Cat Bucyrus 1570W Walking Dragline Mechanical Maintenance Manual BI006738 - PDF DOWNLOAD

Technical Manual

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FOREWORD

The purpose of this mal}ual is to provide information concerning the mechanical maintenance of the 1570W Walking Dragline.

The purpose of this mal}ual is to provide information concerning the mechanical maintenance of the 1570W Walking Dragline.

The Model 1570W 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 build-up 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.

The Model 1570W 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 propel machinery, and the electrical systems required to control machine functions. It also contains an filtration system to minimize heat and dirt build-up 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.

This manual consists of chapters, 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 and use extreme care while performing that particular function.

Throughout this manual words CAUTION, and NOTE appear in bold face type. CAUTION is preceded by the alert symbol A and indicates that injury to personnel could occur if the proper procedures are during operation or maintenance. Always read the CAUTION note extreme while 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.

WARNING indicates a possible to its components if the proper procedures are not followed. Whenever the word '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.

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. ItisimpossibleforBucyrus-ErieCompanyto 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.

These CAUTION's and WARNING's are not all-inclusive. ItisimpossibleforBucyrus-ErieCompanyto 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 uses a service procedure or tool which is not recommended by Bucyrus-Erie Company to that service procedure or tool he chooses will not jeopardize his own safety, the safety of others, or cause machine or component damage.

TABLE OF CONTENTS

TABLE OF CONTENTS

CHAPTER 2- AIR SYSTEM

3-

CHAPTER!

MECHANICAL MAINTENANCE

SECTION 1 - MAINTENANCE PROCEDURE

SECTION 1- MAINTENANCE PROCEDURE

GENERAL

This section of the manual describes those aspects of maintenance such as schedules, reports, and safety as related to the Model 1570W Walking Dragline.

MAINTENANCE SCHEDULES

MAINTENANCE SCHEDULES AND REPORTS

Ideally, all maintenance should be approached from the preventive standpoint and on a regularly scheduled basis. Obviously, this approach keeps downtime to a minimum and results in reduced maintenance costs. To establish a preventive up- _ keep program, scheduled inspections and an operator's daily report are the most useful tools available. Scheduled inspections should be conducted by the Mine Mechanical and Electrical Maintenance Departments since they are the most qualified. Either department should generate a certain amount of paperwork, such as inspection records, that become a part of the mine's permanent file on the machine. The inspection records should be explicit, complete, and cover every part of the machine. Each machine operator should complete a daily record of the machine's performance. This record should include time worked, time down, reasons for all delays, and observations on any unusual conditions encountered during operation. From these records, items that can potentially cause machine downtime can be corrected or prevented immediately, or scheduled for a future date when the machine availability can be coordinated with the other mine activities.

Each problem should be thoroughly reviewed and evaluated before scheduling any maintenance or repair. The following points should be considered during the evaluation.

maintenance should be from the preventive standpoint and on a regularly scheduled basis. Obviously, this approach keeps keep are able. Scheduled should be conducted Maintegenerate a a part permanent on explicit, complete, and cover every part of the machine. Each machine operator should complete From these items can machine downtime be corrected prescheduled date when the machine availability be coordinated evaluated before scheduling maintenance repair. The following points should be considered the evaluation.

1. Is the problem one of normal wear?

2. Is the problem caused by machine application?

3. Is the problem a result of operator error?

4. Is the problem a result of unavoidable circumstances?

5. Is the problem of a repetitive nature?

1. Is operator 4. a stances? a nature?

6. By leaving repairs to a later date, will any other component be affected?

By to date, other component be affected?

7. Can repairs be accomplished immediately?

8. Will the cost of repairs immediately, rather than later, be worthwhile?

9. How long will the machine be down?

Once maintenance or repair has been scheduled, take the following points into consideration to minimize downtime and expense.

expense.

1. Are all tools and equipment needed to accomplish maintenance or repair available on the job, and are they in good repair?

2. Are on hand and available?

2. Are all replacement parts on hand and readily available?

replacement auxiliary such seals Is

3. Is replacement of auxiliary parts, such as seals and bearings, necessary to accomplish repair, and have they been ordered?

4. Is all disassembly and reassembly data available?

5. Have repair crews been scheduled?

6. Will there be adequate supervision on hand for the repair crews?

7. Has the manufacturer been consulted for Service or Engineering assistance?

5. Have repair crews been scheduled? there vice or assistance?

long will the machine be down? should

8. How long will the machine be down?

Once repair has been accomplished, the problem should again be reviewed with the following things in mind.

