GL-250 30 150 -1 66

Sept. 2010 3 - 33 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

GEAR LUBRICANTS ~ HGL (OIL TYPE)

NOTE: Solid additives, such as graphite or molybdenum disulfide, are excluded from use in
HGL gear lubricant.
CODE or ASTM HGL HGL HGL
SYMBOL SET or TEST ARCTIC MODERATE HOT
Ambient Temp — -40 to +50 +5 to +122 +40 to +150
Range (oF)
Ambient Temp — -40 to +10 -15 to +50 +4 to +65
Range (oC)
Viscosity - CTS — 20 - 31.5 80 - 125 —
at 50oC
Viscosity - CTS — 28 - 49 135 - 220 300 - 350
at 40oC
Viscosity - CTS — 15,000 max. 12.0 at 100oC 22.0 at 100oC
at -40oC min. min.
I.S.O. Visc. — 32 and 46 150 and 220 320
Grade
Pour Point oC D-97 -45 -15 -9
max.
Flash Point oC D-92 160 200 200
min.
Viscosity - SUS — 150 - 230 750 - 1200 1200 - 1700
at 100oF
Viscosity - SUS — 46 - 53 70 - 100 110 min.
at 210oF
Viscosity - SUS — 79,000 max. — —
at -40oF
Viscosity Index — 120 90 90
min.
E.P.Timken — 55 Lbs.(25 Kg) 55 Lbs.(25 Kg) 55 Lbs.(25 Kg)
min. OK-Load
Foam Test D-892 Pass Pass Pass
Weld Point Kg. — 220 220 230
min.
FZG Gear Test — 12 12 12
Rusting D665B Pass Pass Pass
Oil Sump — -40oF to +122oF +5oF to +180oF +40oF to +190oF
Temperature
(operating oil) -40oC to +50oC -15oC to +82oC +4oC to +88oC

Manual No. 10954 3 - 34 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

TEMPERATURE CHART ~ HGL OILS

OIL TEMPERATURE
o
F o
C
Gear Lubricant Min. Max. Min. Max.
HGL Arctic -40 +122 -40 +50
HGL Moderate +5 +180 -15 +82
HGL Hot +40 +190 +4 +88

Sept. 2010 3 - 35 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

LUBE POINTS

Machine components are lubricated either by hand (manually) or by the automatic lubrication
system on board the machine. This system dispenses measured amounts of lubricants at preset
intervals via 3 piping circuits to selected points. A description of how this auto lube system operates
is given elsewhere in this section. These automatic and manually lubed areas are listed here for
easy reference.

CAUTION: Lubrication inspection or cleanup is a dirty and dangerous task if not

done regularly. Follow these recommendations for machine
lubrication and setup.

SAFETY CHECK LIST - for inspection, lubrication, and maintenance:

• Clean up spilled petroleum products immediately.

• Do not use gasoline, naphtha, turpentine, or similar solvents to remove oil or grease
from your skin.

• Do not wear oil soaked garments.

• Promptly remove any petroleum product that gets on your skin.

• Do not use dirty wipe cloths.

• Avoid breathing oil mist or solvent vapors.

• Check all lubrication and air line connections, remembering that they could be
pressurized.

• Remove lubricant accumulation from around bearings and gears.

• Keep all walkways, ladders, stairs, and floor areas clear of lubricants.

Manual No. 10954 3 - 36 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

POINTS ON AUTO LUBE SYSTEM USING "MPG"

(59 Total Served)

Name of Part Type No. of Points Location

LOWER FRAME GREASE CIRCUIT (24 points)

Front Idler Roller Bushing 2 (1 each side) End of Shaft
Shafts
Load Rollers Bushing 16 (8 each side) End of Shaft
Rear Idler Rollers Bushing 2 (1 each side) End of Shaft
Inboard Bearing - Anti-Friction 2 (1 each side) Thru Wall of Gearcase Bracket
Main Propel Shafts
Outboard Bearing - Anti-Friction 2 (1 each side) O.D. of Retainer
Main Propel Shafts

UPPER FRAME GREASE CIRCUIT (35 points)

Boom Foot Pins Plain 4 (2 each side) Each End of Pin
Center Journal Bushing and 6 Top of Rot. Frame
Thrust Washer near Right Swing Case
Main Rotating Shaft Anti-Friction 2 (1 each side) Thru Deck Plate
- Lower between Swing Cases
Boom Support Rope Plain 4 (2 each side) End of Pin
Sockets At Gantry
Boom Support Plain 2 (1 each side) O.D. of Equalizer Link
Equalizer Links
on Gantry
Dipper Trip Pinion -- 1 Drip onto Mesh Thru Guard
and Gear Teeth
Intmd. Crowd Shaft Anti-Friction 1 O.D. of Retainer
Bearing - Left
ntmd. Crowd Shaft Anti-Friction 1 Face of Housing in Boom
Bearing - Right

Sept. 2010 3 - 37 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Name of Part Type No. of Points Location

Shipper Shaft Flanged 2 (1 each side) Thru Top Plate of Ctr. Boom
Bushings Bushings Structure
Yoke Block Bushing 4 (2 each side) O.D. of Yoke Blocks
Bushings

Dipper Trip Rope Bearing 2 End of Shaft

Guide Sheaves
Boom Point Sheaves Bushing 2 (1 each side) At Each End of Sleeve
Boom Support Bushing 4 (2 each side) End of Pin
Sockets on Boom

POINTS ON AUTO LUBE SYSTEM USING "OGL"

(26 Total Served)

OPEN GEARS CIRCUIT (26 points)

Hoist Drum Gear Teeth 8 (4 places~ Dripped thru Guard
front & rear)

Intmd. Hoist Gear Teeth 4 (2 places, Dripped thru Guard

front & rear)

Main Rotating Pinions Teeth 4 (2 each side) Dripped at Mesh

and Rotating Gear
Roller Circle Rails -- 2 (1 each side) Drip Point on Each
Side of Rot. Frame
Intermediate Teeth 1 Dripped thru Guard
Crowd Gear
Shipper Shaft Teeth 1 Dripped thru Guard
Gear
Shipper Shaft Pinions Teeth 2 (1 each side) Dripped into Mesh at
and Handle Racking Each Pinion
Handle Slide Blocks 4 (2 each side) Dripped on Top of Handle

Manual No. 10954 3 - 38 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

MANUAL LUBE POINTS

Name of Part Type No. of Points Location Lube Sym. Frequency

CRAWLERS

Proper Motor Anti-Friction 4 Motor Bell EMG Semi-Annually

(2 ea. side) Housings (2500 hrs.)
Motor Couplings Steelflex 2 Fill thru Plugs LTG Keep Full;
(1 ea. side) in Cover (1250 hrs.)
Check
Quarterly
Propel Gear Planetary 2 Fill thru Top HGL Check Weekly
Cases - (1 ea. side) Plug Hole to (150 hrs);
Capacity each - Oil Level Plug Chg. Annually
33.0 US Gallons In End of Case (5000 hrs.)
(125 liters)

NOTE: Change oil in new or rebuilt propel gearcase after initial 150 hours of machine
operation. Thereafter, change it every 5000 hours or as indicated by oil sample
analysis. Maximum replacement interval is once per year. Flush gearcase before
refilling it with new oil.

ROLLER CIRCLE

Rollers Nylatron 42 End of Spacer MPG Lube Each at

Spacers Assembly
Only!

AUXILIARY COLLECTOR RING/ROTOSEAL ASSEMBLY

Top Bearing Anti- 1 In Housing MPG Annually

Friction Flange (5000 hrs.)
Base Bearing Dbl. Sealed 1 -- --
Lubed for Life
Anti- by the
Friction Manufacturer:
Check Seals
Annually
(5000 hrs.)
DANGER! HIGH VOLTAGE! The protective housing on the Collector Rings
must be opened/removed to inspect these bearings. Disconnect,
isolate, and lock out the main power supply to this machine before
performing this procedure. Failure to do so could result in personal
injury or death.

Sept. 2010 3 - 39 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Name of Part Type No. of Points Location Lube Sym. Frequency

ROTATING FRAME

"MPG" Auto Lube -- 2 On Right MPG Check Level

Reservoir Wing Daily (24 hrs.);
Cap. Ea. - Refill as
16 US Gal. needed
(60.5 liters)
"OGL" Auto Lube -- 1 On Right OGL Check Level
Reservoir Wing Daily (24 hrs.)
Cap. - Refill as
16 US Gal. Needed
(60.5 liters)
Air Compressor -- 1 Check MO Change
Crank Case Dipstick Monthly
Cap. - Daily (24 hrs) (425 hrs.)
5 US Pints
(2.4 liters)
Air Line
Lubricator -- 1 Check Level PO Refill When
Indicated
Trip Rope at Wire 1 At Drum WRL As Needed
Drum In Gantry
Trip Rope Drum Anti- 2 O.D. of MPG Monthly
Shaft Bearings Friction Housings (425 hrs.)
Dipper Trip Anti- 2 Motor Bell EMG Semi-Annually
Motor Friction Housings (2500 hrs.)
House Air Vent. Anti- 4 O.D. of EMG Semi-Annually
Fan Motors Friction (2 each) Housings (2500 hrs.)
Boom Support IWRC 4 Area of WRL Semi-Annually
Ropes at Gantry Wire (2 ea. side) Sockets (2500 hrs.)
House Doors Hinges 12 Apply to HL Annually
(3 per door) Part (5000 hrs.)
House Doors Latches 2 Apply to HL Annually
(1 per door) Part (5000 hrs.)
House Doors Locks 4 Apply to MO Annually
(2 per door) Part (5000 hrs.)
Access Ladder Anti- 12 End of MPG Annually
Cam Followers Friction Roller Shaft (5000 hrs.)

Manual No. 10954 3 - 40 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Name of Part Type No. of Points Location Lube Sym. Frequency

BOARDING STAIRWAY

Top Sheave Oilite 2 Pin HL Semi-Annually

Bushing (1 each side) (2500 hrs.)
Counter-Balance Wire 2 At top WRL Semi-Annually
Rope (1 each side) sheave (2500 hrs.)
Counter-Balance Sliding 2 Apply to MPG As needed
Weights (1 each side) weight
and guide tube
Stairway Rollers Integral 4 Roller I.D. HL Semi-Annually
Nylatron (2 ea. side) Bushing (2500 hrs.)
Rope Link at Oilite 2 Pin HL Semi-Annually
Moveable Stairway Bushing (1 ea. side) (2500 hrs.)

OPERATOR'S CAB

Operator's Seat Jack 1 Apply HL Semi-Annually

Screw to Part (2500 hrs.)
Shaft under Seat
Operator's Seat Swivel 1 Apply HL Semi-Annually
Assembly to Parts (2500 hrs.)
in Base
Cab Door Hinges 3 Apply to HL Annually
Part (5000 hrs.)
Cab Door Latch 1 Apply to HL Annually
Part (5000 hrs.)

SWING MACHINERY

Rotating Motors Anti- 4 Motor Bell EMG Semi-Annually

Friction (2 each) Housings (2500 hrs.)
Rotating Gear Enclosed 2 Fill thru GL Check Weekly
Cases Breather (100 hrs.):
Cap. Ea. - Port to Level Change
51.5 US Gal. on Dip Stick Semi-Annually
(195 liters) (2500 hrs.)

NOTE: Change oil in new or rebuilt rotating gearcase after initial 150 hours of machine
operation. Thereafter, change it every 2500 hours or as indicated by oil sample
analysis. Maximum replacement interval is semi-annually. Flush gearcase before
refilling it with new oil.

Sept. 2010 3 - 41 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Name of Part Type No. of Points Location Lube Sym. Frequency

HOIST MACHINERY

Hoist Rope IWRC Wire 2 At Lagging WRL As Needed

Mtr. Ext. Shaft Anti- 2 Face of Brg. MPG Monthly
(Pinion) Brgs. Friction Retainers (425 hrs.)
Hoist Intermediate Anti- 2 Face of Brg. MPG Monthly
Shaft Bearings Friction Retainers (425 hrs.)
Hoist Drum Anti- 2 O.D. of Brg. MPG Monthly
Shaft Bearings Friction Housing (425 hrs.)
Hoist Motor Anti- 2 Motor Bell EMG Semi-Annually
Friction Housings (2500 hrs.)
Motor Coupling Gear Type 1 Fill thru Plugs LTG Keep Full:
in Sleeves Check
Quarterly
(1250 hrs.)
Relube Every
3 Years
(15000 hrs.)
Rope Reeving Cycle 1 Fill thru HGL Check Before
Winch Drive Filler Plug Use at Sight
Cap. - Gauge:
3 US pints Change
(1.4 liters) Bi-Annually
(10000 hrs.)

NOTE: Change oil in new or rebuilt rope winch after first usage. Thereafter, change it every
10,000 hours (2 years) or as indicated by oil sample analysis. Maximum replacement
interval is once every 2 years. Flush gearcase before refilling it with new oil.

BOOM

Hoist Rope IWRC Wire 2 At Sheaves WRL As Needed

(1 ea. side)
Trip Rope Wire 1 At Guide WRL As Needed
Sheaves

Manual No. 10954 3 - 42 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Name of Part Type No. of Points Location Lube Sym. Frequency

Intmd. Crowd Oilite 1 Inboard Hub MPG Quarterly

Gear Bearing of Bushing (1250 hrs.)
Gear Piped
to Near Rim
Boom Support IWRC 4 Area of WRL Semi-Annually
Ropes @ Point Wire (2 ea. side) Sockets (2500 hrs.)
Crowd Motor Anti- 2 Motor Bell EMG Semi-Annually
Friction Housings (2500 Hrs.)
Gearcase at Enclosed 1 Fill Sump to HGL Check Weekly
Crowd Limit Worm Red. Vented Plug (100 hrs.)
Cap. - Level on top of Change
.4 US pint gearcase Semi-Annually
(.2 liters) (2500 hrs.)

NOTE: Change oil in new or rebuilt gearcase for crowd limit after initial 150 hours of machine
operation. Thereafter, change it every 2500 hours of operation or as indicted by oil
sample analysis. Maximum replacement interval is once every 6 months. Flush
gearcase before refilling it with new oil.

DIPPER/HANDLE

Hoist Rope Steel 1 End of Pin MPG Twice per

Equalizer Sheave Bushing Shift (4 hrs.)
Equalizer Steel 1 End of Pin MPG Twice per
to Bail Connection Bushing Shift (4 hrs.)
Bail to Dipper Steel 1 End of Pin MPG Twice per
Connection Bushing Shift (4 hrs.)
Pitch Braces to Steel 2 End of Pins MPG Twice per
Dipper Connection Bushings (1 ea. side) Shift (4 hrs.)
Dipper Door Steel 2 End of Pins MPG Twice per
Hinges Bushings (1 ea. side) Shift (4 hrs.)
Dipper Door -- 2 Apply to HL Check Twice
Latch Bar (upper & Sliding per
lower wear Surfaces Shift (4 hrs.):
inserts) Keep Coated
Trip Chain -- 2 Apply at HL Check Twice
Shackle Pins Part per
(both ends) Shift (4 hrs.):
Keep Coated
Trip Lever Pin -- 1 Apply to HL Check Twice
at Handle Part per Shift (4 hrs.)

Sept. 2010 3 - 43 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Keep Coated
Name of Part Type No. of Points Location Lube Sym. Frequency

Trip Rope Link -- 1 Apply to HL Check Twice

Pin at Handle Part per
Shift (4 hrs.):
Keep Coated
Trip Rope Wire 1 At Trip Lever WRL As Needed
Link
Door Lever -- 1 Apply to HL Check Twice
wearing per
surfaces Shift (4 hrs.):
Keep Coated

CABLE REEL

Level Wind Bushing 6 In Roller MPG Bi-Monthly

Guide Rollers (850 hrs.)
Level Wind Bushing 2 In Roller MPG Bi-Monthly
Trolley Rollers (850 hrs.)
Level Wind Plain 2 Apply to Pin MPG Bi-Monthly
Trolley Rollers (850 hrs.)
Keep Coated
Drive Chains -- 3 Apply to Part HL Check Ctrl.
(1250 hrs.):
Keep Coated
Chain -- 1 Apply to Part HL Check Ctrl.
(1250 hrs.)
Keep Coated
Right Angle Enclosed 1 Fill thru Plug See Check Ctrl.
Drive Gearcase in Top of Unit Vendor (1250 hrs.)
Spec. Keep Filled
Reel Drum Anti- 2 In Pillow MPG Semi-Annually
Bearings Friction Blocks (2500 hrs.)

NOTE: FREQUENCY OF LUBRICATION - The hours and elapsed time periods in the
frequency column of this listing are machine operating hours or periods, NOT
component usage hours. Lubricate components at frequency indicated in this listing.
These lubrication frequencies DO NOT apply to an idle or parked machine.

Manual No. 10954 3 - 44 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

LUBRICANT SPECIFICATIONS

Planetary Propel Gearcase require ISO VG 220 Gear Oil

Candidate products can be found in SPECIFICATION FOR ENCLOSED GEARCASE LUBRICANTS

for Rotary Blasthole Drills - SD4722.

Non-Planetary Swing Gearcase requires ISO VG 1000 Gear Oil

Candidate products can be found in SPECIFICATION FOR ENCLOSED GEARCASE LUBRICANTS

for Draglines - SD4721 Part A.

Non-Planetary Hoist and Crowd Gearing uses "Open Gear Lubricant"

Candidate products can be found in SPECIFICATION FOR OGL - OPEN GEAR LUBRICANTS -
SD4713.

Multi-Purpose grease

Candidate products can be found in SPECIFICATION FOR MPG - MULTIPURPOSE GREASE -

SD4711.

Open Gear Lubricant

Candidate products can be found in CERTIFIED LUBRICANT LISTING FOR OGL, MPG AND EGL
LUBRICANTS.

Sept. 2010 3 - 45 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Manual No. 10954 3 - 46 Sept. 2010

Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4722 (June 26, 2006)

Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole
Drills.

SCOPE:

This specification covers the requirements for “Enclosed Gearcase Lubricant” used on
models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

The materials furnished under this specification are intended to lubricate spur and
helical gears as well as anti-friction bearings at the interior of enclosed planetary and
non-planetary type gearcases (Propel, Rotary, Pull Down and Pump Drive).

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:

Step #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 (Rotary, Pull Down and Propel Gearcases).

b. Use machinery house temperature for gearcases located inside of the

machinery house (Pump Drive Gearcase) for some machines are equipped with
machinery house heaters.

c. For cold weather applications, the pour point of the lubricant must be at least
5°C (9°F) below the minimum ambient starting temperature. If the ambient
starting temperature approaches the lubricant pour point, oil sump heaters may
be required to facilitate starting and ensure proper lubrication. Use oil
temperature for gearcases having oil sump heaters.

Page 1 of 4
Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4722 (June 26, 2006)

Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole
Drills.

Table 1

Ambient Temperature Range ISO Viscosity Grade / Oil Type

14°F to 100°F (-10°C to 37°C) ISO VG 220 / Mineral or Synthetic (poly-α-olefin) Oil
Less than 14°F to 120°F
ISO VG 220 / Synthetic (poly-α-olefin) Oil
(Less than -10°C to 50°C)

Step #2

Select an approved lubricant for the Propel, Rotary, Pull Down and Pump Drive Gearcases
from the Approved Lubricant Tables 2 & 3.

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.

APPROVED LUBRICANTS:

Lubricants that have been approved for use by the Gearcase manufacturers are listed in
the Approved Lubricant Tables 2 & 3. The use of non-approved lubricants may
invalidate the Bucyrus International, Inc. 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.

Page 2 of 4
Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4722 (June 26, 2006)

Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole
Drills.

Table 2
Approved Mineral Oil Lubricants (ISO VG 220)

Manufacturer Product Description

BEL-RAY Bel-Ray 100 Gear Oil 90
Energol PM 220
BP Energol GR-XP 220
Energol GR-XF 220
Alpha SP 220
Alpha MAX 220
CASTROL
Optigear BM 220
Tribol 1100/220
Chevron Ultra Gear Lube 220
CHEVRON
Gear Compound EP 220
Spartan EP 220 (Only Product
ESSO
Originating from Europe)
FUCHS Renolin CLP 220 Plus
LE (Lubrication
Almasol 607
Engineers)
MOBIL Mobilgear XMP 220
PETRO CANADA Ultima EP 220
SHELL Omala F 220
Auriga EP 220
TEXACO Meropa 220
Meropa W M 220
W HITMORE Paragon 220

Page 3 of 4
Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4722 (June 26, 2006)

Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole
Drills.

Table 3
Approved Synthetic (Poly-α-olefin) Oil Lubricants (ISO VG 220)

Manufacturer Product Description

BEL-RAY Synth. Gear Oil 6690
Enersyn EP-XF 220
BP
Enersyn HTX 220
Optigear Synth. A 220
Optigear Synth. X 220
Alphasyn EP 220
CASTROL
Alphasyn T 220
Tribol 1510/220
Tribol 1710/220
CHEVRON Tegra Synth. Gear Lube 220
FUCHS Renolin Unisyn CLP 220
Mobil SHC 630
MOBIL Mobilgear SHC 220
Mobilgear SHC XMP 220
PETRO CANADA Ultima Synth. EP 220
SHELL Omala HD 220
TEXACO Pinnacle EP 220
WHITMORE Decathlon F 220

SPECIFICATION REVISIONS:

This specification is subject to change without notice. Please refer to the Bucyrus
International, Inc. web site www.bucyrus.com for the latest specification.

Page 4 of 4
Bucyrus International, Inc.

SPECIFICATION FOR
MPG – MULTI-PURPOSE GREASE
SD4711 (August 18, 2005)
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.

Page 1 of 4
Bucyrus International, Inc.

SPECIFICATION FOR
MPG – MULTI-PURPOSE GREASE
SD4711 (August 18, 2005)
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)
NLGI 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
Shell Four Ball EP
Load wear index (LWI) kg ASTM D-2596 65 65 65
Minimum
Load Weld kg ASTM D-2596 400 400 400
Minimum
Shell Four Ball Wear
Wear Scar mm
Maximum ASTM D-2266 0.6 0.6 0.6
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
Mechanical Stability ASTM D-217A 10% 10% 10%
10,000 strokes,
Maximum change
Roll Stability Test
Maximum change ASTM D-1831 15% 15% 15%
in 2 hours
Wheel Bearing Test
6 hours @ 104°C(220°F) ASTM D-1263 10% 10% 10%
Maximum loss (NLGI #1 Only)
Water Washout Test
Loss @ 38°C(100°F), ASTM D-1264 5% 5% 5%
Maximum (NLGI #1 Only)

Loss @ 80°C(175°F), 15% 15% 15%

Maximum (NLGI #1 Only)

Page 2 of 4
Bucyrus International, Inc.

SPECIFICATION FOR
MPG – MULTI-PURPOSE GREASE
SD4711 (August 18, 2005)
PROPERTY REFERENCE REQUIREMENT
Pressure Oil Separation The Lubrication Engineers U.S. Steel test method - Cake
Manual (United States Steel). penetration not less than
25% of grease penetration.
Grease Mobility The Lubrication Engineers U.S. Steel method - not less than 0.10
Manual (United States Steel). 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 (127 kgf/cm^2)
Lincoln Ventmeter Manual (United States Steel). 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
(Molybdenum Disulfide, Less than or equal to 5%
Graphite, Etc.)
% by Weight
Lubricating Solids
(Molybdenum Disulfide, 10 Microns
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.

Page 3 of 4
Bucyrus International, Inc.

SPECIFICATION FOR
MPG – MULTI-PURPOSE GREASE
SD4711 (August 18, 2005)
CERTIFIED LUBRICANTS:

Lubricants certified by their manufacturers as complying with this specification will be

listed on the “Certified Lubricants Listing for Multi-Purpose Grease” (see the
Bucyrus International, Inc. web site www.bucyrus.com for the latest listing). The use of
non-certified lubricants may invalidate the Bucyrus International, Inc. product warranty
obligation.

Specific product selection is the responsibility of the equipment operator/owner and is

dependent on climate, application, performance and regional/local regulatory
requirements.

Lubricant manufacturers seeking to certify their products should contact the following for
direction:

Bucyrus International, Inc.

Engineering Services & Technical Support
1100 Milwaukee Avenue
South Milwaukee, Wisconsin 53172
Phone (414) 768-4000

SPECIFICATION REVISIONS:

This specification is subject to change without notice. Please contact the following for
the latest specification:

Bucyrus International, Inc.

Engineering Services & Technical Support
1100 Milwaukee Avenue
South Milwaukee, Wisconsin 53172
Phone (414) 768-4000

Page 4 of 4
Bucyrus International, Inc.

SPECIFICATION FOR
OGL – OPEN GEAR LUBRICANT
SD4713 (August 18, 2005)

SCOPE:

1. This specification covers “Open Gear Lubricant”.

2. 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.

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, metering blocks,
or spray nozzles.

4. 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.

PHYSICAL CHARACTERISTICS:

1. Materials furnished under this specification may be asphaltic (bitumen) compounds,

or blends of a thickener and mineral oils and/or synthetic fluids. They may be in the
form of viscous fluids, semi-fluid greases or pastes.

2. 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.

3. 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 under all operating conditions.

4. 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.

Page 1 of 4
Bucyrus International, Inc.

SPECIFICATION FOR
OGL – OPEN GEAR LUBRICANT
SD4713 (August 18, 2005)

5. 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.

6. 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.

7. 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.

8. 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.

9. 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.

Page 2 of 4
Bucyrus International, Inc.

SPECIFICATION FOR
OGL – OPEN GEAR LUBRICANT
SD4713 (August 18, 2005)

MINIMUM PERFORMANCE REQUIREMENTS:

PROPERTY REFERENCE REQUIREMENT

Flash point of product as applied, minimum
(base product with diluent) ASTM D92 / ISO 2592
Ambient Temperature (See Note #1)
-50°C(-58°F) to +10°C(50°F) 61°C (142°F)
Above +10°C(50°F) 80°C (176°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
maximum rating ASTM D 4048 2e
24hr. @ 100°C (212°F)
Four ball EP test
weld point, minimum kgf ASTM D 2596 800
(base product without diluent)
Load wear index (LWI), minimum ASTM D 2596 120
(base product without diluent)
Four ball wear test
60 minutes @ 40 kgf. ASTM D 2266 0.7
Maximum scar, mm
(base product without diluent)
Adhesive properties Must adhere to surfaces at the lowest
anticipated ambient temperature.
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 (Testing temperature
not less than -25°C/-13°F).
Minimum Base Fluid Viscosity
Ambient Temperature ASTM D 445
(See Note #1)
°C (°F)
-50 to +10 (-58 to +50) 680 cSt at 40°C
-20 to +40 (-4 to +104) 1860 cSt at 40°C
+10 to +50 (+50 to +122) 3600 cSt at 40°C
Lubricating Solids
(Molybdenum Disulfide, Graphite, Etc.) 15 Microns
Particle Size, (Microns, max.)

NOTE:
1. Ambient Temperature - The ambient temperature shall be the temperature at the
point of lubricant application.

Page 3 of 4
Bucyrus International, Inc.

SPECIFICATION FOR
OGL – OPEN GEAR LUBRICANT
SD4713 (August 18, 2005)

CERTIFIED LUBRICANTS:

Lubricants certified by their manufacturers as complying with this specification will be

listed on the “Certified Lubricants Listing for Open Gear Lubricant” (see the
Bucyrus International, Inc. web site www.bucyrus.com for the latest listing). The use of
non-certified lubricants may invalidate the Bucyrus International, Inc. product warranty
obligation.

Specific product selection is the responsibility of the equipment operator/owner and is

dependent on climate, application, performance and regional/local regulatory
requirements.

Lubricant manufacturers seeking to certify their products should contact the following for
direction:

Bucyrus International, Inc.

Engineering Services & Technical Support
1100 Milwaukee Avenue
South Milwaukee, Wisconsin 53172
Phone (414) 768-4000

SPECIFICATION REVISIONS:

This specification is subject to change without notice. Please contact the following for
the latest specification:

Bucyrus International, Inc.

Engineering Services & Technical Support
1100 Milwaukee Avenue
South Milwaukee, Wisconsin 53172
Phone (414) 768-4000

Page 4 of 4
 Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

(January 22, 2007)

SCOPE:
Materials furnished under the specifications for “OGL–Open Gear Lubricant
(SD4713)”, “MPG-Multi Purpose Grease (SD4711)” and “Dragline Enclosed Gearcase
Lubricant” (SD4721 Part A) are intended for use on Bucyrus International, Inc.
mining machinery (Electric Mining Shovels, Draglines and Rotary Blasthole Drills).

Lubricants certified by their manufacturers as complying with these Bucyrus

International, Inc. specifications are listed in the tables below.

LUBRICANT SELECTION:
Specific product selection is the responsibility of the equipment operator/owner
and is dependent on climate, application, performance and regional/local
regulatory requirements.

Each lubricant listed in the tables below has a unique operating temperature
range. It is the responsibility of the lubricant manufacturer to recommend the
appropriate products based upon the applicable Bucyrus lubricant specification
(SD4711, SD4713 and SD4721 Part A) and the anticipated ambient temperature range
for each application.

CERTIFIED LUBRICANT LISTING FOR “OGL–OPEN GEAR LUBRICANT (SD4713)”

Manufacturer Product Description

Bel Ray Molylube SF 100 Sub-Arctic 77070
Bel Ray Molylube SF 100 Arctic 77020
Bel Ray Molylube SF 100 Light 76990
Bel Ray Molylube SF 100 Medium 77010
Bel Ray Molylube SF 100 Heavy 77000
Bel Ray Molylube Unee NS 70550
Bel Ray Molylube Unee 70600
Bel Ray Molylube Unee 70540
Bel Ray Molylube SD-1 70620
Bel Ray Molylube Gear TAC Light 68990
Bel Ray Molylube Gear TAC Regular 68940
Bel Ray Molylube Gear TAC Medium 68950
Castrol Molub-Alloy 936 SF Light
Castrol Molub-Alloy 936 SF Medium
Castrol Molub-Alloy 936 SF Heavy
Castrol Molub-Alloy 936 SF Heavy A
Chemtool Inc. Alpha OGL-680
Chemtool Inc. Alpha OGL-1860
Chemtool Inc. Alpha OGL-3600
Haycock Petroleum Shovel Lube OGL 1.5 Ultra

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 Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

(January 22, 2007)

Imperial Oil / Esso Dynagear Heavy

Imperial Oil / Esso Dynagear Extra
Lubritene Lubrene Multi Serv OGL
Lubritene Lubrene Multi Serv OGL-H
Lubritene Lubrene OGL-e
Lubritene Lubrene Bio Serv OGL
Petro-Canada Vulcan Synthetic All Season
Petro-Canada Vulcan Synthetic 2200
Petro-Canada Vulcan Heavy
Petron Petrotac EP Premium 30-B
Petron Petrotac EP Premium 10-B
Schaeffer Mfg. Silver Streak Quickvent All Season (#196ALL)
Schaeffer Mfg. Silver Streak Quickvent Arctic (#196ARC)
Schaeffer Mfg. Silver Streak BGL 100
Schaeffer Mfg. Silver Streak BGL 200
Schaeffer Mfg. Silver Streak BGL 300
Shell Malleus Grease GL 3500
Shell Malleus OGM Heavy
Shell Malleus OGM Extra Heavy
Stewart Lubricants & SLS BI OGL Heavy
Service Co. (SLS)
Talcor OGP V
Whitmore Mfg. Co. Axiom Multiservice Mining Lubricant – Arctic / SurStik 800 – Arctic
Whitmore Mfg. Co. Axiom Multiservice Mining Lubricant – Medium / SurStik 800 – Medium
Whitmore Mfg. Co. Axiom Multiservice Mining Lubricant – Heavy / SurStik 800 – Heavy

CERTIFIED LUBRICANT LISTING FOR “MPG-MULTI-PURPOSE GREASE (SD4711)”

Manufacturer Product Description

Bel Ray Molylube AC 1000 40890
Bel Ray Molylube AC 1000 40900
Bel Ray Molylube AC 1000 40922
Bel Ray Molylube LC135 67800
Bel Ray Molylube LC135 67810
Bel Ray Molylube LC135 67820
Bel Ray Molylube LC135 67832
Bel Ray Molylube LC133 67840
Bel Ray Molylube LC133 67850
Bel Ray Molylube LC133 67860
Bel Ray Molylube LC133 67872
Bel Ray Molylube LC131 27660
Bel Ray Molylube LC131 27670
Bel Ray Molylube LC131 27680
Bel Ray Molylube LC131 27692

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 Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

(January 22, 2007)

Bel Ray Molylube 126 EP 23200

Bel Ray Molylube 126 EP 23220
Bel Ray Molylube 126 EP 23242
Bel Ray Termalene EP 72400
Bel Ray Termalene EP 72420
Castrol Molub-Alloy 4086-0
Castrol Molub-Alloy 4086/460-1
Castrol Molub-Alloy 777-1 ES
Castrol Molub-Alloy 777-2 ES
Chemtool Inc. CSC 174 MGD
Chemtool Inc. CSC MP1-220
Chemtool Inc. CSC MP1
Chemtool Inc. CSC MP0
Chemtool Inc. CSC MP00
Exxon Ronex Extra Duty 2
Exxon Ronex Extra Duty Moly 2 / Mobilgrease XHP 462 Moly
Haycock Petroleum Calcuplex M5 NLGI #1
Haycock Petroleum Calcuplex M5 NLGI #2
Imperial Oil Epic EP Moly
Imperial Oil Unirex EP 1 Moly
Lubrication Engineers Almagard Vari-Purpose 3750
Lubrication Engineers Almagard Vari-Purpose 3751
Lubrication Engineers Almagard Vari-Purpose 3752
Lubrication Engineers Almaplex Ultra-Synthetic 1299
Lubritene Lubrene Li 500 EP 2
Lubritene Lubrene LiM 500 EP 2
Lubritene Lubrene AXM 1000 EP 1
Lubritene Lubrene AXM 1000 EP 2
Lubritene Lubrene AXM 500 EP 1
Lubritene Lubrene AXM 500 EP 2
Lubritene Lubrene LXCa 700 EP 2
Lubritene Lubrene Li 900 WP EP 2
Lubritene Lubrene EMV-2
Petro-Canada Supreme Arctic
Petro-Canada Supreme EP1
Petro-Canada Supreme EP2
Petro-Canada Precision XL 3 Moly EP1
Petro-Canada Precision XL 3 Moly EP2
Petro-Canada Precision XL 5 Moly EP0
Petron Petro-Plate M5/800 NLGI #1
Schaeffer Mfg. Moly Ultra 800 EP #1 (#221)
Schaeffer Mfg. Moly Ultra Red EP #1 (#229)
Schaeffer Mfg. Moly Supreme #1 (#238)
Schaeffer Mfg. Moly EP Synthetic Blend #1 (#274)
Shell Albida Grease HDX2
Shell Albida Grease MDX 1
Shell Albida Grease MDX 2
Shell Alvania Grease SDX2

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 Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

(January 22, 2007)

Shell Albida SLC 460

Shell Limona LX1
Shell Limona LX2
Shell Albida HLS00
Shell Albida HLS2
Talcor Super HD 2-M5
Whitmore Mfg. Co. Omnilith 500 Extreme Pressure Grease EP 0
Whitmore Mfg. Co. Omnilith 500 Extreme Pressure Grease EP 1
Whitmore Mfg. Co. Omnilith 500 Extreme Pressure Grease EP 2
Whitmore Mfg. Co. Omnilith 500 M Extreme Pressure Grease EP 0
Whitmore Mfg. Co. Omnilith 500 M Extreme Pressure Grease EP 1
Whitmore Mfg. Co. Omnilith 500 M Extreme Pressure Grease EP 2
Whitmore Mfg. Co. Caliber 3M Extreme Pressure Grease EP 00
Whitmore Mfg. Co. Caliber 3M Extreme Pressure Grease EP 0
Whitmore Mfg. Co. Caliber 3M Extreme Pressure Grease EP 1
Whitmore Mfg. Co. Caliber 3M Extreme Pressure Grease EP 2
Whitmore Mfg. Co. Caliber 5M Extreme Pressure Grease EP 00
Whitmore Mfg. Co. Caliber 5M Extreme Pressure Grease EP 0
Whitmore Mfg. Co. Caliber 5M Extreme Pressure Grease EP 1
Whitmore Mfg. Co. Caliber 5M Extreme Pressure Grease EP 2

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 Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

(January 22, 2007)

CERTIFIED LUBRICANT LISTING FOR “DRAGLINE ENCLOSED GEARCASE

LUBRICANT (SD4721 Part A)”

Mineral Oils

Manufacturer Product Description

Bel Ray 100 Gear Oil 140 (ISO VG 460)
Bel Ray 100 Gear Oil 250 (ISO VG 1000)
Bel Ray 100 Gear Oil 350 (ISO VG 1500)
Bel Ray 100 Gear Oil 460 SBF (ISO VG 460)
Bel Ray 100 Gear Oil 1000 SBF (ISO VG 1000)
Bel Ray 100 Gear Oil 1500 SBF (ISO VG 1500)
Exxon / Esso Spartan EP 460 (ISO VG 460)
Exxon / Esso Spartan EP 1000 (ISO VG 1000)
Lubritene Lubrene Syn 1500 (ISO VG 1500)
Lubritene Lubrene Super Series Gear Oil 1500 (ISO VG 1500)
Lubritene Lubrene Super Series Gear Oil 1000 (ISO VG 1000)
Mobil Mobilgear 600XP 460 (ISO VG 460)
Mobil Mobilgear 634 (ISO VG 460)
Mobil Mobilgear XMP 460 (ISO VG 460)
Mobil Mobilgear 639 (ISO VG 1000)
Petro-Canada Ultima 460 (ISO VG 460)
Petro-Canada Ultima 1000 (ISO VG 1000)
Schaeffer Mfg. #209A Universal Gear Lube (ISO VG 460)
Schaeffer Mfg. #209A Universal Gear Lube (ISO VG 1000)
Schaeffer Mfg. #294 Supreme Gear Lube (ISO VG 460)
Schaeffer Mfg. #294A Supreme Gear Lube No Tack (ISO VG 460)
Shell Omala 460 (ISO VG 460)
Shell Omala 1000 (ISO VG 1000)
Shell Omala 1500 (ISO VG 1500)
Shell SP Plus Gear Oil (ISO VG 1500)
Talcor Gear Oil EP (ISO VG 1000)
Whitmore Mfg. Co. Paragon Heavy Duty Enclosed Gear Oil (ISO VG 460)
Whitmore Mfg. Co. Paragon Heavy Duty Enclosed Gear Oil (ISO VG 1000)
Whitmore Mfg. Co. Paragon Heavy Duty Enclosed Gear Oil (ISO VG 1500)
Whitmore Mfg. Co. Paragon Gold High Performance Gear Oil (ISO VG 1000)

Synthetic (PAO) Oils

Manufacturer Product Description

Bel Ray Synthetic Gear Oil 460 (ISO VG 460)
Bel Ray Synthetic Gear Oil 1000 (ISO VG 1000)
Lubrication Engineers 9846 Synolec Gear Lubricant (ISO VG 460)
Lubrication Engineers 9899 Synolec Gear Lubricant (ISO VG 1000)
Mobil Mobil SHC 634 (ISO VG 460)

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 Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

(January 22, 2007)

Mobil Mobilgear SHC XMP 460 (ISO VG 460)

Mobil Mobilgear SHC 460 (ISO VG 460)
Mobil Mobil SHC 639 (ISO VG 1000)
Mobil Mobilgear SHC 1000 (ISO VG 1000)
Mobil Mobilgear SHC 1500 (ISO VG 1500)
Schaeffer Mfg. #167 Pure Synthetic Gear Lube (ISO VG 460)
Schaeffer Mfg. #167 Pure Synthetic Gear Lube (ISO VG 1000)
Shell Omala HD 460 (ISO VG 460)
Shell Omala HD 1000 (ISO VG 1000)
Whitmore Mfg. Co. GF 365 Synthetic Gear Fluid (ISO VG 460)
Whitmore Mfg. Co. GF 365 Synthetic Gear Fluid (ISO VG 1000)
Whitmore Mfg. Co. Decathlon HD Series Synthetic Enclosed Gear Oil (ISO VG 460)
Whitmore Mfg. Co. Decathlon HD Series Synthetic Enclosed Gear Oil (ISO VG 1000)

LUBRICANT CERTIFICATION PROCESS:

Lubricant manufacturers seeking to certify their products should contact the
following for direction:

Bucyrus International, Inc.

