FOREWORD
The purpose of this manual is to provide information concerning the mechanical maintenance of the 1570-W Walking Dragline.
The Model 1570-W consists of three major units, the lower works, the rotating deck and the front end equipment.
• The lower works provides a foundation for the revolving frame and contains the base, swing rack and roller circle.
• The rotating deck includes the revolving frame and machinery house. The machinery house encloses all of the hoist, swing, drag and propel machinery, and the electrical systems required to control machine functions. It also contains an air filtration system to minimize heat and dirt buildup in the machinery house. An elevated cab mounted on the house provides the machinery operator's station. The cab contains all machine operating controls.
• The front end equipment is comprised of the A-frame, fairlead, mast, boom, running ropes, boom structural strands, and dragline bucket.
This manual consists of four chapters, each divided into sections. A table of contents is located in the front of the manual.
Throughout this manual the words CAUTION, WARNING and NOTE appear in bold face type. CAUTION is preceded by the safety alert symbol A and indicates that injury to personnel could occur if the proper procedures are not followed during operation or maintenance. Always read the CAUTION note carefully and use extreme care while performing that particular function.
WARNING indicates a possible hazard to the machine or its components if the proper procedures are not followed. Whenever the word WARNING appears, special attention should be given to prevent possible equipment damage.
NOTE is used to stress a point or to give additional information concerning the procedure being discussed.
These CAUTION's and WARNING's are not all-inclusive. It is impossible for Bucyrus-Erie Company to know, evaluate, and advise maintenance and service personnel in every conceivable way a service operation might be performed and of the resulting possible hazardous consequences of each method. It is therefore extremely important that anyone who uses a service procedure or tool which is not recommended by Bucyrus-Erie Company to first satisfy himself that the service procedure or tool he chooses will not jeopardize his own safety, the safety of others, or cause machine or component damage.
Every effort has been made to make this manual as complete and accurate as possible at the time of pubHcation. Bucyrus-Erie Company reserves the right, however, to continually improve its products. Therefore changes to the equipment herein may have been made that are not reflected in this manual.
MACHINE SERIAL NUMBER
BUCYRUS-ERIE COMPANY
General Offices: South Milwaukee, Wisconsin, U.S.A. S/N 140884 and up
Lit. S375 BECOM 492
BI615842
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PAGE CHAPTER 1 MECHANICAL MAINTENANCE SECTION 1 - MAINTENANCE PROCEDURE General ................................................................................................................................... 1-1-1 Maintenance Schedules and Reports ................................................................................. 1-1-1 Safety ...................................................................................................................................... 1-1-2 General ......................................................................................................................... 1-l-2 In-Operation Maintenance ......................................................................................... 1-1-2 Precautions Before and During Maintenance Work .............................................. 1-1-2 SECTION 2 - LOWER WORKS Base ........................................................................................................................................ 1-2-1 Swing Rack ............................................................................................................................ 1-2-2 Roller Circle .......................................................................................................................... 1-2-3 Lifting Hook and Hook Path .............................................................................................. 1-2-5 Center Pintle ......................................................................................................................... 1-2-7 SECTION 3 - ROTATING DECK Revolving Frame ................................................................................................................... 1-3-1 Machinery Units ................................................................................................................... 1-3-1 Hoist and Drag Machinery ........................................................................................ 1-3-2 Swing Machinery ...................................................................................................... 1-3-12 Propel Machinery ...................................................................................................... 1-3-31 Brakes ......................................................................................................................... 1-3-40 Drag Rope Support ............................................................................................................. 1-3-46 Synchro-Tie .......................................................................................................................... 1-3-49 Machinery House and Cabs .............................................................................................. 1-3-51 Structural Members and Panels ............................................................................. 1-3-51 Dynavane Air Cleaner .............................................................................................. 1-3-52 House Fans (Chicago Blower) ................................................................................. 1-3-52 Walkways and Stairways ........................................................................................ 1-3-52 Rear Door Openers ................................................................................................... 1-3-53 Windshield Wiper ..................................................................................................... 1-3-53 Swing Control Unit .................................................................................................. 1-3-53 SECTION 4 - FRONT END EQUIPMENT Boom ....................................................................................................................................... 1-4-1 Upper and Lower Deflection Sheaves and Towers ................................................ 1-4-3 Boom Point ................................................................................................................... 1-4-3 Mast ........................................................................................................................................ 1-4-8 A-Frame ................................................................................................................................. 