1. Was the cause of the coror

1. Was the cause of the problem permanently corrected or just patched?

2. What guarantee is there the same problem will not occur again?

3. Is consultation with the manufacturer for design improvement necessary?

4. What costs were incurred in downtime, parts, tools and labor?

2. What is there the same will again? parts, Could the problem have been prevented by

5. Could the problem have been prevented by prior action?

h CAUTION: Many of the component parts of the 1570W are heavy, bulky items. Extreme caution should be used when lifting these items. Personnel should be certain of the weights of components before attempting to lift them, either manually or with some lifting device.

h CAUTION: Many of the component parts of the 1570W are heavy, bulky items. Extreme caution should be used when lifting these items. Personnel should be certain of the weights of components before attempting to lift them, either manually or with some lifting device.

All applicable safety rules should be followed when using cranes or other lifting equipment. Be sure of the load, lifting height and radius, and capacity of the machine before lifting a load. Failure to follow all applicable safety rules when lifting heavy parts can cause serious or fatal injury.

All applicable safety rules should be followed when using cranes or other lifting equipment. Be sure of the load, lifting height and radius, and capacity of the machine before lifting a load. Failure to follow all applicable safety rules when lifting heavy parts can cause serious or fatal injury.

MECHANICAL MAINTENANCE

MECHANICAL MAINTENANCE

SECTION 2 - LOWER WORKS

2-

should be checked periodically for wear and damThe base should be checked monthly

rails proper lubrication, and of the wear surfaces. The or should also be this time ing close attention the condition of the pinion

The lower works (figure 1) of the 1570W dragline should be checked periodically for wear and damage. The base structure should be checked monthly for cracking or buckling, especially in the areas of the center pintle and the roller circle diaphragms. The roller circle rails and rollers should be checked weekly for proper lubrication, pitting, spalling, and galling of the wear surfaces. The rail clamp bolts and chocks should be checked for tightness. The swing rack should be checked weekly for proper lubrication, cracked or broken teeth and pitting, spalling or galling of the teeth. The swing pinions should also be inspected at this time paying close attention to the condition of the pinion

teeth and that the pinion retainer bolts are in place and tight.

BASE

the entire base (figure 1) for at intervals, no one month check the interior surfaces of the top plate welds that join the top plates the Observe the condition of all welds and plates

Inspect the entire base structure (figure 1) for cracked or buckled plates and cracked welds at regularly scheduled intervals, no less than one month apart. Carefully check the interior surfaces of the top plate welds that join the top plates to the roller circle rail pads. Check them both inside and out. Observe the condition of all welds and plates of the interior with special attention given to the vertical diaphragm plates and welds underneath the roller circle path. Examine the welds that join

1. BASE

3. ROLLER CIRCLE

2. LOWER RAILS

4. SWING RACK

5. CENTER PINTLE

6. PINTLE CLAMP COLLAR

INSIDE CONVEX

8 FILLET WELD RACK TO PAD ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;::r-- 7

REPAIR

To replace a roller, frame section or rail section (figure 3), proceed as follows:

1. Move the machine to a safe area with adequate space to perform the repair.

2. Swing the machine so the damaged part is located under roller circle not having an upper rail. Shut down the machine and tag the controls.

NOTE: If an upper rail section is to be replaced, the machine will have to be jacked up slightly to remove it. Contact the BucyrusErie Service Department for the correct procedure.

3. Remove the roller lube fittings and roller pin retaining bolts. Remove the outer and inner frame splice plate bolts. With a torch, break the weld at the top of the splice plate. Follow all safety rules when using the torch.

NOTE: The inner and outer frame splice joints are not in line but are staggered.

4. Remove the splice plates and inner and outer frames. With suitable equipment, lift the rollers from the lower rail. Remove the pin and bushings from the roller.

but Remove outer from the lower rail. Remove the and bushings from the roller.

5. With a torch, break the welds securing the chocks to the base top plate. Remove the rail clamps and chock. Remove the rail section.

chocks the base top plate. the rail or

6. Repair or replace all worn or damaged parts and reassemble in reverse of disassembly.

7. If a new rail section is being installed, the rail section must be machined to match the rails on either side. If a new roller is being installed, the roller flange must be machined to match the existing rollers. Refer to appendix for procedure for matching rollers.

on

1. SWING RACK SECTION

5. LEVELING SCREW

2. LOWER RAIL AND PAD

6. SHIMS

3. RAMPS

7. RACK PAD

4. BASE

8. RACK BOLT

6.

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