Engineering Services & Technical Support
1100 Milwaukee Avenue
South Milwaukee, Wisconsin 53172
Phone (414) 768-4000

REVISIONS:
This listing is subject to change without notice. Please refer to the Bucyrus
International, Inc. web site www.bucyrus.com for the latest listing.

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Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4721 (January 16, 2006)

Applicable to Bucyrus, Marion and Ransomes-Rapier Draglines.

SCOPE:

This specification covers the requirements for “Enclosed Gearcase Lubricant” used on
Bucyrus, Marion and Ransomes-Rapier Draglines.

The materials furnished under this specification are intended to lubricate spur, helical
and herringbone gears as well as anti-friction bearings at the interior of enclosed non-
planetary and planetary type gearcases (Hoist, Drag, Swing and Propel).

COMPOUNDING:
a. Contains antiscuff / antiwear EP additives.
b. Includes both mineral oil and synthesized hydrocarbon (Polyalphaolefin) fluids.

c. Excludes the use of solid lubricant additives such as graphite, molybdenum

disulfide, etc. The use of borates as an EP additive is not excluded.

d. Must not contain any lead or lead based additives.

AMBIENT TEMPERATURE:

The ambient temperature is defined as the air temperature in the immediate vicinity of
the gearcase.

a. Use machinery house temperature for gearcases located inside of the

machinery house (Hoist, Drag, Swing and Propel Gearcases) for some
machines are equipped with machinery house heaters.

b. The pour point of the lubricant must be at least 5°C (9°F) below the minimum
ambient starting temperature. If the ambient starting temperature approaches
the pour point, oil sump heaters may be required to facilitate starting and
ensure proper lubrication. Use oil temperature for gearcases having oil sump
heaters.

Page 1 of 8
Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4721 (January 16, 2006)

Applicable to Bucyrus, Marion and Ransomes-Rapier Draglines.

SD4721 Part A
LUBRICANT SELECTION GUIDELINES FOR DRAGLINES EQUIPED WITH NON-
PLANETARY TYPE GEARCASES:

SCOPE:

Includes lubricants for Hoist, Drag, Propel and non-planetary type Swing Gearcases.
See the following section (SD4721 Part B) for planetary type swing gearcase lubricants.

Based upon the anticipated ambient temperature range (as defined on page #1),
determine the recommended oil type (Mineral or Synthetic PAO) and ISO viscosity
grade of oil. (see table below).

Note: At many locations, a winter and summer grade of gear oil will need to be used.

Page 2 of 8
 Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4721 (January 16, 2006)

Applicable to Bucyrus, Marion and Ransomes-Rapier Draglines.

MINIMUM PERFORMANCE REQUIREMENTS FOR ANTISCUFF / ANTIWEAR (EP) OILS:

PROPERTY TEST METHOD REQUIREMENT
ISO / ASTM
Ambient Temperature +5°C to +65°C 0°C to +50°C -40°C to +10°C
(As defined on page #1) (+41°F to +150°F) (+32°F to +122°F) (-40°F to +50°F)
(See Note #3 Below)
Oil Type Mineral Oil or Mineral Oil or Mineral Oil or
Synthetic (PAO) Synthetic (PAO) Synthetic (PAO)
(See Note #2 Below) (See Note #2 Below)
ISO Viscosity Grade 3448/D2422 1500 1000 460

Viscosity @ 40°C, mm2/s 3104/D445 1350 – 1650 900 - 1100 414 - 506

Pour point °C (°F), max. None/D97 Mineral Oil +5 (+41) Mineral Oil 0 (+32) Mineral Oil -12 (+10)
Synthetic -18 (0) Synthetic -24(-11) Synthetic -27(-17)
(See Note #3 Below)
Viscosity index, min. 2909/D2270 Mineral Oil 85 Mineral Oil 85 Mineral Oil 90
Synthetic 140 Synthetic 140 Synthetic 140
Bulk fluid dynamic None/D2983 150,000 150,000 150,000
viscosity @ cold start-up,
mPa-s, max.
Flash point, °C, min. 2592/D92 200 200 200

Resistance to aging @ None/D2893 Mineral Oil – Mineral Oil – Mineral Oil 10

121°C – max. %
increase in kinematic Synthetic 6 Synthetic 6 Synthetic 6
viscosity @ 100°C
Water content, ppm, 12937/D6304 300 300 300
max. (See Note #1
Below)
Foam suppression – 6247/D892 Temp. 5 min blow 10 min settle 5 min blow 10 min settle
Volume of foam (mL), Seq l- 24°C 75 10 50 0
Seq ll- 93.5°C 75 10 50 0
max. after: 50 0
Seq lll- 24°C 75 10
Scuffing load capacity, 14635-1/ >12 >12 >12
FZG visual method, D5182
A/8.3/90, fail stage, min.
Timken O.K. Load, Lbs. None/D2782 65

EP Test – 4 Ball Method None/D2783 1. Load wear index (LWI), min. kg=40
2. Load weld, min. kg=250
Wear Test – 4 Ball None/D2266 Wear scar diameter, mm. Max.=0.4
1hr. @ 130°F @ 1800 RPM @ 40 kg.

Page 3 of 8
 Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4721 (January 16, 2006)

Applicable to Bucyrus, Marion and Ransomes-Rapier Draglines.

PROPERTY TEST REQUIREMENT

METHOD
ISO / ASTM
Water separation: None/D2711
(Procedure B)
- % Water in oil after 5 2.0 2.0 2.0
hr. test, max.

- Cuff after centrifuging 4.0 4.0 4.0

mL, max.

- Total free water 50.0 50.0 50.0

collected during entire
test, starting with 90 mL
water, mL, min.

Rust Prevention, Part B 7120/D665 Pass Pass Pass

Compatibility with None/ Pass Pass Pass

elastomer materials D4289-03
(Nitriles, Viton) used for
shaft sealing rings.
Copper corrosion 2160/D130 1b 1b 1b
prevention, 3 hr. @
100°C, rating, max.
Cleanliness None/None Must be free of visible suspended or settled contaminants at the
Visual time it is installed for use.
Resistance to Separation None/ None Should not separate in storage and should maintain extreme
pressure characteristics when subjected to centrifugal forces
while in use.
Additive Solubility None/None Must be filterable to 20 microns (wet or dry) without loss of EP
additive.
Notes:

1) Water content of virgin lubricant as packaged.

2) Synthetic (PAO) oil is preferred.
3) Machinery house heaters and/or gearcase oil sump heaters will be required to ensure that the lubricant
pour point remains at least 5°C (9°F) below the minimum ambient temperature as defined on page #1.

Page 4 of 8
Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4721 (January 16, 2006)

Applicable to Bucyrus, Marion and Ransomes-Rapier Draglines.

CERTIFIED LUBRICANTS:

Lubricants certified by their manufacturers as complying with this specification will be

listed on the “Certified Lubricants Listing for Dragline Enclosed Non-Planetary
Type Gearcases – SD4721 Part A” (see the Bucyrus International, Inc. web site
www.bucyrus.com for the latest listing). The use of non-certified lubricants may
invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is

dependent on climate, application, performance and regional/local regulatory
requirements.

Lubricant manufacturers seeking to certify their products should contact the following for
direction:

Bucyrus International, Inc.

Engineering Services & Technical Support
1100 Milwaukee Avenue
South Milwaukee, Wisconsin 53172
Phone (414) 768-4000

Page 5 of 8
Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4721 (January 16, 2006)

Applicable to Bucyrus, Marion and Ransomes-Rapier Draglines.

SD4721 Part B
GUIDELINES FOR SELECTING AN APPROVED LUBRICANT FOR PLANETARY
TYPE SWING GEARCASES ONLY:

SCOPE:

Does not include lubricants for Hoist, Drag and Propel gearcases. See the preceding
section (SD4721 Part A) for Hoist, Drag and Propel gearcase lubricants.

Step #1

Based upon the anticipated ambient temperature range (as defined on page #1),
determine the recommended ISO viscosity grade of oil and type (Mineral or Synthetic
PAO). (see table #1).

Note that machinery house heaters and/or gearcase oil sump heaters may be required
to ensure that the lubricant pour point remains at least 5°C (9°F) below the minimum
ambient temperature as defined on page #1.

Table 1

Ambient Temperature Range ISO Viscosity Grade / Oil Type

(As defined on page #1)
14°F to 100°F (-10°C to 37°C) ISO VG 320 / Mineral or Synthetic (Polyalphaolefin) Oil
Less than 14°F to 120°F
ISO VG 320 / Synthetic (Polyalphaolefin) Oil
(Less than -10°C to 50°C)

Step #2

Select an approved lubricant from the Approved Lubricant Tables 2 & 3.

Note that 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.

Page 6 of 8
Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4721 (January 16, 2006)

Applicable to Bucyrus, Marion and Ransomes-Rapier Draglines.

APPROVED LUBRICANTS FOR PLANETARY TYPE SWING GEARCASES:

Lubricants that have been approved for use by the planetary swing gearcase
manufacturers are listed in the Approved Lubricant Tables 2 & 3. The use of non-
approved lubricants may invalidate the Bucyrus International, Inc. 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
Alpha SP 320
Alpha MAX 320
CASTROL
Optigear BM 320
Tribol 1100/320
Chevron Ultra Gear Lube 320
CHEVRON
Gear Compound EP 320
Spartan EP 320 (Only Product
ESSO
Originating from Europe)
FUCHS Renolin CLP 320 Plus
LE (Lubrication
Almasol 605
Engineers)
MOBIL Mobilgear XMP 320
PETRO CANADA Ultima EP 320
SHELL Omala F 320
Auriga EP 320
TEXACO Meropa 320
Meropa WM 320
WHITMORE Paragon 320

Page 7 of 8
Bucyrus International, Inc.

SPECIFICATION FOR
ENCLOSED GEARCASE LUBRICANT
SD4721 (January 16, 2006)

Applicable to Bucyrus, Marion and Ransomes-Rapier Draglines.

Table 3
Approved Synthetic (Polyalphaolefin) Oil Lubricants (ISO VG 320)

Manufacturer Product Description

BEL-RAY Synth. Gear Oil 6692
Enersyn EP-XF 320
BP
Enersyn HTX 320
Optigear Synth. A 320
Optigear Synth. X 320
Alphasyn EP 320
CASTROL
Alphasyn T 320
Tribol 1510/320
Tribol 1710/320
CHEVRON Tegra Synth. Gear Lube 320
FUCHS Renolin Unisyn CLP 320
Mobil SHC 632
MOBIL
Mobilgear SHC XMP 320
Ultima Synth. EP 320
PETRO CANADA
Traxon E Synth. 80W-140
SHELL Omala HD 320
TEXACO Pinnacle EP 320
WHITMORE Decathlon F 320

SPECIFICATION REVISIONS:

This specification is subject to change without notice. Please contact the following for
the latest specification:

Bucyrus International, Inc.

Engineering Services & Technical Support
1100 Milwaukee Avenue
South Milwaukee, Wisconsin 53172
Phone (414) 768-4000

Page 8 of 8
 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 4
Preventive Maintenance

Table of Contents

DESCRIPTION .............................................................................................................................. 3
ELEMENTS OF A MAINTENANCE PROGRAM ....................................................................... 5
SCHEDULED PREVENTIVE MAINTENANCE PROGRAM ...................................................... 5
PRE-STARTUP INSPECTION ................................................................................................. 6
INSPECTION SCHEDULE ............................................................................................................ 7
ANNUAL CALENDAR OF INSPECTION INTERVALS .............................................................. 7
INSPECTION SCHEDULES .................................................................................................... 8
PREVENTIVE MAINTENANCE CHECK LIST .............................................................................. 20
CRAWLER ............................................................................................................................. 20
PROPEL MACHINERY .......................................................................................................... 20
LOWER FRAME .................................................................................................................... 21
ROTATING FRAME ............................................................................................................... 22
SWING MACHINERY ............................................................................................................. 22
HOIST MACHINERY .............................................................................................................. 23
GANTRY STRUCTURE ........................................................................................................ 24
LUBRICATION SYSTEMS ..................................................................................................... 24
AIR COMPRESSOR .............................................................................................................. 24
OPERATOR’S CAB ............................................................................................................... 25
HOUSE .................................................................................................................................. 25
FRONT END COMPONENTS ............................................................................................... 26
ELECTRICAL ......................................................................................................................... 27
INSPECTION FORM ............................................................................................................. 28

Sept. 2010 4-1 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Manual No. 10954 4-2 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 4
Preventive Maintenance

DESCRIPTION

Preventive Maintenance Programs may be defined as 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, 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. This art 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.

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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 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 List, or Lists by your maintenance department, should reduce repair, maintenance cost,
and increase production.

Replacing worn components with genuine Bucyrus parts on a scheduled basis will avoid costly
downtimes 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.

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

ELEMENTS OF A MAINTENANCE PROGRAM

• Preventive Maintenance Program.

• Well Trained and Motivated Work Force.

• Effective Communications.

• Proper Equipment Selection and Procurement.

• Meaningful Paperwork.

• Cooperation with the Operations / Maintenance Department.

• Warehouse Support.

• Good Shop Facilities.

SCHEDULED PREVENTIVE MAINTENANCE PROGRAM

Economically maintaining the productivity and performance of a Bucyrus mining 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 shovel 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 Bucyrus maintenance program that is outlined here to formulate a schedule suited to your
work-force and mining environment. Over a period of time, additional inspection or planned work
may supplement the activities described in this manual.

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

PRE-STARTUP INSPECTION

1. Crawler Frame:

a. Crawler belt adjustment?

b. Belt, sprocket, or idler damage?
c. Lubrication?

2. Lower Frame:

a. Structural damage, loose/broken bolt?

b. Lubrication on circle gear and pinions?
c. Broken pinion or circle gear teeth?

3. Dipper:

a. Excessive dipper lip wear?

b. Missing or worn shrouds/wear plates?
c. Missing tooth points?
d. Latch bar, latch lever, trip chain, dutchman condition?

4. Front end components:

a. Structural cracks boom/handle?

b. Broken or missing lube lines?
c. Structural damage?
d. Lubrication (manual):
1) Equalizer sheaves.
2) Trip levers.
3) Dipper door hinge pins.

5. Rotating Frame:

a. Lube systems on and operating?

b. Hoist rope positioned properly on the drum; broken wires or kinks?
c. Gearcase leaks?
d. Hot bearings?
e. Air system operation?

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

INSPECTION SCHEDULE

ANNUAL CALENDAR OF INSPECTION INTERVALS

Reference Hours Approximate Weeks

5000 50
2500 26
1000 10
500 4
250 2

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182M-AC Electric Mining Shovel

INSPECTION SCHEDULES

Ensure that the machine is positioned firmly and safely on level ground. Attach “DANGER” and
“OUT OF SERVICE” signs where necessary. Remove signs on completion. Samples of any oil
“dropped” must be taken and marked. Indicate work performed or condition of component or OK if
no repairs required in space provided under each inspection description.
Consult service/shop manual for specific details.

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182M-AC Electric Mining Shovel

PREVENTIVE MAINTENANCE CHECK LIST

CRAWLER

1. Check all bolts for tightness.

2. Structural cracks.

3. Inspect all sprocket assemblies:

a. Cracks in castings?
b. Excess wear or metal flow on sprockets?
c. Worn or noisy bearings?
d. Is the lubrication adequate?

4. Inspect all idler roller assemblies:

a. Cracks in castings?
b. Excessive wear or broken rollers?
c. Worn bushings?
d. Is the lubrication adequate?
f. Oil leaks?

5. Are the guards all in place?

6. Inspect the crawler belts:

a. Broken or cracked shoes?
b. Excess wear on shoes?
c. Is the crawler belt tightness correct?
d. Are the bolts tight?

PROPEL MACHINERY

1. Condition of air and lube lines?

2. Gearcase oil level?
3. Coupling bolts tight?
4. Lubrication?
5. Do brakes operate properly?
6. Are brake linings worn?

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

LOWER FRAME

1. Structural Damage:
a. Paint cracks or ripples?
b. Cracks?

2. Inspect the air and lube piping:

a. Broken or bent pipes or hoses?
b. Loose fittings or connections?
c. Loose clamps?
d. Leakage?

3. Inspect the rails on the frame:

a. Are all hold down bolts tight?
b. Broken welds?
c. Spalling?

4. Inspect the roller circle:

a. Excessive or inadequate lubrication?
b. Excess wear on rollers?

5. Inspect main swing gear:

a. Are the hold down bolts tight?
b. Wear pattern?
c Lubrication?
d. Broken gear teeth?

6. Inspect center journal:

a. Clearance?
b. Lubrication?

7. Inspect the cable reel:

a. Correct operation?
b. Damage?
c. Air/fluid leaks?

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182M-AC Electric Mining Shovel

ROTATING FRAME

1. Structural damage:
a. Paint cracks or ripples?
b. Plate distortion?

2. Cracked welds?

3. Main rotating shaft housings:

a. Lubrication?
b. Bearing temperature?
c. Seals?

4. Inspect center journal:

a. Is there evidence of overheating?
b. Is lubrication adequate?
c. Clearance under nut?
d. Side movement?

5. Inspect lubrication lines:

a. Evidence of damaged lines?
b. Leakage evident?
c. Loose clamps?

6. Inspect air piping lines:

a. Damaged lines?
b. Leaks?
c. Loose clamps?

7. Boom foot lugs:

a. Cracks or damage?

8. Inspect gantry:
a. Cracks or damage?
b. Pin wear and retainers?

SWING MACHINERY

1. Swing gearcase:
a. Gearcase bolts?
b. Motor mounting bolts?
c. Guards?
d. Noise?
e. Oil level?
f. Leaks?
g. Brake operation?
h. Brake linings?

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182M-AC Electric Mining Shovel

HOIST MACHINERY

1. Check following bolts:

a. Module/pedestal?
b. Motor?
c. Gearcase?
d. Hoist gear and drum end?
e. Brake assembly?
f. Motor coupling?
g. Guard

2. Inspect wear pattern of gears and pinions:

a. Pattern on motor pinion and intermediate gear?
b. Pattern on intermediate pinion and hoist gear?

3. Check the float (end play) of pinions:

a. Motor pinion float?

4. Inspect enclosed gearcase:

a. Oil level?
b. Correct lubricant?
c. Bearing temperature?
d. Leakage?

5. Inspect hoist brake assembly:

a. Operation?
b. Brake linings?
c. Brake adjustment?

6. Are all guards in place?

7. Lagging condition?

8. Inspect hoist ropes:

a. Rope anchor sockets?
b. Broken or frayed wires?
c. Lubrication?

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182M-AC Electric Mining Shovel

GANTRY STRUCTURE

1. Structural cracks?
2. Connecting pins?
3. Bushings?
4. Lubrication?
5. Ladders and walkway damage?

LUBRICATION SYSTEMS

1. Are all grease tanks filled with correct grease?

2. Grease pump operation?
3. Injector operation?
4. Grease line damage?
5. Do all systems cycle properly?

AIR COMPRESSOR

1. Air compressor operating properly?

2. Compressor and motor mounting bolts?
3. Crankcase oil level?
4. High and low operating pressures to specification?
5. Air filters?
6. Guards in position and secure?
7. Air leaks?
8. Air line damage?
9. Drain water from reservoir?
10. Tanner deicer filled?

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182M-AC Electric Mining Shovel

OPERATOR’S CAB

1. Electrical controls functional?

2. Hand lever operation?
3. Windshield wipers operational?
4. Heaters?
5. Air conditioner?
6. Overhead lights?
7. Seat condition?

HOUSE

1. Panel damage?
2. Window condition?
3. House leaks?
4. House bolts?

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FRONT END COMPONENTS

1. Boom:
a. Structural damage?
b. Bolts?
c. Lubrication?
d. Walkway damage?
e. Foot pins condition?
f. Condition of lube and air piping?
g. Condition of dipper trip mechanism and rope?

2. Point Sheaves:
a. Rope grooves?
b. Cracks?
c. Bearings?
d. Lubrication?

3. Boom Support Ropes:

a. Condition of socket connections?
b. Broken strands?
c. Corrosion?
d. Lubrication?

4. Crowd machinery:
a. Structural cracks or damage?
b. Lubrication?
c. Lube piping?
d. Clearance of yoke block wear pads?
e. Brake operation?
f. Brake linings?
g. Shipper shaft pinions?
h. Crowd gearing?
i. Bolts?

5. Handle assembly:
a. Structural cracks or damage?
b. Worn racking?
c. Lubrication?
d. Bail sheaves.
e. Bail sheave pins.
f. Bail sheave lubrication?

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182M-AC Electric Mining Shovel

6. Dipper assembly:
a. Cracks?
b. Latch wear/latch lever?
c. Snubber pre-load?
d. Dipper teeth?
e. Bushing and pin condition?
f. Lubrication?
g. Shrouds?
h. Liners?
i. Dutchman/insert?

ELECTRICAL

1. Motors

a. Bearings?
b. Brushes?
c. Commutators?
d. Blower bearings and fan?

2. Contactor condition?

3. Lights?

4. Motor commutation?

5. Air conditioner operation?

6. Air filtering system?

7. Warning systems?

8. Operator controls?

9. Auxiliary controls?

10. Electrical cabinets?

a. Cleaned out?
b. Mounting bolts?
c. Wiring connections?

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

182M Mining Shovel

INSPECTION FORM

Remarks:

Inspected By:

Date:

Correction:

Authorized By:

Date:

Manual No. 10954 4 - 28 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 5
Service Procedures
Table of Contents

LOWER FRAME & CRAWLERS ASSEMBLY ................................................................................. 7

Independent Propel - Plan View of Rear Portion ........................................................................ 7
Lower Frame and Crawler Assembly ......................................................................................... 8
ROLLER CIRCLE ASSEMBLY ................................................................................................. 9
Roller Circle Assembly-Isometric View ..................................................................................... 9
BALLAST REQUIREMENT .............................................................................................. 10
Roller Circle Area - Section View ............................................................................................. 10
ROLLER CIRCLE MAINTENANCE .................................................................................. 11
Roller Circle Assembly ............................................................................................................. 11
ROLLER CIRCLE ROLLER REPLACEMENT .................................................................. 12
Mounting Bracket for Roller Circle Guards .............................................................................. 13
ROLLER CIRCLE ADJUSTMENT .................................................................................... 14
MAIN ROTATING GEAR AND ROLLER RAILS ...................................................................... 15
UPPER ROLLER CIRCLE RAIL ....................................................................................... 15
MAIN ROTATING GEAR REPLACEMENT ....................................................................... 16
Lower Frame Structure with Main Rotating Gear ..................................................................... 16
LOWER ROLLER CIRCLE RAIL ...................................................................................... 17
Lower Rail Installation Procedure ............................................................................................ 19
CRAWLER BELTS ....................................................................................................................... 20
CRAWLER BELT ASSEMBLY .................................................................................................. 20
CRAWLER BELT MAINTENANCE ......................................................................................... 21
CRAWLER BELT TENSION ADJUSTMENT .................................................................... 22
REPLACEMENT OF A CRAWLER BELT OR SHOE ........................................................ 23
CRAWLER ASSEMBLY ......................................................................................................... 25
Crawler Assembly - Exploded View ......................................................................................... 26
CRAWLER MAINTENANCE ............................................................................................. 27
Connecting Rods ~Lower Frame to Crawler ............................................................................ 27
PROCEDURE FOR USE OF THE HYDRAULIC TENSIONER: ....................................... 28
SLIDE BAR REBUILD ...................................................................................................... 29
LOAD ROLLERS AND REAR IDLER ROLLERS .............................................................. 30
ROLLER REMOVAL ........................................................................................................ 30
Pit for Load Roller Removal ..................................................................................................... 31
ROLLER INSTALLATION ................................................................................................. 31
FRONT IDLER ROLLER .................................................................................................. 32
Front Idler Roller Assembly - Exploded View .......................................................................... 33
Front Idler Roller- Section View ............................................................................................... 34

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PROPEL MACHINERY ................................................................................................................ 35

Propel Machinery - Plan View .................................................................................................. 35
Propel Machinery - Exploded View .......................................................................................... 36
PROPEL MACHINERY MAINTENANCE ................................................................................ 37
PROPEL MOTORS ............................................................................................................... 37
PROPEL MOTOR MAINTENANCE ................................................................................. 37
PROPEL MOTOR REMOVAL .......................................................................................... 38
PROPEL MOTOR INSTALLATION .................................................................................. 39
PROPEL GEARCASE REMOVAL .................................................................................... 40
Planetary Gearcase, Propel ..................................................................................................... 42
Gearcase Fasteners Recommended Tightening ...................................................................... 42
PROPEL GEARCASE INSTALLATION ............................................................................. 43
MAIN PROPEL SHAFT AND SPROCKET ............................................................................. 44
Main Propel Shaft and Sprocket - Section View ...................................................................... 44
PROPEL SHAFT/SPROCKET REMOVAL ....................................................................... 45
Details of Propel Shaft Removal and Installation Aids ............................................................. 46
MAIN PROPEL SHAFT DISASSEMBLY ........................................................................... 48
MAIN PROPEL SHAFT ASSEMBLY ................................................................................. 51
MAIN PROPEL SHAFT/SPROCKET INSTALLATION ...................................................... 52
Main Propel Shaft and Sprocket - Section View ...................................................................... 55
SPROCKET REBUILD PROCEDURE ....................................................................... 56
Template for Sprocket Rebuild ................................................................................................. 57
CENTER JOURNAL .................................................................................................................... 58
CENTER JOURNAL ADJUSTMENT ...................................................................................... 58
CENTER JOURNAL ASSEMBLY ........................................................................................... 59
CENTER JOURNAL REMOVAL ............................................................................................. 60
Center Journal Installation ....................................................................................................... 61
THRUST WASHER REPLACEMENT .................................................................................... 62
CENTER JOURNAL BUSHING REPLACEMENT .................................................................. 64
ROTATING FRAME ASSEMBLY .................................................................................................. 65
Rotating Frame Structure ......................................................................................................... 65
ROTATING FRAME MAINTENANCE ..................................................................................... 66
MAIN COLLECTOR RINGS (H.V.) ......................................................................................... 66
Main Collector Rings (H.V.) ..................................................................................................... 67
MAIN COLLECTOR RING MAINTENANCE ..................................................................... 68
AUXILIARY COLLECTOR RINGS AND ROTOSEAL ........................................................ 68
Auxiliary Collector Rings - Roto Seal - Section View .............................................................. 69
AUXILIARY COLLECTOR RING MAINTENANCE ............................................................ 71
Collector Ring Assembly .......................................................................................................... 71
COLLECTOR RING INSPECTION AND ADJUSTMENT .................................................. 72
ENCLOSURE INSPECTION ...................................................................................... 74
FREQUENCY OF INSPECTIONS .............................................................................. 75
BRUSH SERVICE ...................................................................................................... 75
HOIST MACHINERY.................................................................................................................... 77

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182M-AC Electric Mining Shovel

HOIST MACHINERY MAINTENANCE ................................................................................... 77

182M Hoist Machinery - Plan View ......................................................................................... 78
HOIST DRUM SHAFT ASSEMBLY REMOVAL ................................................................ 81
HOIST GEAR ALIGNMENT ............................................................................................. 82
HOIST DRUM SHAFT DISASSEMBLY ............................................................................ 84
Connector Plate Alignment Pin ................................................................................................. 85
HOIST DRUM SHAFT ASSEMBLY PROCEDURE .......................................................... 86
Section C - C ........................................................................................................................... 86
HOIST DRUM SHAFT BEARING INSTALLATION ........................................................... 88
SHIM PROCEDURE FOR GAP-"A" - 2 PLACES: ....................................................... 89
INTERMEDIATE HOIST SHAFT ............................................................................................ 90
Hoist Intermediate Shaft Assembly - Section View ................................................................. 90
HOIST INTERMEDIATE SHAFT REMOVAL AND DISASSEMBLY ................................... 91
HOIST MOTOR PINION SHAFT ............................................................................................ 94
HOIST MOTOR PINION SHAFT REMOVAL .................................................................... 94
HOIST MOTOR PINION SHAFT REPLACEMENT .......................................................... 95
HOIST BRAKE ....................................................................................................................... 96
SWING MACHINERY................................................................................................................... 97
SWING MACHINERY MAINTENANCE .................................................................................. 98
182M Swing Machinery - Section View ................................................................................... 99
SWING MOTOR ASSEMBLY ......................................................................................... 100
SWING MOTOR REMOVAL .......................................................................................... 100
Swing Motor ............................................................................................................................100
MAIN ROTATING PINION REPLACEMENT ................................................................... 102
MAIN SWING SHAFT REMOVAL / ROTATING GEARCASE DISASSEMBLY ................. 103
Bolt Pattern on the Swing Gearcase ....................................................................................... 103
Main Rotating Shaft Assembly ................................................................................................ 105
ROTATING GEARCASE ASSEMBLY ............................................................................. 107
MAIN ROTATING GEARCASE ............................................................................................... 108
GANTRY ................................................................................................................................... 110
GANTRY MAINTENANCE ................................................................................................... 111
GANTRY DISASSEMBLY OR REMOVAL ............................................................................ 111
FRONT END EQUIPMENT ....................................................................................................... 113
BOOM ASSEMBLY .............................................................................................................. 113
BOOM ASSEMBLY MAINTENANCE .............................................................................. 114
182M Boom Assembly ........................................................................................................... 115
BOOM LOWERING/RAISING......................................................................................... 115
BOOM REMOVAL .......................................................................................................... 116
BOOM POINT SHEAVE ASSEMBLY.............................................................................. 117
Boom Point Sheave Assembly ~Section View ........................................................................ 118
BOOM JACKING LIMIT .................................................................................................. 119
Boom Jacking Limit Switch ..................................................................................................... 120

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CROWD MACHINERY ............................................................................................................... 121

CROWD MACHINERY MAINTENANCE .............................................................................. 122
Crowd Motor Assembly ...........................................................................................................123
CROWD MOTOR .......................................................................................................... 123
CROWD MOTOR MAINTENANCE .......................................................................... 123
CROWD MOTOR REMOVAL ................................................................................... 124
INTERMEDIATE PINION SHAFT REMOVAL ................................................................. 124
Crowd Intermediate Pinion Shaft Assembly ............................................................................125
CROWD OVERLOAD CLUTCH ........................................................................................... 129
Crowd Overload Clutch Assembly - Section View .................................................................. 129
CLUTCH PRELIMINARY STEPS ................................................................................... 130
CLUTCH WEAR ADJUSTMENT / AIR TUBE REPLACEMENT ..................................... 131
REPLACEMENT OF FRICTION DISCS ......................................................................... 131
OVERLOAD CLUTCH REMOVAL FROM THE INTERMEDIATE PINION SHAFT .......... 131
INTERMEDIATE GEAR REMOVAL ................................................................................ 132
SHIPPER SHAFT ASSEMBLY ............................................................................................. 133
HANDLE WEAR SHOE RUNNING CLEARANCE .......................................................... 135
YOKE BLOCK SIDE PLAY ADJUSTMENT .................................................................... 137
SHIPPER SHAFT REMOVAL AND DISASSEMBLY ....................................................... 138
Shipper Shaft Pinion Alignment ............................................................................................... 139
CROWD LIMIT SWITCH ...................................................................................................... 140
SPEED RATINGS .......................................................................................................... 141
CAM SETTING .............................................................................................................. 143
OPERATION AND ADJUSTMENT OF CAMS ................................................................ 144
VERNIER ADJUSTMENT ........................................................................................ 144
CROWD LIMIT SWITCH MAINTENANCE ..................................................................... 145
CROWD LIMIT RANGE ................................................................................................. 146
DIPPER HANDLE ...................................................................................................................... 147
DIPPER HANDLE MAINTENANCE ...................................................................................... 147
DIPPER HANDLE REMOVAL .............................................................................................. 148
DIPPER HANDLE RACK WELD REPLACEMENT ............................................................... 149
Dipper Handle .........................................................................................................................150
Dipper Handle Rack Welding .................................................................................................. 151
HANDLE WEAR BARS ON THE BOOM .............................................................................. 152

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DIPPER ASSEMBLY .................................................................................................................. 153

DIPPER MAINTENANCE ..................................................................................................... 154
DIPPER TEETH AND BASES .............................................................................................. 155
Dipper Tooth Assembly - Section View ................................................................................... 155
Detail ~Template for Tooth Base ............................................................................................. 156
DIPPER REMOVAL .............................................................................................................. 157
DIPPER DOOR LATCH ASSEMBLY .................................................................................... 158
Dipper Door Assembly ............................................................................................................ 158
DIPPER LATCH MAINTENANCE ................................................................................... 159
LATCH BAR ADJUSTMENT .................................................................................... 160
LATCH BAR REMOVAL ........................................................................................... 160
LATCH BAR REPAIR ............................................................................................... 161
WEAR INSERTS ............................................................................................................ 161
WEAR INSERT REPLACEMENT............................................................................. 161
DIPPER DOOR SNUBBER .................................................................................................. 162
EQUALIZER ......................................................................................................................... 164
DIPPER TRIP ASSEMBLY ......................................................................................................... 165
DIPPER TRIP MAINTENANCE ............................................................................................ 165
Dipper Trip Assembly .............................................................................................................. 166
Section E-E ............................................................................................................................. 166
Section B-B ............................................................................................................................. 167
Section C-C ............................................................................................................................. 167
View D-D ................................................................................................................................. 168
WIRE ROPE SYSTEMS ............................................................................................................ 169
HOIST ROPE REEVING ...................................................................................................... 169
ROPE REEVING WINCH ............................................................................................... 170
Hoist Rope Reeving Winch Installation ................................................................................... 170
HOIST LIMIT SWITCH ......................................................................................................... 171
BOOM SUPPORT ROPES .................................................................................................. 172
BOOM SUPPORT ROPES REPLACEMENT ................................................................ 172
Boom Support Ropes Installation ............................................................................................ 173

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Manual No. 10954 5-6 Sept. 2010

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182M-AC Electric Mining Shovel

Section 5
Service Procedures

LOWER FRAME & CRAWLERS ASSEMBLY

The LOWER FRAME assembly consists of the crawler belts, crawler side frames (bolt-on), lower
frame structure, propel motors and planetary propel gearcases, center journal, roller circle, main
rotating gear, lower rail, optional cable reel and high voltage collector ring brushes (not shown).
The LOWER FRAME is the primary support structure for the machine. The two bolt-on crawler side
frames each have a propel motor and planetary propel gearcase. This assembly provides the operator
complete independent control of each crawler.

Tension rods which retain the side frame to the lower frame should be checked for tightness
semiannually and inspected for damage after each shift. Both the lower 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.
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 their wear rate will be slow. Refer to Section 6 - BRAKES
AND COUPLINGS, in this manual.

Independent Propel - Plan View of Rear Portion

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182M-AC Electric Mining Shovel

Lower Frame and Crawler Assembly

Manual No. 10954 5-8 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

ROLLER CIRCLE ASSEMBLY

The ROLLER CIRCLE ASSEMBLY supports the rotating frame, deck machinery and front end
equipment. It facilitates the rotation of the entire upper frame assembly around the center journal.

This assembly consists of a set of forty-two 8.5-inch (216 mm) forged-steel, double-flanged flat
rollers held in a circle by inner and outer circle segments. Nylatron spacers assemble through each
roller and are bolted in place to the inner/outer circle cages with two .625 inch (15.9 mm) capscrews
with hardened steel washers and lock nuts.

The roller circle assembly is supported by the one piece main rotating gear and rotates on segmented
continuous rails welded to the main rotating gear. This gear and rail assembly is centered by a pilot
register and bolted to the top of the lower frame structure.

Four rails are bolted to a machined path in the circle of rotation on the bottom of the upper rotating
structure. These rails ride on top of the roller circle assembly and support the entire rotating frame,
deck machinery, and front end. The center journal connects the lower to the upper frame.

Lubrication of the roller circle assembly consists of multipurpose grease inside the Nylatron spacers
(at assembly only) and roller surface with open gear lube (Refer to Section 3 - LUBRICATION, in
this manual).

Roller Circle Assembly-Isometric View

Sept. 2010 5-9 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

BALLAST REQUIREMENT

All machines are ballasted to accommodate the material weight specified at the time the machine
was purchased. However, as digging conditions change, the dipper fill and material weight may also
change.

Check the machine operation for proper ballasting by extending a fully loaded dipper to the maximum
crowd out position. The rear rotating frame roller circle rails should not lift off the rollers in this
condition.

If the machine does lift off the rollers, retract the handle until the upper rails settle on the rollers.
Advise Bucyrus of the distance from the rear of the handle to the yoke block and the weight of the
material in the dipper. Bucyrus can then calculate the additional ballast required.

Roller Circle Area - Section View

Manual No. 10954 5 - 10 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

ROLLER CIRCLE MAINTENANCE

DAILY, inspect the condition of the rails and rollers. Check for adequate lubrication, tightness of
bolts/nuts in Nylatron spacers and splice bars. Once every year (5000 hours), clean the roller circle
of open gear lube and inspect contact surfaces of the rails and rollers to locate any spalling,
cracks, lamination or chipped roller flanges. If damaged, replace these components immediately.

Check the gap that occurs between the rear upper frame rails and the top of the rollers during
machine operation every 200 hours. This gap should not exceed 3/8 inch (10mm). If this gap is
excessive, adjustment of the center journal is required (Refer to the subsection on Center Journal
Adjustment).

It is good practice to rotate the upper frame one full revolution (360o) at the start of each shift to
relocate the rollers so they wear evenly.