1-4-9 Structural Strands ............................................................................................................. 1-4-11 A-Frame Safety Structural Strands ....................................................................... 1-4-14 Upper, Lower and Intermediate Structural Strands .......................................... 1-4-14 Hoist and Drag Ropes ....................................................................................................... 1-4-17 Hoist Rope Replacement .......................................................................................... 1-4-18 Drag Rope Replacement ........................................................................................... 1-4-20 Fairlead ................................................................................................................................ 1-4-23 Repair .........................................................................................-................................ 1-4-23 Buffer Cylinder .......................................................................................................... 1-4-28 Dragline Bucket .................................................................................................................. 1-4-28
TABLE OF CONTENTS
CHAPTER 2
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SECTION 1 - GENERAL MAINTENANCE Safety ...................................................................................................................................... 2-l-l General ................................................................................................................................... 2-1-1 Maintenance of Air System ................................................................................................ 2-1-1 Air Compressor ............................................................................................................ 2-l-1 Air Lines ...................................................................................................................... 2-l-2 Air Tank ....................................................................................................................... 2-1-2 Air Line Lubricator .................................................................................................... 2-1-2 Air Line Filter ............................................................................................................. 2-1-2 Air Line Regulator ...................................................................................................... 2-1-2 Anti-Freezer - Alcohol Type (Optional) ................................................................... 2-1-2 Solenoid Valves ........................................................................................................... 2-1-5 Pressure Switches ....................................................................................................... 2-1-5 Air Dryer ...................................................................................................................... 2-1-5 SECTION 2 - COMPONENT MAINTENANCE Air Line Lubricators ............................................................................................................ 2-2-1 Type L12 & Ll 7 Micro-Fog Lubricators ................................................................. 2-2-1 Air Regulator ......................................................................................................................... 2-2-1 Air Line Filters ....................................................... ; ............................................................. 2-2-2 Type F12 & Fl 7 Auto Drain Filters ....................................................................... 2-2-2 Anti-Freezer ........................................................................................................................... 2-2-3 Air Dryer ................................................................................................................................ 2-2-4 CHAPTER
LUBRICATION SECTION 1 - GENERAL MAINTENANCE General ................................................................................................................................... 3-1-1 Lubrication Benchmarks ..................................................................................'................... 3-1-1 Lubrication Charts ............................................................................................................... 3-1-2 SECTION 2 - AUTOMATIC LUBE SYSTEMS System-A ................................................................................................................................ 3-2-1 System-B ................................................................................................................................ 3-2-1 System-C ................................................................................................................................ 3-2-1 System-D ................................................................................................................................ 3-2-1 System-E ................................................................................................................................ 3-2-2 System-F ................................................................................................................................ 3-2-2 System-G ................................................................................................................................ 3-2-2 System-H ................................................................................................................................ 3-2-2 System-I ................................................................................................................................. 3-2-3 System-J ................................................................................................................................. 3-2-3 System-K ................................................................................................................................ 3-2-3 System-L ................................................................................................................................ 3-2-3 Control Panels ....................................................................................................................... 3-2-3 Pump Control Stations ........................................................................................................ 3-2-3 Pumps ..................................................................................................................................... 3-2-3 Warning Devices ................................................................................................................... 3-2-4 Gearcase oil Filtration Systems (Optional) ...................................................................... 3-2-4 Cold Weather Equipment (Optional) ................................................................................. 3-2-4 Lubricant Drum Handling Equipment (Optional) ........................................................... 3-2-5
AIR SYSTEM
3
