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 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.
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 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.
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MACHINE SERIAL NUMBER ______________________ BUCYRUS-ERIE COMPANY General Offices: South Milwaukee, Wisconsin, U.S.A 1M SPS 1085 © BUCYRUS-ERIE COMPANY, 1985
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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
TABLE OF CONTENTS
BI615835 Hoist and Drag Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Hoist Rope Replacement ............................................................... 87 Drag Rope Replacement ............................................................... 88 Fairlead .................................................................................. 90 Buffer Cylinder ....................................................................... 95 Dragline Bucket .......................................................................... 95 CHAPTER 2
AIR
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 (WABCO 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 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 D7 A) (Main Air System) .................................... 114 Maintenance ......................................................................... 114 Air Regulator ........................................................................... 114 Air Dryer (Boom Pressurization) ......................................................... 115
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SYSTEM
BI615835 CHAPTER
- LUBRICATION Section 1 - GENERAL MAINTENANCE General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 7 Lubrication Benchmarks ................................................................ 117 Lubrication Charts ...................................................................... 118 Section 2 - AUTOMATIC LUBE SYSTEMS AP System .............................................................................. 133 AS System .............................................................................. 133 AW System ............................................................................. 133 B System _ ............................................................ 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 CHAPTER 4 - 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
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Appendix Al - GEAR INSPECTION lA 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 llA Recommended Electrodes and Preheat .................... l lAes ................... 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 MAINTENANCECHECKLISTS Daily 43A Weekly ............................................................................... 45A Monthly .............................................................................. 48A Quarterly ............................................................................. 51A Semi-Annual 53A
APPENDICES
CHAPTERl MECHANICAL MAINTENANCE
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 2570W Walking Drag line.
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 prever.tive upkeep 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.
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?
6. By leaving repairs to a later date, will any 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.
1. Are all tools and equipment needed to accomplish maintenance or repair available on the job, and are they in good repair?
2. Are all replacement parts on hand and readily available?
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?
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 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?
5. Could the problem have been prevented by prior action?
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SAFETY GENERAL
The importance of overall safety in the maintenance of a drag line should always be emphasized; excavating operations may involve a variety of hazardous conditions. Many critical dragline components are subject to wear and other deterioration which limits their useful life; thus they are expendable. When new, all such parts have a builtin reserve strength against unknown factors and reasonable loss of durability from gradual wear. If, however, inspection and adjustment are neglected, these parts eventually reach a condition where they become a safety problem. Similarly, failure to replace various mechanisms to insure proper performance of the dragline also constitutes a safety problem. Study this manual carefully and follow all recommended procedures to avoid unsafe conditions. Review the manual periodically to refresh your knowledge of these procedures. Supervisors, operators and maintenance men should continuously follow safe practices.
IN-OPERATION MAINTENANCE
Safety requirements dictate that all draglines in active service be inspected at regular intervals for proper adjustment of operating mechanisms, excessive wear of components, system cleanliness and any other defects. In-operation deficiences should be carefully investigated. It should be determined if a safety problem exists. Remember, maintenance is vital to safe operation. It should be performed systematically by competent personnel.
From an economic standpoint, it is advisable to perform as much of the upkeep as can be safely accomplished while the dragline is running. Obviously, there are some maintenance procedures, such as gear tooth inspection and replacement, which require machine shutdown. However, many supduties can be safely and effectively handled at shift change when the drag line is still activated.
Automatic lubrication systems function throughout the operational cycles of the machine. These systems release premeasured lubricant which lengthen the wear life of the machinery units. Other parts of the machine may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the operator's hands at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.
A repair or maintenance job on dragline equipment is not complete until guards, plates and other safety devices have been replaced before the equipment is restored to operation.
PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK
The operator must be sure the drag line equipment is in a safe position before repairs or adjustments are made. The machine should not be endangered by falling rock or a yielding support surface. Before beginning repair or adjustment, the operator shall:
• Set the bucket on the ground.
• Set all brakes.
• De-energize control functions.
• Do whatever else is necessary to prevent accidental movement of the machine.
NOTE: If power is essential to the repair, it should only be energized when all personnel are clear of electrical and mechanical hazards. The power should only be energized during the required period and not when repair work is being done.
Prior to undertaking any work, maintenance personnel should notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the starting controls should be locked in the "off' position and tagged. The lock and tag should be removed only by the maintenance people who installed them or other authorized personnel. During all phases of maintenance, use extreme caution when working near electrical equipment. Never work near exposed, energized high voltage connections.
Approved protective equipment such as gloves and insulated hooks or tongs should always be used when high voltage electrical cables are handled. Only qualified electricians are permitted to directly maintain electrical equipment such as motors, transformers, and switches.
While performing maintenance, the awkward positions assumed often increase injuries due to handling heavy parts. As a precautionary measure, use mechanical handling equipment whenever possible. The mining foreman can facilitate safer and easier maintenance work by providing blocking materials. Service crews should have a fundamental knowledge of lifting practices so their knees and legs are used rather than their backs.
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