NOTE: If the center journal requires excessive adjustment and the roller circle rails and roller
require more than normal maintenance, check the machine for proper ballast.

Roller Circle Assembly

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

ROLLER CIRCLE ROLLER REPLACEMENT

When inspection of the roller circle assembly identifies a failed roller, it should be removed from
the roller circle as follows:

1. Move the machine to a level work area.

2. Remove the roller circle guard at one side of the machine.

DANGER! HIGH VOLTAGE! CHECK THAT THE HIGH VOLTAGE COLLECTOR

RING GUARD IS IN PLACE. If the guard is missing, isolate the
machine from the mine substation and confirm the collector rings
have been grounded by a qualified electrician and replace the guard.
Failure to comply with these instructions could result in serious
injury or death.

NOTE: The roller circle guards on each side of the rotating frame are welded in place.
Remove and plug the OGL line to the roller circle rollers. Remove the roller circle
guard by cutting the welds which attach the guard to the rotating frame.

CAUTION: Protect the rollers and rails when cutting the guard(s) loose.

3. Mark the location of the damaged roller(s) and rotate the machine to place the roller in the
open area at the side of the rotating frame.

4. Shut down the machine and tag the controls with a notice that the machine is not in service.

DANGER! IF THE MACHINE IS OPERATED WHILE PERSONNEL ARE WORKING

ON THE ROLLER CIRCLE, INJURY OR DEATH COULD RESULT.
ALWAYS LOCK OUT THE MACHINE CONTROLS AND LINE
EXCITATION WHEN SERVICING THE MACHINE.

5. Remove the 2 capscrews which

secure the roller spacer to the
roller circle cage.

NOTE: If the capscrew head is toward

the inside of the roller circle,
push the capscrew in, cut off
the head and remove it
toward the outside of the roller
circle.

6. Clean and inspect the roller. If

necessary to replace, be sure to
check the correct part number in
the parts book for this machine.

Manual No. 10954 5 - 12 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Reassembly is the reverse of disassembly:

- If a new roller is used, the diameter must

match the two adjacent rollers within .03mm
(.001 inch). Measure the diameter of the
adjacent rollers and machine grind the new
roller(s) to match.

- Coat the new or existing Nylatron spacer

with multipurpose grease.

- Install the roller/spacer and insert the 2

capscrews with their heads to the outside
of the roller circle. Tighten to 50 Ft.Lbs.(68
Nm). DO NOT OVERTIGHTEN.

Install the roller circle guard and restore power to

the machine.

NOTE: Fabricate guard support brackets and

weld to the guard. Position the guard
and weld to the rotating frame as
shown.

Mounting Bracket for Roller Circle Guards

Sept. 2010 5 - 13 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

ROLLER CIRCLE ADJUSTMENT

Roller circle adjustment is not required with double flange, cylindrical roller design. However, if
vibration, popping, snapping, or cracking noises occur during rotation of the machine, check for
the following problems:

• Roller spacers or capscrews worn or missing.

• Inner/outer circle segments out of round or loose due to missing/loose splice plates.

• Incorrect hardness of rail (upper/lower) or roller material.

• Worn center journal.

• Upper rails not concentric with lower rails.

• Improper machine ballast.

• Continuous operation on a steep grade.

Inspect these areas and identify if any of the above are causing problems in the roller circle
assembly. Replace components as required or investigate operational profile.

Manual No. 10954 5 - 14 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

MAIN ROTATING GEAR AND ROLLER RAILS

The Main Rotating Gear is a single piece cast gear machined with teeth on the outside diameter
which mesh with the swing machinery main rotating pinions to produce upper frame rotation.

The main rotating gear is attached to the lower frame with 24 high tensile strength screws with nuts
and hardened flat washers. The main rotating gear is located on the lower frame by pilot register.

The LOWER ROLLER RAILS consist of eight hardened steel sections welded to the main rotating
gear. The upper rails consist of four hardened steel sections bolted to the underside of the rotating
frame. The roller circle rotates between these rails.

UPPER ROLLER CIRCLE RAIL

The UPPER ROLLER CIRCLE RAIL

consists of four 60° track sections bolted to
machined pads on the bottom of the upper
frame. Ten 1.25 inch diameter finished bolts
hold each upper rail in place. Tighten
finishing bolts in 3 steps to a final torque of
1200 Ft-Lbs (1627 N•m) - Drythreaded.

Preventive maintenance consists of a

periodic check for movement between the
rail sections and the upper frame. If any
movement is evident, retighten the bolts
immediately. Check the concentricity of the
upper rails to the center journal.

Sept. 2010 5 - 15 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

MAIN ROTATING GEAR REPLACEMENT

The Main Rotating Gear should last the life of the machine with proper lubrication and maintenance.
After the first machine rebuild (25,000-30,000 hours), the main rotating gear can be turned 180o on
the lower frame to expose the back side of the gear teeth to the most frequent path of the swing
pinions.

Lower Frame Structure with Main Rotating Gear

Manual No. 10954 5 - 16 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Should the main rotating gear require replacement due to damage and or failure, frame separation is
necessary. It is recommended the factory be contacted for this procedure.

Maintenance inspection of the ring gear consists of a periodic check of the torque on the 24 capscrews
(semiannually or 2500 hours, which ever comes first). Should any capscrews need to be replaced,
use the following procedure:

1. Heat each high strength capscrew and its nut to 370oF (180oC) above ambient.

DANGER! PROTECTIVE GLOVES SHOULD BE WORN DURING THIS

PROCEDURE AS HEATED CAPSCREWS WILL CAUSE SERIOUS
BURNS.

2. Install the capscrews in ring gear/lower frame hole and tighten the nuts to 100 Ft.Lbs. (136
Nm). If heating the capscrews and nuts is not used, they must be installed cold to a torque of
2520 Ft.Lbs.(3417 Nm). Tighten in sequence shown in illustration.

DANGER! HIGH VOLTAGE! DO NOT ENTER THE AREA BETWEEN THE

FRAMES UNLESS POWER SUPPLY TO MACHINE HAS BEEN
DISCONNECTED. ISOLATE MACHINE FROM MINE SUBSTATION AND
CONFIRM ELECTRICAL COLLECTOR RINGS HAVE BEEN
GROUNDED BY A QUALIFIED ELECTRICIAN. FAILURE TO COMPLY
WITH THESE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY
OR DEATH.

LOWER ROLLER CIRCLE RAIL

The lower roller circle rails consists of 8 - 45° sections assembled into a machined groove on the
ring gear. Each of the main rotating gear lower rail sections is held in place with equally spaced
weld joints on each side of the groove.

To install the lower rail sections to the main rotating gear:

1. Thoroughly clean surfaces to be welded of all dirt, oil, paint and grease. Any possible source
of moisture or contaminants must be removed.

2. Magnetic particle test (MPT) or penetrate test (PT) to ensure no cracks are present before
welding.

3. Position the lower rails radially outward in the main rotating gear groove while maintaining
equal gaps between the ends of the lower rails. Securely clamp each into place. Use copper
or brass spacers at the contact points of the clamps to prevent surface damage. Check that
the height of adjacent lower rails is within .002 inch (.051mm).

Sept. 2010 5 - 17 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

NOTE: The side with the .25 inch (6 mm) x 45o chamfer is the top surface of the lower rail.
Refer to Section K-K.

4. Uniformly preheat repair area to 250°F (Temp. held a minimum 6 inches away from weld in all
directions) and maintain preheat during welding. Do not let temperature fluctuate during repair
and always maintain this minimum temperature. Do not exceed 450°F for the T-1 material.

5. Weld using the above parameters.

6. Thoroughly chip and wire brush all weld passes immediately

after depositing. Blend all starts and stops.

7. After completion of welding, let repair slowly cool by wrapping

in insulated blankets (such a kaowool).

8. MPT or PT to insure no cracks.

9. Grind and blend to match original part profile.

10. Remove all undercut.

NOTE: No under fill permitted.

11. MPT or PT to insure no cracks. Also ensure no other visual defects such as slag inclusions
or porosity are present.

Manual No. 10954 5 - 18 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Lower Rail Installation Procedure

Sept. 2010 5 - 19 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CRAWLER BELTS

Each CRAWLER BELT assembly contains 51 shoes. It is an endless assembly that is moved by
the crawler drive sprocket on the main propel shaft.

The shoes connect with two through-hardened, alloy steel pins. The shoes assemble to form a belt
with the male lug of each shoe on the ground facing toward the front of the crawler side frame
when the belt is on the bottom of the crawler frame.

The belt can be separated at any shoe, no master pin(s) exist. With the lock bolt removed, the pin
can be pulled out of the shoe. Burn out bent or deformed pin(s).

The pitch of the 182M crawler belt is a nominal 380 mm (14.96 inches nominal) when new.

CRAWLER BELT ASSEMBLY

Manual No. 10954 5 - 20 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CRAWLER BELT MAINTENANCE

Maintenance of the crawler belts consists of daily inspection of the shoes, pins, and locking bolts.
Should any bolts be lost or become loose, replace or tighten them immediately.

To replace an old pin, drive the pin out of the shoe boss, if possible - otherwise burn it out with a
cutting torch.

Annually inspect the crawler shoes and remove any metal flow from the path of the roller that may
interfere with belt motion. Use an air arc to remove metal flow within 1/8 inch (3 mm) of the final
surface, grind the remainder smooth.

Monitor the fit of the crawler shoes over the sprocket monthly and also:

THE CORRECT CRAWLER BELT ADJUSTMENT PROLONGS BELT SERVICE LIFE.

Sept. 2010 5 - 21 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CRAWLER BELT TENSION ADJUSTMENT

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, insure that the
crawler shoes effectively engage the drive sprocket. This is achieved when their is a
minimum of radial shoe movement as it enters the load area of the drive sprocket.

• BOTH CRAWLER BELTS SHOULD BE ADJUSTED TO THE SAME TENSION AND

THE SAME OVERALL LENGTH. This is to insure that the machine will propel in a
straight line. The machine will have a tendency to turn toward the shorter belt when
propelling forward.

Correct tension of the crawler belt requires repositioning the idler adjusting block in the crawler
side frame. Forward-movement tightens the belt, rearward movement loosens the belt. The idler
bearing blocks fit in a rectangular opening, inboard and outboard, in each crawler side frame.
Shims in front of each idler adjusting block are spares for use in tensioning the belt as pins and
shoe bores wear and belt stretches. A fixture welded to each frame provides a base for hydraulic
jacks which are used to reposition the idler adjusting blocks during adjustment of the crawler belt.

To prepare the machine for crawler belt adjustment:

1. Propel the machine forward on level ground until nearly all the slack in the belt is located
between the front idler and the first slide bar. Park the machine.

2. Place one hydraulic cylinder at each side of the front idler between the adjusting block and
frame support provided.

3. Remove the shim retainer bars, both sides.

4. Remove the shims of various thickness from the storage space provided in the front of the
idler adjusting block.

5. Slowly pressurize the hydraulic cylinders. Maintain equal distance across both cylinders to
prevent idler misalignment.

6. Tighten the belt until dimension "A" is 20 to 25 mm (.75 to 1.00 inch). Dimension "A" is
measured with a straight edge on the pins of one shoe to the pins of an adjacent shoe,
between the front idler and the first slide bar, as shown in VIEW K-K.

Manual No. 10954 5 - 22 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

7. Install the shims at the rear of the idler adjusting block, leaving a 25 mm (1 inch) gap. See
VIEW J-J. Install shims of equal thickness at both sides of the idler to maintain correct idler
alignment.

8. Release the cylinders. Return extra shims to the storage space in front of the idler adjusting
block.

9. Replace the shim retainer bars and tighten the bolts to 265 NM (195 Ft.Lbs..).

REPLACEMENT OF A CRAWLER BELT OR SHOE

To replace a CRAWLER BELT:

1. Prepare a level work area and propel the machine to this area.

2. Assemble the new belt on the ground in front of the machine, in line with the belt on the
crawler to be replaced.

3. Remove the belt tension (See crawler belt adjustment).

4. Separate the belt by removing two opposite pins from a shoe at the lowest point forward of
the front idler.

5. Connect the new belt to front shoe under the front idler roller at the separation of the old belt.

6. Attach a wire rope to the upper portion of the old belt at the separation point, then to a truck
or dozer.

Sept. 2010 5 - 23 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

7. Slowly propel the machine forward, controlling the old belt coming off the top of the crawler
with the attached truck or dozer, until the new belt has replaced the old.

8. Disconnect the old belt from the new, remove the old belt from the work area, and pin the two
ends of new belt together at the front idler roller. Adjust the tension of crawler belt.

To replace a CRAWLER SHOE:

1. Park the machine on level ground with shoe to be replaced at front idler position for belt
separation.

2. Remove belt tension by using hydraulic jacks to remove the shims behind the idler adjusting
blocks on each side of the front idler.

NOTE: Should the idler adjusting blocks be stuck, propel the machine slightly back and forth
to free them.

3. Block or support the shoe below the one to be removed, and remove the two bottom pins
from end of shoe to be removed.

4. Rig a sling to support the shoe (approx. 484 Lbs. or 220 Kgs.) to be removed and then
remove the two top pins from the shoe.

5. Remove the shoe from the crawler belt.

6. Position the new shoe into the belt and insert two top pins. Remove the sling.

7. Align the two shoes to close the belt, and assemble the two bottom pins through the new
shoe. Adjust the tension of the belt.

Manual No. 10954 5 - 24 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CRAWLER ASSEMBLY

The CRAWLER assembly provides the motion path and frame for each crawler belt. Each assembly
bolts to the lower frame structure and contains propel machinery to drive its respective belt.

Each side frame assembly consists of the following components:

- Eight load rollers which transfer machine weight to the belt.

- One front idler roller which adjusts belt tension.

- One rear idler roller which guides belt to the sprocket.

- Drive sprocket shaft that drives the sprocket.

- Propel gearcase, planetary type, totally enclosed with right angle input.

- Propel motor with single disc (dry) spring set, air released brake.

- Heavy duty fabricated crawler structure with four slide bars to guide belt.

Sept. 2010 5 - 25 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Crawler Assembly - Exploded View

Manual No. 10954 5 - 26 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CRAWLER MAINTENANCE

Maintenance and inspection requirements for each crawler side frame assembly includes:

• Check the tension of the rod bolts joining the crawler structure to the lower frame structure.
• Inspect the crawler structure for cracks quarterly.
• Inspect lubrication coverage daily.
• Check the operation of the auto lube injectors daily.
• Change the oil in the propel gearcase yearly, or as determined by lab analysis of oil samples.
• Monitor all component parts for damage and wear, replace or rebuild as required.

Refer to Section 4 - PREVENTATIVE MAINTENANCE in this manual for complete preventive

maintenance procedures.

Connecting Rods ~Lower Frame to Crawler

Sept. 2010 5 - 27 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

PROCEDURE FOR USE OF THE HYDRAULIC TENSIONER:

1. The rod threads should be clean and the fit of the nuts on the rods should be very free. This
is to allow for stretch of the rod during tensioning.

2. Assemble the rods to the 4.80 inch (122 mm) "standout dimension", see section E-E in the
illustration (one nut at each end).

3. For hydraulic tensioner operation refer to Section 9 ~ ENGINEERING DATA.

4. Tension the rods in four steps:

4.1 Tension the rods to 935 Kn (210,000 Lbs..). Reference equivalent tightening torque of
11,960 NM (8,820 Ft.Lbs.) in the sequence shown in the illustration. Turn the nut down
using the tensioner drive gear mechanism. When the nut bottoms, seat it with a firm
twist of the drive gear.

4.2 Tension the #1 rod to 1335 KN (300,000 Lbs..). Reference equivalent tightening torque
of 17,080 NM (12,600 Ft.Lbs.). Turn the nut down.

4.3 Before moving on to the next rod, relax the tensioner, wait one minute and then bring
the tensioner back to 1335 KN (300,000 Lbs.). Turn the nut down, if possible. Repeat
the procedure in steps 4.2 and 4.3 for each rod in the sequence shown.

4.4 After all the rods are tensioned per steps 4.2 and 4.3, repeat step 4.2 for the first two
rods. If additional turning of the nut down is possible when the tensioner is brought up
to 1335 KN (300,000 Lbs.) Continue step 4.2 on subsequent rods until the nut cannot
be turned down at this tensioning load.

5. Install the third nut and 3 hardened flat washers on the outboard end of each rod (for thread
protection), after tensioning, and tighten to 1360 NM (1,000 Ft.Lbs.).

6. Repeat step 4.2 for all the rods, in the sequence shown, after twenty hours of digging
operation.

This procedure is only required when assembling the crawler structures to the lower frame structure.

Manual No. 10954 5 - 28 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

SLIDE BAR REBUILD

The SLIDE BARS on top of the crawler structure can be rebuilt by applying weld material to top of
slide bar surface.

The Procedure for welding is as follows:

1. Prepare a template of the top surface of the slide bar (Refer to the Figure Below).

2 Clean the slide bar of all spalled, mushrooming, or loose material, grease, and contaminants.
Use a grinder to remove imperfections. DO NOT USE A TORCH.

3. Preheat the slide bar to 260oC (500oF) soaking.

4 Use Hobart Tufanhard #375 or McKay Hardalloy #48, or an equivalent electrode. Deposit
welds using stringer bead technique. Thoroughly chip and clean between passes and layers.

5. POSTHEAT to 260oC (500oF), hold for two hours, and then slowly cool.

6 Grind the top surface of the slide bar to the final contour as required to fit the shoe surface.

Sept. 2010 5 - 29 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

LOAD ROLLERS AND REAR IDLER ROLLERS

The LOAD and REAR IDLER ROLLERS are located at the bottom of each crawler structure. The
load rollers distribute the machine weight on the crawler belt. The rear idler roller guides the
crawler belt to the drive sprocket.

Each of the load rollers and the rear idler roller turns independently on a fixed shaft secured in the
crawler structure by a lock collar and pin. Each roller has a full bronze bushing in its bore.

Thrust washers are placed on each end of the shaft between the roller and crawler structure
bosses to retain lubrication and minimize entry of dirt.

Removal of either the load or rear idler rollers requires separation of the crawler belt. Since the
rollers are captured in the crawler, removal and/or replacement requires lowering the roller below
the bottom of the crawler structure. This is accomplished by digging a pit to the dimensions shown
in the chart below.

ROLLER REMOVAL

To remove a roller from the crawler structure:

1. After a pit has been prepared, using the dimensions from the table shown below, position a
handling fixture in the bottom of the pit to support the roller when its 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. Each end of the belt should fall into the pit
exposing the roller for removal.

3. Proceed by removing the auto lube line from the end of the roller shaft. Plug line to prevent
dirt entry.

4. Remove the shaft retaining bolt.

5. Drive the shaft out of the crawler structure to the outside being careful to support roller on
handling fixture, jack or cribbing. Remove thrust washers as they come free.

Use the same procedure to remove the rear idler roller.

Manual No. 10954 5 - 30 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Pit for Load Roller Removal

ROLLER INSTALLATION

To install or replace a load or idler roller:

1. Position the replacement roller in the pit on cribbing, handling fixture or jack.

2. Start the shaft through the outside crawler structure member. When the shaft begins to exit
the other side, install the thrust washer.

3. Raise the roller/idler into position and continue to drive the shaft through roller/idler.

4. As the shaft exits roller, install the other thrust washer.

5. Continue to drive the shaft through the crawler structure until the bolt retainer hole aligns
with the hole in collar.

NOTE: Install the load/idler roller shafts with the lubrication hole toward the inside plate of the
crawler side frame.

6. Install the lock bolt and nut.

7. Install the auto lube hose and reinstall the guard.

Sept. 2010 5 - 31 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

NOTES:

1. Install the shaft with the Lubrication Hole toward the Inside of the Crawler.
2. The Flat of the Shaft and the Lube Hole Indicated by the Punch Mark is to be toward the
Front of the Crawler.
3. The Flat of the Shaft is to be toward the Front of the Crawler.

FRONT IDLER ROLLER

The FRONT IDLER ROLLER functions as the tensioner for the crawler belt. Its removal and/or
replacement will be required when the bronze bushing or thrust washers wear out or the idler roller
requires repair or replacement.

To remove the front idler:

1. Park the machine on a level work area.

2. Rotate the upper frame to give clear access to a crane line for handling the crawler belt and
idler.
3. Release the belt tension and separate the belt behind the top of the front idler roller.

DANGER! 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.

Manual No. 10954 5 - 32 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Front Idler Roller Assembly - Exploded View

4. Lift a portion of the separated belt from the front idler roller and lay it forward on the ground.

5. Support the front idler roller with a hoist/crane line and remove the auto lube line.

6. Remove all shims from around the idler adjusting blocks.

7. Remove the pins from the idler adjusting blocks on each side of the shaft.

8. Push or pull the idler shaft out of the roller. Catch the spacers and thrust washers as the shaft
is being removed.

DANGER! THE IDLER ADJUSTING BLOCKS ARE UNRESTRAINED ONCE THE

IDLER SHAFT IS REMOVED.

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

9. Reinstallation of the idler is in reverse of removal.

NOTE: When repositioning the idler adjusting blocks, install with depression for the hydraulic
jack tensioning cylinder rod toward the sprocket.

10. After tensioning the crawler belt, secure the shims with the retainer bars.

Front Idler Roller- Section View

Manual No. 10954 5 - 34 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

PROPEL MACHINERY

The PROPEL MACHINERY consists of a drive motor and brake, motor coupling and a right-
angled planetary gearcase for each crawler. The left planetary gearcase is similar and can be used
for the right gearcase - after exchanging the oil breather with oil drain and the eye bolt with the
screw plug.

The electric A.C. drive motors are similar between the right and left crawler assemblies. The planetary
gearcases and A.C. motors mount inboard at the rear of the crawlers. Junction boxes are located on
the tops of the motors. The planetary gearcase mounts on a bell housing via a pilot register using
through-bolts. The A.C. motor mounts on a structural bracket. A disc brake mounts on the rear of
each motor frame. A shrink-fit brake gear mounts on the armature shaft and meshes with the brake
rotor.

Propel Machinery - Plan View

Sept. 2010 5 - 35 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Propel Machinery - Exploded View

Manual No. 10954 5 - 36 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

PROPEL MACHINERY MAINTENANCE

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.

3. Change the oil in the gearcase annually (5000 hours) or as indicated by lab test analysis -
capacity is 33 US gallons (125 liters).

NOTE: Both oil drain plugs are magnetic to collect ferrous metal debris.

4. Inspect the motor coupling quarterly for proper lube level. Keep full.

5. Lubricate the motor bearings semiannually (2500 hours) with EMG (electric motor grease).
Application of grease should be performed by qualified personnel - excess grease could
cause motor failure.

6. Inspect brake operation daily. Monitor the wear rate of the friction disc. Replace the disc
when the wear ring indicates that the lining is worn out.

7. Check the propel gearcase breathers monthly (400 hours) and clean as required.

PROPEL MOTORS

Each PROPEL MOTOR is bolted on mounting pads located on the inside of each crawler side
frame. The propel motor output shafts are coupled to the planetary gearcase with grid-type couplings.
Coupling alignment is assisted with shims beneath the motor mounting feet. Each propel motor is
equipped with a spring-set, air-released single-disc brake.

PROPEL MOTOR MAINTENANCE

See the electrical maintenance manual for this machine for details of scheduled service of electric
A.C. motors and equipment.

• Lubricate the motor armature bearings with EMG semiannually (2500 hours).

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• Inspect the brushes on the motors every 250 hours and replace as required.

• Observe commutator condition each time the brushes are replaced. If discolored, grooved, or
otherwise damaged, consult the electrical maintenance manual.

PROPEL MOTOR REMOVAL

Removal of the PROPEL MOTOR requires the disconnection and removal of the optional cable
reel, if equipped. With the cable reel assembly removed, follow the procedure below for motor
removal:

1. Park the machine on a level work area and rotate the upper frame so access to the propel
motor is available.

2. Have a qualified electrician disconnect power from the machine and wiring from the propel
motor.

DANGER! 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 the guard over the motor coupling. Open the coupling and remove the grid.

NOTE: See the match marking on the coupling covers for use in reassembly.

4. Disconnect and plug the air supply to the disc brake.

DANGER! Loosen the fittings and check for air pressure. DO NOT
COMPLETELY DISCONNECT THE AIR LINE UNTIL THE AIR LINE
PRESSURE IS ZERO.

5. Support the motor with a crane.

6. Remove the four capscrews retaining the motor to the crawler mounting pad and lift the
motor away from the machine to cribbing. Secure the motor shims to use for reassembly.

7. Remove the disc brake from the propel motor. Loosen the six capscrews retaining brake to
motor frame and remove all but two. These should be opposite each other. Support the
brake assembly (470 Lbs../213 kg), remove the remaining two capscrews and slide the brake
off the motor shaft/brake gear.

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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 Section 6 ~ BRAKES & COUPLINGS, in this
manual.

PROPEL MOTOR INSTALLATION

The following procedure assumes that the propel motor being installed is new & that it has none of
the additional parts required for the application.

1. Install the drive coupling hub & 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 Section 7 ~
ENGINEERING DATA, of this manual.

2. Install the brake assembly so that the air inlet is at the bottom after the motor assembly is
installed onto the machine. Refer to Section 6 - BRAKES AND COUPLINGS of this manual
for installation & adjustment.

3. Install the motor and brake assembly on the crawler frame. Check the coupling alignment.
With the motor shaft at midpoint of its axial float, the gap, angular offset & radial offset must
all be within specification. Refer to "Grid Couplings" in Section 6 - BRAKES AND COUPLINGS
of this manual for specifications & mounting instructions.

4. If alignment is required, install shims, tighten the mounting bolts & recheck the alignment.

5. Install all guards, air lines & wiring.

CAUTION: ALL WIRING MUST BE DONE BY A QUALIFIED ELECTRICIAN.

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PROPEL GEARCASE REMOVAL

To remove the PROPEL GEARCASE (right or left):

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 the way.

DANGER! HIGH VOLTAGE! ONLY A QUALIFIED ELECTRICIAN SHOULD

DISCONNECT THE TRAIL CABLE. FAILURE TO COMPLY COULD
RESULT IN BODILY INJURY OR DEATH.

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4. If present, remove the optional cable reel.

5. Drain the oil from the gearcase using both plugs located at the bottom of the gearcase. Both
drains are required to be unplugged to completely drain the gearcase and to remove all
debris.
6. Remove the guard from the propel motor coupling.
7. Open the propel motor coupling and remove the 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 using the

lifting eye on the gearcase.

10. Remove the 36 capscrews which

secure 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 three M36 x 4 capscrews

inserted in the 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 the gearcase away from the
crawler to 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.

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182M-AC Electric Mining Shovel

NOTE: The planetary gearcase design requires a close tolerance and special tools for
disassembly and rebuild. DO NOT ATTEMPT TO DISASSEMBLE WITHOUT A
QUALIFIED FACTORY REPRESENTATIVE PRESENT.

Planetary Gearcase, Propel

NOTE: Gearcase Oil Capacity is approx. 125
Liters. (33 gallons) Recommended oil
grade is 5E - ISO VG 220.
Fill gearcase to oil level plug.
Gearcase Fasteners Recommended Tightening
M8 ................... 20Nm .............. 15 Ft.Lbs.
M10 .................. 40Nm .............. 30 Ft.Lbs.
M12 .................. 64Nm .............. 47 Ft.Lbs.
M16 ................. 160Nm ............ 120 Ft.Lbs.
M24 ................. 530Nm ............ 390 Ft.Lbs.

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182M-AC Electric Mining Shovel

PROPEL GEARCASE INSTALLATION

To install the propel gearcase:

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 the temperature
of the hub to exceed 135 oC (275 oF). Allow the hub to cool to ambient before assembling the
other coupling parts.

2. Install the spacer to the splined

output end of the gearcase.
Tighten the capscrews to 40 NM
(30 Ft.Lbs.). Stretch the rubber
face seal over the inboard end of
the main propel shaft. This seal is
located by a step on the shaft.

3. Pack the rear of spline cavity in

the propel gearcase for the main
propel shaft with .5 liters (1 pint)
of GP lube.

4. Coat the internal and external

spline surfaces GP lube.

5. Install the gearcase by engaging the splines and pilot register. Install 36 fasteners and tighten
to 3,418 NM (2,521 Ft.Lbs.).

NOTE: Align the match marks if the identical gearcase is being reinstalled. This will minimize
the time required to the align coupling. If a NEW gearcase is being installed, add
match marks for future use.

6. Fill the gearcase with the proper lubricant, to a capacity of 33 US gallons (125 liters). Install
the breather and oil inlet plug.

7. Propel motor coupling reassembly can be assisted by releasing the disc brake with the
manual override on the air control valve. This will allow rotation of the motor shaft.

8. Align the coupling to specifications by positioning the motor. Refer to Section 6 ~BRAKES
AND COUPLINGS. Tighten the coupling halves to 312 inch-pounds (35 NM).

9. Fill the propel motor coupling with LTG.

10. If an optional cable reel was removed, reinstall and reconnect the cables.

DANGER! HIGH VOLTAGE! RECONNECTION OF THE TRAIL CABLE SHOULD

ONLY BE PERFORMED BY A QUALIFIED ELECTRICIAN. FAILURE TO
COMPLY COULD RESULT IN SEVERE BODILY INJURY OR DEATH.

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182M-AC Electric Mining Shovel

MAIN PROPEL SHAFT AND SPROCKET

The MAIN PROPEL SHAFT transfers power from the planetary gearcase to the crawler belt sprocket.
This shaft is supported with an inboard (double-tapered) and outboard (cylindrical) bearing and is
splined to the sprocket.

Main Propel Shaft and Sprocket - Section View

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

PROPEL SHAFT/SPROCKET REMOVAL

Removal of the main propel shaft and sprocket requires removal of the planetary gearcase. Follow
the below procedure to remove the main propel shaft and sprocket:

1. Park the machine on level work area and rotate the upper frame so access to the propel
machinery is available.

2. Have a qualified electrician disconnect power from the machine.

DANGER! HIGH VOLTAGE! ONLY QUALIFIED PERSONNEL ARE PERMITTED

TO PERFORM HIGH VOLTAGE ELECTRICAL SERVICE AND
MAINTENANCE. FAILURE TO COMPLY MAY RESULT IN SERIOUS
BODILY INJURY OR DEATH.

3. Remove the optional cable reel assembly, if supplied.

4. Remove guard over motor coupling and disconnect as described in procedure to remove
propel gearcase.

5. Separate crawler belt on top of crawler forward of sprocket and lift belt end to ground at rear
of sprocket.

DANGER! SECURE THE CRAWLER BELT BEFORE SEPARATING IT SO THAT IT

CANNOT MOVE UNEXPECTEDLY UNDER ITS OWN WEIGHT. FAILURE
TO DO SO COULD RESULT IN SERIOUS BODILY INJURY OR DEATH.

6. Mark sprocket and shoe under sprocket with a visible paint so that sprocket can be positioned
in same location in belt. Chock sprocket lug front and rear

7. Support propel gearcase with crane through lifting eye. Remove propel gearcase according
to prior procedure and position on cribbing out of harms way.

8. Remove automatic lubrication line from inboard propel bearing.

9. Remove 12 retainer capscrews with shim pack from outboard end of main propel shaft.
Support sprocket with crane line and chock to prevent side to side movement between crawler
side frame vertical members. When main propel shaft is withdrawn through sprocket, these
chocks prevent the sprocket from moving and causing a resulting binding condition hindering
removal of propel shaft assembly.

10. Pull outboard bearing cartridge with the bearing outer race and rollers from the bore in the
crawler. To prevent this assembly from binding in bore while removing, use three of the
retainer bolts through tapped holes in flange of cartridge as jackscrews to withdraw cartridge
evenly.

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NOTE: DO NOT DAMAGE THE FACE SEAL ON THE BACK FACE OF THE CARTRIDGE. IF
DAMAGED, REPLACE IT WITH A NEW SEAL.

11. Remove retainer with its shim pack from end of main propel shaft.

12. Assemble bearing puller to pull inner race of outboard bearing off end of shaft. Six equally
spaced tapped holes (M12 x 1.75) are provided in spacer behind bearing inner race for use
with threaded rods and other hardware to make a bearing puller.

NOTE: TAPPED .25 - 18 NPT HOLE FOR HYDRAULIC ASSIST SHOULD BE USED TO
EXPAND THE INNER RACE WHILE USING THE PULLER.

Details of Propel Shaft Removal and Installation Aids

13. Go to inboard bearing retainer inside crawler bell housing. Remove 20 equally spaced
lockwired capscrews retaining bearing cartridge to crawler side frame.

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182M-AC Electric Mining Shovel

NOTE: FOUR EQUALLY SPACED SOCKET HEAD CAPSCREWS IN THE RETAINER KEEP
THE BEARING CARTRIDGE ASSEMBLED. THESE ARE NOT TO BE REMOVED.

14. Attach main propel shaft end support fixture to outboard end of shaft. Use tapped hole (M24
x 3) inboard of shaft to mount an eye bolt.

15. Push/bump propel shaft with bump bar from outboard end and withdraw shaft with inboard
bearing cartridge out through the sprocket and crawler side frame. Use eye bolt at inboard of
shaft to assist in supporting and pulling shaft/bearing assembly out of side frame.

NOTE: DO NOT DAMAGE THE FACE SEAL ON THE BACK SIDE OF THE INBOARD
BEARING CARTRIDGE. IF DAMAGED, REPLACE IT WITH A NEW SEAL.

16. Lift sprocket with crane from crawler side frame and place on cribbing. INSPECT ALL PARTS
AND REPAIR OR REPLACE AS REQUIRED.

Removal and Installation Aid Location

for the Main Propel Shaft

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

MAIN PROPEL SHAFT DISASSEMBLY

1. Remove two locking capscrews from bearing nut, and unscrew bearing nut from shaft using
special spanner wrench provided with the machine.

2. Lift face seal from back face of bearing cartridge if not yet removed.

3. Remove four socket head capscrews holding retainer to bearing cartridge.

4. Remove bearing retainer, outboard spacer and lip seal from shaft.

5. Pull bearing cartridge from bearing and remove from other end of shaft.

6. Use bearing puller to remove bearing from shaft.

7. Remove the inboard spacer.

8. Inspect parts and replace as required.

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182M-AC Electric Mining Shovel

NOTES:

1. Fill Bearing Cavity with MPG Grease.

2. If Bearing is heated for Assembly Purposes, Do Not Exceed 149 oC (300 oF)

3. Spray Lip Seal Area with Molylube 1200 AR ( P/N 170025-1).

4. Shim Procedure - Bearing Retainer:

A. Install Retainer and tighten Socket Head Capscrews to 110 NM (80 Ft.Lbs.) for Gap
Measurement.

B. Measure Gap at three places equally spaced around Retainer O.D.

C. Take the average of these three measurements and subtract 0.03 to 0.08mm (.001 -
.003 inches) to obtain Shim thickness.

D. Install Shims and tighten Retainer Capscrew to 440NM (325 Ft.Lbs.)

NOTE: The fit of the inboard bearing to the Shaft is: .005 to .007 inch (.127 to .178 mm)
INTERFERENCE.

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Main Propel Shaft Sprocket Assembly

~Left Shown, Right Opposite

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MAIN PROPEL SHAFT ASSEMBLY

1. Install the inboard spacer.

2. The double-row tapered bearing installation requires heat to install this bearing on the propel
shaft. Use a dry heat source and do not permit temperature of the bearing to exceed 149 oC
(300 oF). Install the outboard spacer and bearing nut. Tighten the bearing nut snug against the
outboard spacer. Allow the bearing to cool to ambient before continuing.

3. Remove the bearing nut.

4. Install the inboard bearing cartridge and bearing retainer with lip seal. Spray the lip seal area
with Molylube 1200AR (P/N 170025-1) or equivalent.

5. Shim gap at bearing retainer according to below procedure:

- Install retainer and tighten socket head capscrews to 110 NM (80 Ft.Lbs.) for gap
measurement.

- Measure gap at three places equally spaced around outside diameter of retainer.

- Take average of these three measurements and subtract .03 to .08 mm ( 001 -.003
inches) to obtain shim thickness.

- Install shims and retainer. Tighten four socket head screws to 440 NM (325 Ft.Lbs.).

6. Install the outboard spacer. Reinstall the bearing nut. Tighten the bearing nut snug against
the outboard spacer.

7. Install two locking capscrews in bearing nut and tighten to 160 NM (115 Ft.Lbs.).

8. Fill bearing cavity with multipurpose grease.

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182M-AC Electric Mining Shovel

MAIN PROPEL SHAFT/SPROCKET INSTALLATION

Installation of the MAIN PROPEL SHAFT must be simultaneous with the sprocket. This procedure
requires lifting hardware to suspend the sprocket in the crawler side frame in position to engage
the main propel shaft assembly. Other lifting hardware needs to be available to handle the propel
shaft while it is being installed.

Use the end support fixture and eye bolt in ends of the main propel shaft to assist handling of the
shaft during this installation procedure.

Another installation aid for main propel shaft alignment consists of 3 threaded pilot rods tapered at
their ends. The rod threads should be same as the threads of the 20 capscrews used to secure the
inboard bearing cartridge to crawler bore (See illustration for pilot rod specifications).

Follow the procedure below for the installation of the main propel shaft and sprocket:

1. Install face seal to labyrinth area of the inboard bearing cartridge. Spray area with Molylube
1200AR (P/N 170025-1).

2. Install 3 threaded rods evenly spaced to threaded holes in crawler side frame bore.

3. Position the sprocket in the crawler side frame and chock in position to receive main propel
shaft. Lubricate the splines and register surfaces with GP.

4. Lift main propel shaft with eye bolt in end of shaft with splines for propel gearcase. Mount the
end support fixture to other end of propel shaft.

5. Using threaded pilot rods, position propel shaft assembly for installation by guiding retainer
onto the rods. Lubricate the crawler side frame bore and inboard bearing cartridge thoroughly
with GP. The lube inlet in the retainer is located toward the front of the crawler and slightly
below the horizontal centerline of the bore. See illustration.

6. Slowly force the inboard bearing cartridge into the crawler side frame bore using progressive
tightening of nuts on rods with increasing packs of spacer washers. This technique assists
installation of the bearing cartridge in the crawler bore as the tolerance is a close fit. Continue
tightening the nuts on the rods until the flange of the inboard bearing cartridge is flush with
crawler bore.

7. Simultaneous with Step 6 support outboard end of propel shaft with lifting line attached to the
end support fixture.

8. At point of propel shaft installation where splines on shaft engage sprocket, it may be necessary
to rotate sprocket to facilitate engagement. Continue to support the sprocket so its weight
does not hinder shaft travel.

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9. When the inboard bearing cartridge is seated in crawler side frame bore, install 17 of the 20
capscrews. Tighten to 590 NM (435 Ft.Lbs.). Remove threaded rods and install remaining 3
capscrews and tighten to 590 NM (435 Ft.Lbs.). Wirelock capscrews.

