Shovels 1

ShovelsAugust 2006 Whitmore's: ShovelsWhitmore 1 This presentation is about Electric Mining Shovels August 2006 Whitmore's: ShovelsWhitmore 2 Shovels are used at both surface mines and the deeper open pit mines August 2006 Whitmore's: ShovelsWhitmore 3 The primary use for Shovels is to load material (coal. ore) into haul trucks August 2006 Whitmore's: ShovelsWhitmore 4 . rock. August 2006 Hydraulic Shovels are also used at mines They are not discussed in this presentation Whitmore's: ShovelsWhitmore 5 . Not discussed in this presentation. August 2006 Whitmore's: ShovelsWhitmore 6 .Front Loaders are also used. Shovel Components and Operations August 2006 Whitmore's: ShovelsWhitmore 7 . Shovels are Electrically Driven August 2006 Whitmore's: ShovelsWhitmore 8 . Shovel Power ‡ Incoming AC is changed to DC by MG Sets ‡ MG Sets deliver DC to motors that drive the Swing. Hoist and Crowd systems (On a Shovel the ³Crowd´ system is similar to the Drag system on a Dragline) ‡ Speed reduction is done through both enclosed gearboxes and open gears August 2006 Whitmore's: ShovelsWhitmore 9 . Propel. usually called the ³Dipper´ August 2006 Whitmore's: ShovelsWhitmore 10 .The Bucket. Shovel Digging Motion The Dipper is filled by hoisting August 2006 Whitmore's: ShovelsWhitmore 11 . The contents of the Dipper are released by opening the Dipper Door August 2006 Whitmore's: ShovelsWhitmore 12 . The House The Dipper August 2006 Whitmore's: ShovelsWhitmore 13 . The Boom August 2006 Whitmore's: ShovelsWhitmore 14 . The Boom Point Sheave Crawler Tracks August 2006 Whitmore's: ShovelsWhitmore 15 . The House Rollers and Swing Rack on a Shovel operate in the same way as a Dragline. and are lubricated by the Multi-Service lubricant The Center Pintle is lubricated either by the Multi-Service lubricant or the bearing grease August 2006 Whitmore's: ShovelsWhitmore 16 . Swing Rack Lubricant: SurStik® August 2006 Whitmore's: ShovelsWhitmore 17 . Hoist Ropes Boom Suspension Ropes (Static) August 2006 Whitmore's: ShovelsWhitmore 18 . The Dipper Sticks (sometimes called Dipper Handles) 1 2 Note: There are no Drag Ropes on a Shovel August 2006 Whitmore's: ShovelsWhitmore 19 . Dipper Sticks August 2006 Whitmore's: ShovelsWhitmore 20 . The ³Thrust´ and ³Retract´ Motion of Dipper Sticks is Called the ³Crowd´ Motion August 2006 Whitmore's: ShovelsWhitmore 21 . P&H uses two rectangular Sticks 10/13/04 22 . Bucyrus uses a single round Stick 10/13/04 23 . P&H Dipper Sticks August 2006 Whitmore's: ShovelsWhitmore 24 . The ³Saddle Blocks´ are guides for the Sticks Dipper The Dipper Sticks slide Stick against guide plates inside the Saddle Blocks SADDLE BLOCK SADDLE BLOCK (hidden) August 2006 Whitmore's: ShovelsWhitmore 25 . Multi-Service Lubricant is applied to the guide plates and Dipper Stick from Dipper Stick Drip Tubes fitted to the Saddle Block SurStikŒ August 2006 Whitmore's: ShovelsWhitmore 26 . August 2006 Rack gears are Crowd Rack built into the underside of the two sticks. These Crowd Rack are called the Whitmore's: ShovelsWhitmore Crowd Racks. 27 . Crowd Pinion is inside saddle block August 2006 Whitmore's: ShovelsWhitmore Crowd motion comes from the Crowd Pinion that engages with the Crowd Racks 28 . Multi-Service lubricant is applied to the Crowd Rack and Pinion Note the mess created by the use of an asphaltic lubricant August 2006 Whitmore's: ShovelsWhitmore 29 . The Crowd Pinion is Driven by the Crowd Motor + Enclosed Gearbox on the Boom August 2006 Whitmore's: ShovelsWhitmore 30 . Bucyrus Dipper Sticks August 2006 Whitmore's: ShovelsWhitmore 31 . The Bucyrus Round Dipper Stick August 2006 Whitmore's: ShovelsWhitmore 32 . The Saddle Block on a Bucyrus Shovel is circular Boom Saddle Block Dipper Stick August 2006 Whitmore's: ShovelsWhitmore 33 . A View of the Dipper Stick in the Saddle Block August 2006 Whitmore's: ShovelsWhitmore 34 . Lubricant Ports in the Saddle Block August 2006 Whitmore's: ShovelsWhitmore 35 . the Hoist Cable and the Crowd Cable Both cables are driven by Drums in the House August 2006 Whitmore's: ShovelsWhitmore 36 .Bucyrus dipper sticks are controlled by two sets of wire ropes that operate independently. Hoist Cable Crowd Cable Hoist Cable Crowd Cable August 2006 Whitmore's: ShovelsWhitmore 37 . they control the Crowd Motion (Thrust and Retract) August 2006 Whitmore's: ShovelsWhitmore 38 .The Crowd Cables perform the same function as the