FOREWORD
The purpose of this manual is to provide information concerning the mechanical maintenance of the 2570W Walking Dragline.
The Model 2570W 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 ofthe 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.
This manual consists offour 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 orits 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 as possible at the time of printing. However, Bucyrus-Erie Company reserves the right to continually improve its products. For this reason changes may be made that are not in this manual.
MACHINE SERIAL NUMBER
BUCYRUS-ERIE COMPANY General Offices: South Milwaukee, Wisconsin, U.S.A . 1M SPS 1085 © BUCYRUS-ERIE COMPANY. 1985 BI005545
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CHAPTER 1- MECHANICAL MAINTENANCE PAGE Section 1- MAINTENANCE PROCEDURE General -. 1 Maintenance Schedules and Reports 1 Safety 2 General 2 In-Operation Maintenance 2 Precautions Before and During Maintenance Work 2 Section 2- LOWER WORKS Base 5 Swing Rack 6 Roller Circle. 6 Lifting Hook and Hook Path 9 Center Pintle 9 Section 3- ROTATING DECK Revolving Frame 11 Machinery Units ' 12 Hoist and Drag Machinery 12 Swing Machinery 18 Propel Machinery 32 Brakes 44 Drag Rope Support 49 Drag Rope Dirt Trough Cleaning System 51 Selsyn-Tie 52 Machinery House and Cabs 53 Structural Members and Panels 53 Dynavane Air Cleaner 54 House Fans 54 House Fans (Propellair) 55 House Fans (Chicago Blower) 55 Auxiliary Hoists and Overhead Crane 55 Walkways and Stairways 57 Rear Door Openers 57 Windshield Wiper 61 Operator's Seat 61 Swing Control Unit 61 Section 4- FRONT END EQUIPMENT Boom 63 Hoist Rope Deflection Rollers and/or Sheaves and Towers 65 Boom Point 66 Mast 69 A-Frame 69 Hoist Rope House Deflection Rollers or Sheaves 75 Structural Strands ,., .. ,....................................... .. 75 A-Frame Safety Structural Strands 76 Upper, Lower and Intermediate Structural Strands 77 © BUCYRUS-ERIE COMPANY, 1985 BI005545
TABLE OF CONTENTS
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CHAPTER 2- AIR SYSTEM
Hoist and Drag Ropes 86 Hoist Rope Replacement 87 Drag Rope Replacement 88 Fairlead. 90 Buffer Cylinder 95 Dragline Bucket 95
Section 1- GENERAL MAINTENANCE Safety 97 General 97 Maintenance of Air System 97 Air Compressor 97 Air Lines. ........................................................................... .. 97 Air Tank 99 Air Line Lubricator 99 Air Line Filter " 99 Air Line Regulator 99 Anti-Freezer - Alcohol Type (W ABCO 510333) 99 De-leer (Tanner T87) 99 Air Dryer (Kellogg-American D7 A) (Main Air System) 101 Solenoid Valves 104 Pressure Switches 104 Air Dryer (Boom Pressurization) 104 Section 2- COMPONENT MAINTENANCE Air Compressor (Kellogg-American) (B462) " 105 Daily Maintenance 105 Weekly Maintenance " 105 Monthly Maintenance " 105 Head Valve Service 105 Piston Ring Service 107 Overhaul Procedure 107 Reassem bly ........................................................................ .. 108 Centrifugal Unloader Service 109 Air Line Lubricators 110 Micro-Fog Lubricator 110 Oil Fog Lubricator (Type 10-002, 3 oz. and 1/3 pint size) 110 Oil Fog Lubricator (Type 10-002, 1/2 pint size) 110 Automatic Drain Filter 111 Anti-Freezer - Alcohol Type (WABCO 510333) 113 De-leer (Tanner T87) 113 Maintenance " 113 Air Dryer (Kellogg-American D7A) (Main Air System) 114 Maintenance 114 Air Regulator 114 Air Dryer (Boom Pressurization) 115 BI005545
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CHAPTER 3- LUBRICATION
CHAPTER 4-
Section 1- GENERAL MAINTENANCE General 117 Lubrication Benchmarks 117 Lubrication Charts 118 Section 2- AUTOMATIC LUBE SYSTEMS AP System 133 AS System -' 133 AW System 133 BSystem 133 D System 134 E System 134 F System 134 G System 134 H System " , 134 I System 135 J System 135 K System 135 Control Panels 135 Pumps 135 Warning Devices " 135 Cold Weather Equipment (Optional) 136 Lubricant Drum Handling Equipment (Optional) 136
TROUBLESHOOTING Base Components 137 Revolving Frame 138 Hoist, Drag, Swing and Propel Machinery 138 Machinery House and Cabs 139 Lubrication Systems 140 Air System 141 Air Compressor 141 Centrifugal Unloader 143 Air Line Regulator 143 Air Lines and Storage Tank 143 Air Line Lubricator 143 Automatic Drain Filter 143 Air Dryer (Main Air System) 143 Dynavane Air Cleaner 145 A-Frame 145 Mast 145 Boom 146 Dragline Bucket 146 Drag and Hoist Ropes '" 147 Fairlead 147 © BUCYRUS-ERIE COMPANY, 1985 BI005545
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Appendix Al . GEAR INSPECTION 1A Appendix A2· BOLT TORQUING Torque Wrench Method 3A Turn of the Nut Method 4A Appendix A3 ADJUSTMENTS Boom Structural Strand Adjustments 5A Brake Adjustment Tabulation 5A Appendix A4· PINION, BRAKE DRUM, AND COUPLING INSTALLATION 7A Appendix A5 . MAINTENANCE WELDING Section 1- Repair Welding of Base, Revolving Frame, A-Frame, Walking Shoes and Drag Bucket 11A General 11A Recommended Electrodes and Preheat 11Aes 12A General Procedure for Repair of Cracks 12A Preheat 13A Welding Techniques 13A General Procedure for Repair of Broken Parts 13A Procedure for the Repair of Cracked or Broken Drag Bucket Lips " 14A Stress Relieving 16A Procedure for Replacement of Bucket Lip Shrouds 16A Drag Bucket Tooth Repair 16A Drag Bucket Clevis Plates 18A Section 2· Repair Welding Swing Rack Teeth 21A Section 3· Welding and Cutting Equipment 25A Section 4- Stress Relieving and Temperature Measuring Equipment 26A Appendix A6 - LUBRICATION BENCHMARKS MPG - Multi-purpose Type Grease 27 A ACPL - Air Compressor (Piston Type) Lubricant 28A CSWL - Cam and Slide Walking Mechanism Lubricant 29A MPO - Multi-purpose Oil 31A OGL - Open Gear Lubricant 32A RGL - Regular Type Gear Lubricant 33A RCRL - Roller Circle Rail Lubricant 37 A RWRL - Running Wire Rope Lubricant 39A SWRL - Structural Strand and Stationary Wire Rope Lubricant 40A Appendix A7 - TAPERED ROLLER REPLACEMENT Bulletin 2-76-1 Appendix A8 - RAIL CHOCKING TIGHTNESS 41A Appendix A9 - PREVENTIVE MAINTENANCE CHECKLISTS Daily 43A Weekly 45A Monthly 48A Quarterly 51A Semi-Annual 53A BI005545
APPENDICES
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