10. Move to outside of crawler side frame to install the outboard bearing cartridge. Install the
spacer. Heat the bearing inner race and install on shaft. Do not exceed 149 oC (300 oF). Hold
in place with the retainer, allow to cool prior to further assembly. The fit of the inner race to
the shaft is .002 to .0044 inch (.051 to .112 mm) interference.

11. Assemble shaft retainer to the end of the shaft with 12 capscrews tightened to 100 NM (74
Ft.Lbs..) for gap measurement necessary to size shim pack. (Shim pack prevents retainer
flexing which could cause heads of capscrews to break off.)

12. Use a depth micrometer to measure distance from outer face of retainer to end of shaft
through the three equally spaced 6mm holes in the plate.

13. Remove the retainer and measure its thickness at each 6 mm hole.

14. Take average of three measurements from Step 12 and subtract average of three
measurements from Step 13. From this difference subtract .001 - .003 inch (.03 to .08 mm)
to obtain shim pack thickness.

15. Install shims and tighten capscrews of end plate retainer to 590 NM (435 Ft.Lbs.). Wirelock
capscrews.

16. Install the outer race of the bearing with rollers to the outboard bearing cartridge and install
the face seal to back groove of cartridge. Position the outboard bearing cartridge in the bore
of the crawler side frame.

17. Install the outboard retainer and tighten 12 capscrews to 100 NM (74 Ft.Lbs.) for gap
measurement necessary to determine the shim pack. Lube inlet in retainer is located toward
front of crawler on horizontal centerline of bore. See illustration.

18. Measure gap at three equally spaced places around outside diameter of the outboard retainer.

19. Take average of three measurements and subtract .03 to .08 mm (.001 - .003 inches) to
obtain shim pack thickness.

20. Install shim pack and tighten the outboard retainer capscrews to 590 NM (435 Ft.Lbs.).

21. Fill the bearing cavity with MPG.

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182M-AC Electric Mining Shovel

INSTALLATION NOTES

1. After thorough cleaning, coat both the internal and external splines and register surfaces with
GP.

2. Shim Procedure - Outboard Bearing:

a. After the bearing inner race is installed, assemble the retainer to the shaft with capscrews.
Tighten to 74 Ft.Lbs. (100 NM) for gap measurement.

b. Using 3 equally spaced .24 dia. (6 mm) holes in the retainer, measure the distance from
the outer face of the retainer to the end of the shaft with a depth micrometer.

c. Remove the retainer and measure the thickness at the 3 holes.

d. Take the average of the 3 measurements from step B and subtract the average of the 3
measurements from step C. This is the gap measurement. From this dimension, subtract
.001-.003 inch (.03-.08 mm) to obtain the shim thickness required.

e. Install the shims and tighten the capscrews to 435 Ft.Lbs. (590 NM).

3. Shim Procedure - Outboard Retainer:

a. Install the outboard retainer and tighten the capscrews to 74 Ft.Lbs. (100 NM) for gap
measurement.

b. Measure the gap between the retainer and the cartridge at 3 places equally spaced
around the O.D. of the retainer.

c. Take the average of the 3 measurements and subtract .001-.008 inch (.03-.08 mm) to
obtain the shim thickness.

d. Install the shims and tighten the capscrews to 435 Ft.Lbs. (590 NM).

4. Fill the bearing cavity with MPG grease.

5. Tighten capscrews to 435 Ft.Lbs. (590 NM).

6. Wirelock capscrews.

7. Tighten to 40 NM.

8. Pack cavity with 1 pint (.5 liters) GP prior to gearcase installation onto the shaft.

9. Match mark with a scribe line after coupling alignment. Locate opposite the input shaft.

10. Tighten to 3265 Ft.Lbs. (4424 NM).

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182M-AC Electric Mining Shovel

Main Propel Shaft and Sprocket - Section View

11. Spray the lip seal area with Molylube 1200AR ( P/N 170025-1).

12. The direction of the lip on the face seal is as indicated by the arrow.

13. Four socket head capscrews are 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.

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

SPROCKET REBUILD PROCEDURE

The drive sprocket can be repaired by weld buildup applied to the 11 driving lugs. To build up the
lugs, proceed as follows:

1. Prepare a template as indicated in the sketch on following page. The template can be made
of sheet metal, wood or template paper. Contact Bucyrus for any details.

2. Clean the sprocket of all spalled or loose material, grease and contaminants. Use a grinder
to remove any imperfections. DO NOT USE A TORCH.

3. Preheat the sprocket rim to 550°F. (273°C.). Keep the hub area below 200°F. (93°C.). Maintain
this temperature during welding.

4. Hold a medium arc length - slight weaving permitted but keep 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, a maximum of 3 layers
is permitted.

5. Weld up to within 5mm (.19 inch) of the final contour with weld rod that conforms to AWS E-
9018. Use only new low hydrogen electrodes.

6. Finish contour buildup using Hobart "Tufanhard 550" electrode, or its equivalent. Use small
diameter electrodes and deposit with stringer bead technique.

7. Allow the sprocket to cool slowly.

8. If needed, grind to a final lug contour.

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Template for Sprocket Rebuild

Sept. 2010 5 - 57 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CENTER JOURNAL

The Center Journal pin connects the Rotating Frame to the Lower Frame at the center of rotation.
This design keeps both frames in concentric alignment and transfers machine digging reactions to
the Lower Frame where a heavy gudgeon supports the pin. A retaining bar on the bottom flange of
the Lower Frame and welded shear blocks prevent vertical pin movement and rotation during
machine operation.

A lock plate with 4 lugs fits over the center journal pin and engages 4 slots at the top of the pin. The
circumference of the lock plate is tapped with 12 holes (1.25-7UNC). Threaded holes provide
alternate positions for the center journal nut.

A split thrust washer under the lockplate provides a wear surface between the rotating frame and
the lockplate.

CENTER JOURNAL ADJUSTMENT

Adjustment required for the center journal involves turning the nut in increments of 30° clockwise
(tightening) or counterclockwise (loosening) until the bolts in the nut engage the tapped holes in
the lockplate.

To determine the degree of adjustment necessary, use the following procedure:

1. Park the machine of level ground.

2. With the dipper positioned just clear of grade and under the boom point, rotate the machine
1 or 2 revolutions.

3. Remove power from the machine.

DANGER! HIGH VOLTAGE! THE AUXILIARY COLLECTOR RINGS ARE

MOUNTED ABOVE THE CENTER JOURNAL NUT - ISOLATE MACHINE
POWER. Failure to perform this procedure COULD RESULT IN
SEVERE BODILY INJURY OR DEATH

4. Check that the center journal flange is tight against the boss in the lower frame. If it is not
tight, tighten the retainer screws. It may be necessary to jack the journal into place.

5. Measure the gap between the center journal lockplate and the thrust washer. If the gap is
greater than .060 inch (1.5 mm), tighten the center journal nut.

6. To estimate the amount of nut rotation required, use the following formula:

Nut Rotation Required = Total Measured Gap - .020 Inch (.5 mm)
0.333 Inch (8.5 mm) / Nut Revolution

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182M-AC Electric Mining Shovel

CENTER JOURNAL ASSEMBLY

NOTE: The Center Journal nut threads advance

the nut .333 inches (8.5 mm) vertically
every full turn. The lockplate has 12
equally spaced holes which allow for
center journal nut adjustment in 30°
increments. For every 30° index (or to the
next- hole location) the nut will move
vertically .028 inch ( that is: 30 / 360 x
.333).

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182M-AC Electric Mining Shovel

CENTER JOURNAL REMOVAL

Remove the center journal through the lower frame. This is accomplished by propelling the machine
over a pit or up a ramp with approximately 6 feet (1830 mm) of under-clearance. The center
journal is 93.5 inches (2375 mm) long and weighs 4658 Lbs. (2113 Kgs.)

DANGER! HIGH VOLTAGE! THE COLLECTOR RINGS ARE LOCATED

BETWEEN THE LOWER FRAME AND THE ROTATING FRAME.
DISCONNECT AND ISOLATE THE SUBSTATION POWER FROM THE
MACHINE BEFORE BEGINNING ANY INSPECTION, MAINTENANCE
OR REPAIR IN THIS AREA.

1. Before starting, make sure the machine is setting firmly on a level grade and that the rotating
frame is resting squarely on the roller circle, front and back. THE UPPER AND LOWER
FRAMES MUST NOT MOVE RELATIVE TO EACH OTHER WHILE THE CENTER JOURNAL
IS OUT OF ITS HOUSINGS.

2. Remove auxiliary collector rings/rotoseal assembly from machine. See procedure on this
assembly in this section.

3. Remove electrical enclosure junction box) from bottom of center journal.

4. Support under the center journal with hydraulic jacks and cribbing. Remove retainer angle at
the bottom of center journal.

5. Remove the two capscrews from center journal nut and lock plate. Unscrew nut from top of
center journal and lift off lock plate. Place them out of the work area.

6. Slowly lower center journal out of machine. Weight is 4,658 Lbs.. (2113 kg).

Installation of the center journal is reverse of this procedure. Fit of the center journal to bores in
lower frame is loose .006 to .013 inches (.15 to .33 mm). Reposition shear blocks to center journal
flange as needed.

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Center Journal Installation

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THRUST WASHER REPLACEMENT

Periodic inspection of the thrust washer beneath the center journal lock plate will indicate gradual
wear. When the thrust washer thickness becomes less than or equal to 1.25 inch (31.5 mm)
measured from top of rotating frame to bottom of lockplate, including the .06 inch (1.5 mm) running
clearance, replace the thrust washer. At this point, washer has worn off .5 inch (12 mm).

Replace center journal thrust washer according to the following procedure:

1. Remove two capscrews in locknut retaining

locknut to lock plate.

2. Unscrew the center journal nut

(counterclockwise) until it touches the bottom
of the auxiliary collector rings. This gives
sufficient clearance to disassemble halves of
split thrust washer from deck and remove
them over the lube catch basin walls.

3. Lift center journal lock plate and re-bolt it to

nut.

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4. Remove 8 capscrews holding thrust washer halves to the deck and remove the worn thrust
washer halves. Clean the mounting surface and install the new thrustwasher halves.

5. Lower the center journal lock plate and tighten the nut. Adjust the running center journal
clearance to .06 inch (1 .5mm).

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CENTER JOURNAL BUSHING REPLACEMENT

Auxiliary collector ring/rotoseal assembly must be removed and the center journal pin from rotating
frame bore to change out the center journal bushing.

Complete the procedures to remove CENTER JOURNAL and AUXILIARY COLLECTOR RING/
ROTOSEAL ASSEMBLY before replacing the bushing.

To replace the center journal bushing:

DANGER! DISCONNECT AND ISOLATE POWER FROM MACHINE BEFORE

ATTEMPTING TO REMOVE CENTER JOURNAL AND AUXILIARY
COLLECTOR RINGS/ROTOSEAL ASSEMBLY.

1. Clean the area of all

grease.

2. Use an air arc torch and

cut bushing from top to
bottom. Let cool and
remove bushing from
bore.

3. Replace the bushing by

cooling with dry ice to
shrink outside diameter
for inserting in the
rotating frame bore.
Bushing will self locate
by dropping to ledge in
bore.

NOTE: Check alignment of bushing lubrication grooves with auto lube ports before installing
the bushing.

4. Allow time for expansion of the bushing and use a grease gun to test if the bushing lubrication
grooves are properly aligned with the auto lube ports.

5. Install the center journal and auxiliary collector ring/rotoseal assembly to the machine. Adjust
the center journal nut to the proper running clearance.

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ROTATING FRAME ASSEMBLY

The rotating frame assembly is a platform which supports the hoist & swing machinery, the front
end, gantry & electrical control systems. The platform consists of the rotating frame structure, right
& left wing assemblies and ballast box.

Rotating Frame Structure

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ROTATING FRAME MAINTENANCE

Rotating Frame Structure maintenance consists primarily of inspection for areas of distress quarterly
(every 1250 hours):

• Inspect house panels and operator cab base for loose bolts.

• Inspect gantry flashing and machinery house roof panels for water leaks.
• Keep dust level in electrical cabinets at a minimum to prevent short circuits. Cleaning should
be performed by electrical personnel. Use low pressure compressed air to blow dust from
cabinets.
• Inspect auto lube lubricant supply and keep filled for continuous operation.
• Check inside the rotating frame manholes for rotating frame structure cracks. Repair as
required.
• Check the ballast for mounting bolts. Tighten and replace as required.

MAIN COLLECTOR RINGS (H.V.)

DANGER! HIGH-VOLTAGE AREA! DISCONNECT, ISOLATE AND LOCK OUT

MINE SUBSTATION POWER SUPPLY TO THE MACHINE BEFORE
ENTERING OR WORKING IN THE MAIN COLLECTOR RING AREA.
NEVER TOUCH THE COLLECTOR RINGS UNLESS THEY HAVE BEEN
PROPERLY EARTHED (GROUNDED) BY A QUALIFIED ELECTRICIAN.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD RESULT

IN PERMANENT SERIOUS INJURY OR DEATH.

The MAIN COLLECTOR RINGS are the electrical conductor which transfer high voltage from the
lower frame to the upper rotating frame. These conductors are located inside the roller circle in the
area between the lower and upper frames. The collector rings are mounted on ceramic insulators
which are bolted to the bottom of the rotating frame. Four concentric ring assemblies are provided.

Eight collector assemblies with two brushes each are mounted on the lower frame top plate with
insulators and mounting bars.

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Main Collector Rings (H.V.)

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MAIN COLLECTOR RING MAINTENANCE

This area of the machine must be kept clean and clear of any debris or lubrication overflow from the
roller circle area.

Inspect and clean the top of the lower frame area during replacement of brushes, or at each 1000
hour inspection interval, whichever occurs first.

AUXILIARY COLLECTOR RINGS AND ROTOSEAL

DANGER! THE AUXILIARY COLLECTOR RINGS ARE CONNECTED TO HIGH-

VOLTAGE. DISCONNECT AND ISOLATE THE ELECTRIC POWER
SUPPLY FROM THE SUBSTATION TO THE MACHINE BEFORE
PERFORMING ANY MAINTENANCE OR INSPECTION.

The Auxiliary Collector Rings are located over the top of the center journal. They are integral with
the rotoseal unit. The brush portion of the auxiliary collector ring assembly is held stationary with 6
capscrews threaded into the top of the center pin. The rings are mounted in a concentric assembly
and rotate with the rotating frame through a drive pin mounted on the underside of the hoist rope
guard. This assembly transmits electrical power as well as air and lubrication to the propel machinery.

The Rotoseal consists of 2 concentric tubes through the center of the auxiliary collector rings that
extend down inside the center bore of the center journal pin. It permits transfer of compressed air
for propel brake operation and grease for lubrication of the crawler side frame components. A dual
passage rotoseal at the top of this assembly rotates with the rotating frame while the tube portion
through the center journal remains fixed with the lower frame.

Removal of the auxiliary collector ring/rotoseal assembly requires:

1. Park the machine of level and firm grade with the front end positioned for maximum access
to the work area. Run all of the hoist rope off the drum and shut down the machine.

2. Remove the hoist rope from the drum and secure the ends inside the machinery house, out
of the work area.

3. Remove the house roof hatch cover above the auxiliary collector ring assembly.

4. Remove the section of the hoist rope guard directly above the auxiliary collector rings.

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Auxiliary Collector Rings - Roto Seal - Section View

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5. Disconnect the air and auto lube lines from the dual rotoseal above the auxiliary collector rings
housing. Cap and plug the lines and ports to keep the systems free of contaminants.

CAUTION: BLEED OFF THE AIR PRESSURE BEFORE DISCONNECTING THE

HOSES.

6. Disconnect the air and auto lube lines from the bottom of the auxiliary collector rings/rotoseal
assembly. Cap and plug the lines and ports to keep the systems free of contaminants.

7. Have a qualified electrician disconnect the wiring from the junction boxes above and below
the auxiliary collector ring assembly. Remove the junction box from the side of the collector
ring housing.

8. Use slings, etc. to attach lifting equipment to the lifting lugs provided on the top of the auxiliary
collector ring assembly.

9. Remove the 6 capscrews under the collector housing that hold the assembly to the top of the
center journal. Note the match markings between the center journal and the mounting flange
of the auxiliary collector rings/rotoseal assembly.

10. Carefully lift the auxiliary collector ring/rotoseal assembly out of the center journal and then
out of the machinery house. Place it on cribbing to transport it to a shop for any repairs.

Reinstallation of the auxiliary collector rings/rotoseal assembly is the reverse of the above procedure.

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AUXILIARY COLLECTOR RING MAINTENANCE

Periodic inspection and adjustment are essential

to the maintenance of a collector ring assembly.
Proper care of brushes, brush rigging, rings and
current collection parts is a fundamental necessity
for satisfactory performance of a collector ring
assembly.

Environmental conditions affect the performance

of the collector ring and these conditions should
be considered in the enclosure design. Periodic
inspection of the collector ring assembly is
essential.

Collector Ring Assembly

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COLLECTOR RING INSPECTION AND ADJUSTMENT

A. Brush Rigging

1. Brush studs are supported between 2 outboard bearings. The brush studs extend
through the outboard bearings and they are secured by a setscrew in the outboard
bearing. The setscrews prevent rotation of the brush stud. The setscrews should be
checked for tightness. Some collector ring assemblies are furnished with additional
brush stud anti-rotation devices. These devices are located on the outboard side of the
outboard bearings. They incorporate an additional setscrew to prevent brush stud
rotation. The additional setscrew must also be checked for tightness.

2. The spacing between the outboard bearings is critical to assure the free rotation of the
brush rigging. The brush stud insulator sleeves are cut to length in order to provide the
proper spacing. The outboard bearings should be located snugly against the insulator
sleeve without any deformation of the materials. Hand tighten the outboard jam nuts
and then secure the brush stud with the setscrews referred to above.

CAUTION: DO NOT OVERTIGHTEN THE OUTBOARD JAM NUTS. Overtightening

can preload the bearings and cause excessive friction.

A final check should be made to assure no binding of outboard brush rigging or binding
of brushes with insulator barriers.

B. Brush Holders

1. Inspect the brush holders for proper alignment. Brush holders should be located so
that the entire brush contact surface rides squarely on the ring with the brush moving
freely in the brush box. The top of the brush should be parallel with the top of the brush
box.

2. Brush holder clamps should be checked for tightness. Clamp bolts should be set at a
maximum of 75 in-lbs. Loose clamps will allow the brush holder to rotate, causing the
brush to lift from the surface of the ring. Brush lift will cause arcing and excessive heat
concentration.

3. Brush terminations at the holder should be inspected to assure that no external force
is imposed on the holder that would cause rotation of the holder on the stud. Flexible or
soft wire leads are recommended for these terminations. External clamps should be
used to support the entire weight of the leads.

4. A final check should be made to assure that the brush studs can not rotate. Refer to
Brush Rigging above.

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C. Brushes

1. Inspect for wear. If the distance from the top of the brush to the top of the brush box is
over half the depth of the brush box, the brush should be replaced.

2. Inspect brush contact surface by removing the brush and checking the brush surface for
dirt, oxidation, pitting or other contaminants. Remove any large particles and follow
seating instructions in the following paragraph.

3. Check brush contact surface for proper seating. If the seating is not proper, the contact
surface will be tracked differently in different areas. To reseat the brushes, lay a piece
of sandpaper between the ring and the brush. Install the brush in the brush holder in
proper alignment and rotate the core while applying pressure on the brush. If the core
cannot be rotated, the sandpaper must be pulled across the brush surface. Wrap
sandpaper at least 180°` around the ring to prevent rounding of the brush edges. Recheck
the brush contact surface and repeat the sanding process if necessary until the entire
contact surface appears uniform and without pits.

CAUTION: DO NOT USE EMERY PAPER OR CLOTH TO SEAT THE BRUSHES -

EMERY WILL BECOME EMBEDDED IN THE BRUSH AND CONTINUE
THE ABRASIVE ACTION AGAINST THE RING AND BRUSH. Emery and
many other abrasives are conductive and must not be used.

D. Brush Springs

1. Inspect and test springs for proper tension. The brush tension springs should be set at
1.5-3.0 lbs. per spring and as uniform as possible. Uniform settings for each brush
prevent selective action by which certain brushes carry more or less than their share of
the load. Insufficient brush pressure can cause loss of contact and over-tension can
cause excessive brush and ring wear.

2. The spring tension should be periodically tested on all brushes to assure uniform
brush tension. Test for tension as shown in the figure. For spring tension adjustment
refer to Removing and Replacing Brushes and Spring Tension Screws later in this
section.

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E. Rings

1. Inspect the ring surface for dirt, oxidation or other contaminants. A properly operating
ring will have a film that appears burnished in color where the brushes track with a
darker surrounding color. If this condition does not exist, cleaning will be necessary.

2. The ring should be cleaned with a nonconductive abrasive such as Ideal Industries'
Flexible Abrasive for collector rings. Hold the abrasive against the ring with a medium
amount of pressure while turning the core. If the core cannot be turned, the abrasive
must be rubbed over the ring. Continue this process until the ring surface is polished
without any dirt or contaminants left on the surface. To prevent abrasive from being
lodged in the brushes, they should be lifted off the ring.

3. Inspect rings for pitting. Pitting of the ring must be corrected since pits will produce
arcing, leading to the development of larger and more pits. Small pits can be removed
by hand stoning of the area. If large pits and/or a considerable amount of pits are
present on the surface, the surface must be machined. Machining is also necessary if
concentricity of the surface is questionable. When stoning or machining rings, remove
only enough material to eradicate the pits. Again, the brushes should be lifted from the
surface when stoning or machining. Finish the ring surface to a 16-32 micro-finish as
described in step 2 above.

F. Electrical Connections

Inspect all electrical connections for corrosion and tightness. Clean corroded parts with a
wire brush and/or muriatic acid. Loose and/or corroded terminations will cause a concentration
of excessive heat.

ENCLOSURE INSPECTION

A. Moisture is a major cause of collector ring deterioration. Corrosion of parts and insulation
breakdown can be attributed to the presence of water. Dust and dirt present within the enclosure
will affect the proper operation of the assembly. Most dusts cause excessive brush and
collector ring wear and conductive dusts, if allowed to accumulate, will form a path for short
circuiting.

B. A properly designed enclosure will be dust tight and watertight; however, condensation may
still form on the walls of the enclosure. In some environments, condensation can be eliminated
with the addition of a breather and drain. Other environments, particularly dusty ones, require
a thermostatically controlled heater to eliminate condensation.

C. An inspection should be periodically performed by removing the enclosure and checking for
condensation, water and dust collection. If contaminants are found, the enclosure and the
assembly should be wiped down with a lint free cloth. If the problem appears persistent,
steps should be taken to remedy the leakage or condensation problem.

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FREQUENCY OF INSPECTIONS

The first inspection should be made shortly after installation and before operation. Continuing
inspections should be made on a regular basis after every 200-400 hours of operation under
normal conditions.

BRUSH SERVICE

A. Brush Holders with nonadjustable spring tension.

1. Refer to the figure below. Pull spring free end (It.#B) out of brush holder recess and
slide spring off of fixed hub (It.#A).

2. Unscrew binder screw (It.#C) and take off brush shunt connector (It.#D) and remove
brush (It.#E).

3. Install a new brush, reversing the above procedure.

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B. Brush Holders with adjustable spring tension.

1. Refer to the figure on the following page. Release the spring tension on the brush
spring by holding the spring tension screw with a screwdriver at slot (It.#A) and loosening
spring tension nut on opposite side. Do not completely remove the nut, just loosen.
The screws can be adjusted with a 9/32 wrench without removing from the stud.

2. Pull spring (It.#B) up and out of the way and unscrew binder screw (It.#C). Take off
brush shunt connector (It.#D) and remove brush (It.#E).

3. Install a new brush, reversing the above procedure.

4. Tension is applied on the brush spring by holding the nut with a wrench and turning the
screw with the screw driven clockwise until the inner coils are tight. Back off 1/4 turn,
then tighten the nut. The spring should have a minimum of 1 pound pull at the brush.
See COLLECTOR RING INSPECTION AND ADJUSTMENT - BRUSH SPRINGS.

5. To replace brush spring tension screw (It.#A), simply take the spring tension screw nut
off and pull the screw and spring out of the holes in brush holder (It.#F). Use the above
steps in reverse order to replace the spring tension screw.

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HOIST MACHINERY

The HOIST MACHINERY is a winch used to raise and lower the dipper and consist of:

• A.C. electric drive motor with disc brake;

• Motor pinion shaft;

• Intermediate shaft/pinion and gear;

• Hoist drum shaft and gear assembly;

The shafts are supported by pedestals that bolt to the rotating frame structure.

NOTE: All gearing is aligned at the factory. The pedestals are aligned and secured to the
rotating frame structure with body fit bolts. The drum shaft pedestals have shims under
the bearing housings to align the hoist bull gear to the intermediate shaft pinion if the
need arises.

HOIST MACHINERY MAINTENANCE

General maintenance and inspection of the hoist machinery includes:

• Keep all pedestal and motor mounting bolts tight.

• Inspect hoist motor coupling quarterly for proper lubrication level; keep full.

• Inspect disc brake operation weekly. Every 250 hours, check wear indicator step located on
the friction disc outside diameter. (Inspection requires removal of shield.)

• Check automatic lubrication systems to gear mesh weekly.

• Inspect lubricant (OGL) supply daily at auto lube center.

• Check hoist rope U-bolt anchors daily for tightness.

• Inspect oil level in rope winch gearcase - keep it full; change every 2 years with gear oil.

• Clean out OGL and MPG lubricant contained in catch basin under hoist machinery and
around center journal annually or semiannually depending on need. Keep drop tube opening
near center journal clear for drain of lubricant waste to ground.

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• Lubricate the hoist drum shaft, intermediate shaft and motor pinion shaft monthly (400 hours).

182M Hoist Machinery - Plan View

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182M-AC Electric Mining Shovel

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182M-AC Electric Mining Shovel

HOIST DRUM SHAFT ASSEMBLY REMOVAL

The HOIST DRUM SHAFT ASSEMBLY weight is 19,620 Lbs. (8,900 kg). Removal requires crane
with adequate lift capacity at the radius necessary to reach over the boom support ropes and
through the machinery house roof.

DANGER! HIGH VOLTAGE! THE HOIST MACHINERY IS DIRECTLY BEHIND

THE AUXILIARY COLLECTOR RINGS. DISCONNECT POWER FROM
THE MACHINE AND ISOLATE ALL SWITCHGEAR BEFORE
PROCEEDING WITH THE REMOVAL OF THE HOIST MACHINERY
COMPONENTS.

To remove the hoist drum shaft from machine:

1. Park the machine on a level work area with room for a crane on either side of the machine.

2. Remove the hoist rope from the drum and secure the ends out of the work area..

3. Remove the gantry front leg flashing and the center roof panels above the center journal and
hoist drum.

NOTE: The roof panels are welded and bolted together to form a one-piece assembly.
Removal of individual panels will require that the welds at the panel joints be cut loose
and the section of roof panel behind the front gantry legs be removed.

4. Disconnect and plug all lube lines.

5. Remove the auxiliary collector ring/rotoseal assembly. Refer to Rotating Frame Assembly in
this section of the manual.

NOTE: The drum shaft assembly can be removed without removing the auxiliary collector
rings as long as special attention is given to maneuvering the assembly. Removal of
the collector rings is recommended however to prevent possible damage to the
collector ring assembly.

6. Remove the hoist gear and drum end guards.

7. Remove the nut on each of four threaded rods that retain the hoist drum shaft bearing
housings to the hoist drum pedestals.

8. Remove the four rods and slotted nuts from the pedestals.
CAUTION: THE BEARING HOUSING ASSEMBLY ON THE RIGHT END OF THE
HOIST DRUM SHAFT CAN SLIDE OFF THE SHAFT IF NOT SECURED
TO THE HOIST GEAR WITH SAFETY WIRING.

9. Attach slings to the drum shaft and carefully lift out of pedestals and through roof of machinery
house.

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NOTE: Since the bearing housings are mounted on an angle, lifting the drum shaft requires
careful maneuvering. When the bearing housings are free of the pedestal openings,
hoist the shaft to clear the pedestals, move it forward (approx. 45 inches) and carefully
lift it clear of the machine.

10. Support the hoist drum shaft assembly on cribbing after it is removed from the machine.

11. Record the shim thickness at each bearing housing. Store for reassembly.

Installation is the reverse of this procedure: Tighten the 3.00 diameter bearing housing rods with
a slugging wrench. The assembly can be shimmed between either pedestal and its bearing housing
to improve hoist gear mesh contact pattern.

NOTE: The pedestal shims will only correct out-of-plane misalignment between the hoist drum
and intermediate hoist shafts. To correct out-of-parallelism for these shafts refer to the
procedure below and also Section 9 - ENGINEERING DATA.

HOIST GEAR ALIGNMENT

The Hoist Gear alignment must be checked after any maintenance which would affect alignment.
This includes gear or pinion replacement, pedestal replacement, hoist drum removal and/or major
weld repairs. If the gear face contact is not a minimum of 80% of the helix face, adjust the contact
pattern.

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NOTE: Before adjusting the tooth contact pattern, remove the left hand bearing housing and
machine as shown.

When the alignment has been corrected, measure the gap "X" and grind a new shim to fit. Tack weld
the shim in place.

CAUTION: Use only a one-piece shim to fill the gap "X".

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HOIST DRUM SHAFT DISASSEMBLY

1. Remove the hoist drum shaft assembly from the machine using the procedure outlined in
HOIST DRUM SHAFT ASSEMBLY PROCEDURE in this section of the manual. After removing
the assembly, set the drum securely on cribbing with the shaft horizontal.

2. Remove the bearing housings and bearings.

NOTE: The bearing housing and cover on the gear end of the shaft is not retained and will
slide off the bearing as a unit.

Hoist Drum Shaft Assembly

End View

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3. Remove the 24 - 1.25 inch capscrews which secure the drum and gear connector plates.

4. Press the gear and drum off the shaft. To facilitate removal, apply heat to the gear hub.

NOTE: A 200 ton [91 M. Tons] press is required for this operation.

5. Clean and inspect all parts. Replace damaged parts and bearings.

Connector Plate Alignment Pin

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HOIST DRUM SHAFT ASSEMBLY PROCEDURE

1. Assemble the drum connector plate to the drum lagging with 6 special capscrews, locknuts
and cotter pins.

2. Install an alignment pin onto the drum connector plate in one of the 2 holes provided. (Refer
to the detail.)

3. Assemble the gear connector plate to the gear with 6 special capscrew, locknuts and cotter
pins.

4. Cool the shaft in DRY ICE.

DANGER! DRY ICE IS -110oF. (-79oC) - IT CAN CAUSE SERIOUS BURNS.

ALWAYS WEAR PROTECTIVE CLOTHING WHEN WORKING WITH
DRY ICE.

Section C - C

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5. Heat the drum bores to 250°F and set the drum on 30 in. high blocking with the large bore up.

6. Using a hoist, lower the cooled shaft into the drum lagging until firmly seated against the shaft
shoulder.

7. Heat the bore of the gear to 250°F.

8 Set the gear on 8 inch high blocking with the connector plate up. Install the shaft into the gear,
using the pin to align the connector plates. Fasten the 2 connector plates together with 24-
1.25 inch capscrews, flat washers and nuts. Tighten the nuts to 1820 Ft.Lbs. (2468 NM).
Remove the alignment pin after assembly.

NOTE: Be sure the shaft is firmly set in the drum before setting the shaft in the gear.

9. Install the bearings and bearing housings per the following procedure.

CAUTION: Secure the gear end housing to the drum shaft until the drum has
been installed in the bearing pedestals.

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HOIST DRUM SHAFT BEARING INSTALLATION

1. Prepare the shaft O.D. for the bearing. Fit of bearing to shaft is .0020-.0044 inches (.051 to
.112 mm) interference.

2. If there is a spacer between the bearing and its shaft shoulder seat, place it onto the shaft.

3. Heat the bearing with a dry heat source to 200°F (93°C) for installation. Do not heat it over
250°F (121°C) .

4. Install the bearing to the shaft. Immediately assemble the bearing end plate to the end of the
shaft, tightening the 8 capscrews to 115 ft. Lbs.. (156 NM). Make sure the bearing is securely
seated against the shaft shoulder and/or spacer.

CAUTION: Use proper protective clothing when handling the hot bearing to
avoid injury.

5. Permit the bearing to cool to ambient. Follow the shim procedure for Gap A to properly clamp
the end plates.

6. Assemble the bearing housing to bearing complete and lube the bearing with MPG.

NOTE: The Hoist Drum Shaft bearings can be replaced without removing the shaft assembly
from the machine. Jacking the shaft up out of its pedestal seats, remove the bearing
housing from the bearing, pull the old bearing from the end of the shaft, and install the
new bearing.

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SHIM PROCEDURE FOR GAP-"A" - 2 PLACES:

1. After bearing installation, assemble the end plate to the shaft and tighten the screws to 15
Ft.Lbs. (20 NM) for the gap measurement.

2. Using the 4 - .24 dia. holes in the retainer measure the distance from the end of the shaft to
the outer face of the retainer with a depth micrometer. Average these 4 measurements.

3. Remove the retainer and measure its thickness at the 4 - .24 dia. holes and average these 4
measurements.

4. Subtract the average measurement from step 3 from the average measurement from step 2.
This is the nominal shim thickness.

5. Install a shim thickness which is .000-.003 inch (.000 to .076 mm) less than the nominal
thickness from step 4.

6. Tighten the capscrews to 115 Ft.Lbs. (156 NM).

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INTERMEDIATE HOIST SHAFT

Hoist Intermediate Shaft Assembly - Section View

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HOIST INTERMEDIATE SHAFT REMOVAL AND DISASSEMBLY

1. Remove the hoist drum shaft assembly. Refer to Hoist Drum Shaft Assembly Removal later in
this section.

2. Remove the hoist rope winch assembly.

3. Remove the hoist motor coupling guard and disconnect the motor coupling, hoist motor wiring
and air line to the motor brake. Remove the motor mounting bolts, and aligning dowel pins.
Note the shim locations and store in a safe place.

CAUTION: RELEASE THE AIR PRESSURE TO THE BRAKE BEFORE

DISCONNECTING THE AIR LINE. Plug the line immediately after
disconnecting. Failure to comply could result in personal injury.

4. Move the hoist motor to provide a 10 inch gap between the motor and pinion shaft ends.

5. Remove the intermediate shaft guards and add support under the pinion.

6. Remove the retainer from the inboard pedestal.

7. Remove the bearing end plate from the left end of the shaft.

8. Remove the 12 bolts holding the inboard pedestal to the deck. Four of these are body fit.
Note their location.

9. Rig a bearing puller to the inboard pedestal, pull the spherical bearing, bearing cartridge and
inboard pedestal simultaneously. The fit of the bearing to the shaft is .0020 to .0044 inch
(.051 to .112 mm) interference.

10. Lift the inboard pedestal out of the machine and remove bearing cartridge with the spherical
bearing seal. The spherical bearing and seal can be withdrawn from the cartridge.

11. Remove the retainer from the outboard pedestal.

12. Attach a hoist to the pinion/gear assembly and support its weight.

13. Push the bearing cartridge with the bearing outer race and rollers out of the outboard pedestal,
using wedges between the intermediate hoist gear and the bearing cartridge.

14. Maneuver the intermediate shaft and gear assembly out of mesh with the hoist motor pinion
shaft and lift it out of the machine. (The weight is 3300 Lbs. (1315 kg)).

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15. Position the shaft/gear assembly vertically with the gear uppermost and resting on cribbing so
the bottom (left) end of the shaft is about 14 inches (355 mm) off the ground for further
disassembly. If the inner bearing race needs to be removed from the shaft, use a puller to do
this or cut it off . The fit of the race to the shaft is .0018 to .0038 inches (.046 to .097 mm)
interference (tight). The shaft is interference fit into the gear bore. To separate them, push on
the top (right) end of the shaft. Fit is .003 to .006 inches (.076 to .152 mm) interference
(tight). When the shaft is free, support it from falling over and then lift the gear from it. Take
the key out of the keyway in the shaft.

16. Withdraw the bearing outer race and rollers from the cartridge of the outboard pedestal and
remove the seal.

Reassembly and reinstallation is the reverse procedure:

- Thoroughly inspect all parts prior to assembly. Replace or repair any found defective.
Clean parts before installation.

- Install new bearings, lip seals and gaskets.

- The inner race for the straight roller bearing can be heated to assist with installation to
the shaft. Use a dry heat source and do not heat it over 250°F (121 °C).

CAUTION: Use proper protective clothing when handling the hot bearing to
avoid injury.

- Freeze the end of the intermediate hoist shaft in DRY ICE to assist with the installation
of the spherical bearing to the shaft. The spherical bearing bore can be heated slightly
to assist with installation, but do not cause it to seize in the bore of the cartridge. Do not
damage the lip seal with heat. The seal can withstand 250 oF (121 oC).

DANGER! DRY ICE IS -110oF. (-79oC) - IT CAN CAUSE SERIOUS BURNS.

ALWAYS WEAR PROTECTIVE CLOTHING WHEN WORKING WITH
DRY ICE.

- The machined surfaces between the inboard and outboard pedestals must be clean
and free of nicks and burrs for proper alignment at assembly.

- Lubricate the bearings with MPG lubricant after assembly. Coat the gear and pinion
teeth with OGL lubricant prior to installing the guards.

- Refer to Section 9 - ENGINEERING DATA, procedure to Lockwire the heads of the

screws that are drilled for wire.

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HOIST MOTOR PINION SHAFT

HOIST MOTOR PINION SHAFT REMOVAL

1. Park the machine, placing the dipper on the ground and setting the brakes, slacken the hoist
ropes and block the drum to prevent rotation. Remove machinery house roof panel above
the hoist motor to give access for lifting.

DANGER! HIGH VOLTAGE! DISCONNECT AND ISOLATE ELECTRICAL

POWER FROM THE HOIST MOTOR BEFORE ATTEMPTING TO WORK
ON THE HOIST MACHINERY. DISCONNECTION MUST BE DONE BY A
QUALIFIED ELECTRICIAN.

2. Remove the guarding over the motor coupling and the motor pinion shaft. Disconnect and
plug the air line to the motor brake.

CAUTION: RELEASE THE AIR PRESSURE TO THE BRAKE BEFORE

DISCONNECTING THE AIR LINE. Plug the line immediately after
disconnecting. Failure to comply could result in personal injury.

3. Separate the halves of the hoist motor coupling.

4. Remove ten hoist motor mounting bolts from motor feet and disconnect the wiring..

5. Remove dowel pins from the two motor feet. Use a .5-13 inch nut on the end of the dowel pin
to pull dowel out.

6. Attach a crane line to the hoist motor lifting eyes and move the motor to provide 33 inches
between the motor and inboard pedestal. Record the shims at the motor feet.

CAUTION: THE WEIGHT OF THE HOIST MOTOR BRAKE AND COUPLING IS

APPROX. 8600 LBS.(3900 Kg). USE A CRANE WITH SUFFICIENT
LIFTING CAPACITY AT SPECIFIED RADIUS.