BI615842 CHAPTER 4 TROUBLESHOOTING Base Components ................................................................................................................... 4-1 Revolving Frame ...................................................................................................................... 4-2 Hoist, Drag, Swing and Propel Machinery ......................................................................... .4-2 Machinery House and Cabs ................................................................................................... 4-3 Lubrication Systems ................................................................................................................ 4-4 Air Line Regulator ................................................................................................................... 4-5 Air Lines and Storage Tank .................................................................................................. 4-5 Air Line Lubricator ................................................................................................................. 4-6 Automatic Drain Filter ........................................................................................................... 4-6 Dynavane Air Cleaner ............................................................................................................ 4-6 A-frame ...................................................................................................................................... 4-6 Mast ........................................................................................................................................... 4-7 Boom .......................................................................................................................................... 4-7 Dragline Bucket ....................................................................................................................... 4- 7 Drag and Hoist Ropes ............................................................................................................. 4-8 Fairlead ..................................................................................................................................... 4-8 APPENDICES APPENDIX Al - GEAR INSPECTION ............................................................................................... Al-1 APPEN.DIX A2 - BOLT TORQUING .................................................................................................. A2-1 Torque Wrench Method ........................................................................................................ A2-1 Turn-Of-The-Nut Method ..................................................................................................... A2-2 APPENDIX A3 - ADJUSTMENT ......................................................................................................... A3-1 Boom Structural Strand Adjustments ............................................................................... A3-1 Hoist Rope Deflection Sheaves and Guards Location ..................................................... A3-1 APPENDIX A4 - PINION AND COUPLING INSTALLATION ...................................................... A4-1 Removal from Shaft .............................................................................................................. A4-1 Mounting Pinion or Coupling on Shaft ............................................................................. A4-1 APPENDIX A5 - MAINTENANCE WELDING .............................................................................. A5-1-1 Section 1 - Repair Welding of Base, Revolving Frame, A-Frame, Walking Shoes and Drag Bucket .................................................................................................. A5-1-l General ....................................................................................................................... A5-1-1 Recommended Electrodes and Preheat ................................................................. A5-1-1 Welding Electrodes ................................................................................................... A5-1-1 Repair Welding Procedures .................................................................................... A5-1-2 General Procedure for Repair of Broken Parts ................................................... A5-1-3 Procedure for the Repair of Cracked or Broken Drag Bucket Lips A5-1-4 Stress Relieving ........................................................................................................ A5-1-5 Procedure for Replacement of Bucket Lip Shrouds ............................................ A5-1-6 Drag Bucket Tooth Repair ...................................................................................... A5-l-6 Drag Bucket Clevis Plates .................... ,................................................................. A5-1-8 Section 2 - Repair Welding Swing Rack Teeth ......................................................... A5-2-1 Preparation ................................................................................................................ A5-2-1 Welding Electrodes ................................................................................................... A5-2-2 Preheat ....................................................................................................................... A5-2-2 Welding ...................................................................................................................... A5-2-2 Section 3 - Welding and Cutting Equipment ............................................................. A5-3-1 Section 4 - Stress Relieving and Temperature Measuring Equipment A5-4-1
BI615842 APPENDIX A6 - LUBRICATION BENCHMARKS A6-1 MPG - Multipurpose Type Grease ................................................................................... A6-1 ACPL - Air Compressor (Piston Type) Lubricant ........................................................ A6-2 MWCL - Monighan Walking Cam Lubricant .............................................................. A6-3 MPO - Multi-Purpose Oil ................................................................................................... A6-4 OGL - Open Gear Lubricant A6-5 RGL - Regular Type Gear Lubricant .............................................................................. A6-6 RCRL - Roller Circle Rail Lubricant A6-9 RWRL - Running Wire Rope Lubricant ........................................................................ A6-11 SWRL - Structural Strand and Stationary Wire Rope Lubricant A6-12 APPENDIX A7 -TAPERED ROLLER REPLACEMENT A7-1 APPENDIX AS - PREVENTIVE MAINTENANCE CHECKLISTS ............................................. AS-1 Daily Checklist AS-1 Weekly Checklist .................................................................................................................. AS-3 Monthly Checklist AS-6 Quarterly Checklist AS-9 Semi-Annual Checklist AS-11 APPENDIX A9 - BRAKE OR CLUTCH MAINTENANCE CHECKLIST A9-1 Brake Lining Burnish-In Procedure A9-2 APPENDIX AlO - RAIL CHOCKING TIGHTNESS Al0-1 APPENDIX All - LOAD INDICATOR WASHER INSTALLATION ........................................ All-1
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