Crowd Rack and Pinion on a P&H Shovel. Lubricants August 2006 Whitmore's: ShovelsWhitmore 39 . Enclosed Gearbox Oil August 2006 Whitmore's: ShovelsWhitmore 40 . It drives the Crowd Rope Drum. It drives the Crowd Pinion. Drives the Hoist Rope Drum ‡ Crowd enclosed gearbox ‡ In a P&H the Crowd gearbox is located on the Boom. ‡ Swing enclosed gearbox ‡ In the House.Enclosed Gearboxes on Shovels: ‡ Hoist enclosed gearbox ‡ In the House. Turns the House ‡ Propel enclosed gearbox August 2006 Whitmore's: ShovelsWhitmore 41 . ‡ In a Bucyrus the Crowd gearbox is located in the house. or consult Whitmore Technical Services Dept. use DecathlonŒ F August 2006 Whitmore's: ShovelsWhitmore 42 .Recommended Products ‡ Whitmore recommends ParagonŒ for Shovel gearboxes ‡ Choose viscosity based on the OEM recommendations and the climate. use DecathlonŒ HD series ‡ Where a Flender-approved oil is needed. ‡ Where synthetic oil is required. Grease August 2006 Whitmore's: ShovelsWhitmore 43 . Bearings ‡ Many customers use Whitmore¶s SurStikŒ Multi-Service lubricant in the automatic system for lubricating bearings ‡ Whitmore greases used on Shovels: ± OmnilithŒ 360 EP 1 ± DuraFilmŒ EP 1 ± Matrix® EP 1 ± LegacyŒ M EP 1 ± Based on synthetic oil ± Used year round in very cold conditions August 2006 Whitmore's: ShovelsWhitmore 44 . Multi-Service Lubricant Applied by automatic lubrication system August 2006 Whitmore's: ShovelsWhitmore 45 . Multi-Service Lubricant Applications ‡ Hoist: Open Gear on Hoist Rope Drum ‡ Crowd: ± P&H: Crowd Rack and Pinion (on the Dipper Stick) ± Bucyrus: Open Gear on Crowd Rope Drum ‡ ‡ ‡ ‡ Dipper Stick (and Saddle Block) Swing Rack and Pinion Circle Rail and Rollers SurStikŒ Multi-Service lubricant may be used in bearings (except electric motor bearings) Whitmore's: ShovelsWhitmore 46 August 2006 . Because it Performs Exceptionally Well on Dipper Sticks. Whitmore Recommends SurStikŒ MultiService Lubricant for use on Shovels August 2006 Whitmore's: ShovelsWhitmore 47 . SurStikŒ on Dipper Sticks ‡ SurStikŒ does not make the Dipper Stick prone to contamination by dust ‡ Easy to maintain a good coating using SurStikŒ ‡ On Bucyrus machines SurStikŒ spreads easily around the Stick to form a black protective coating ‡ SurStikŒ will not flake off in freezing conditions August 2006 Whitmore's: ShovelsWhitmore 48 . Choosing the Grade of SurStikŒ ‡ Choose the grade based on the climate ± Use SurStikŒ Extra Heavy: ± Use SurStikŒ Summer: ± Use SurStikŒ Winter: -7°C to 110°C -12°C to 110°C -35°C to 25°C ‡ Distributors report that the best results are obtained using the heaviest possible grade for the climate conditions August 2006 Whitmore's: ShovelsWhitmore 49 . Whitmore Lubricants for Wire Ropes ‡ Same as for Draglines ‡ Wire Ropes: ± Whitmore¶s Wire Rope Lubricant, or ± Renew® 20 or 30 (uses recycled oil), or ± WR-5 (contains a solvent) August 2006 Whitmore's: ShovelsWhitmore 50 Motor Couplings ‡ ‡ ‡ ‡ Use Whitmore¶s VortexŒ Specially designed for use in couplings Extremely tacky Very low bleed on the K36 Centrifugal bleed test ‡ Shell Coupling Grease: 1.87% loss after 24 hours ‡ Whitmore¶s VortexŒ: 0.94% loss after 24 hours August 2006 Whitmore's: ShovelsWhitmore 51 Shovel Models August 2006 Whitmore's: ShovelsWhitmore 52 Bucyrus (formerly Bucyrus Erie. now Bucyrus International) August 2006 Whitmore's: ShovelsWhitmore 53 . 9 m3 August 2006 Whitmore's: ShovelsWhitmore 54 .Bucyrus 195B Shovels Dipper capacities: 9.2 to 23. 48 to 39.27 m3 August 2006 Whitmore's: ShovelsWhitmore 55 .Bucyrus 295B Shovels Dipper capacities: 18. Bucyrus 395B Shovels Dipper capacities: 26.5 m3 August 2006 Whitmore's: ShovelsWhitmore 56 .7 to 53. 2 m3 August 2006 Whitmore's: ShovelsWhitmore 57 .6 to 61.Bucyrus 495B Shovels Dipper capacities: 30. 3 m3 August 2006 Whitmore's: ShovelsWhitmore 58 .5 to 64.Bucyrus 595B Shovels Dipper capacities: 24. Marion Marion is now part of Bucyrus August 2006 Whitmore's: ShovelsWhitmore 59 . 6 m3 August 2006 Whitmore's: ShovelsWhitmore 60 .Marion 182-M Dipper capacities: 5.7 to 17. P&H August 2006 Whitmore's: ShovelsWhitmore 61 . 2 to 53.P&H 2800XPB Dipper capacities: 25.5 m3 August 2006 Whitmore's: ShovelsWhitmore 62 . 6 to 61.P&H 4100BOSS Dipper capacities: 30.2 m3 August 2006 Whitmore's: ShovelsWhitmore 63 . 5 m3 August 2006 Whitmore's: ShovelsWhitmore 64 .9 to 76.P&H 4100XPB Dipper capacities: 35. August 2006 Whitmore's: ShovelsWhitmore 65 .