7. Remove both inboard and outboard bearing retainers. Attach a hoist and support the motor
pinion shaft.

8. Using brass drift and hammer, tap inboard bearing cartridge out of pedestal bore. The
cartridge with the bearing outer race /rollers will slide out of the bore without the inner bearing
race as this is a straight type design.

9. Remove the outboard bearing cartridge with the bearing outer race /rollers in the same
manner.

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10. The motor pinion can now be taken out of mesh with the intermediate hoist gear. Using a
hoist, maneuver the motor pinion shaft out of pedestal bores. Remove from the machine.
(Weight: 292 Lbs./132 kg).

11. Disassemble the coupling from the end of the motor pinion shaft. Use a bearing puller.

HOIST MOTOR PINION SHAFT REPLACEMENT

When replacing the Motor Pinion Shaft, use new seals and bearings.

1. Assemble inner race of bearings to each end of the shaft using a dry heat source to expand
race for assembly. Install on shaft flush with shaft shoulder area. Do not heat races over
250oF(121oC).

2. Position shaft in the pedestal bores.

3 Install the bearing outer race/rollers and lip seals into the bearing cartridges. Install on shaft
and into the bores on the inboard and outboard pedestals. DO NOT MIX PARTS BETWEEN
THE TWO BEARING ASSEMBLIES.

NOTE: Spray lip seal contact surfaces with Molycote M-8800 or an equivalent.

4. Install the lip seal into the inboard bearing retainer. Assemble both bearing retainers. Lubricate
both bearings with MPG grease.

5. Shrink fit coupling hub onto the motor pinion shaft. Refer to procedure for Installation of
Shrink Fit Pinion/Hubs in Section 9 - ENGINEERING DATA.

6. Using crane, reposition hoist motor to the motor pinion shaft. Use the shims removed, install
dowel pins and 10 hold down bolts.

7. Check hoist motor coupling halves alignment. Make any necessary alignment adjustment as
required. Clearance between end of hoist motor shaft and the motor pinion shaft is .25 inch
(6mm). Reinstall the dowel pins at the motor feet. If the dowel pin holes do not realign,
relocate using .500 inch (12.700 mm) reamed holes. (Oversized dowel pins are an alternative.)
Refer to Section 6 -BRAKES AND COUPLINGS for coupling assembly and alignment.

8. Assemble the motor coupling halves AND lubricate with LTG grease. Reinstall guards and
air lines.

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HOIST BRAKE

The hoist brake is a single disc unit attached to the commutator end of the hoist motor. It is not a
dynamic (operating) brake intended to stop or retard hoist motion during normal operation. It is a
HOLDING BRAKE. Hoist motion should be slowed to a stop by plugging the motor (Refer to
Section 2 - OPERATION before setting the hoist brake). The brake is spring set and air released.
Refer to Section 6 - BRAKES & COUPLINGS for detailed information on disassembly and
replacement.

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SWING MACHINERY

The SWING MACHINERY includes the two identical rotating gearcases with A.C. electric motors/
blowers and disc brakes. Swing torque is transmitted through the main rotating pinions to the main
rotating gear on the lower frame structure.

The Disc Brakes are spring-applied, air-released, single-disc units with rotor centering devices.

The gearcases are double-reduction spur gear type. The motor pinion drives an intermediate gear
splined to a vertical pinion shaft. The pinion is supported by two anti-friction bearings.

The integral pinion of the intermediate shaft meshes with the main rotating shaft gear. It is splined to
the vertical main rotating shaft. The main rotating shaft is mounted on two spherical roller bearings.
A double oil seal is provided under the top bearing of the main rotating shaft to retain oil in the
gearcase.

A main rotating pinion splined and bolted to the bottom of the main rotating shaft meshes with the
main rotating ring gear mounted on the lower frame structure.

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SWING MACHINERY MAINTENANCE

General maintenance and inspection of the swing machinery includes:

• Check gearcase hold down bolts weekly for loose condition.

• Inspect for oil leaks daily.

• Check oil level in both gearcases daily. Dip stick is attached to oil fill tube cap.

• Change oil in gearcases annually, or as required by lab test analysis. Capacity is 51.5
gallons U.S.(195 liters) each.

• Lubricate electric motor bearings semiannually with Electric Motor Grease (EMG) .
See Section 3 - Lubrication.

• Inspect disc brake operation daily. Check friction disc wear quarterly by removing the
shield and examining progress of wear on the friction disc step indicator.

• Keep auto lube supply and system operational for open gear lubricant (OGL) to the
main rotating pinions and multipurpose grease lubricant (MPG) to the lower main rotating
shaft bearings.

• Check lubricant (OGL) coverage on swing pinions and rotating gear daily.

• Inspect the main rotating pinion retainer bolts weekly.

• Inspect the gearcase breathers quarterly (1200 hours).

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182M Swing Machinery - Section View

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SWING MOTOR ASSEMBLY

SWING MOTOR REMOVAL

Swing motor removal requires lifting crane with 3000 Lbs.(1364 kg) at radius of 15 feet.

DANGER! HIGH VOLTAGE! ONLY A QUALIFIED ELECTRICIAN SHOULD

PERFORM THE DISCONNECTION OF THE SWING MOTOR. FAILURE
TO COMPLY WITH THIS WARNING COULD RESULT IN SERIOUS
INJURY OR DEATH.

Swing Motor

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Procedure for swing motor removal:

NOTE: This procedure includes removal of disc brake with motor. Follow brake removal
procedure when only brake is to be removed from machine.

1. Park the machine on level ground with the dipper setting on grade.

2. Remove machinery house roof panel directly over motor to be removed and dismantle hoist
rope guard enough for motor to clear it.

3. Disconnect electrical cables from motor.

4. Disconnect and plug air line from brake.

CAUTION: RELEASE THE AIR PRESSURE TO THE BRAKE BEFORE

DISCONNECTING THE AIR LINE. Plug the line immediately after
disconnecting. Failure to comply could result in personal injury.

5. Remove seven motor mounting bolts from gearcase.

6. Sling motor to lifting equipment and lift motor off case through the roof opening. Place it on
cribbing.

7. Remove the brake.

- Loosen six capscrews holding brake housing to motor.

- Brake assembly can now be removed off motor shaft/gear.

8. When the motor is replaced, the motor pinion and brake gear should be removed from old
shaft and reinstalled on new motor per the procedure in Section 7 of this manual.

9. Disassemble and rebuild disc brake as identified in Section 6 - BRAKES and COUPLINGS.

10. Assemble the brake to the motor in the reverse order of removal. Tighten the brake mounting
bolts to 250 Ft.Lbs. (339 Nm).

Installation of motor to swing case is reverse of the above procedure. Use a new gasket between
the motor and case. Tighten the seven capscrews holding motor to case to 525 Ft.Lbs.(712 Nm).

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MAIN ROTATING PINION REPLACEMENT

To replace the Main Rotating Pinion:

1. Park the machine on a level work area. Position the rotating frame so that the main rotating
pinion to be removed is at the front center of the lower frame structure, in an area with no
obstructions to access.

2. Place the dipper securely on grade, set all brakes, and SHUT DOWN THE MACHINE.

3. Disconnect and plug the auto lube lines and remove main rotating pinion guard.

4. Position support cribbing under the pinion, leaving access to the main rotating pinion retainer
and capscrews.

5. Unbolt the pinion retainer and remove it, with shims, from the counterbore in the main rotating
pinion.

6. Lower the main rotating pinion and the spacer above it clear of shaft and set them on cribbing.

Install a new pinion with spacer in the reverse of the removal procedure:

- If lip seal in retainer above pinion is damaged, replace it first.

- Coat internal and external splines with Molub-Alloy grease paste or its equivalent.
- Install the main rotating pinion and spacer above it. Spray lip seal area with Molycote
M3402 or its equivalent. Tighten 3 capscrews to 36 Ft.Lbs. (48 Nm) for gap
measurement.
- Measure distance from end of shaft to outer face of pinion retainer with a depth
micrometer using the three .25 inch (6mm) diameter holes in the retainer. Average
these measurement.
- Remove the pinion retainer and measure retainer thickness at the three .25 inch (6mm)
holes. Average these measurements.
- Subtract the average pinion retainer thickness from the average distance to the end of
the shaft from the outer face of the pinion retainer when in place to obtain the nominal
gap dimension.
- Make a shim pack that is .010 inch (.254mm) thicker than the nominal gap dimension.
- Reinstall swing pinion retainer with shimpack and tighten 3 capscrews holding it to
shaft to 265 Ft.Lbs. (360 Nm). Lockwire capscrew heads.
- Reassemble pinion guard and auto lube lines.

NOTE: IT IS NOT NECESSARY TO REMOVE THE ROTATING GEARCASE UNLESS THE

GEARCASE STRUCTURE NEEDS TO BE REPLACED. THE COMPONENTS IN THE
GEARCASE CAN BE REPLACED WITHOUT ITS REMOVAL.

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MAIN SWING SHAFT REMOVAL / ROTATING GEARCASE DISASSEMBLY

The swing motor/brake assembly must be removed, and the gearcase must be disassembled, to
remove and replace the main rotating shaft.

CAUTION: PARK THE MACHINE ON A LEVEL WORK AREA. PLACE THE DIPPER
ON GRADE AND ISOLATE ELECTRIC POWER FROM THE MACHINE.

CAUTION: COMPONENT SIZE AND WEIGHT REQUIRE ADEQUATE LIFT

CAPACITY EQUIPMENT AND CORRECT LIFTING METHODS.

1. Remove the main rotating pinion. See the previous procedure.

2. Drain oil from the gearcase through the valve provided on the underside of the rotating
frame near pinion. Use a suitable container to hold the oil. Capacity of case is 51.5 gallons
U.S. (195 liters). Save the oil for reuse after filtering or dispose of it properly. DO NOT
CONTAMINATE YOUR ENVIRONMENT.

Bolt Pattern on the Swing Gearcase

Bolts: Gearcase hold-down bolts: 1.25 Dia. Gr.5, Tighten to 1045 Ft.Lbs. (1417 NM) ~8 Places.
Gearcase Cover bolts: .75 Inch Dia. Gr.5, Tighten to 250 Ft.Lbs. (339 NM) ~12 Places.

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3. Remove motor/brake assembly from gearcase. Refer to the procedure given previously. Remove
the retainer cap, 3 - .5 inch capscrews, the shims below the retainer cap and the spacer from
the top of the intermediate shaft.

4. Disassemble the 8 capscrews and 4 body-fit bolts that hold the gearcase cover to the gearcase
structure. Lift the gearcase cover from gearcase structure and on up through a roof opening.
Place it on cribbing.

5. Dismantle the outer bearing spacer, inner bearing retainer, bearing, spacer collar, intermediate
gear, and lower spacer from the intermediate pinion shaft inside gearcase. Use a bearing
puller for bearing removal. Lay all pieces removed out of the work area in a protected location.

6. Disassemble the gear retainer and the main rotating shaft gear from the end of the main
rotating shaft inside gearcase. Place components safely out of work area and properly protect
them.

7. Lift the intermediate shaft assembly (pinion and gear), with its bottom bearing, from the
gearcase structure. Two threaded holes with .5-13UNC-2B threads in the top of the shaft are
for lifting eyebolts.

8. Remove the bearing retainer for the top spherical bearing on the main rotating shaft from the
gearcase structure.

9. Build a secure jacking platform under the main rotating shaft, between the crawler side
frames.

10. Using a high capacity hydraulic jack, push up on the bottom of the main rotating shaft to
press it out of the bottom spherical bearing.

NOTE: The maximum interference fit is .0029 inch (.074 mm). It will require 19,000 Lbs.
(8,618 Kgs.) of axial force to overcome this fit.

11. When the shaft is free from the bottom spherical bearing, lift the main rotating shaft from the
upper frame housing and gearcase structure and on up out of the machinery house. Place it
on cribbing. The threaded hole for lifting in the top center of the shaft has 1-8UNC-2B threads.

12. Disassemble the retainer from the bottom of the rotating frame housing.

CAUTION: HOLD THE BOTTOM SPHERICAL BEARING TO PREVENT IT FROM

FALLING.

13. Remove the bottom spherical bearing and spacer above it from the housing bore. The spherical
bearing width is less than the space between the bottom of the rotating frame housing and
the main rotating gear.

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Main Rotating Shaft Assembly

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14. Complete the disassembly of parts from the shafts and gearcase as desired.

- Use bearing pullers to remove bearings from the intermediate swing shaft and top of
main swing shaft. The top spherical bearing on the main rotating shaft requires 20,000
Lbs. (9,022 Kgs.) axial force to overcome the maximum interference fit of .0036 Inch.
(.091 mm)

- Remove all old gasket and any other sealing material from the gearcase where it is
exposed during disassembly.

- Thoroughly clean and flush the gearcase structure and bore in the rotating frame
housing and the gearcase cover.

- Inspect the double oil seals inside the gearcase for damage or wear. Replace if
conditions warrant.

- Using a bearing puller, remove the pinion from the motor shaft.

NOTE: It is not necessary to remove the rotating gearcase from the machinery deck unless
the case structure needs to be replaced or repaired. Check that the 8 hold-down bolts
are tight. Tighten to 1200 Ft.Lbs. (1519 Nm).

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ROTATING GEARCASE ASSEMBLY

1. Clean gearcase and all components thoroughly. Remove all old gasket and sealing material.

2. Check inspection covers for seal and bolt tightness.

3. Make sure the bolts holding the gearcase to the deck are tightened to 1045 Ft.Lbs.(1417 Nm)
and that 2 body-fit bolts are correctly located and fit their holes properly.

4. Install the top spherical bearing onto main rotating shaft. Heat bearing to assist with assembly.
Use only dry heat source and do not heat over 250 oF(121 oC). Let the bearing cool to
ambient before installing shaft. Use the main rotating shaft gear to temporarily clamp this
bearing in place while cooling.

5. Assemble the 2 oil seals into the large bore inside the gearcase with the lips of the seals
facing up.

6. Freeze the end of the main rotating shaft in DRY ICE to assist in installation.

DANGER! DRY ICE IS -110oF. (-79oC) - IT CAN CAUSE SERIOUS BURNS.

ALWAYS WEAR PROTECTIVE CLOTHING WHEN WORKING WITH
DRY ICE.

Position main rotating shaft vertically over the gearcase structure and the rotating frame housing.
The threaded hole for lifting in top center of shaft has 1-8UNC-2B threads. Lower the shaft into the
housing.

7. Before main rotating shaft enters bottom bore in the rotating frame housing, place the spacer
above the bottom spherical bearing and place the spherical bearing into bore. Install the
bottom retainer without lip seal into position under the rotating frame housing. Put a jacking
brace or collar in position under the bottom retainer. Be sure it can be removed after shaft is
in place.

8. Lower the main rotating shaft into place. Use a hydraulic jack as needed to push or pull down
on the shaft to press it into the bottom spherical bearing. The bearing can be heated to
250 oF (121 oC) to assist with installation. Let bearing cool to ambient before further assembly.

IMPORTANT: This is a critical procedure. Be sure that the spherical bearing and the spacer above
it are aligned and securely seated against shaft shoulder and that the bearing is not tilted. There is
a limited time period for the temperature affects to allow assembly.

CAUTION: USE PROPER PROTECTIVE CLOTHING (GLOVES) WHEN HANDLING

THE HEATED BEARING.

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9. Install the seal into the bottom retainer. Tighten 8 capscrews to 250 Ft.Lbs.(339 Nm) and
lockwire heads.

MAIN ROTATING GEARCASE

10. Install the bearing retainer to the top spherical bearing on the main rotating shaft inside the
gearcase structure. Tighten capscrews to 75 Ft.Lbs.(100 Nm) and lockwire heads.

11. Fill bottom bearing with MPG lube. Make sure lube access passage is unobstructed.

12. Install the main rotating pinion and spacer above it. Refer to the Main Rotating Pinion
Replacement procedure in this section.

13. Assemble bottom spherical bearing and spacer above it to end of intermediate swing shaft.
Heat bearing to assist with assembly. Use dry heat source only and do not heat it over 250 oF
(121 oC). Let the bearing cool to ambient temperature before installing the shaft into the
gearcase structure.

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14. Install the intermediate swing shaft into the gearcase structure. Assemble the main rotating
shaft gear to the main rotating shaft using the following procedure:

a. Assemble the upper spherical roller bearing, main rotating shaft gear and end
retainer onto the main rotating shaft. Tighten the retainer screws to 36 Ft.Lbs.

b. Using the 3 - .25 inch dia. holes in the retainer, measure the distance from the end
of the shaft to the outer face of the retainer using a depth micrometer. Average
these 3 measurements.

c. Remove the retainer and measure the retainer thickness at the 3 - .25 inch diameter
holes. Average these measurements.

d. Subtract the average measurement from Step "c" from the average measurement
from Step "b". This is the nominal shim thickness.

e. Install shims that are .001 to .003 inch LESS in thickness than the nominal shim
thickness from Step "d".

f. Install the shims, retainer and capscrews. Tighten the retainer capscrews to 255
Ft.Lbs. and lockwire in place.

15. Install the spacer, intermediate gear and spacer collar onto the intermediate swing shaft.

16. Assemble the bearing and its retainer to the top end of the intermediate swing shaft. Heat
the bearing to assist with assembly. Use dry heat source only and do not heat it over 250oF
(121oC). Let the bearing cool to ambient.

17. Install a new gasket with sealant and the gearcase cover to the gearcase structure. Be sure
the four body-fit bolts fit the holes properly and are correctly located. Tighten the gearcase
cover bolts to 250 Ft.Lbs.(339 Nm).

18. Install the spacer above the ball bearing. Add the proper shims to the top of the spacer to
achieve a gap of .02 - .06 inch between the shims and the top of the gearcase cover. Assemble
a new gasket with sealant, the retainer cap and the 3 - .5 inch capscrews to the gearcase
cover above the intermediate swing shaft. Tighten the capscrews to 70 Ft.Lbs.

19. Fit the pinion to the motor shaft, if not already done.

20. Install the motor/brake assembly to the gearcase. Refer to the Swing Motor Removal
procedure in this section.

21. Refill the gearcase with GL oil. Capacity is 51.5 gallons U.S. (195 liters). Check the MPG
lube supply from the deck to the lower spherical bearing on the main rotating shaft.

22. Reassemble the house roof panel and the hoist rope guard.

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GANTRY

The GANTRY supports the boom via four boom support ropes. Each rope (two per side) is pin
connected to equalizer links at each side of the gantry frame and to both sides of the boom point
shaft. Each pin is lubricated by the automatic multipurpose grease system. The equalizer links
distribute boom loads evenly to each rope.

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The compression members of the gantry frame are box section steel plate fabrications, joined together
with double-plate cross members at the top. This gantry frame pins to lugs on the deck of the
rotating frame near the rotating gearcases.

The tension members of the gantry, or backlegs, are made from one continuous plate section (no
weld joints). These backlegs pin below the deck at the rear of the rotating frame and at the top of
the gantry frame next to the equalizer links, thus completing the boom support structure.

The dipper trip assembly is mounted on the right side of the gantry frame.

GANTRY MAINTENANCE

1. Keep the metal flashing at the house roof sealed watertight around the gantry frame and
backlegs.

2. Check the operation of the auto lube injectors at the equalizer link pins weekly.

3. Inspect the condition of the equalizer link pins and boom support rope pins monthly.

4. Inspect the gantry frame and backlegs for cracking quarterly. Any cracks should be repaired
immediately. Report any cracks and repairs to the Bucyrus Service department for advice.

5. Observe and record the relative movement at the gantry pinned connections to the rotating
frame and at the top semiannually.

6. Inspect the boom support ropes at the socket joint connections for any sign of rust, corrosion
or failure semiannually.

Refer to Section 4 - PREVENTIVE MAINTENANCE, for complete maintenance information.

GANTRY DISASSEMBLY OR REMOVAL

To disassemble or remove the GANTRY it is necessary to lower the boom. Refer to BOOM
REMOVAL in this section, then proceed with following:

1. With the boom lowered, remove the gantry platform and railings.

2. Remove the dipper trip assembly.

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3. Disconnect the automatic lubrication lines to the equalizer links. Disconnect the lubricant supply
line running up the left side of the gantry frame, near the rotating gearcase in the machinery
house.

4. Remove the flashing on the gantry members as they pass through the house roof. Remove all
of the house roof panels above the machinery deck (upper frame).

5. Position a crane with sufficient capacity (gantry frame weight is approximately 6,000 Lbs.(2720
kg) and connect the crane line to the gantry frame cross member.

6. While supporting the gantry frame with crane, remove the pins joining the backlegs to the
top of the gantry.

CAUTION: THE EQUALIZER LINKS ARE HELD IN THE GANTRY STRUCTURE BY

THE SAME PINS ATTACHING THE BACKLEGS TO THE TOP OF THE
GANTRY - DO NOT REMOVE THE PINS UNTIL THE EQUALIZER IS
SECURED.

Use a smaller crane to handle the removal of the equalizer links while another crane supports the
gantry structure. Link weight is approx. 450 Lbs.(204 Kgs.) each.

7. Choke the small crane line around the top of one back leg before removing the top pin. After
the back leg is unpinned from the gantry frame, remove the pin at the bottom of back leg in
the rotating frame. Back leg weight is approx. 1725 Lbs.(784 Kgs). Slowly lift the back leg out
of the machine, using personnel in the house to guide it . Remove the other back leg in same
manner.

8. Disconnect the pins holding the bottom of the gantry frame to the front portion of the rotating
frame. Slowly lift the structure from the machine, using personnel in the house to guide it.

NOTE: Gantry removal would only occur during a major machine rebuild. When removed, it is
advised to inspect the entire gantry frame and backlegs carefully for cracks or
structural deterioration.

CAUTION: Weld repair the GANTRY FRAME as required. HOWEVER, WELD

REPAIR ON THE BACKLEGS IS NOT RECOMMENDED AS THESE ARE
CRITICAL TENSION MEMBERS SUPPORTING THE ENTIRE FRONT
END OF THE MACHINE.

Also inspect the lugs on the rotating frame for fatigue cracks. Weld repair as required. Report any
problems to the Bucyrus Service Department for advice.

The Gantry is installed in reverse of the procedure for removal.

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FRONT END EQUIPMENT

BOOM ASSEMBLY

The BOOM ASSEMBLY on the front end of the machine supports the dipper handle and dipper. It
is the working end of the machine and is pinned to the rotating frame structure at the boom feet. It
is suspended at the boom point by four pendant ropes attached to the gantry structure mounted on
the rotating frame structure.

The Crowd Machinery, mounted midpoint on the boom, extends and retracts the dipper handle
using a A.C. motor controlled from the cab through a double-reduction spur gear drive. Drive output
is through an air-actuated clutch and shipper shaft pinions meshing with racking on the dipper
handle members.

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Components on the boom include:

• Boom structure.

• Boom point sheaves.

• Crowd motor with disc brake.

• Intermediate crowd shaft assembly with overload clutch.

• Shipper shaft assembly.

• Auto lubrication systems.

• Operating limit system.

BOOM ASSEMBLY MAINTENANCE

Routine maintenance of the boom components needs to be performed daily, weekly, monthly as
well as semiannually. Refer to Section 4 - PREVENTIVE MAINTENANCE, in this manual, for
specific scheduled items.

General maintenance includes:

• Inspect the automatic lubrication and air systems daily. Repair any faults immediately which
are identified by control signals.

• Thoroughly inspect the boom support ropes at their socket connections for signs of failure
semiannually.

• Check the platforms, ladders and handrails weekly and maintain good repair.

• Visually inspect the boom structure monthly for damage.

• After 15000 hours, or 3 years, whichever comes first, lower the boom and thoroughly inspect
the boom structure.

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182M Boom Assembly

BOOM LOWERING/RAISING

Before the boom can be lowered, the handle must be removed from the crowd machinery. Refer to
HANDLE REMOVAL in this section.

To lower the boom:

1. Position the rotating frame structure so that the boom feet are over the propel machinery.

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2. Set all brakes and shut down machine. Disconnect trail cable.

3. Build cribbing support in line with the boom for receiving boom point structure. Cribbing should
be positioned 32 ft.(9.75m) from centerline of boom foot.

4. Disconnect the boom jacking limit switch actuating cable at the boom.

5. Remove the hoist rope from the machine and store it on a reel to prevent damage.

6. Attach a crane line to both boom point sheaves.

7. Disconnect the auto lube lines on the equalizer link pins on each side of the gantry. Cap and
plug them to protect against contaminating the system.

8. Relieve the tension on the boom support ropes by raising the boom with a crane line.

9. Using a second smaller crane, choke each support rope (2 per side) and remove the two
pins retaining the boom support rope socket to the equalizer. Lower the boom support ropes
to rest on top of the boom.

10. The boom can now be SLOWLY lowered to cribbing. Adjust the position of cribbing as required.

Raising the boom is the reverse of the boom lowering procedure.

BOOM REMOVAL

1. Lower boom to cribbing using BOOM LOWERING procedure.

2. Crib under ballast box.

3. Disconnect lube and air lines to boom from rotating frame at boom foot.

4. Disconnect all wires from boom at crowd junction box inside machinery house.

- Unclamp cable leads to boom from crowd junction box and bundle for exit through
opening in front wall of house.

5. Disconnect, cap and plug the auto lube lines at both boom foot pins.

6. Rig a crane line to lift the boom.

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7. Remove retainers from foot pins. Push/pull boom foot pins from foot bores. Leave pins in
bore of lug on rotating frame structure.

8. Slowly withdraw boom feet from rotating frame structure lugs.

9. Move boom so it clears lower frame structure and crawlers.

10. Set boom on cribbing.

BOOM POINT SHEAVE ASSEMBLY

The BOOM POINT SHEAVE ASSEMBLY consists of two identical, single grooved rope sheaves
mounted at the boom point on a fixed shaft. Each sheave rotates on a two full bushings which are
supported by a steel sleeve carried by the fixed shaft. The steel sleeve is keyed to the boom
structure to prevent rotation.

NOTE: REMOVAL OF THE SHEAVES REQUIRES LOWERING THE BOOM. Follow the
procedure given in this section of the manual.

With the boom lowered and supported on cribbing:

1. Remove cotter pins in T-head pin retaining collars at each end of fixed shaft.

2. Remove collars and boom support rope equalizer links.

3. Remove auto lube lines from sheave assembly. Cap and plug them for protection.

4. Fixed shaft must be driven out of boom point by bumping with a heavy bar or pulling with
cable inserted through end of pin hole. This is not an interference fit.

5. Before removing shaft, attach crane line around spacer at center of sheave assembly to
support sheaves and full length steel sleeve.

6. Slowly remove boom point shaft until sheave assembly can be lifted out of boom point.
Weight of this sheave assembly is 4,090 Lbs.(1855 kg).

CAUTION: THE SHEAVES ARE NOT SECURED ON THE SLEEVE, THE THRUST
WASHERS ARE LOOSE ITEMS. HANDLE THE ASSEMBLY
CAREFULLY - TIE THE SHEAVES TOGETHER BEFORE MOVING TO A
DISASSEMBLY AREA.

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Boom Point Sheave Assembly ~Section View

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7. Position the assembly horizontally on cribbing so it is level.

8. Remove lube piping and thrust washers on each end of the sleeve.

9. Push the steel sleeve out of one sheave; remove the thrust washers and spacer between
them as they come free.

10. Withdraw the sleeve from the other sheave. Lay both sheaves down flat.

Reassemble the boom point sheave in reverse order of disassembly.

NOTE: Assemble the equalizers with their part number facing outboard at both ends of the
shaft.

BOOM JACKING LIMIT

The BOOM JACKING LIMIT is an electrical switch located on the front inside wall of the machinery
house just left of center. The purpose of the boom jacking limit is to control the amount of boom
jacking. This is a situation where, the boom is raised beyond its normal 45 degree operating angle
because too much crowd force is being applied at the face.

Effects of boom jacking can be serious damage to boom foot lugs and boom support ropes.

The boom jacking limit is activated by the closing of the switch when the cable attached to the top
of the boom goes slack due to a condition of boom jacking.

When the spring loaded, plunger type switch is activated, crowd out control reference is removed
and an audible bell will sound in the operators cab. Crowd reference is regained by retracting
handle from face.

Adjustment of the switch consists of maintaining the distance between the plunger face and switch
contact. This is done by adjusting nuts on the front and rear of the plunger rod. Correct adjustment
is .75 inch (19mm) distance between face of front adjusting nuts and front of guide assembly. (See
illustration for location of adjusting nuts.)

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Boom Jacking Limit Switch

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CROWD MACHINERY

The CROWD MACHINERY is located approximately at the midpoint on the boom. Its function is to
mechanically move the dipper fore and aft during the dig cycle.

Motion is generated by a A.C. motor mounted on the boom. The motor pinion meshes with an
intermediate gear which drives a pinion shaft through an air clutch. The shipper shaft gear, driven
by the intermediate pinion shaft, is splined to the shipper shaft. A pinion on each end of the shipper
shaft meshes with a rack on the underside of the two dipper handle members.

Shipper shaft pinion rotation causes the dipper handle to crowd out or retract depending on operator
control selection. A yoke over each handle member pivots on the shipper shaft and guides the
handle members as they extend and retract.

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Components of the crowd machinery assembly consist of:

- A.C. Crowd motor with brake

- Crowd motor pinion
- Crowd overload clutch
- Intermediate pinion shaft
- Intermediate crowd gear
- Shipper shaft gear
- Shipper shaft
- Shipper shaft pinions
- Yoke blocks/wear shoes/shims

CROWD MACHINERY MAINTENANCE

General maintenance and inspection of the Crowd Machinery:

• Keep motor hold down bolts tight.

• Lubricate crowd motor bearings semiannually with electric motor grease.

• Inspect motor pinion wear every 600 hours.

• Inspect auto lube system for correct distribution and supply of open gear lube and multipurpose
grease.

• Inspect air clutch every 250 hours for friction disc wear.

• Perform manual lubrication of intermediate crowd gear bushing quarterly.

• Inspect shipper shaft collar thrust washers every 250 hours. Shim for wear as required.

• Check retention bolts of shipper shaft collars monthly.

• Check wear of shipper shaft pinions every 1,000 hours. Replace when teeth on outside end
of pinion become rounded significantly.

• Adjust clearance as required between wear shoe and top handle plate in each yoke block
every 250 hours. Clearance not to exceed .12 inch (3mm). Adjust clearance with shims.

DANGER! THE DIPPER TRIP ROPE HAS CONSTANT TORQUE WHEN ELECTRIC
POWER IS ON THE MACHINE. SECURE THE ROPE TO THE FRONT
OF THE ROTATING FRAME WHEN IT IS DISCONNECTED.

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Crowd Motor Assembly

CROWD MOTOR

The CROWD MOTOR is a heavy A.C. unit mounted directly on the boom. The crowd motor pinion
meshes with the intermediate crowd gear to drive the crowd machinery. The crowd motor feet are
bolted directly to a machined surface on the boom. Shear blocks, welded to the boom, lock motor in
position to hold gear alignment and backlash.

The crowd brake is a single disc, spring engaged, air disengaged unit bolted to one end of the
crowd motor. For a full description of maintenance requirements for the crowd brake refer to
Section 6 - BRAKES and COUPLINGS.

CROWD MOTOR MAINTENANCE

1. Lubricate motor armature bearings with electric motor grease semiannually.

2. Motor pinion and brake gear are shrunk fit on armature shaft. Follow critical installation
procedures in Section 7 - ENGINEERING DATA, which define correct lead and temperature
guidelines for installing.

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CROWD MOTOR REMOVAL

1. Remove ladder/handrails over the motor guard and clutch and the intermediate crowd gear
guard over the motor pinion.

DANGER! HIGH VOLTAGE! DISCONNECT AND ISOLATE THE MACHINE

FROM THE TRAIL CABLE PRIOR TO REMOVAL OF THE CROWD
MOTOR. USE ONLY A QUALIFIED ELECTRICIAN FOR THIS
PROCEDURE.

2. Disconnect crowd motor electrical wiring at motor junction box on boom.

3. Attach crane line to motor lifting lugs. Remove air lines at the brake & clutch..

CAUTION: RELEASE THE AIR PRESSURE TO THE BRAKE BEFORE

DISCONNECTING THE AIR LINE. Plug the line immediately after
disconnecting. Failure to comply could result in personal injury.

4. Remove four motor hold down bolts.

5. Lift the motor assembly off boom to cribbing on ground.

Installation of motor assembly may require refitting shear blocks at motor feet on the boom. Check
gear alignment and backlash. Reposition motor as required. Refer to Section 9 - ENGINEERING
DATA for the assembled backlash. Tooth contact should be a minimum of 80% of the tooth width.

INTERMEDIATE PINION SHAFT REMOVAL

To remove the INTERMEDIATE PINION SHAFT it is necessary to remove the crowd clutch and
the intermediate gear on the left side of the boom. On the right side of the boom it will be necessary
to remove the crowd limit switch assembly and unbolt the drive lug from the right end of the
intermediate pinion shaft.

The right end of the intermediate pinion shaft is seated inside the boom in a bearing boss. The
spherical bearing is retained on the end of the shaft with a snap ring.

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Crowd Intermediate Pinion Shaft Assembly

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Remove the shaft as follows:

1. Park the machine on a level work area. Set the dipper on the ground with the handle
perpendicular to the boom. Set all brakes.

2. Disconnect and plug the clutch airline. Loosen the fitting between the check valve and clutch.
Allow the air pressure to bleed off.

DANGER! Release the airline pressure before reducing air pressure to the
clutch. DO NOT ATTEMPT TO REMOVE ANY FITTINGS UNTIL THE
AIR PRESSURE HAS COMPLETELY BLED OFF. Failure to use caution
could result in personal injury.

3. Remove intermediate crowd gear/clutch guard, crowd clutch and intermediate crowd gear
from left end of shaft. Refer to Clutch Preliminary Steps in this section of the manual for
clutch and removal. Take sleeve and spacer off shaft.

4. Remove crowd limit switch assembly and drive lug on right end of intermediate pinion shaft.

NOTE: When reinstalling, reset the crowd limit switch. Refer to Crowd Limit Switch in this
section for the procedure

5. Remove the rotoseal and adaptor from left end of shaft.

6. Remove the hoist rope guard over the shipper shaft gear guard. Disconnect and plug all
lube lines between the guard and boom. Remove the shipper shaft gear guard.

7. Remove the handrail on left side of boom platform that interferes with shaft removal. Remove
the 6 capscrews securing the bearing retainer to the boom side plate. Remove retainer and
shims.

8. Wrap a sling around the intermediate shaft at the right hand side of the pinion. Apply lift to
support the shaft.

9. Insert a 1.5 inch(38mm) long eyebolt, threaded .625-18UNF-2B, into tapped hole in the left
end of the shaft. Using a puller, apply force to remove pinion shaft with bearings from the left
side of the boom.

CAUTION: THE INTERMEDIATE PINION SHAFT, WITH BEARINGS, WEIGHS

APPROX. 445 LBS. (202 Kgs). RIG APPROPRIATE SLINGS FOR
HANDLING THE SHAFT.

10 Use bearing pullers to remove both bearings from shaft. Heat the bearings for installation on
the shaft, Use dry heat and do not exceed 250 oF(121 oC).

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Reassembly and installation is the reverse of disassembly and removal.

- Coat pinion teeth with OGL lubricant.

- Shim between left bearing retainer and boom side plate so there is no gap. To determine
shim thickness, install retainer and tighten capscrews to 70 Ft.Lbs.(95 Nm). Measure
gap at three equally spaced points around retainer and take average. This is the shim
gap. Make the shim to this thickness and install with the retainer.

- Lubricate bearings and bushing with MPG lubricant.

IMPORTANT:

When replacing the intermediate shaft, provision for installing a spacer block on the pinion end
must be made on the new shaft. Proceed as follows:

1. Remove the tapped block from the old shaft and grind smooth all rough edges.

2. Drill out the tapped two holes to .56 diameter.

3. Drill and tap the pinion end of the new shaft.

4. Use two .5 x 4.0 Grade 5 capscrews to secure the drive lug and spacer block to the end of
the shaft after the shaft has been installed into the boom. Drill the head of the capscrews .12
diameter for lock wire.

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CROWD OVERLOAD CLUTCH

The CROWD OVERLOAD CLUTCH is designed to protect crowd machinery, dipper and dipper
handle. When air pressure is properly adjusted, the clutch will transmit full stall torque but will slip
when a shock is encountered.

Air pressure, which determines slip

point, can be adjusted higher by
operator from the cab at the air panel
stand regulator to suit digging
conditions. The air must be exhausted
directly from air tube, bypassing safety
check valve in supply line, to lower
pressure. Initial pressure setting
should be approximately 80 PSI (5.5
bars/552 kPa).

Crowd Overload Clutch Assembly - Section View

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CLUTCH PRELIMINARY STEPS

Any work on the OVERLOAD CLUTCH will require an elevated work platform at the left side of the
boom (high-lift truck) for access to, and handling of, the overload clutch components during
disassembly. The first steps in performing any procedure on overload clutch are:

1. Park the machine in a flat work area and position the dipper on the ground so that the handle
members do not interfere with removal of the overload clutch. SHUT DOWN MACHINE.

2. Shut off the air compressor and bleed out the tank air. Disconnect the air line at the rotoseal
to the clutch.

CAUTION: RELEASE THE AIR PRESSURE TO THE CLUTCH BEFORE

DISCONNECTING THE AIR LINE. Plug the line immediately after
disconnecting. Failure to comply could result in personal injury.

3. Remove the guard from the overload clutch.

4. Bleed off air from the overload clutch by loosening the air line between the check valve and
the air inlet port.

IMPORTANT: Use caution in this procedure to prevent injury.

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CLUTCH WEAR ADJUSTMENT / AIR TUBE REPLACEMENT

When the overload clutch will not hold, the friction discs are worn to point of adjustment. Remove
the shim for added service life before replacing the friction discs. If the air tube leaks, replace it.
The friction discs should be replaced when the axial movement of the pressure plate with the air
pressure applied and then released exceeds .62 inch (15.9 mm). The procedure for each of these
operations is the same.

1. Disassemble the air tube holding plate and the air tube from the overload clutch assembly.

2. Replace the tube if damaged.

3. Remove the shim before reassembly to adjust for initial friction disc wear (for added service
life).

If the shim has already been removed and the air tube is functional, but the overload clutch will still
not hold when air pressure is admitted, then the friction discs must be replaced.

REPLACEMENT OF FRICTION DISCS

1. Disassemble air tube holding plate and air tube from clutch assembly.

2. Remove pressure plate and floating plate.

3. Remove the outer friction disc, center plate, and inner friction disc in order. Note location of
release springs during disassembly.

4. Use new or rebuilt friction discs during reassembly. Be sure to install initial wear shim with
new friction discs.

OVERLOAD CLUTCH REMOVAL FROM THE INTERMEDIATE PINION SHAFT

1. Disassemble rotoseal/adaptor from the left end of the intermediate pinion shaft.

2. Remove the overload clutch components as described in REPLACEMENT OF FRICTION

DISCS.

3. Unscrew the lock nut from the end of the shaft after bending back the lockwasher tang
attached to the 1-8UNC tapped holes. Remove the lockwasher and flatwasher.

4. Pull the hub/backplate from the intermediate pinion shaft using a hydraulic jack and pulling
fixture.

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5. Remove the key from the keyway in the intermediate pinion shaft.

6. Disassemble the drive ring from the intermediate gear if required.

Reassembly is reverse of this procedure. The hub / backplate will have to be pressed onto the end
of the intermediate pinion shaft. The backplate can be heated for installation. Use dry heat and do
not exceed 250 oF (121 oC). Be sure it seats firmly against sleeve. Refer to Section 9 -
ENGINEERING DATA for torque values of fasteners.

INTERMEDIATE GEAR REMOVAL

Removal of the INTERMEDIATE GEAR requires

that the overload clutch be removed. With the
overload clutch removed, the intermediate gear
can be removed without removing the dipper
handle. However, the dipper handle must be
positioned perpendicular to the boom so that the
"flat" on the bottom of the left yoke block is toward
the boom foot as shown in the figure. This will
provide the .25 inch (6mm) clearance necessary
to remove the intermediate gear off the end of
the intermediate pinion shaft.

Once the dipper handle is positioned and the

dipper grounded, SHUT DOWN THE MACHINE
and begin removal of intermediate gear.

1. Pull the overload clutch from the end of the shaft.

2. Remove the washer behind the overload clutch hub/backplate from the intermediate pinion
shaft.

3. Support the intermediate gear and withdraw it from the left end of the intermediate pinion
shaft.

4. Remove the sleeve from the intermediate shaft if it did not come off with the intermediate
gear/bushing.

NOTE: The sleeve is grooved and has a drilled hole for lubrication.

Reassembly is the reverse of the above procedure. Clean and inspect all parts thoroughly before
installation. Replace those found defective. Lube the intermediate gear bushing with MPG lubricant.

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SHIPPER SHAFT ASSEMBLY

This assembly is the final gear reduction

in the crowd machinery. It is the horizontal
shipper shaft mounted near the midpoint
of the boom. The shipper shaft gear in the
center of the shipper shaft is driven by the
intermediate pinion shaft. The shipper
shaft pinions at each end of the shipper
shaft on each side of the boom engage
the racks on the bottom of each handle
member to drive the dipper handle. The
dipper handle is held in place by yoke
block assemblies.

A YOKE BLOCK Assembly consists of a

slide plate clamped between the inside
and outside yoke block members by
shoulder bolts and slotted nuts. The slide
plate supports the wear shoe, which is
shimmed for the proper running clearance
with the dipper handle member. The wear
shoe is retained with a lock pin. Washers
are placed between the end of the lock
pin and the retainer bolt in the slide plate.
These washers act as shims to provide
the maximum engagement of the lock pin
and wear shoe. Note that the wear shoe
and shims can fall out when the dipper
handle member is removed.

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NOTES:

1. Assemble the shipper shaft pinions with the king teeth in line with the king tooth on the shipper
shaft spline. (Note the punch marks.)

2. Assemble the shipper shaft pinions with the counterbore in the hub toward CL Boom.

3. Assemble the shipper shaft gear with the counterbore in the hub toward the spline runout on
the shipper shaft. (The left side of the boom.)

4. The OUTSIDE Yoke Block structure and the OUTSIDE Thrust Collar are the same on both
sides of the boom.

5. The INSIDE Yoke Block structure and the INSIDE Thrust Collar are different from one side to
the other due to bushing size.

HANDLE WEAR SHOE RUNNING CLEARANCE

The WEAR SHOES on top of the dipper handle members in each yoke block assembly provide a
bearing surface for the dipper handle when moving through the yoke block assemblies. As the
shoes wear adjustment must be made by shimming between each wear shoe and its slide plate.
When the running clearance between the dipper handle and wear shoes is greater than .38 inches
(10 mm), the wear shoes must be shimmed.

To measure the running clearance of the dipper handle member in the yoke block assemblies:

1. Park machine on level ground with top of dipper

handle members and determine the horizontal
maximum depth of each member along the
length of the racking.

2. Reposition the handle with the maximum depth

centered in the yoke block and the top of the
horizontal. BE SURE HANDLE RACKS ARE
SITTING SQUARELY AGAINST SHIPPER
SHAFT PINION SHROUDS.

3. Remove the shim retainer plates and shims. Drive wedges between the wear shoe and slide
plate until the gap at each end of the slide plate is approximately equal.

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4. Measure the gap between the wear shoe and slide at each end. Average the two
measurements. Subtract .12 inch (3 mm) from the average gap.

NOTE: This is the shim pack thickness required. The proper running clearance between the
dipper handle members and the wear shoes is when it is just loose enough so the
dipper handle can operate full travel without binding.

5. Install the shims and retainer plates.

6. Adjust the wear shoe pin clearance. With pin touching the handle, add washers until the
retainer bolt cannot be inserted. Remove two washers and install the retainer bolt.

NOTE: The dipper handle might have to be repositioned for each yoke block. Check for the
maximum depth location of each leg.

7. Shim the wear shoes in both yoke block assemblies so that the dipper handle
members have identical running clearances through each. When the wear shoes have
worn to .75 inches (19 mm) thick, the wear shoes must be replaced.

To replace a wear shoe in the yoke block assembly:

1. Follow the procedure for adjusting the wear shoe running clearance with the following
exceptions.

2. After removing the wear shoe shims, remove the lock pin and washers from the slide plate.
Thread the retainer bolt removed (.75 diameter x 6 inches, 152 mm long) into the top of the
lock pin for removal/replacement.

3. Withdraw worn shoe from yoke block assembly.

4. Install the new wear shoe and lock pin.

5. Adjust the wear shoe for running clearance with the dipper handle members. Refer to
procedure.

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YOKE BLOCK SIDE PLAY ADJUSTMENT

The shipper shaft is assembled with split collars at each end. Between each outside yoke block
structure and the split collar is a split thrust washer fastened to the split collar by four special bolts.
If excessive play develops between the yoke blocks and the thrust washers, the split thrust washers
can be shimmed. The nominal shaft end play is .12 inch. Add shims if the total end play exceeds
.44 inch.

To shim split thrust washers in split collars at end of the shipper shaft:

1. Hold slotted end with a screw driver so special bolt does not turn while loosening jam nuts, 2
places on each half of the split collar.

2. Loosen jam nut on square headed set screw, 1 place on each split collar half, and back out
screws enough to insert new split shims.

3. Insert an equal thickness of split shims between the split thrust washer and split collar halves
at each end of the shaft. Adjust the shims to obtain .12 +.12/ -.00 inch total end play.

4. Run square head set screws down into split collar halves again and tighten jam nuts on them
against face of split collar.

5. Retighten jam nuts onto special bolt while holding it from rotating at slotted end.

Install equal amount of split shims at split collars on each end of shipper shaft. This is to keep the
ends of the splines on the shipper shaft pinions and the shipper shaft gear from gouging the
shipper shaft. Split thrust washers must be replaced when .12 inches (3 mm) of split shim thickness
is necessary to eliminate side play of the outside yoke block structure at each washer.

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SHIPPER SHAFT REMOVAL AND DISASSEMBLY

1. To remove the shipper shaft, the dipper handle must first be removed from boom. Refer to
Dipper Handle Removal in this section.

2. Disconnect the trip rope from the handle trip lever and run it back through the guide sheaves
on the right side yoke block assembly. Secure the trip rope so it can not move.

3. Disconnect all auto lube lines around shipper shaft area. Cap and plug lines and ports to
protect against system contamination.

4. Remove the hoist rope guard over the shipper shaft gear guard and remove shipper shaft
gear guard from the boom.

5. Remove the split collars from each end of the shipper shaft.

6. Rig right side yoke block assembly to lifting equipment. The complete yoke block assembly
with the shipper shaft pinion weighs 2113 Lbs. (958 Kgs).

7. Pry and/or push right yoke block assembly including shipper shaft pinion off end of shipper
shaft. Secure the shipper shaft pinion to the yoke block assembly so it does not come out
during handling.

8. In same manner, remove left side yoke block assembly and shipper shaft pinion from the
end of the shipper shaft.

9. Sling shipper shaft gear to lifting equipment and have crane assume its weight.

10. Push and pull the shipper shaft from the boom. It must come out left side of boom due to
geometry of the shipper shaft gear splines. Handling hole in each end of shipper shaft is
threaded with 1-8UNC-2B threads.

11. When shaft is free of boom, place it on cribbing.

12. Take shipper shaft gear out of boom well and place it on cribbing.

13. Remove shipper shaft pinion from each yoke block assembly.

14. Disassemble yoke block assemblies by separating the inboard and outboard yoke block
structures.

Clean all parts thoroughly and inspect them completely. Replace those found defective.

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Shipper Shaft Pinion Alignment

Reassembly is the reverse of this procedure.

- If bushings in boom bores are to be replaced, freeze them before pushing them into
place.

- Assemble the shipper shaft gear with the counterbore in the hub facing the left side of
the boom.

- Assemble the shipper shaft pinions with the counterbore in the hub toward the CL of
the boom.

- The Shipper Shaft Pinions and the Shipper Shaft have king teeth identified with punch
marks to allow the pinions to be timed. The shipper shaft pinions must be installed to
shipper shaft with the king teeth in line with those on the spline of the shipper shaft.
Refer to the figure.

Lubricate the bushings, splines and sliding surfaces liberally with MPG lubricant. Lubricate the
shipper shaft pinions and the shipper shaft gear teeth with OGL. Check that all lube access lines
are open.

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CROWD LIMIT SWITCH

NOTE: The speed reducer requires ½ pint of the listed oil. Check the oil level every 200 hours
and change it at 2500 hours.

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SPEED RATINGS

The CROWD LIMIT SWITCH, located on a bracket on the right side of the boom in-line with the
intermediate pinion shaft, is a rotating-cam type electrical-mechanical unit designed for continuous
rotation in either the clockwise or counterclockwise direction. Electrical contacts in the switch are
provided for controlling four circuits.

Each set of contacts is actuated by cams which are supported on a separate disk welded to the
main shaft of the switch. As the shaft rotates, the cams open and close . The sequence of operation
of the contacts depends on the position of the various cams with respect to the shaft.

Torque requirements of the switch are a maximum of 12 inch-pounds to open a contact. The
contacts are forced open by direct cam action and are spring closed. This design provides a fail-
safe condition so opening of the circuit is not dependent on springs or other parts that could fail.

A cross section view of the switch shows the contact unit (It.#1) in the open position. Switch in
normal operation (within limits) is in the closed position. In the open position, the camshaft (It.#2)
has been rotated so that the contact arm roller (It.#3) is shown riding on the high portion of the cam
(It.#4) and has depressed the plunger of the contact unit opening the contacts. As the cam continues
to rotate, the arm roller will drop down to the lower portion of the cam allowing the spring loaded
plunger to return to its normal (open) position.

CAUTION: NEW SPEED REDUCERS DO NOT CONTAIN OIL

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The speed reducer has a 50: ratio

The limit switch must be reset after maintenance which requires removal of any one of the following
(dipper handle, shipper shaft, intermediate crowd shaft and limit switch).

1. Contact unit
2. Camshaft
3. Contact-arm roller
4. Operating cam
5. Switch-unit plunger
6. Contact arm
7. Vernier-adjustment locking screw
8. Vernier plate
9. Cam-follower bracket
10. Filler strips

When installing a replacement limit switch, carefully align the switch with the intermediate crowd
shaft using shims. This will prevent excessive wear on switch bearings and provide long mechanical
service life. The switch is equipped with self-aligning sealed ball bearings which prevent entry of
dust and dirt minimizing level of torque to drive the shaft.

ELECTRICAL RATINGS

Carry Continuously 15 Amps.

A.C. "Make" Value 75 Amps.

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CAM SETTING

SCORED CAM

The disc lineup on the cam shaft, to which the cams are
attached, have indicated marks at 15o intervals. The keyway
slots in the ends of the shaft coincide with the zero point.

After determining the number of degrees that the contacts

should be opened, select the proper cam section from Table 1.

Use two cams of the same section number to obtain the desired range of settings given in the table
for each circuit. The left hand column of Table 1 indicates what cam sections are to be broken off
to obtain a particular cam number.

TABLE 1: OPERATION and ADJUSTMENT of CAMS

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OPERATION AND ADJUSTMENT OF CAMS

For ease in snapping off the cam portions at the scored points it is recommended that an adjustable
wrench be used. Extra care should be used when snapping off cam portion No. 4 (leaving portions
No. 5 and 6) to avoid breaking off cam portion No. 5. It is recommended that a second adjustable
wrench be used.

Place the two scored cams on each cam holder and align the cams to give the approximate
desired contact opening and closing. When placing the cams on the shaft, be sure that the cams
are placed back-to-back with the markings of each cam facing outward. This will prevent an
interrupted cam surface and also prevent the roller from striking a broken cam surface. Secure the
cams to the cam holder at 180o intervals with the two bolts and lock washers furnished. Before
tightening the bolts, finer cam adjustment can be made, if required, by lining up the start of the
cam rise with respect to the camholder indicating marks at the desired points of contact opening
and closing.

VERNIER ADJUSTMENT

The vernier-adjustment mechanism fulfills two purposes. It provides vernier or fine incremental
adjustment of the switch open and closed contact positions, and allows for adjustment while the
switch is actually rotating. The vernier-adjustment locking screw (It.#7) varies the relative position
of the cam-follower roller with the operating cam. To adjust a specific circuit for desired open or
closed contact position, loosen the vernier adjustment locking screw (It.#7) and slide it up or down
to open or close contact sooner or later as desired.

The markings on the vernier plate (It.#8) represent two-degree increments of adjustment. It should
be noted that the vernier adjustment affects the opening and closing of the contact unit by the
same amount. It is not possible to get individual incremental adjustment of the opening and closing
position on any one circuit If this is required, then the closing position must be set on another
circuit. The two contact units involved can then be electrically tied together. After final settings are
established, securely tighten the adjusting screw to prevent any accidental movement.

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CROWD LIMIT SWITCH MAINTENANCE

No further lubrication beyond that provided at the factory is required on the limit switch. The contact
unit is a completely self-contained device which may be replaced by removing two metal screws
and inserting a new unit. The silver contacts require no attention but must be replaced before all
the silver is worn away. Filing or otherwise dressing the contacts results only in loss of silver and
reduction of the normal contact life.

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.

Remove the cast cover. Remove both seal plates, the cam follower bracket, and the four bolts
which secure the internal switch to the cast box. Remove the internal switch from the box.

Remove three bolts holding flange on shaft extension side of switch. After removing the filler strips,
loosen the thrust collars on each end of the shaft and slide them inward along the shaft. Lift entire
cam shaft assembly up and out of the switch frame.

After replacing parts as required, reassemble the filler strips and the three bolts holding the flange.

Reinstall the internal switch into the cast box with the shaft extension protruding from the desired
side and tighten the four mounting bolts which secure the switch to the box. Reinstall the seal
plates.

Visually center the shaft in the seal plate hole and tighten the internal flange. Reassemble 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 sequence by adjusting
the cam and vernier adjustment.

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CROWD LIMIT RANGE

The two-stage CROWD LIMIT consists of two independent sets of limits for both the extend and
retract positions: an initial limit and a final limit.

The purpose of the initial limit is to alert the operator that he is approaching the final limit. Should
the initial limit be over-traveled, the final limit is actuated. The final limit sets the crowd brake. The
working ranges between limits are shown below.

In the extend, when the shipper shaft pinion reaches position 'C' on the rack, the initial crowd limit
cam (No. 1) should be set to terminate reference from the operator control.

Cam No. 3 should be set to trip at position 'D' on the rack. When the shipper shaft reaches this
point the crowd brake will set automatically. Similarly, for the extend (crowd-out) position, Cam No.
2 should be set to terminate reference at position 'A'. For the final crowd-out limit, Cam No.4
should be set to apply the crowd brake at position

NOTE: The actual limits for working ranges AC and BD should be determined for each
machine application. Normal conditions use 4 inches (102 mm) from each end of the
rack as the final limit and 18 inches (457 mm) from each end of the rack as initial
limits.

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DIPPER HANDLE

The DIPPER HANDLE supports the dipper and is powered by the crowd machinery.

The dipper handle consists of fabricated, quenched and tempered, high-strength, carbon steel
plate reinforced with internal gussets at high stress areas. Three sections of gear rack are welded
end to end on bottom plate of each dipper handle member. The racks mesh with the shipper shaft
pinions of the crowd machinery.

Steel bushings are inserted in the pin bores where dipper and pitch braces are attached. Rope
guards bolt to rear end of each dipper handle member to protect hoist ropes and boom support
ropes from abrasion damage should they contact the ends of the dipper handle member.

The dipper handle and shipper shaft pinions are lubricated automatically by injectors mounted on
the yoke blocks.

DIPPER HANDLE MAINTENANCE

Standard maintenance and inspection of the dipper handle includes:

• Check operation of automatic lubrication system for OGL application at mesh of shipper
shaft pinions and racks daily.

• Check clearance of dipper handle members in yoke block every 250 hours of operation.
Clearance between top of the dipper handle and wear shoes should be .125 inch (3mm).
Adjust for proper clearance when the clearance exceeds .38 inch for proper clearance.

• Inspect the dipper handle structure for damage, cracks or rack failure every 1000 hours of
operation. Repair as required to prevent more serious breakdowns.

• Inspect shipper shaft pinion(s) for wear or damage every 1000 hours. Improper or abusive
operation (sweeping) can reduce service life of the shipper shaft pinions significantly.

• Inspect handle racks for wear or damage every 1000 hours. The racks can be replaced in
sections (three per side). See special preheat and post heat procedure required for installation
of replacement rack segments.

• Measure clearance between right and left dipper handle member (inside plate) and wear
bars on bottom right and left side of the boom. Clearance in new condition should be .19 inch
(4.8mm) minimum on each side. If clearance exceeds .69 inch (17.5mm) each side, replace
boom wear bars. See illustration for measurement of clearance.

NOTE: Excessive clearance between the handle and boom wear bars could be due to a bent
handle(s). Be sure the handles are straight before replacing the wear bar.

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DIPPER HANDLE REMOVAL

To remove the dipper handle:

1. Position machine in area where maintenance can be performed without interference from
production units. Remove rope guards (which are welded in place) from ends of dipper handle
members

2. Extend the dipper handle to within two feet from the greenhorns and set the dipper on the
ground.

3. Isolate the dipper trip motor and remove the dipper trip rope from at the dipper trip lever on
the handle. Tie end of rope off so it can not move.

DANGER! THE TRIP ROPE HAS CONSTANT TENSION FROM THE DIPPER TRIP
MOTOR WHEN LE IS ACTIVATED, ISOLATE THE TRIP MOTOR
BEFORE DISCONNECTING THE TRIP ROPE MOTOR.

4. Remove the equalizer block from the dipper bail and attach it to midpoint of dipper handle
members. Place a tie bar between the handle members to prevent distortion of the handle
members.

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5. Secure the yoke blocks to the top of the boom so they cannot swivel.

6. Remove wear shoes, and shims from both yoke blocks.

NOTE: To facilitate removal, the slide plates can be removed from yoke block assemblies.
Thoroughly clean and inspect the handle. Repair all cracks.

7. Remove the bolted-on greenhorns from ends of the dipper handle members.

8. Isolate the crowd limit switch with jumpers from 5K15B to 5K39K and 5K15B to 5K42H in the
DC cabinet.

9. While supporting the dipper handle with the hoist machinery, crowd out and propel the
machine slowly away from the dipper handle assembly. Stabilize yoke blocks so exit of
dipper handle members is not binding.

DANGER! KEEP ALL PERSONNEL ON THE GROUND CLEAR OF THE DIPPER

HANDLE.

10. When dipper handle clears the yoke blocks, lower the of dipper handle on to blocks.
Disconnect the dipper handle from the equalizer and shut down machine.

Reassembly is reverse of this procedure. Coat racks and shipper shaft pinions with OGL lubricant.

DIPPER HANDLE RACK WELD REPLACEMENT

1. Fit up and align prewelded rack (if more than one segment is being replaced) to dipper
handle member. Use hold down clamps (seven equally spaced, approximately 36 inches -
915 mm between clamps).

NOTE: The rack teeth on the handle legs must be aligned within .19 inches. Stretch a wire
across the face of the rack teeth at several locations to check alignment.

2. Use paint tube, and identify skip weld sequence, preheat, and electrode type. See illustration
on following page.

3. Place and secure gas tube heater on top of rack, cover with head cloth and preheat to 450oF
(232oC). (Welder to have proper Tempil stick in his possession.)

4. Weld sequence using two welders, one on each side of rack following sequence per illustration.

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Dipper Handle

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Dipper Handle Rack Welding

5. Stagger beginning and ends of beads to allow for proper blending into next weld block.

6. Three passes should complete bevel requirement.

7. Allow for slow cool, leaving weldment covered before removing clamps.

NOTES:

- Material for rack casting- CKQS.

- Material for handle steel plate- FHL.
- Pre-assemble new rack pieces following the rack tooth pitch tolerances noted.
- Begin weld in root section, then turn complete rack assembly over, re-clamp and finish
weld at bottom of joint.
- Complete weld of new rack assembly per instruction on illustration.

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HANDLE WEAR BARS ON THE BOOM

Wear bars are welded to each side of the

boom structure below and in front of the
shipper shaft. These provide a contact surface
for the inside portion of the dipper handle
members to run against. These wear bars are
constantly in use and eventually require
replacement. When the overall clearance
between the dipper handle members and the
wear bars is greater than or equals 1.37
inches/35mm (or .68 inch/17.5mm on each
side), the wear bars must be renewed.

1. Park machine in a level, firm work area.

2. Erect work platform to reach wear bars.

3. Remove old bar from boom with air arc

torch.

4. Smooth up and clean surfaces for new

wear bar on boom.

5. Position new wear bar on boom. Weight is

375 Lbs.(170 kg).

6. Weld wear bar to boom with .25 inch (6mm) fillet welds spaced 2 to 6 inches (51 to 152
mm) on each side full length and .25 inch (6 mm) fillet welds at the ends.

7. Use same procedure for other side.

8. Coat bars liberally with OGL lubricant before start-up.

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DIPPER ASSEMBLY

The DIPPER ASSEMBLY on this machine is a 13 Yd3 (10 M3), hard rock dipper fabricated from high
strength low alloy steel plate. The manganese steel lip accommodates 6 Whisler WH-8 style dipper
teeth.

The dipper assembly is attached to the end of the handle with hardened steel pins. Pitch braces set
the angle of the dipper teeth at 60o to the CL handle.

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The dipper assembly components are:

- Dipper structure.

- Dipper bail.

- Dipper door.

- Dipper teeth/adapters.

- Snubber.

- Pitch braces.

- Equalizer sheave.

The dipper door closes by gravity.

Snubber action slows the door closing
so that it does not slam against dipper
structure. The dipper latch bar
engages the dutchman in the dipper
front to lock the door in position.

DIPPER MAINTENANCE

Standard maintenance and inspection of the dipper assembly includes:

• Inspect dipper structure, lip, tooth adapters, tooth points, point locks, and door daily for
missing parts, cracks, or damage. Repair before operation.

• Inspect dipper trip lever and latch bar engagement at the dutchman to determine if adjustment
is required.

• Lubricate the equalizer sheave pins and all dipper greased pin connections each shift.
Lubrication of door/snubber pin assembly and latch bar clearance should also be a part of
each daily pre-start inspection routine.

• Inspect the dipper trip chain, clevis, and wire rope daily for possible damage. Repair before
operation.

• Inspect the dipper bail and equalizer sheave pins and bores for bushing wear. Replace pins/
bushings as required.

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DIPPER TEETH AND BASES

The dipper front has six replaceable teeth. Each adaptor is attached to the lip casting with a C-
clamp and wedge. Each tooth attaches to its respective adaptor with a pin and a rubber point lock.
Tooth points can be reversed for even wear to keep the same angle of entry.

To replace or reverse tooth points:

1. Position dipper with teeth three to four feet(.9 to 1.2 meters) above ground. Apply all brakes
and shut down machine.

2. Remove rubber point lock and point retainer pin. Use heavy hammer and maul to bump
tooth point off adaptor.

3. Replace or reverse point and reinstall pin with rubber point lock. Grooved edge of point lock
faces pin.

To replace an adaptor:

1. Position dipper same as for point replacement.

2. Use spike maul, ground to fit wedge, and heavy hammer to drive wedge out from bottom of
adaptor. Remove C-clamp and use hammer to bump adaptor off lip.

3. If the lip is deformed or worn to the extent that a new adaptor cannot be installed correctly,
rebuild the lip with weld material and finish grind to a template. Hold the template tight against
the leading edge of the front radius and centered about Line X-X (shown below). The gaps
between the template and pad surfaces must not exceed .03 inch (.76 mm). Refer to the
drawing for the following template and also to Repair Welding Procedures in Section 9 -
ENGINEERING DATA.

4. Install new adaptor on lip. Insert C-clamp and drive in wedge from top of lip. Wedge pushes
on clamp to lock adaptor on lip.

Dipper Tooth Assembly - Section View

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Detail ~Template for Tooth Base

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DIPPER REMOVAL

To remove the dipper, propel machine to location where dipper is to be removed. Ground dipper and
apply brakes.

1. Disconnect the equalizer at the connection to the dipper bail and tie it to the cross member
on the dipper handle. Snug up the hoist ropes to support the handle.

2. Disconnect the dipper trip chain at the door trip lever. Lift the chain out of the door.

3. Remove the pins retaining the pitch braces to the dipper. Assistance of porta-power may be
required to drive the pins from the bore. Secure the pitch braces.

4. Remove the two pins at the end of the handle. Use porta power to drive the pins out.

5. Hoist the handle to clear the dipper and move the machine to the replacement dipper. Attach
the new dipper the reverse order of removal. Use never-seez on all pins at assembly.

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DIPPER DOOR LATCH ASSEMBLY

The dipper door latch assembly uses a lever arm to gain mechanical advantage to raise the latch
bar. The latch bar (by gravity) engages the dutchman and keeps the dipper door closed during the
dig cycle. When the operator activates the trip mechanism, the trip motor pulls the rope attached
to the handle trip lever. The handle trip lever pulls a chain attached to the dipper door trip lever. The
door trip lever lifts the latch bar out of engagement with the dutchman, allowing the door to open by
gravity.

Dipper Door Assembly

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DIPPER LATCH MAINTENANCE

The latch bar engagement is adjusted by raising and lowering the left end of the door trip lever by
means of T-shaped shims captured in the latch bracket by a retaining pin. The retaining pin is held
in place by a .38 x 2.5 inch long Gr.5 capscrew and hex lock nut through a pipe on the latch
bracket. The left end of the door trip lever rests on a T-shaped wear plate which is also captured in
the same way as the shims. The door trip lever is secured with the guide pin.

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LATCH BAR ADJUSTMENT

1. Check the amount of latch bar engagement with the dutchman. Normal engagement is 1.5
inches.

2. Block the door trip lever to relieve the weight from the wear plate. Remove the .38 x 2.5 inch
capscrew and pull out the retaining pin.

3. The shims provided are .25 and .12 inches thick. The latch bar engagement will vary the
same as shim thickness added or removed. Adjust the shims to obtain 1.25 to 1.50 latch bar
engagement.

4. Reinstall the shim retainer pin and the .38 inch capscrew.

NOTE: When replacing the wear plate, the chamfer must be up to prevent interference with
the door trip lever.

LATCH BAR REMOVAL

1. Lower the dipper to the ground.

2. Disconnect the trip chain shackle from the end of the door trip lever.

3. Support the latch bar end of the latch lever and remove all the shims and the wear plate from
the latch bracket. Refer to the Latch Bar Adjustment procedures.

4. Lower the left end of the door trip lever so that the guide pin aligns with the hole in the latch
bracket.

5. Withdraw the guide pin using a .5-13 UNC threaded rod with a handle.

6. Remove the 170 lb door trip lever to the right side of the door until clear of the latch bar.

7. Support the 290 lb latch bar, remove the .5 plate and lower the latch bar out of the door.

NOTE: 48 inches of clearance below the door will be required.

Assembly is the reverse of the removal procedure.

CAUTION: The upper and lower wear shoes could fall out and the latch bar is
removed. Be prepared to catch these parts.

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LATCH BAR REPAIR

It is advisable to have a spare latch bar available to replace a worn latch bar. Rebuild a worn latch
bar as shown below:

WEAR INSERTS

The top and bottom wear inserts guide the latch bar and protect the door structure. The 2 top and
2 bottom wear inserts are captured in the door structure by the latch bar. Replace the wear inserts
when replacing the latch bar.

WEAR INSERT REPLACEMENT

1. Replace the wear inserts when the total gap between the latch bar and wear inserts is .62
inches.

2. Remove the latch bar. Refer to the Latch Bar Removal procedure.

3. Wear inserts can now be removed.

Assembly is the reverse of the removal procedure.

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DIPPER DOOR SNUBBER

The dipper door SNUBBER, whose

mounting base is welded to the dipper
structure, retards door swing during
opening and closing to avoid over travel
and consequent slamming shut which
could deform dipper door and fatigue the
structure.

The snubber mechanism consists of two

sets of four pressure plates sandwiched
between two sets of four friction discs. This
assembly is held together by a threaded
tension rod captured in a spring loaded
housing.

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Spring tension adjustment is required as the friction disc material wears. Adjustment procedure is as
follows:

1. Tighten adjusting nut on the snubber assembly until the door closes and latches, but does
not slam. Do not tighten to point that prevents gravity door operation to dump and latch.

2. When replacing friction discs, set tension on spring with adjusting nut to one and a half
inches (38mm) each end for the initial setting. (Refer to the figure.)

NOTE: Adequate clearance exists between snubber base and dipper door hinge pin to permit
removal of spring housings when replacing friction discs. Rod can be shifted axially to
install discs one side at a time. The four snubber plates (see illustration) can be
replaced by shifting Pin #1 axially. To replace tension rod, it is necessary to remove
dipper door hinge pin.

3. Inspect snubbers prior to each shift for correct operation. Report any adjustment required
and repair soon as prolonged operation under poor adjustment accelerates friction disc wear.

4. Avoid over tightening to point where gravity cannot close door. This will frustrate the operator
and accelerate friction disc wear.

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EQUALIZER

The EQUALIZER sheave block assembly attaches to the dipper bail. Its function is to guide the hoist
rope as it raises and lowers the dipper. A stop is included in the block assembly to prevent damage
when the dipper handle is raised to extreme positions.

The equalizer sheave is pinned in the block and rides on a full steel bushing. Lube fittings for grease
are provided for manual lubrication. Lube with MPG every 4 hours. No other maintenance is required.

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DIPPER TRIP ASSEMBLY

The dipper trip assembly consists of a D.C. motor driven assembly mounted on a bracket on the
front of the right gantry frame. The motor pinion drives a spur gear splined to a shaft which supports
a trip rope drum.

The trip rope runs through a set of guide sheaves mounted on the right yoke block. The trip rope
continues its route from the guide sheaves along the handle and terminates at the handle trip lever
mounted on the bottom of the handle near the dipper door.

A trip chain attached to the handle trip lever is attached to the door trip lever on the rear of the
dipper door. Trip action by the operator causes motor to spool trip rope which moves the handle
trip lever. This in turn causes trip chain to lift the door trip lever and unlatches the latch bar from the
dutchman.

DIPPER TRIP MAINTENANCE

• Inspect automatic lubrication distribution of GREASE to dipper trip gear on gantry and needle
bearings in the guide sheaves on boom. The drum shaft bearings are lubricated manually.

• Inspect the condition of the trip rope daily. Replace it if frayed or damaged.

• Check the trip chain clevis links and replace as required.

• When replacing the dipper trip motor or pinion, use shims to establish the correct motor
pinion mesh alignment and backlash with the trip gear.

• When removing trip gear to replace bearings, install the bearing retainers so that notch for
automatic lubrication passage is clear. Install all bearings with grease seal next to gear. Pack
bearings with MPG at assembly. Refer to View C-C.

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Dipper Trip Assembly

Section E-E

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Section B-B

Section C-C

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View D-D

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WIRE ROPE SYSTEMS

HOIST ROPE REEVING

The Model 182M uses one hoist rope. The rope is looped around an equalizer sheave block on the
dipper bail. The single ends are routed up over the two boom point sheaves, through the machinery
house roof, and then under the hoist drum, with the ends terminating on each side of the hoist
drum. U-bolt anchors attach the two rope ends to the drum. Be sure these are tight on the rope
before operating the machine.

DANGER! IMPROPERLY REEVED ROPES CAN CAUSE SERIOUS PERSONAL

INJURY. HANDLE ALL ROPES WITH EXTREME CARE. ROPE
REPLACEMENT MUST MEET ORIGINAL SPECIFICATIONS.

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ROPE REEVING WINCH

DANGER! ISOLATE THE POWER FROM THE WINCH AT THE CIRCUIT BREAKER
WHEN THE WINCH IS NOT IN USE.

The rope reeving winch is operated by an electric motor and is used to reeve the hoist rope onto
the hoist drum. The rope reeving winch is mounted to the deck behind the hoist drum.

Hoist Rope Reeving Winch Installation

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HOIST LIMIT SWITCH

The HOIST LIMIT switch is a simple dual direction, spring centered machine tool limit switch mounted
on the left side of the boom at its centerline.

This switch prevents the bail equalizer sheave block assembly from colliding with the boom point
sheaves when the operator lets the dipper hoist too high. The dipper handle activating the switch
causes reference to be removed from the hoist motion control and applies the hoist brake
automatically. To return the machine to operation, the operator must move the hoist joystick to its
NEUTRAL position; press the EXCITATION START pushbutton in the cab to release the brake;
and finally lower the handle out of the limit.

The switch is initially adjusted to operate when the handle angle approaches 25o as shown above.
After commissioning the shovel, the switch angle can be repositioned by moving to an adjacent set
of mounting holes in the bracket for fine tuning.

The Hoist Limit Switch is watertight, oil-tight and dust-tight. However, wear will eventually cause
failure. For replacement components for this switch refer to the parts book for this machine.

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BOOM SUPPORT ROPES

The BOOM SUPPORT ROPES are pinned to equalizer links on each end of the boom point shaft
and to equalizer links at the top of the gantry. The equalizer links pivot on mounting pins to equalize
load distribution on the boom support ropes. The boom support ropes are wire rope, 6 x 37 class,
IWRC, regular lay construction with specified minimum breaking strength of 190 tons. Each rope
is prestressed and measured at a tension of 25% of the breaking strength. Four boom support
ropes are supplied in a matched set.

For information on wire rope maintenance, refer to Wire Rope in Section 9 - ENGINEERING DATA
of this manual.

BOOM SUPPORT ROPES REPLACEMENT

As pendants should give a service life of from 3 to 5 years, they can be changed out as part of a
scheduled boom lowering and detailed inspection of the front end. ALWAYS REPLACE ALL FOUR
BOOM SUPPORT ROPES WITH A NEW SET. Never replace just part of a set.

1. Lower the boom onto cribbing. Refer to procedure under Boom Lowering / Raising.

2. Remove the four boom support ropes and equalizer links from the boom point.

3. Thoroughly examine boom point structure and all four equalizer links for signs of fatigue.
Report any problems to Bucyrus for consultation.

4. Install a new set of boom support ropes to the boom point equalizer links.

5. Raise the boom and attach new boom support ropes to the equalizer links in the gantry.

NOTE: The two bottom boom support ropes must be pinned to the gantry equalizer links first
to avoid assembly problems and also for easier installation.

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Boom Support Ropes Installation

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Section 6
Brakes and Couplings

Table of Contents

BRAKES ........................................................................................................................................ 3
BRAKE OPERATION ............................................................................................................... 7
MAINTENANCE ....................................................................................................................... 7
REMOVAL OF THE BRAKE AS A UNIT ................................................................................... 8
INSTALLING THE BRAKE AS A UNIT ...................................................................................... 8
SWING BRAKE - CENTERING THE ROTOR ......................................................................... 9
BRAKE ADJUSTMENT .......................................................................................................... 10
REPLACEMENT OF FRICTION DISCS ........................................................................... 10
SINGLE ROTOR DISC BRAKES: .................................................................................... 10
REPLACEMENT OF SPRINGS ............................................................................................. 11
REPLACEMENT OF A DIAPHRAGM ..................................................................................... 12
COUPLINGS................................................................................................................................ 13
GRID COUPLINGS ................................................................................................................ 13
INTRODUCTION ............................................................................................................. 13
PARTS IDENTIFICATION ................................................................................................ 13
LUBE FITTINGS .............................................................................................................. 13
LUBRICATION ................................................................................................................. 14
COUPLING DISASSEMBLY AND GRID REMOVAL ......................................................... 14
GRID COUPLING INSTALLATION ................................................................................... 14
COUPLING DATA ............................................................................................................ 17
GEAR COUPLINGS ~GENERAL INFORMATION .................................................................. 18
INSTALLATION ................................................................................................................ 18
COUPLING DATA ............................................................................................................ 20

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182M-AC Electric Mining Shovel

Manual No. 10954 6-2 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 6
Brakes and Couplings

BRAKES

The 182M Mining Shovel uses spring-set, air-released brakes on the Hoist, Swing, Crowd and
Propel 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 monitors air pressure
at the brake. The brakes cannot be released for motor operation until the air pressure switches are
satisfied.

The brakes used include:

NOTE: The maximum operating air pressure is not to exceed 120 PSI on all brakes.

Sept. 2010 6-3 Manual No. 10954

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182M-AC Electric Mining Shovel

Hoist Brake Assembly

Single-Rotor

The Hoist brake assembly is a single-rotor brake mounted on the commutator end of the hoist motor
frame. For installation and maintenance refer to the end of this section.

Manual No. 10954 6-4 Sept. 2010

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182M-AC Electric Mining Shovel

Swing Brake Assembly

Single-Rotor with Lifter

Two Swing brakes are used on this mining shovel. The brake is a single-rotor assembly, with one
mounted on top of each swing motor. This is the same assembly used for the crowd/propel ~except
this brake has a rotor lifter assembly that is required for vertical shaft mounting to prevent the rotor
from rubbing. The lifter assembly consists of the cone, the lifter spring and the centering plug.

For installation and maintenance refer to the end of this section.

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182M-AC Electric Mining Shovel

This machine uses the same brake assembly in 1

place on the crowd motor and in 2 places on the
propel motors.

The brakes are mounted on the commutator end

of each motor frame.

For installation and maintenance, refer to the end

of this section.

Crowd/Propel Brake Assembly

Single Rotor

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182M-AC Electric Mining Shovel

BRAKE OPERATION

When air is exhausted from the air diaphragm cavity, the spring force "clamps" the rotor between
the friction discs mounted on the mounting flange and pressure plate. To disengage the brake, air
enters through the end plate into the air diaphragm cavity. As air pressure increases, overcoming
the springs, the end plate moves away from the stationary spring housing. The stationary spring
housing is fixed to the mounting flange by the clamp tubes, studs and locknuts. The pressure plate
is bolted to the end plate and travels in the same direction with it compressing the springs and
releasing the brake. The movable pressure plate slides relative to the stationary spring housing.
The rotor is splined to the gear and is allowed to slide.

DANGER! PRIOR TO THE INSTALLATION OR MAINTENANCE ON A BRAKE,

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

CAUTION: 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!

CAUTION: DO NOT OPERATE THE MACHINE WITHOUT ALL BRAKE GUARDS

INSTALLED.

MAINTENANCE

• No lubrication is required.

• Replace a friction disc(s) when worn to the step on the O.D.

DANGER! If a friction disc(s) is not replaced when worn to the step on the O.D.,
then braking effort of the assembly will be significantly reduced.

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REMOVAL OF THE BRAKE AS A UNIT

1. Park the machine in a level work area with the dipper on the ground and the hoist ropes
slackened. Set the brake to be removed and disconnect the air supply at the end plate.

NOTE: If removing a swing brake, remove the roof hatch above the swing motor.

2. Remove the outer shield from around the brake assembly.

3. Remove the capscrews that attach the mounting flange of the brake to the motor housing.

4. Take the entire brake assembly off the brake gear and the motor housing.

NOTE: Refer to beginning page of this section for the weight of each brake assembly.

5. Remove the gear and key from the motor shaft. This is a shrink type fit on a tapered bore.

6. Check the gear splines for wear or damage. Remove any burrs or nicks or sharp edges.
Replace any parts as required.

INSTALLING THE BRAKE AS A UNIT

The gear for each brake shrink fits onto the tapered motor shaft. Refer to Hub/Gear installation -
Section 9 - ENGINEERING DATA for gear mounting. Use the motor nut furnished with the machine
to retain the gear.

Lightly coat the gear teeth with Molycote M8800 or equivalent and install the brake assembly in the
reverse order of disassembly. Apply air to release the brake rotor. This will allow alignment of the
mounting holes. Tighten the mounting screws according to the chart at the beginning of this section.

Operate the brake several times to insure that the rotor will fully release. Check that the swing
brake rotor floats mid-way between the friction discs when the brake is released. Adjust as required.

CAUTION: INSTALL ALL BRAKE SHIELD AND GUARDS BEFORE OPERATING

THE MACHINE.

Manual No. 10954 6-8 Sept. 2010

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182M-AC Electric Mining Shovel

SWING BRAKE - CENTERING THE ROTOR

After the swing brake has been assembled to the swing motor, the rotor must be centered between
the friction discs so it will not rub when released during operation. Check this running clearance
once per operating week and readjust it when required.

1. Remove the shield and lifter guard from the brake unit.

NOTE: Only two capscrews hold the lifter guard to the end plate. Do Not remove the other 4
capscrews from the end plate during this procedure.

2. Remove the top hex jam nut from the centering plug extending through the lifter housing.

3. Release the brake, using the manual override on the air control valve. MAKE SURE THE
MACHINE CANNOT ROTATE!

DANGER! STAY CLEAR OF THE SPRING LOADED BRAKE ASSEMBLY WHEN

ACTUATING IT FOR TEST.

4. Hold the bottom jam nut on the centering plug with a wrench and turn the centering plug to
obtain equal running clearance between the rotor and the two friction discs.

5. When the running clearance is equal on each side of the rotor, install the top hex jam nut to
the centering plug and tighten.

6. Reinstall the shield and lifter guard.

DANGER! BE SURE TO RESET THE MANUAL OVERRIDE ON THE AIR CONTROL

VALVE TO NORMAL OPERATING MODE AFTER CENTERING THE
ROTOR ON THE SWING BRAKES. Failure to do so could result in
major machine damage and possibly personal injury or death.

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182M-AC Electric Mining Shovel

BRAKE ADJUSTMENT

The single rotor brake is NOT ADJUSTABLE.

REPLACEMENT OF FRICTION DISCS

When the friction discs have worn to their wear indicator

step on the O.D., then the discs must be replaced. To
visibly check the friction discs for wear, remove the outer
shield from around the brake unit, set the brake, and
observe the wear indicator step(s). If the steps are
visible, no replacement is necessary. Make sure the
surfaces of the discs are not contaminated with oil or
grease.

SINGLE ROTOR DISC BRAKES:

1. Remove the locknuts in an alternating sequence shown here

and in increments of one quarter of the exposed stud thread
length. If a stud comes loose from the mounting flange, clean
the stud thread thoroughly. Apply Loctite 277 or equivalent. The
stud must be threaded back in until it bottoms in the mounting
flange.

2. With the locknuts removed, the end plate, spring housing, and
pressure plate can be removed as an assembly.
Locknut Removal
Sequence

3. Remove the rotor disc from the gear hub. Inspect the disc for wear. If either surface of the
disc is worn more than .03 inch, replace the rotor disc. Removal of the rotor disc from the
gear hub will expose the friction disc mounted on the mounting flange.

4. Remove the old friction discs and replace with new friction discs and NEW flat head screws.
Tighten the screws to 20 Ft.Lbs.

5. Reinstall the rotor disc to the gear hub.

6. Install the end plate assembly consisting of the end plate, spring housing, and pressure
plate onto the mounting flange studs.

7. Lubricate the stud threads with 30 weight oil or “Never Seize”.

8. Assemble the locknuts” in same alternation sequence as they were removed. Tighten the
locknut to 200 Ft.Lbs.

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9. If applicable, center the rotor disc between the friction discs, using procedure given previously.

10. Reinstall the outer shield around the brake.

REPLACEMENT OF SPRINGS

1. Disassemble the end plate, spring housing, and pressure plate

as an assembly from the brake, using procedure given under
“Replacement of Friction Discs”.

2. Position this assembly on a clean working surface with the

end plate up.
Locknut Removal
Sequence
3. Remove the hex head capscrews holding the end plate and lifter guard, if applicable, to the
pressure plate in an alternating sequence shown here, two turns at a time on each.

4. Lift off the end plate diaphragm, outer clamp ring, and inner clamp ring as an assembly.

5. Remove the spring housing from the pressure plate.

6. Remove the springs and the spring retainer plates.

7. Replace the springs and reassemble with the spring retainer plates.

NOTE: No spring retainer plates should cross over the ribs in spring housing.

Reassembly is the reverse of this procedure:

• Make sure the pockets in spring housing line up with the pockets in the pressure plate.

• Coat the rubbing surfaces between the spring housing and the pressure plate with
Molycote M8800 or an equivalent lubricant.

• Using the same alternating sequence as employed in disassembly, tighten the hex
head capscrews holding the end plate to the pressure plate to the following:

Single Rotor Disc Brakes

50 Ft.Lbs. ( 68 Nm)

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182M-AC Electric Mining Shovel

REPLACEMENT OF A DIAPHRAGM

1. Disassemble the brake until you have an assembly consisting of end plate, diaphragm, outer
clamp ring, and inner clamp ring, using procedure given under "Replacement of Springs".

2. Place this assembly on a clean working surface with the diaphragm up.

3. Disassemble the hex head screws from the outer and inner clamp rings.

4. Lift off the outer and inner clamp rings.

5. Replace the diaphragm.

6. Reassemble the brake, using the reverse of this procedure. Tighten the hex head capscrews
which hold the inner clamp ring to 10 Ft.Lbs. ( 14 Nm). Clean the threads thoroughly and
apply loctite 262 (or equivalent).

7. Tighten the hex head capscrews which hold the outer clamp ring to 20 Ft.Lbs. (27 Nm).
Clean the threads thoroughly and apply loctite 262 (or equivalent). See "Replacement of
Friction Discs" and "Replacement of Springs" procedures for more instructions.

8. Check for air leaks.

DANGER! CLOSE THE AIR VALVE MANUAL OVERRIDE BEFORE OPERATING

THE MACHINE - OR THE BRAKES WILL NOT OPERATE.

CAUTION: Excessive air pressure can cause diaphragm or end plate failure. DO
NOT APPLY AIR PRESSURE GREATER THAN 120 PSI (8.3 BAR).
Insufficient air pressure can cause the brake to partially release and
generate heat due to dragging on the rotor.

Manual No. 10954 6 - 12 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

COUPLINGS

GRID COUPLINGS

Part Numbers
1.Seal (T10)
2.Cover (T10)
3.Hub (Specify
bore and keyway)
4.Grid
5.Gasket (T10)
6.Fasteners(T10)
7.Lube Plug

INTRODUCTION

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 you install and service them. Carefully follow these instructions for optimum performance and
trouble free service.

PARTS IDENTIFICATION

All coupling parts have identifying part numbers as shown above. When ordering parts, always
SPECIFY SIZE and TYPE shown in the coupling data table in this section.

LUBE FITTINGS

Cover halves have 1/8 NPT lube holes. Use a standard grease gun and lube fitting.

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182M-AC Electric Mining Shovel

LUBRICATION

Adequate lubrication is essential for proper operation of the coupling. Refer to Table 9 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.

COUPLING DISASSEMBLY AND GRID REMOVAL

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.

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 275oF (135oC)
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.

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182M-AC Electric Mining Shovel

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 90o
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 midpoint
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 90o 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.

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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182M-AC Electric Mining Shovel

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, assembly 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 an 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.

Manual No. 10954 6 - 16 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

COUPLING DATA

PROPEL

Part No. ................................................ S106736

Vendor Part No. .................................... 1100T10
End Gap ..................................... .188(4.775 mm)
Installation Limits:
Offset .......................................... .010(.254 mm)
Angular ....................................... .009(.229 mm)
Cover Bolt:
Torque Lb/In ..................................... 312(35NM)
No. of Bolts ...................................................... 4
Grease Wt.- Lbs. .......................... 1.62(.73Kgs.)

OFFSET: Dim. "A", The amount of offset between the 2 shafts.

ANGULAR ALIGNMENT: The difference between Gap "B" and Gap "C".

END GAP: Dim. "D", the gap between the shaft ends, with the motor shaft at the mid point of its
total end play.

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

GEAR COUPLINGS ~GENERAL INFORMATION

INSTALLATION

Part Numbers:
1. Seal Ring
2. G Flanged Sleeve
3. G Flex Hub
(Specify bore and keyway)
4. Gasket
5. Lube Plug
6. Fasteners
9. Rigid Hub

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 275oF.
(135oC.) for mounting. Refer to the appropriate motor shaft installation instructions in this
manual 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 table.

Mount flanged sleeve,

seal and hubs

2. Mount the flanged sleeves, seal and hubs. Place the flanged sleeves WITH the seal rings on
the shafts before mounting the hubs.

CAUTION: 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.

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182M-AC Electric Mining Shovel

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 90o 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.

Offset Alignment

5. Insert gasket, DO NOT DAMAGE the GASKET,

between flanges. Position flanged covers with lube
holes at 90o and draw flanged cover into position.
Use bolts, nuts and lockwashers furnished with
couplings.

IMPORTANT: Tighten the flange bolts and nuts

to the torque specified in the Table.

Insert gasket and join

flanged sleeves

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 .010 thick SMOOTH feeler gauge between seal and
hub. Fill until excess appears at feeler. Repeat at 90o
intervals.

Lubricate

CAUTION: Make certain all plugs are inserted after lubricating.

Sept. 2010 6 - 19 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

COUPLING DATA

HOIST

Part No.: ....................................... MP165169

Vendor Part No. ............................... 1040G20
Gap ....................................... .250(6.350 mm)
Installation Limits:
Offset ..................................... .007(.178 mm)
Angular .................................. .018(.457 mm)
Bolt Torque Lb/In .................. 3000 (340 NM)
No. of Bolts ................................................. 8
Grease Wt.-Lbs. ................... 5.25(2.38 Kgs.)

OFFSET Dim. “A”, The amount of offset between the 2 shafts.

ANGULAR
ALIGNMENT The difference between Gap “B” and Gap “C”.

END GAP Dim. “D”, the gap between the shaft ends, with the motor shaft at the mid point
of its total end play*.

Manual No. 10954 6 - 20 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 7
Compressed Air System

Table of Contents

AIR COMPRESSOR SYSTEM ...................................................................................................... 3

AIR COMPRESSOR ................................................................................................................ 4
REGULATING AND MONITORING SYSTEM PRESSURE ...................................................... 4
COMPRESSOR MAINTENANCE ............................................................................................ 5
COMPRESSED AIR SUPPLY ........................................................................................................ 6
AIR LINE FILTERS ................................................................................................................... 6
DEICER ................................................................................................................................... 7
PRESSURE REGULATORS .................................................................................................... 8
AIR LINE LUBRICATORS ........................................................................................................ 9
FLOW RATE CONTROL VALVES .......................................................................................... 11
Flow Rate Control Valve ............................................................................................................ 11
QUICK RELEASE VALVE ....................................................................................................... 12
AIR PRESSURE SWITCHES ................................................................................................. 13
SYSTEM MAINTENANCE ..................................................................................................... 13
HOUSE AIR FILTRATION SYSTEM ............................................................................................ 14
MAINTENANCE ..................................................................................................................... 15
Dynavane Air Filters ................................................................................................................. 15

Sept. 2010 7-1 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Manual No. 10954 7-2 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 7
Compressed Air System

AIR COMPRESSOR SYSTEM

The air compressor system and the house air filter system are covered in this section.

The 182M AIR COMPRESSOR SYSTEM is simple in operation and easy to maintain. Maintenance
of its several components, described herein, is vital to the successful daily operation of this machine.

Compressed air is used to operate the propel, swing, crowd, and hoist brakes; the crowd overload
clutch; signal whistle; the windshield wiper; and the pumps and vent valves in the auto lube system.
It also operates the optional trail cable reel, if supplied. Refer to system schematic on the following
page.

CAUTION: AIR PRESSURE IS CRITICAL TO THE SAFE OPERATION OF THIS

MACHINE. It is important that the operator be constantly aware of the
system pressure indicated on the gauge on the air panel stand in the
Operator's cab. Any time this pressure drops below 100 PSI (690 kPa),
SHUT DOWN THE MACHINE AND INVESTIGATE THE CAUSE BEFORE
OPERATING FURTHER. Failure to do this could result in permanent
damage to machine components, especially the motion brakes.

The air system consists of:

• A tank mounted compressor.

• Supply lines to the components.
• Various control valves and flow regulators.
• An in-line lubricator, filter, and a deicer.
• Various gauges and pressure switches for monitoring the system.

As an option, any variable compressed air supply can be provided. The one described here is
standard for the 182M shovel. Any unit(s) provided should function in a similar manner. Each
mining operation should become familiar with the system on-board the particular machine.

CAUTION: System pressure in excess of 120 PSI (827 kPa) will damage the
brake diaphragms.

IMPORTANT: For AIR and HYDRAULIC QUALITY RECOMMENDATIONS and

QUALITY MAINTENANCE PROCEDURES, refer to Section 9 -
ENGINEERING DATA in this manual.

Sept. 2010 7-3 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

AIR COMPRESSOR

The air compressor is mounted near the

midpoint of the right wing, inside the
machinery house. It is a multiple-stage,
reciprocating-piston type compressor,
equipped with an intake filter and driven by
an A.C. electric motor through belts. The
compressor/motor unit assembles to the top
of a vertical air receiver tank that is bolted to
the deck.

The receiver tank is equipped with a pressure

gauge, a safety valve, a manual shutoff valve
for the delivery line, and a manual drain for
moisture removal. The air compressor motor
is controlled by a pressure switch (adjustable)
mounted on the unit that turns it ON at 125
PSI (862 kPa) and OFF at 150 PSI (1034 kPa).

REGULATING AND MONITORING SYSTEM PRESSURE

An adjustable regulator is just downstream from the air receiver and mounted on the right hoist
drum pedestal opposite the compressor. This device keeps the system air pressure at 120 PSI
(823 kPa). System pressure is indicated on a gauge in the Operator's cab, beside the operator.

A pressure switch in the air delivery line monitors the system pressure. It is located next to the
compressor unit on the auto lube control panel framework. The contacts in this switch CLOSE on
increasing pressure of 115 PSI (793 kPa) and OPEN on decreasing pressure of 100 PSI (690
kPa). Line excitation (LE) CANNOT be activated unless this switch's contacts are CLOSED.

Manual No. 10954 7-4 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

COMPRESSOR MAINTENANCE

WARNING: Before servicing the compressor, turn the air compressor off and
open the isolator switches located near the compressor.

• Check the oil level of the crankcase daily with the dipstick furnished. Keep it full.

• Bleed off condensed moisture daily from the receiver tank. Be sure to close the bleed valve.

CAUTION: Exhaust the air slowly to prevent dirt or debris to be blown in the
eyes of personnel.

• Check the belt tension adjustment between the electric motor and the compressor pulley
weekly. The tension is adjusted by moving the motor on its base toward or away from the
compressor.

DANGER! REMOVE AND LOCK OUT THE POWER TO THE COMPRESSOR

BEFORE PERFORMING ANY MAINTENANCE ON IT. Always
reassemble the belt guard before start-up.

• Inspect the hold-down bolts weekly. Keep them tight.

• Check the pressure switch settings weekly.

• Change the oil in the crankcase monthly. Refer to Section 3 - LUBRICATION in this manual.

• Inspect the air intake filter weekly. Clean it at least quarterly, more frequently if required.

Sept. 2010 7-5 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

COMPRESSED AIR SUPPLY

AIR LINE FILTERS

Air Line Filters are placed at strategic points in the air distribution system. They are designed to
remove moisture, solid contaminants, pipe scale, rust, pipe dope, etc., which may plug small
orifices or cause excessive wear and premature failure of pneumatic components. Each filter has
a metal bowl with a sight gauge and is equipped with a manually activated drain that requires only
finger tip touch to control. Each filter comes with a 40 micron plastic filter element that can be
removed, cleaned, and reused.

First Stage Filtration: Air enters at inlet port and flows

through deflector plate (It. A) which causes a swirling
action. Liquids and coarse particles are forced to the
bowl interior wall (It. B) by the centrifugal action of
the swirling air. They then carry down the bowl wall
by the force of gravity. Shroud (It. C) assures that the
proper swirling action occurs and that the air does
not pass directly through the filter element (It. D) until
the large particles and liquids are removed. The baffle
(It. E) separates the lower portion of the bowl into a
"quiet zone" where the removed liquid and particles
collect, unaffected by the swirling air, and are therefore
not re-entrained into the flowing air.

Second Stage Filtration: After liquids and large

particles are removed in the first stage of filtration,
the air flows through element (It. D) where smaller
particles are filtered out and retained. The filtered air
then passes downstream.

Collected liquids and particles in the "quiet zone"

should be drained before their level reaches a height
where they would be re-entrained in the flowing air.
This can be accomplished by using the manual drain
(It. F) which is actuated by pushing it to the side from
any direction. It requires only a fingertip touch to drain
the condensate, even in hard to reach places.

Remove the element by unscrewing the threaded bowl and the baffle (It. E). Wash the element
and bowl in mild soapy water and reinstall. Check the unit for unwanted air leaks around seals,
gaskets, or O-Rings. Replacement kits are available for these filter units. Refer to the Parts Book
for this machine.
CAUTION: Do not use acetone, benzene, carbon tetrachloride, ethylene
dichloride, gasoline, toluene, or any other solvents to clean plastic
components. These solvents are fire hazards and will also degrade
the plastic.

Manual No. 10954 7-6 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

DEICER

This component, located just downstream from the

air receiver and next to the in-line filter, injects a
chemical into the compressed air system to prevent
component freeze-up in cold weather. The rate of
delivery to the air system is controlled by the
ADJUSTING SCREW on top of the unit. Turning it
counterclockwise (CCW) increases flow, and
clockwise (CW) decreases it. Be sure to adjust the
flow rate only when there is air movement through it.
The deicer delivers all the desiccant downstream that
passes through its sight dome. Delivery rate
automatically changes with varying air flow rates
through the deicer once set. Adjust the flow rate for
normal usage so a steady drip is observed in the sight
dome.

Disclaimer:
The use of any desiccant other than TANNERGAS in
a Tanner De-Icer voids its warranty.

The fluid level in the deicer should be checked once per shift in cold weather when in use. Keep it
full. To fill the deicer, slowly unscrew BUT DO NOT REMOVE the BLEED PLUG at the top of the
deicer to vent the air pressure in the deicer.

CAUTION THE DEICER IS UNDER PRESSURE. Loosen the bleed plug until the
air pressure is vented completely. DO NOT REMOVE THE BLEED
PLUG.

SLOWLY open the GATE VALVE and add desiccant as determined by the sight gauge on the side
of the tank. Close the gate valve and the bleed plug. The deicer used on this machine has a 2 U.S.
gallon (7.6 liter) capacity bowl. Drain off any contaminants which collect in the bottom of the bowl
using its drain cock.

The deicer can be disassembled for cleaning/maintenance. Clean any contaminants from the
components with an approved solvent. When replacing any O-rings, coat them lightly with winter
grade MPG lubricant.

CAUTION: Deicer fluid is caustic to the eyes and skin. If contact is made, seek
first aid immediately and flush the contaminated area with water.

Sept. 2010 7-7 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

PRESSURE REGULATORS

These regulators are used in compressed air systems to maintain a nearly constant downstream
(outlet) pressure despite changes in the upstream (inlet) pressure and in the downstream flow
requirements. These units are of the relieving, diaphragm type and are each fitted with a gauge
that indicates outlet air pressure.

Outlet pressure is controlled by an adjusting screw (1) on top of the regulator that is fitted with a T-
handle. Clockwise (CW) rotation increases outlet pressure, and counterclockwise (CCW) decreases
outlet pressure.

When the adjustment (1) is rotated fully

counterclockwise, no force is applied to
the regulating spring (2), and the valve
(6) is held closed by the valve spring (7).
Clockwise rotation of the adjustment (1)
compresses the regulating spring (2)
which applies a downward force on top
of the diaphragm (4). The diaphragm
and valve pin (5) move downward,
forcing valve (6) off its seat (10) which
allows air to flow through the regulator
to the downstream system.

Outlet pressure increases in the downstream system and sensing chamber (9) and applies an
upward force on bottom of diaphragm (4). The diaphragm, valve pin (5), and valve (6) move
upward, compressing the regulator spring (2). Upward movement stops when the forces below the
diaphragm balance the forces above the diaphragm. When there is no downstream flow demand,
the balance of forces occurs with the valve (6) closed. When there is downstream flow demand,
the balance of forces occurs when the valve opens sufficiently to compensate for demand, thus
maintaining the desired outlet pressure.

These air pressure regulators require no maintenance. If a unit leaks air excessively or malfunctions,
replace it.

Manual No. 10954 7-8 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

AIR LINE LUBRICATORS

Lubricators inject a finely divided "fog" of oil into a flowing stream of compressed air to automatically
provide internal lubrication for the operating components in the air system. Oil feed density is
controlled by the drip rate adjusting knob (It.#1) on top of the unit. This knob is integral with a sight
feed dome. Counterclockwise rotation (CCW) of the knob increases oil flow (density), and clockwise
rotation (CW) decreases it.

The lubricator utilizes a flexible flow sensor (It.#5) to

control the flow of a small amount of inlet air into the
reservoir through fog generator (It.#3) in proportion to
the air flow past the sensor. The high velocity air flowing
through the generator aspirates oil up the siphon tube
(It.#8) into the sight-feed dome (It.#2), where it drips
downward through needle valve (It.#4) into the generator.
The oil drops are then atomized and mixed with the air
flowing through the generator into the reservoir. Most of
the larger oil particles return to the reservoir. The finer
particles ("fog") remain airborne and are carried through
passage (It.#6) into the downstream system. Only a small
portion of the drops visible in the sight-feed dome are
delivered downstream to the operating components.
Check ball (It.#7) keeps the siphon tube full during periods
of no air flow.

The lubricator used in this air system has a 2 quart (1.9

liter) capacity metal bowl with a manual drain cock (It.#9)
and a sight glass. It cannot be filled under pressure. To
add type PO lube to the bowl, exhaust the air pressure
from the circuit and then remove the oil fill plug from the
bowl. Add oil to the prescribed level indicated on the sight
glass. Replace the fill plug.

Adjust the oil flow rate to satisfy the lubrication

requirements of the operating components in the air
system downstream. The bowl reservoir can be removed
and cleaned with a mild soapy water solution.

Sept. 2010 7-9 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Salem 3-Way Air Valve

(Normally Closed)

The valves controlling air flow to the two auto lube pumps are Skinner 3-Way valves. The signal
horn valves are Skinner 2-Way, or equivalent.

NOTE: Some valves may have internal pilot lines, not external as shown below.

Skinner Air Valves

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 Bucyrus International, Inc.
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When a valve fails to shut off or admit the proper air volume, clean out the dirt and scale that cause
it to leak. Open and close the valve manually several times. This procedure to clean it usually
postpones its disassembly for cleaning. When this first-aid remedy fails, dismantle it and clean
and replace any worn or damaged parts. All parts for normal maintenance and repairs are available
in a repair kit. Refer to the Parts Book.

NOTE: These valves all require a minimum pilot pressure of 5 PSI (35 kPa) to operate. If a
valve leaks on compressor start-up after a shutdown period or maintenance interval,
especially those near the end of the supply circuit, and will not function, close the
delivery line valve at the air receiver. Permit the pressure in the receiver to reach the
maximum system operating pressure before reopening the delivery line valve. This will
provide the proper pilot pressure to the valves and they should all be functional then. If
not, clean or replace them.

CAUTION: Reset the manual override on all air valves so equipped, prior to
machine startup, to assure proper brake and component operation.

FLOW RATE CONTROL VALVES

An adjustable flow control valve is used in the swing brake circuit. It controls the setting time for
both brakes.

Flow Rate Control Valve

Turn the adjustment screw counterclockwise (CCW) to restrict air flow more back through the
valve (opposite direction to free flow). Turn it clockwise (CW) to increase air flow (decrease
restriction) back through valve. The internal parts of this valve are easily accessible if maintenance
is required.

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QUICK RELEASE VALVE

This valve is used in the optional cable reel circuit.

The exhaust port in this valve closes when full system air pressure (regulated) is applied to the inlet
port and all flow through the valve is out the outlet port. When pressure is reduced at the inlet port,
the differential in pressure between the outlet and inlet ports causes the exhaust port to open,
directing air flow from the outlet port to the atmosphere until a differential no longer exists.

This valve is non-adjustable. If it does not function properly, disassemble it and clean it. Inspect for
damaged parts and replace any that are damaged or worn. A repair kit is available that contains
the most frequently replaced parts. Refer to the Parts Book.

Manual No. 10954 7 - 12 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

AIR PRESSURE SWITCHES

These devices are used in the air receiver supply line and in the swing, crowd, hoist, and propel
brakes circuits to monitor system pressure and brake operation. These switches are all double-
make double-break units that have snap action switching elements. They automatically reset by a
snap-action of the switch. DO NOT PLUG THE DRAIN PORT ON THESE UNITS. Each switch is
adjustable externally within the ranges listed on it. Refer to the air system schematic for the setting
on each pressure switch.

If the air pressure in any of these circuits falls

below a preset value on its pressure switch,
then an electrical interlock will be activated that
will alert the operator of the malfunction and, in
some instances, shutdown the machine.

A pressure switch in the auto lube air supply

circuit monitors that system for pressure in
excess of a preset amount. If this pressure is
exceeded, then the operator is again notified
of the situation via the annunciator panel.

SYSTEM MAINTENANCE

• Check compressor crankcase oil level(s) daily with the dipstick furnished. Keep full.

• Drain air compressor receiver tank(s) daily to bleed off condensed moisture. Be sure
to close the bleed valve(s) after the moisture is out.

CAUTION: Exhaust the air slowly to keep dirt or debris from blowing into the
eyes of personnel.

• Check the automatic drip leg drain daily for operation.

• Inspect air line lubricators and filters daily. Add lube or clean filter(s) as required.

Sept. 2010 7 - 13 Manual No. 10954

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182M-AC Electric Mining Shovel

• Check the belt tension adjustment between the electric motor and the compressor
pulley weekly. Tension is adjusted by moving the motor on base toward or away from
the compressor.

DANGER! To prevent the air compressor from starting, remove and lock out
power to the compressor before performing any maintenance. Always
reassemble the belt guard before start-up.

• Check pressure switch settings weekly.

• Inspect all components and the system weekly for operation.

• Inspect the system for leaks weekly. Repair any found immediately.

• Change the oil in the compressor crankcase(s) monthly (every 400 hours).

• Clean the air intake filters on the compressor(s) quarterly (1200 hours).

HOUSE AIR FILTRATION SYSTEM

The HOUSE AIR FILTRATION SYSTEM uses filter fans to create

a slight pressure above the outside air to reverse any possible
IN-FLOW through rope and other openings. Thus, all air entering
the house is filtered. NOTE: An open access door or cover will
defeat this system, allowing dust and dirt to enter. Filtered air
circulation reduces dust accumulation and related maintenance.

CONCEPT: Dirty air enters the filter house and inlet end of the
wedge shaped filter cells. Most air (about 90%) changes direction
quickly and passes through the narrow side passages. Dirt
particles, with greater mass, tend to continue straight into the
bleed air duct; thus, dirt particles and bleed air return outside.

Manual No. 10954 7 - 14 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

MAINTENANCE

• Periodically check that the bleed air ducts are open and clear.

• Keep inlet passages free of paper, leaves, wiping cloths, or any debris that would obstruct air
flow.

• Look for deposit buildup on filter blades. A light coat of dust is normal, but a heavier coating
requires cleaning.

• Brush surface and remove dust with compressed air. If necessary, wash heavy buildup with
water or suitable solvent.

DANGER! THE MACHINERY HOUSE ROOF MAY BE SLIPPERY. Use the hand
rails as well as extreme caution during any maintenance or service on
the roof.

NOTE: Mine conditions will dictate the maintenance frequency of the filters. Monitor the filters
closely and establish a schedule to suit conditions.

Dynavane Air Filters

Sept. 2010 7 - 15 Manual No. 10954

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182M-AC Electric Mining Shovel

Manual No. 10954 7 - 16 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 8
Air Conditioner

Table of Contents

DESCRIPTION OF UNIT ............................................................................................................... 3

SPECIFICATIONS .................................................................................................................... 5
COMMISSIONING ......................................................................................................................... 6
SERVICING ................................................................................................................................... 8
FAULT FINDING ............................................................................................................................ 9
SYSTEM DEAD ....................................................................................................................... 9
NO FANS ................................................................................................................................. 9
NO COOLING ~ALL FANS OK, BUT COMPRESSOR DOESN’T RUN. .................................. 9
INADEQUATE COOLING ....................................................................................................... 10
INADEQUATE HEATING........................................................................................................ 11
RECOVERY OF REFRIGERANT ................................................................................................ 11
MATERIAL SAFETY DATA SHEETS............................................................................................ 12
TROUBLE ANALYSIS .................................................................................................................. 20
TROUBLE ANALYSIS CHART NOTES ....................................................................................... 26

Sept. 2010 8-1 Manual No. 10954

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182M-AC Electric Mining Shovel

Manual No. 10954 8-2 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 8
Air Conditioner

DESCRIPTION OF UNIT

The MPV9 is a heavy duty system suitable for rooftop mounting on the cabs and electrical enclosures
of large pieces of mining and industrial equipment. This includes shovels, draglines, drills, ship
loaders, and track maintenance equipment. Case is stainless steel.

Evaporator: Air is drawn from under the unit, passes over the heat exchange coil (and heating
elements when fitted) into the double wheel fan deck and is discharged through the
base into the conditioned space.

Refrigerant flow is metered by an externally equalized TX valve, and is cut off by a

liquid line solenoid valve.

Sept. 2010 8-3 Manual No. 10954

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Heat exchange coil is large, with heavy gauge tubing and coarse fin pitch to reduce
clogging.

Fan motor is single shaft and of totally enclosed, fan cooled motor construction.

Drain pan is large and of “V” design for ease of cleaning and to facilitate draining.

All pressure controls are in the evaporator section.

Condenser: The compressor is a heavy duty, 2 cylinder, suction, gas cooled, semi-hermetic
unit. The assembly is mounted to heavy flexible mounts to reduce noise transmission
to the structure.

All connections are stainless and most joints are soldered.

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.

Condenser fan is single speed.

Electrics: The main control panel is mounted on the condenser for ease of service. Most
switchgear is Siemens, and motor protection is by circuit breaker thermal
overloads. Heater and transformer have circuit breakers.

The pilot controls, when supplied, have OFF-LOW-HIGH fan switch and HEAT-
VENT-COOL-DEMIST mode switch, plus a set point adjuster for thermostat.

Controls voltage is 24VDC.

Manual No. 10954 8-4 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

SPECIFICATIONS

Dimensions : T9071004

Cooling Capacity: 27,000 Btu/hr. @ 415V/50Hz

Heating Capacity : 12 kw @ 415V/50Hz

Power Requirement : 415V/3ph/50Hz (21.0 Amps.) Norm.

Refrigerant : HFC 134a environmentally friendly 24 Lbs.

Oil : POE Variety Mobil Artic EAL22CC or ICI Emcarate RL32CF

Compressor : Fully sealed scroll compressor.

Condenser Coil : 5 row, 3/8” inch copper tube with 8 aluminum fins per inch.

Evaporator Coil : 4 row, 3/8” inch copper tube with 10 aluminum fins per inch.

Condenser Fan : Multi-blade axial, 17¼ inch diameter, two speed, 35o pitch to provide in
excess of 3000 cfm @ 50Hz.

Supply Air : One forward curve double inlet fan supplies a nominal 1300 cfm (610 l/s) @
50Hz.

Leak Detection : A dye which glows under UV light is added to aid leak detection.

Pressure Controls : HIGH- 350/250 PSI high pressure cut out

LOW - 10 psi cut out, 25 psi cut in

Pressurization : A large Donaldson filter with a single inlet blower wheel provides
pressurization. Motor is 24V DC and mounted within the condenser.

Thermostat: 5-Stage electronic, 1.5 oC within stage.

Sept. 2010 8-5 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

COMMISSIONING

With all the cabling run and the system mounted, the system is ready for commissioning.

• Turn selector switch “OFF”.

• Check that the control voltage is 24VDC.

Proceed to live test.

A. Select ‘VENT’ on Mode switch. Select 'LOW' on FAN switch.

This should result in evaporator fan running on low speed and pressurization unit only.

Check correct phase rotation of evaporator fan. This can be done by either switching
'OFF' and have an observer looking into the evaporator cover; or by closing the Main
Isolator at the unit if on you own.

Please be aware that air will flow in the right circuit no matter what direction the fan runs
- but the wrong direction will only result in approximately 30% of the flow.

Select ‘HIGH’ on fan switch and check that speed and flow increase.

B. Select ‘HEAT’ on Mode switch.

Rotate thermostat knob fully clockwise.

Under normal temperatures of 70 F nominal, both heater contactors will close bringing
on both heat stages.

In the event that ambient and the cab temperature are too high, immerse the temperature
probe (in return air section of evaporator) in a glass of cold water.

Check the individual staging of heater contactors as the probe either cools - or warms
up.

Check HIGH & LOW fan operation. Fans will automatically switch to HIGH in high heat.

C. Select ‘COOL’ on Mode switch.

Rotate thermostat adjustment fully counterclockwise.

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182M-AC Electric Mining Shovel

As with heating, the ambient should be in the 70 F range for cooling to operate.

In the event that it isn't, warm the return air probe in you hand. The compressor should
start, along with the condenser fan.

If the compressor does not start, check phase rotation as a device is installed to ensure
correct rotation.

Observe the charge as indicated in the liquid line sight glass (located in the condenser).
The air conditioner is fitted with a HEAD PRESSURE CONTROL VALVE which maintains
a minimum pressure of 130 psi at all ambient. This works by backing refrigerant up into
the condenser. Charge in the air conditioner is high for this reason, but it provides great
flexibility of application.

System should be capable of operating in the COOLING mode down to 10 F ambient.

Check fan speed operation.

D. Select DEMIST on Mode switch.

This mode assists in demisting inside the cab window surfaces by operating one stage
of heating continuously and either COOLING if it is hot, or 2nd stage of HEAT if it is cold.

Heating the air dries it and by passing over a cool heat exchange coil, moisture is
condensed and removed from the air stream. This greatly increases the speed of
demisting.

Check fan speed operation, but again be aware that full heat will result in HIGH fan.

Sept. 2010 8-7 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

SERVICING

Recommended service schedule. Site conditions may alter this.

1st Week
- Check charge and add if required.

- Leak Test - with ultraviolet black lamp and 134a specific detector.

- Tighten all mounting bolts, fasteners, terminals, etc.

- Check drains.

- Check operation.

Daily
- Clean filter if in dusty conditions.

- Clean pressurizer if in dusty conditions.

- Observe charge.

Monthly
- Daily checks.

- Check for leaks.

- Check fans for tightness on shafts.

- Clean out coils.

- Flush drains.

3 Monthly
- All monthly phases.

- Check structure.

- Check hoses and fittings.

Annually
- All previous phases.

- Give system a good cleaning out.

- Check motor bearings and replace if necessary.

Manual No. 10954 8-8 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

FAULT FINDING

This section is written on the assumption that the service mechanic is a qualified trades person in
refrigeration and air conditioning. They must have a good understanding of the operation prior to
fault diagnosis and repair.

SYSTEM DEAD

• Check main supply.

• Check control transformer and fuses.

• Check power lines on the schematics to ascertain where power is lost.

NO FANS

• Check power lines to find where the loss or break in supply occurs.

• Check motors.

NO COOLING ~ALL FANS OK, BUT COMPRESSOR DOESN’T RUN.

• Check “COOL” selected, and if there is 24V power to terminal 22.

• Check HP and LP control are closed by testing for 24V at 11 (re-set HP anyway - in evaporator
liquid line). If LP is open, system may have lost charge. Find leak and repair.

• Check that pump down relay closes and 24V power is supplied to compressor thermal overload.

• Check that liquid line solenoid valve operates.

• If power is supplied to the contactor, but no action, the coil will have failed.

• Check contactor is closing.

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• Check overloads, circuit breakers.

• Check phase rotation relay.

• If power is being supplied to the compressor, but still no action, isolate the power, disconnect
the terminals and check for open circuit in the motor.

• If breaker keeps tripping, the compressor may be grounded.

• Check thermostat operation and stage 3 is closed between K3C and K3NO.

INADEQUATE COOLING

System may not be performing as well as it should be.

• Check pressures. A system would normally operate between 130-200 PSI on the high side
and 25-45 PSI on the low side.

High pressure could indicate air in the system, dirty condenser, overcharge. Low high side pressure
could indicate low charge or failing scroll in compressor.

If the low side has a much higher than 45 PSI pressure it could indicate broken valves, liquid
floodback, and/or poor TX valve adjustment.

• Check refrigerant charge in sight glass. It should be full at all times when compressor is
running. Low charge will first become evident at low ambient.

• Check for restriction in the system. This can be done by feeling the plumbing before and after
a “device”. If it is noticeably cooler, expansion has taken place from a drop in pressure. There
is restriction, and steps should be taken to clear it. Check for a:

- Blocked return air filter.

- An open lid admitting outside air.
- Coil for cleanliness.
- TX valve for superheat adjustment.

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

INADEQUATE HEATING

The system has 6 equal elements in star formation and as the system operates in extremes of
ambient, a high capacity system has been provided. It is also 2 stage in operation for improved
comfort.

If heating is inadequate, check:

• Circuit breakers. One breaker will knock out 1 stage capacity.

• Elements for open circuit.

• Thermostat for correct switching of contactors.

• Over temperature sensor cutting out failed evaporator fan.

RECOVERY OF REFRIGERANT

Although HFC134a is environmentally friendly, it is still good practice to recover refrigerant prior to
opening up the system. Devices are fitted to minimize the amount required, but venting to
atmosphere is to be avoided.

The lubricant is a POE style, and does not mix with other mineral oils.

A dedicated recovery unit should be used, as should a gauge set.

MATERIALS SHOULD NOT BE MIXED WITH R12, R22, MP39, OR OTHER REFRIGERANTS.

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MATERIAL SAFETY DATA SHEETS

Manual No. 10954 8 - 12 Sept. 2010

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Sept. 2010 8 - 13 Manual No. 10954

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Manual No. 10954 8 - 14 Sept. 2010

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Sept. 2010 8 - 15 Manual No. 10954

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Manual No. 10954 8 - 16 Sept. 2010

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182M-AC Electric Mining Shovel

Sept. 2010 8 - 17 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Manual No. 10954 8 - 18 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Sept. 2010 8 - 19 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

TROUBLE ANALYSIS

RECOMMENDED
POSSIBLE CAUSE SYMPTOMS ACTION

COMPRESSOR FAILS TO START

If the compressor does not start after turning the switch to the “COOL” position, check the following
7 items inclusive:

Power Failure Test lamps show no Check for blown line

current on line side of fuse or broken lead.
main isolator switch.

Fuse blown or faulty Test lamps shows Replace fuse or

current on line side but contactor. Check load
not on compressor motor on motor.
side of fuse.

Low voltage Test lamps glow but not Call electrician.

at full brilliance.

Defective motor Full voltage at motor Repair or replace

terminals but motor
will not run.

Frozen compressor Compressor will not pump Overhaul compressor

due to:

(a) Lack of oil

(b) Broken piston

(c) Broken valve strip

jamming the piston

Complete loss of Check suction, head pressure Repair leak and

sight glass recharge

Head pressure too High pressure cutout See “HEAD PRESSURE

high TOO HIGH”

Manual No. 10954 8 - 20 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

RECOMMENDED
POSSIBLE CAUSE SYMPTOMS ACTION

COMPRESSOR “SHORT CYCLES”

Thermostat Normal operation except too Reset differential to

differential set too frequent stopping and starting as job conditions permit
close

Low line voltage Motor overheats Call electrician

Faulty condensing Excessively high head See “HEAD PRESSURE

TOO HIGH”

Overcharge of High head pressure Purge or remove excess

refrigerant

High pressure control System appears OK Reset high pressure to

set too low correct setting

COMPRESSOR RUNS CONTINUOUSLY

Excessive load High temperature in Check for excessive

conditioned area fresh air or infiltration.
Check for inadequate
insulation of space.

Air or non-condensable Excessive head pressure Purge system

gases in system

Thermostat set too low Low temperature in Reset thermostat

conditioned area

Too little or too High head pressure Provide adequate cool

warm condenser air condenser air

Fouled condenser High head pressure Clean coil

Lack of refrigerant Low suction pressure Repair leak and charge

Overcharge of High head pressure Purge or remove excess

refrigerant

Leaky valves Suction pressure rises faster Overhaul compressor

than 13 kPa per minute after
Shutdown

Sept. 2010 8 - 21 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

RECOMMENDED
POSSIBLE CAUSE SYMPTOMS ACTION

COMPRESSOR LOSES OIL

Insufficient oil charge Oil level gradually drops Add oil

Traps in hot gas and Oil level gradually drops Pitch lines and
suction lines provide lift

Clogged strainers Oil level gradually drops Clean, or repair

or valves and replace

Loose expansion Excessively cold suction Provide good contact

valve bulb between bulb
and suction line

Liquid slugging back Excessively cold suction Readjust super heat

to compressor setting or thermal bulb
contact

Short cycling Too frequent starting and See items under

stopping of compressor “COMPRESSOR SHORT
CYCLES”

Shortage of refrigerant Low suction pressure Repair leak and charge

COMPRESSOR IS NOISY

Lack of oil Low oil level Add oil

Excess oil in High oil level Drain off excess oil to

crankcase required level

Broken compressor Compressor knocks. Overhaul compressor

valve strip Suction pressure rises faster
than 13 kPa per minute after
shut down

Worn or scored Compressor knocks Overhaul or replace

bearings in compressor compressor

Manual No. 10954 8 - 22 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

RECOMMENDED
POSSIBLE CAUSE SYMPTOMS ACTION

Compressor hold Noise and vibration Tighten hold down

down bolts loose transmitted to structure bolts

Expansion valve stuck Abnormally cold suction line, Repair or replace

in open position compressor may knock

Liquid “Slug Back” Abnormally cold suction line, Reset super heat.
compressor may knock valve
may be too large or bulb loose
on suction line. Air entering
evaporator coil too cold for
complete evaporation of liquid.

Excessive head Compressor will knock Reduce head pressure.

pressure See “HEAD PRESSURE
TOO HIGH”

SYSTEM SHORT OF CAPACITY

Improper super heat Continuous running Adjust expansion valve

adjustment

Flash gas in liquid line Expansion valve hisses Subcool liquid or add
refrigerant

Expansion valve too Continuous running Repair with larger valve

small

Expansion valve stuck Continuous running Repair or replace

or obstructed

Clogged strainer Cold liquid line Clean or repair

beyond strainer

Excess pressure drop Superheat too high Adjust expansion valve

in evaporator

Ice or dirt on Reduced air flow Clean coil or defrost.

evaporator coil
Check suction pressure.

System short of Low suction pressure Check system. Find and

refrigerant repair. Add refrigerant.

Sept. 2010 8 - 23 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

RECOMMENDED
POSSIBLE CAUSE SYMPTOMS ACTION

HEAD PRESSURE TOO HIGH

Air or non-condensable Condenser appears OK Purge. Check system

gas in system for leaks

Overcharge of Condenser appears OK Purge or remove excess

refrigerant

Blocked air flow to Condenser appears OK Ensure condenser coil

condenser is clean (blow off dirt).
Ensure air access to
condenser and fan.

Condenser air too hot Condenser appears OK Relocate high side to

obtain cooler air into
condenser or remove source
of heat if possible.

All the above Tripping of compressor

HEAD PRESSURE TOO LOW

Lack of refrigerant Low suction pressure Repair leak and charge

Leaky oil return Hot oil return Repair or replace

Broken or leaky Suction pressure rises Overhaul compressor

compressor valves faster than 13 kPa
per minute after
shut down.

SUCTION PRESSURE TOO HIGH

Excessive load on Compressor runs See “COMPRESSOR

evaporator continuously RUNS CONTINUOUSLY”

Expansion valve Abnormally cold suction line Replace valve

too large

Manual No. 10954 8 - 24 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

RECOMMENDED
POSSIBLE CAUSE SYMPTOMS ACTION

Expansion valve stuck Abnormally cold suction line Repair or replace valve
in open position

Broken suction valve Noisy compressor Overhaul compressor

in compressor

SUCTION PRESSURE TOO LOW

Light load on Compressor short cycles Plant should not be run-

evaporator ning under these conditions

Flash gas in liquid line Expansion valve hisses Provide sub-cooling

Clogged strainer Liquid line cold beyond Clean or replace

strainer

Obstructed expansion Loss of capacity Repair or replace valve

valve

Expansion valve too Lack of capacity Replace with larger valve

small

Expansion valve lost Erratic valve response Repair or replace

charge

Expansion valve Erratic valve Refix bulb

Lack of refrigerant Low suction pressure Repair leak and charge

Evaporator fan stopped Low suction pressure Check fan motor and circuits
~ensure fan blades secure
on motor shaft

Dirty filters Lack of air flow Replace or clean filters

through evaporators

Sept. 2010 8 - 25 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

TROUBLE ANALYSIS CHART NOTES

Note 1 - Clogged Strainer or Filter:

Occasionally the strainer or filter in the liquid line may become clogged with foreign material left in
the system during erection. When this happens, the liquid line leaving the strainer will feel cooler
than the liquid entering. If it is badly clogged, some seat or frost may appear at the strainer outlet.

Note 2 - Thermal Expansion Valve Leaks:

A leaky expansion valve may allow the evaporator to fill with liquid which will be slugged into the
suction line and into the compressor when the system starts. Liquid slugging within the compressor
is detrimental to valves, gasket, etc. and should be avoided.

Note 3 - Thermal Expansion Valve Stuck in Open Position:

If the expansion valve is stuck in an open position, there will be an excessive amount of sweating
on the suction line and compressor crankcase due to the large amount of liquid being passed into
the suction line. Expansion valve should be checked for loss of charge or faulty thermal bulb
contact with the suction line.

Note 4 - Power Element:

The power element of an expansion valve consists of the thermal bulb, capillary tube and the
bellows or diaphragm which actuates the valve pin. If this power element is defective or has lost its
charge, the valve will either maintain an almost closed position or may completely close. To test for
a defective power element, the bulb should be removed from the suction line and warmed by
holding it tightly in the hand. The valve will open if the power element is not defective. If the power
element is defective, the valve will remain closed.

Note 5 - Thermal Expansion Valve Improperly Adjusted:

If the expansion valve is adjusted for too low a superheat, too much liquid will be passed to the
evaporator. The suction line will be abnormally cold and liquid may slug back to the compressor. If
the expansion valve is adjusted for too high a superheat, too little liquid will be passed to the
evaporator and the suction line will be abnormally warm. Superheat should always be adjusted
carefully using thermometer and suction gauge.

Note 6 - Thermal Expansion Valve Too Large:

If a replacement thermal expansion valve has been improperly selected, and its capacity is too
great for the system, the valve will not maintain a consistently level suction pressure. The thermal
bulb will attempt to control the flow of liquid at its superheat setting, but the oversized valve port will
pass liquid too rapidly. The presence of liquid near the thermal bulb will close the valve and the
pressure in the evaporator will drop until the valve opens to pass another slug of liquid. This
“hunting” will cause a suction pressure variation noticeable on the suction pressure gauge.

Manual No. 10954 8 - 26 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Note 7 - Thermal Expansion Valve Too Small:

If the replacement thermal expansion valve is too small, it cannot pass a sufficient amount of liquid to
satisfy the evaporator. Under conditions of heavy load, the superheat will be excessive and the
system will lose capacity. Under conditions of light load, the system may function properly. Too
small expansion valves usually result in abnormally low suction pressure.

Note 8 - Thermal Expansion Valve is Obstructed:

Unless the expansion valve is properly protected by a strainer or filter, foreign matter may obstruct
the valve port. If the obstruction is small, the resulting operation will be much the same as though
the valve were undersized as described in Note 7. If the obstruction holds the valve open during
shutdown, the operation will be as described in Notes 2 and 3. An obstructed expansion valve is
usually indicated by a partly warm evaporator.

Note 9 - Shortage of Refrigerant:

There should always be sufficient liquid in the receiver to completely submerge the inlet to the
liquid line pipe. If there is a shortage of refrigerant, the liquid level will fall below the inlet to the
liquid line. Frequently there will be a hissing or whistle at the expansion valve. The coil and suction
line will be relatively warm while the suction pressure will be low due to little or no liquid being
supplied to the evaporator if the shortage is severe.

Note 10 - Overcharge of Refrigerant:

An overcharge of refrigerant will cause high head pressure. Liquid will back up in the condenser
and decrease the amount of surface available for condensing and as a result the head pressure
will rise. In extreme cases, it may rise to a point where the thermal overload elements in the
compressor motor or the high pressure cutout will stop the compressor. This may result in short
cycling.

Note 11 - Air System, Purge:

If air or other non-condensable gases are present in the system, they will tend to move toward and
collect at the condenser. The head pressure will rise to a point above the pressure corresponding
to the temperature at which the vapor is condensing. In extreme cases, the pressure may rise to a
point where either the high pressure cutout or the thermal overload elements in the compressor
motor may stop the compressor.

Note 12 - Broken Valves in Compressor:

Broken or leaky discharge valves in a compressor are generally indicated by the suction pressure
rising rapidly as soon as the machine is stopped. If the suction pressure rises faster than 13 kPa
per minute, it is an indication that the compressor discharge valves are not holding. Before the
compressor is opened, however, it should be determined that the pressure rise is not due to other
causes such as leaky expansion valve.

Sept. 2010 8 - 27 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Manual No. 10954 8 - 28 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 9
Engineering Data
Table of Contents

ENGINEERING DATA .................................................................................................................... 3

BUSHINGS .................................................................................................................................... 3
SEALS ........................................................................................................................................... 4
SEAL INSTALLATION .............................................................................................................. 4
CORD GASKET SEALING ....................................................................................................... 6
O-RING GASKET SEALING .................................................................................................... 7
CONTACT PATTERN .................................................................................................................... 8
SPLINES ..................................................................................................................................... 12
INVOLUTE SPLINE ASSEMBLY ............................................................................................ 12
MOTOR SHAFT, HUB OR GEAR INSTALLATION ....................................................................... 13
INSTALLATION OF SHRINK FIT COMPONENTS ................................................................. 14
REMOVAL OF SHRINK FIT COMPONENTS ......................................................................... 16
CAPSCREW (BOLT) GRADE ...................................................................................................... 16
BOLT TIGHTENING .................................................................................................................... 17
TORQUE WRENCH METHOD ............................................................................................. 17
Table 1 - Lubricated or Plated Threads or with Hardened Washers ........................................ 17
Table 2 - Dry Threads .............................................................................................................. 17
TURN-OF-NUT METHOD ..................................................................................................... 18
Table of Snug Tight Torque Values ........................................................................................... 18
WIRE LOCKING CAPSCREWS ................................................................................................... 19
Patterns for Wirelocking Capscrews ....................................................................................... 19
HYDRAULIC TENSIONER ..................................................................................................... 20
MAINTENANCE WELDING ......................................................................................................... 21
WELDING ELECTRODES ..................................................................................................... 22
REPAIR WELDING OF CRACKS ........................................................................................... 23
Joint Preparation for Repair of Cracks .................................................................................... 23
PREHEAT ........................................................................................................................ 24
WELDING TECHNIQUE .................................................................................................. 24
REPAIR WELDING OF BROKEN PARTS .............................................................................. 25
REPAIR WELDING SWING RACK TEETH ............................................................................ 26
PREPARATION ................................................................................................................ 26
SWING RACK WELDING ELECTRODES ....................................................................... 27
PREHEAT ........................................................................................................................ 27
WELDING PROCEDURE ................................................................................................ 28
WELDING AND CUTTING EQUIPMENT ..................................................................................... 30

Sept. 2010 9-1 Manual No. 10954

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT ....................................... 30

SHEAR BLOCK INSTALLATION ............................................................................................ 32
WELDING PROCEDURE ................................................................................................ 32
WIRE ROPE CARE AND MAINTENANCE ................................................................................... 33
STORAGE ............................................................................................................................. 33
CHECKING DIAMETER ......................................................................................................... 33
Correct Method for Checking Wire Rope Diameter ................................................................. 33
HANDLING WIRE ROPE ....................................................................................................... 34
Improper Methods for Uncoiling Wire Rope ............................................................................. 35
SEIZING WIRE ROPE ........................................................................................................... 35
END PREPARATIONS/TERMINATIONS................................................................................ 36
WIRE ROPE CLIPS ............................................................................................................... 37
WIRE ROPE CLIP APPLICATION .................................................................................... 37
WEDGE SOCKETS ......................................................................................................... 39
INSPECTION OF SHEAVES AND DRUMS ............................................................................ 40
Examples of Sheave Groove Conditions .................................................................................. 40
Groove Gauge for New or Re-Worked Sheaves ...................................................................... 40
Inspecting for Worn Sheave ..................................................................................................... 41
BREAKING IN A NEW WIRE ROPE ....................................................................................... 41
INSPECTION DATA ............................................................................................................... 42
GUIDELINE TO INSPECTIONS AND REPORTS ............................................................ 43
Wire Rope Stretch vs Rope Life .............................................................................................. 45
Examples of Broken Wires ...................................................................................................... 48
DIAGNOSTIC GUIDE TO COMMON WIRE ROPE DEGRADATION ...................................... 49
AIR AND HYDRAULIC SYSTEM QUALITY .................................................................................. 50
AIR AND HYDRAULIC SYSTEM QUALITY RECOMMENDATIONS ....................................... 50
AIR AND HYDRAULIC SYSTEM QUALITY MAINTENANCE .................................................. 51

Manual No. 10954 9-2 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Section 9
Engineering Data

ENGINEERING DATA

The design of Bucyrus machines follows standards established by industry practices and procedures,
material specifications and design/manufacturing disciplines developed by Bucyrus. This section
supplements the manual with additional information on maintenance practices and procedures.
Some of this information may not apply to your specific machine.

BUSHINGS

There are several types of bushings used on Bucyrus machines. Two most common are the bronze
sleeve bushing and the flange bushing. The sleeve type mounts in a machined bearing boss
opening with a light press fit. A flange bushing rests in an opening and is held in place with a
minimum of 4 dowels. Dowel material is softer than bushing materials to prevent scoring of shafting
over the life of the bushing.

Bushing service life depends on several factors. Various environmental conditions, lubricant types
& maintenance practices will result in various replacement frequencies.

Bushing replacement requires disassembly of machinery shafting and gearing. Removal of bushings
may require the use of an air chisel to slit the bushing for removal. Use extreme care to avoid
cutting or scoring the bearing boss. Once the bushing is removed CLEAN bearing boss thoroughly
of metal burrs and debris, grease, and dirt.

A clean new bushing can be easily installed in a bore if it is cooled in a bath of dry ice and alcohol.
This will shrink the outside diameter of the bushing allowing it to drop or slide freely into the
bearing boss bore.

An alternate method installs the bushing using a long

threaded rod, steel plates and a hollow center jack.
Assemble items as shown. Lightly coat bushing O.D.'s
and boss I.D. with high quality anti-scoring, extreme
pressure, pressing oil. Then PULL the bushing into place.

Sept. 2010 9-3 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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, Bucyrus has specified the use
of the most common solid molded element type seals for use on Bucyrus 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.

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.

CAUTION: 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 key-ways 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 .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.)

Manual No. 10954 9-4 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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:

• Remove garter spring and separate at the hook and eye.

• Open the seal, ends sideways, for installation on shaft as

shown by moving the butt ends along the axis of the seal.

• Lubricate spring and install around shaft. Connect ends and

insert spring in lip groove with spring ends 90o away from
butt joint.

CAUTION: 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.

Sept. 2010 9-5 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CORD GASKET SEALING

Use the following procedure to seal bolted joints:

1. Clean flanges of all dirt, rust and scale.

2. Use a cord gasket material .12 inch wide (part no.

469229-2) on machined joints and .25 inch wide (part
no. 469230-6) on non-machined joints.

3. To apply the seal, peel the protective strip off the

adhesive and install the adhesive edge against 1
surface of the joint. Place 2 cord gaskets around the
joint to be sealed ~ 1 inboard of the bolt holes and 1
outboard. Keep the seal approximately ½ its width away
from the edge of the bolt holes. (See figure on this page)

4. Complete the seal of a continuous flange by crossing

the ends near a bolt hole. Cross 1 end over the other
end and cut the cord. For a discontinuous flange, see
the end joints in the figure.

5. When tapped holes are THROUGH HOLES into the

interior of a gearcase, apply sealant (part no. 134562-
1) thoroughly to both the male and female threads of
the fasteners prior to assembly.

6. Assemble the joint and tighten the bolts, in a sequence,

in 2 steps as follows:

- Tighten ALL the bolts to approximately 50% of their

maximum torque (per spec.).

- Tighten ALL the bolts to 100% or their maximum

torque.

Manual No. 10954 9-6 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

O-RING GASKET SEALING

Seal movable eccentrics per the following procedure:

1. Refer to the figure on this page. Contact surfaces

A and B are designed with O-Ring seals for
maintaining positive sealing characteristics while
being movable for adjusting purposes.

2. Fit the O-Ring material into the groove and cut it to

the proper length. Splice the ends together with a
sealant (part no. 130957-9).

3. Use a minimum amount of grease to hold the O-

Ring in place during assembly.

4. When tapped holes are THROUGH HOLES into

the interior of a gearcase, apply sealant (part no.
134562-1) thoroughly to both the male and female
threads of the fasteners prior to assembly.

5. Retainer cap flange surfaces may or may not utilize shims, depending on their design.
Eccentrics designed per the detail shown would have shims installed beneath the retainer
cap.

Sept. 2010 9-7 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

CONTACT PATTERN

The contact pattern between mating gear teeth may be established by any method that indicates
the contact area. However, the reliability of the method must be considered. The following methods
have provided excellent results when applied to Bucyrus gearing.

PASTE TYPE LAYOUT BLUE: Clean several teeth on the pinion and the mating teeth on the gear.
Apply a "thin" coat of Prussian Blue to the pinion teeth. Roll the pinion through mesh once so that
each "blued" tooth contacts its mating gear tooth. Then roll the teeth back through mesh to the
original starting position of the pinion. The Prussian blue will transfer from the pinion to the gear
teeth when contact is made. Record the pattern (with sketches) and location of the pattern on the
gear. Repeat until patterns are taken 4 places (every 90o) on the gear. Adjust the pinion to provide
the "best" (or optimum) pattern on the four gear locations. Repeat for each pinion contacting gear
teeth. It helps to put clear scotch tape on the mating gear teeth. The bluing shows up better and
the tape can be carefully removed and attached to paper thus providing an excellent record of the
pattern.

SPRAY BLUE: Clean as many teeth on the pinion as possible then spray on the layout blue and let
it dry. Dry cycle (without digging for hoist and drag, slow speed for swing, and no lifting for propel)
the machine several times. (About 5 minutes) Where contact is present the blueing will be rubbed
off. This is by far the fastest method for checking patterns and hence the most popular.

If the pinion and gear are spur on single helical then block off one helix on the following pattern
examples to change from double helical to spur or single helical.

The following pages illustrate examples of contact patterns and the adjustments necessary to
improve the pattern of a typical drum gear mesh.

- Example Contact Patterns -

Corrective Adjustment: None Required.

Manual No. 10954 9-8 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Corrective Adjustment:
Move the left hand drum shaft bearing housing forward.

Corrective Adjustment:
Move the left hand drum shaft bearing housing to the rear and remove shims to lower.

Corrective Adjustment:
Move the left hand drum shaft bearing housing forward and remove shims to lower.

Sept. 2010 9-9 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Corrective Adjustment:
Move the left hand drum shaft bearing housing to the rear and add shims to raise.

Corrective Adjustment:
Move the left hand drum shaft bearing housing forward and remove shims to lower.

Corrective Adjustment:
Move the left hand drum shaft bearing housing forward and add shims to raise.

Manual No. 10954 9 - 10 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

Corrective Adjustment:
Move the left hand drum shaft bearing housing to the rear and remove shims to lower.

Corrective Adjustment:
Move the left hand drum shaft bearing housing to the rear and add shims to raise.

Sept. 2010 9 - 11 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

SPLINES

Cured splines disassemble by breaking the bond with puller, press or hydraulic jack and then
removing. Temperatures at least 400 oF. (204 oC.) - NOT TO EXCEED 650 oF. or 343 oC. - also
weaken the bond. Apply pressure and remove while hot.

INVOLUTE SPLINE ASSEMBLY

Involute spline assemblies develop a permanent fit with adhesive as indicated by Class #2 design.
The approved adhesive is Loctite CVV 82 (key fit). Standard parts joined with involute splines
assemble with a liquid adhesive that hardens when confined in the absence of air.

Anti-friction bearings installation on a shaft requires an interference fit, assemble BEST by shrinking
the inner race onto the shaft. This means creating a difference in temperature between shaft and
the inner race. Heating the bearing is easier than cooling the shaft. Heat the bearing in a suitable
oven or other means of dry heat.

NOTE: DO NOT APPLY HEAT DIRECTLY TO THE BEARING.

WARNING: Do not use a water or oil bath to heat bearings. DO NOT HEAT
ABOVE 250 oF.

Manual No. 10954 9 - 12 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

MOTOR SHAFT, HUB OR GEAR INSTALLATION

HUB ADVANCE and TEMPERATURE CHART

NOTE: The motor shaft diameter is measured at the large end of the taper.

Sept. 2010 9 - 13 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

INSTALLATION OF SHRINK FIT COMPONENTS

1. Thoroughly clean the seating surface on the shaft and the tapered bore of the component
using a recommended standard safety solvent such as the "Stoddard" type solvents, and
wipe dry with a cloth.

2. Remove any scoring or high spots on either part and check with "Bluing" by spotting the cold
component on the shaft by hand to obtain at least 75% FIT. If not at 75% or better, the
component should be scraped until desired fit is indicated by repeating bluing and cold fitting.

3. Break all sharp edges of the key with a fine file so there will be approximately .015 inch
radius at each edge. Fit the key to the shaft, taking care to avoid upsetting the metal of the
shaft next to the key. The key should be tight in the shaft but not so tight that it must be
hammered in place.

4. The cold component must be tried on the shaft to make certain it does not bind on the key.

5. Mount the component cold on the shaft and snap it into position by hand.

6. Measure the cold position using a micrometer depth gauge as indicated in the detail. Record
the measurement. Mark where the depth gauge was resting so measurements can be made
from the same position after the component has been mounted.

7. Remove the component from the shaft and thoroughly clean all bluing marks from the bore
and shaft. Remove or protect seals or other items that may be damaged by heat.

8. With the component removed, heat in a suitable oven or other means of dry heat. Control
the temperature as directed using values indicated in the table.

• Do not use oil or water to heat the component.

• Component temperature must never exceed 350oF. (177oC.).

• The temperature differentials indicated in the table represents calculated values to

obtain the listed hub advance. The values represent the difference in degrees
(Fahrenheit or Celsius) required between the shaft and the component at the time of
assembly. For example, if the shaft is 77oF. (25oC.) and the temperature difference in
the table is 155oF. (86oC.) then heat the component to 232oF. (111oC.) for mounting.

• To check the temperature of the component, use a Fahrenheit or Celsius thermometer

by placing putty over the bulb and holding it against the hub. Heat component a few
degrees above the desired temperature before removing it from the oven.

Manual No. 10954 9 - 14 Sept. 2010

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9. After the component has been removed from the oven, wait a few minutes until the bore has
cooled to the temperature required, remove the thermometer and quickly mount as described.

10. After making sure the bore is clean, quickly locate the component in the same angular position
of the shaft as when cold. When nearly engaged with the taper fit, but not actually in contact,
snap it forcibly into place with a quick push. It is important that the hot component be instantly
snapped into position before it has cooled appreciably. Otherwise, it will immediately freeze
to the shaft and cannot be adjusted further.

11. Check the hot shrunk-on position of the component on the shaft using the micrometer depth
gauge as before. The actual advance is the difference between the depth gauge reading at
the hot and cold positions. To control the stresses in the component the advance must be
within the limits specified in the table.

NOTE: If the advance is not within the limits given, the component should be pulled and
remounted.

12. After the component has been properly shrunk on the shaft, assemble the lock washer and
nut or other means of locking.

13. When shoulder nuts are used, make certain the shoulder does not bottom before the main
body of the nut tightens on the locking plate. In case the shoulder on the nut bottoms before
tightening on the locking plate, the nut should be removed and the shoulder ground or
machined off so clearance is available.

14. After it is certain that the nut is securely tight, turn up the locking plate on at least two faces
of the nut.

NOTE: It should be kept in mind that the component fit on the shaft and the fit on the key are
important points in doing a good job of holding the component on the shaft. The
locking plate simply serves to hold the nut on the shaft. With the correct fit between
the tapered bore and shaft there is no load on the nut and locking plate.

Sept. 2010 9 - 15 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

REMOVAL OF SHRINK FIT COMPONENTS

When removing the component from a motor armature, always use a suitable puller to avoid causing
damage to either the component, motor frame, bearings or armature shaft. DO NOT HEAT THE
COMPONENT BEFORE PULLING. DO NOT USE WEDGES BETWEEN THE COMPONENT AND
THE BEARING CAP. In order to prevent damage to anti-friction bearings, avoid the use of sledge
hammer on the puller.

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.

Manual No. 10954 9 - 16 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

BOLT TIGHTENING

TORQUE WRENCH METHOD

The following tables show torque values for bolt grades 2, 5 and 8 with UNC threads only. Table 1
lists torque values for lubricated or plated threads and for using hardened washers. Table 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.

Table 1 - Lubricated or Plated Threads or with Hardened Washers

Table 2 - Dry Threads

Sept. 2010 9 - 17 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

TURN-OF-NUT METHOD

CAUTION: THIS TIGHTENING PROCEDURE IS ONLY APPLICABLE FOR BOLT

GRADES 5 AND 8 WITH UNC THREADS. For bolts with other than UNC
threads, contact the Bucyrus International Service Department.

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 insure 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 of Snug Tight Torque Values

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 Table 4. It is not necessary
to follow any particular bolt to bolt sequence during this portion of the “turn of the nut” tightening.

Manual No. 10954 9 - 18 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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.

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

Patterns for Wirelocking Capscrews

Use 14 gauge soft annealed lockwire. 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.)

Sept. 2010 9 - 19 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

HYDRAULIC TENSIONER

Proper bolt or rod tension is critical to obtain a trouble free mechanical connection. Because of the
bolt or rod size, a hydraulic tensioner is recommended on the 182M lower frame and crawler
assembly. The table below specifies the location and nut requirements.

HYDRAULIC PUMP PRESSURES for CLAMP LOADS

Reference Group Nut Size Residual Clamp Hydraulic Pump Gauge

Load (Lbs.) Pressure (PSI)

Field Erection - M64 300,000 14,900

Lower Frame M64 210,000 10,400
and Crawlers

The tensioner consists of the following E G & G sealed components:

Component Model Part No.

Jack Tool with Nut 60360-EL-1-M64-6 276689-5

Drive Mechanism

Air-hydraulic Pump 79231 276681-7

Hose Assembly 71895-11-HP 276680-9

NOTES:

• The pressures listed are only for the tensioner equipment specified.

• Observe tensioner operation to be sure the maximum stroke is not exceeded.

Manual No. 10954 9 - 20 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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.

CAUTION: 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.

WARNING: REINFORCING STRUCTURAL MEMBERS SHOULD BE MADE ONLY

UPON RECOMMENDATION BY BUCYRUS INTERNATIONAL, INC.
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.

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.

Sept. 2010 9 - 21 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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. Refer to the STEEL TYPES
Table later in this section for the types of steel used and the recommended electrode and preheat.

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 -20o to -75oF. 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 250oF 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.

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.

Manual No. 10954 9 - 22 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

REPAIR WELDING OF CRACKS

Joint Preparation for Repair of Cracks

Remove the entire crack by arc air-gouging or grinding. Prepare a V-groove of approximately 45-
60o 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.

Sept. 2010 9 - 23 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

PREHEAT

When preheating, apply heat to a broad, general area surrounding the repair location. A soaking
heat which thoroughly penetrates the material through the 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 400oF, 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.

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.

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.

Manual No. 10954 9 - 24 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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 added 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 Bucyrus
International, Inc.

Sept. 2010 9 - 25 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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.

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.

Manual No. 10954 9 - 26 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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
300oF. 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.

PREHEAT

1. Two levels of preheat are required for tooth repair, 250oF minimum for butter welding and
175oF minimum for filling in the groove. Temperatures should be measured with temperature
indicating crayons.

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.

Sept. 2010 9 - 27 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

NOTE: Contract services are available for field application of resistance heating equipment.
Suggested source:
Stresstech
Box 11
Red Wing, MN 55066
(612) 388-7117

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.

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 250oF. (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
½ 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 175oF. (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.

Manual No. 10954 9 - 28 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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.

Sept. 2010 9 - 29 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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 - 45oF 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)
ASBESTOS GLOVES
CUTTING GOGGLES, Dark
SOAPSTONE MARKERS
ANTI-SPATTER COMPOUND
TEMPILSTIKS - 200o and 400o

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 1500oF
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

Manual No. 10954 9 - 30 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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 20oC (66oF) - Chromel - Ohms -
Alumel - .0683 Ohms.
WIRE INSULATION - each Conductor Enamel, Asbestos (Twisted Pair) Overall Asbestos Braid
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 - Swagged 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 Heating Pellets
Range: 1050oF 1100oF - 1200oF 1250oF
Mean Accuracy: +/-1%
These Tempil Pellets will begin to melt at the temperature specified.

Sept. 2010 9 - 31 Manual No. 10954

Bucyrus International, Inc.
182M-AC Electric Mining Shovel

SHEAR BLOCK INSTALLATION

WELDING PROCEDURE

1. Do not weld shear blocks until after the bolted component has been accurately checked for
location and the bolts have been tightened to their proper pretension.

2. Position the shear blocks on the weld surface and against the contact surface per the
engineering drawing. Check for a solid contact fit: hand grind if necessary.

3. Hold the blocks tightly in place (use a hydraulic jack or equal) and tack weld. Set up and tack
all blocks for each component prior to starting the final weld. (See the figure below for tack
weld areas.) Check the contact surface with a .005 (.127 mm) feeler gauge. If the gauge can
be inserted between the contact surfaces, the block must be removed and reinstalled.

4. Fillet weld sides “A” and “B” only, starting from the back and advancing toward the contact
side - alternating equal weld deposits on both sides. This will maintain the desired tight
contact as well as balance the shrinkage stress. Stop the weld deposit short of the contact
surface, for example: never weld the shear block to the component being restrained.

5. Do not weld on the back side of the shear block.

6. A typical weld symbol and notes are shown on the engineering drawing as shown above.

Manual No. 10954 9 - 32 Sept. 2010

 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

WIRE ROPE CARE AND MAINTENANCE

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.

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.

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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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.

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.

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182M-AC Electric Mining Shovel

Improper Methods for Uncoiling Wire Rope

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" diam. 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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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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 the 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.

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182M-AC Electric Mining Shovel

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.

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.

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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 are used than shown in the table, the amount of rope
turn-back should be increased proportionately. THE ABOVE IS BASED ON THE USE OF CLIPS
ON A NEW ROPE.

IMPORTANT: 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.

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182M-AC Electric Mining Shovel

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.
IMPORTANT: Avoid sudden shock loads.
NOTE: This is the recommended procedure. If variations are made to suit special conditions,
they should be carefully evaluated beforehand.

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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.

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.

Groove Gauge for New or Re-Worked Sheaves

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

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.

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.

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.

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182M-AC Electric Mining Shovel

INSPECTION DATA

It is essential to maintain a well-planned program of periodic inspection. Frequently, there are

statutory and/or regulatory agencies who 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. And 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.

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182M-AC Electric Mining Shovel

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; to include, 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.

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182M-AC Electric Mining Shovel

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.

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.

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 dependant 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.

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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.

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.

Rope Stretch

All ropes will stretch when loads are initially applied.

Wire Rope Stretch vs Rope Life

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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.

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.

Kinks

Kinks are permanent distortions caused by loops drawn too tightly. Ropes with kinks must be
removed from service.

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.

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.

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182M-AC Electric Mining Shovel

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.

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.

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 be no greater than 10 degrees.

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.

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.

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.

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182M-AC Electric Mining Shovel

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.

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).

Examples of Broken Wires

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.

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 Bucyrus International, Inc.
182M-AC Electric Mining Shovel

DIAGNOSTIC GUIDE TO COMMON WIRE ROPE DEGRADATION

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Bucyrus International, Inc.
182M-AC Electric Mining Shovel

AIR AND HYDRAULIC SYSTEM QUALITY

AIR AND HYDRAULIC SYSTEM QUALITY RECOMMENDATIONS

PRESSURE

Hose selection shall be made so that the manufacturer’s published maximum recommended
working pressure of the hose is greater than: the maximum pressure switch setting for single
line system pressure; the maximum unloader setting for air system pressure; or the maximum
relief valve or compensating setting for hydraulic system pressure. Surge pressure in the
system higher than the maximum recommended working pressure will cause failure or shorten
hose life. DO NOT use burst pressure for this purpose.

SUCTION

Hose used for suction applications shall be selected to withstand the vacuum and pressure
of the system. Improperly selected hose may collapse in a suction application.

TEMPERATURE

Care must be taken when routing hose near hot objects. Fluid and ambient temperatures,
both steady and transient, shall not exceed the limitations of the hose.

MECHANICAL LOADS

Avoid excessive flexing, twist, kinking, tensile or side loads, and vibration. Provide adequate
bend radius. Use swivel type fittings or adapters to insure no twist is put into the hose.

PHYSICAL DAMAGE

Protect hose from wear, snagging and cutting.

HOSE AND FITTING ASSEMBLY

DO NOT INTERMIX HOSE AND FITTINGS IN HOSE ASSEMBLIES. HOSE AND FITTINGS
MUST BE FROM SAME MANUFACTURER. Use the proper fitting with the proper hose,
(i.e.: a reusable fitting with the hose designated by the manufacturer for usable fittings; crimp
style fittings with hose designated by the manufacturer for permanent fittings, etc.).

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RELATED ACCESSORIES

Use the properly designated crimp or swage machine and dies recommended by the hose
and fitting manufacturer.

REUSABLE/PERMANENT

Do not reuse any reusable hose product that has blown or pulled off a hose. Do not reuse a
permanent (crimped or swaged) hose fitting or any part thereof.

CLEANLINESS

Hose and components vary in cleanliness levels. Care must be taken to insure that they
have an adequate level of cleanliness for the application.

Protection shall be provided for hose, fittings, and assemblies in clean condition and
maintained through purchase, manufacture, storage, shipping, and installation operations.

AIR AND HYDRAULIC SYSTEM QUALITY MAINTENANCE

Any of the following conditions require immediate shutdown of the effected system and replacement
of the hose assembly:

• Fitting slippage on hose.

• Damaged, cut or abraded cover (any reinforcement exposed).
• Hard, stiff, heat cracked, or charred hose.
• Cracked, damaged, or badly corroded fittings.
• Leaks at fitting or in hose, or at any point in the assembly.
• Kinked, crushed, flattened or twisted hose.
• Blistered, soft, degraded, or loose cover.
• Fluid build up beneath the outer cover (bubbling).

The following items must be tightened, repaired, or replaced as required:

• Leaking port conditions.
• Remove excess dirt buildup.
• Clamps, guards, shields.
• System fluid level, fluid type and any air entrapment.

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Sept. 2010 Schematic No. 4