Cat Bucyrus 2570W Walking Dragline Care, Maintenance & Operation Manual BI115946 – PDF DOWNLOAD

Technical Manual

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CARE, MAINTENANCE and OPERATION MANUAL

SERIAL NUMBER

TABLE

INTRODUCTION

MANUAL PURPOSE AND CONTENT

This manual has been developed to instruct mining personnel in the care, maintenance and operation of a Model 2S70-W dragline. 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. Therefore, alterations to the equipment may not be reflected in the current manual. When alterations take place that affect manual substance, Bucyrus-Erie Company will make every attempt to update and distribute service information as soon as possible.

The present manual is divided into four major sections. Pages are numbered within each particular section. For example, page 2-4 is the fourth page of Section 2. Each section is prefaced with a table of contents which is found on the first page of the section. With the exception of Section 4, each section is generously illustrated to support and clarify text coverage of the equipment and service procedures.

NOTE

Notes, Cautions and Warnings serve as critical reminders to alert mining crews of unusual situations and forewarn them of possible hazards on the excavation site. Heed these warnings at all times!

WARNINGS cover potential machine damage that results from failure to comply with the particular instructions therein.

CAUTIONS cover personal injury, death, and machine damage that may result from failure to comply with the instructions.

This section, Section 1, deals with the in troduction and general description of the dragline. The composition and function of each major element that makes up the dragline is discussed in the general description in detailed terms. A glossary of terms is also included for reference purposes.

Section 2 comprises the operating instructions in terms of safety, break-in, a pre-start checklist, machine group operating procedures and hints.

Follow the practices cited in this section before activating any of the· dragline components.

Section 3 establishes the preventive maintenance and lubrication procedures to be applied wheri servicing the mechanical components of Model 2S70-W dragline. The initial portions of this section relate to safety and lubrication, while the bulk of the section treats the inspection, adjustment and replacement phases of each machine group. Mechanical troubleshooting is also included.

Section 4 provides valuable information on electrical inspection, adjustment and troubleshooting.

GENERAL DESCRIPTION FUNCTION OF THE MACHINE

The Model 2S70-W dragline is a11 electrically powered excavating machine. The machine is particularly suited to extracting material many feet below the grade on which the machine rests.

The dragline includes a central base upon which a revolving frame is mounted (figure 1-1). Front end equipment extends forward from the machine. It is used to support and run a bucket and its load. The dragline bucket is loaded by pulling drag ropes toward the machine. The digging depth and the angle at which the bucket penetrates the earth formation is governed by the tension on hoist ropes. When the bucket is filled, the operator draws the hoist ropes in while the drag ropes are simultaneously paid but. The proper coordination of this action, along with the balancing effect of a dump rope, prevents the premature unloading of the mining material. The further raising of the hoist ropes, swinging the front end equipment and bucket dumping completes a dragline pass. The empty bucket is then returned to the dragline location by slacking off on the hoist ropes.

MAJOR MACHINE UNITS

Some of the major units of the dragline are:

• Front end equipment

• Machinery house

• Propel equipment

• Base

• Power plant

The front end equipment generally refers to the mast, boom and bucket as well as their support and running rope systems.

The machinery house encloses all of the dragline machinery and electrical systems. The house also contains a pressurized air system for eliminating dust or heat buildup. The propel equipment is utilized to drive a cam and frame mechanism which produces a smooth walking action for the machine. An integral web-type base carries a center pintle, swing rack and roller assembly. This equipment provides a load distribution structure for the upper works. AC power which originates at an external electrical plant is routed through a trail cable to a transformer substation on board the dragline. From the substation, power is routed to the M-G sets and the auxiliary transformer room. The transformers step down the incoming voltage to power auxiliary equipment including the compressors, lights and heaters.

TEMPORARY INTERMEDIATE BOOM STRUCTURAL STRANDS

COMPONENT DESCRIPTION BASE

The base (figure 1-2) is an all welded, web-i:ype structure fabricated from steel plates and assembled in wedge-shaped segments. A cast center pintle extends down through and is welded integral with the base. The base composition includes a singular center pintle section, intermediate sections and outer sections. One of the intermediate sections is specially constructed to facilitate removal of swing equipment; another of the intermediate sections, as well as jts fdjacent outer section is fashioned to provide access for the electrical trail cable to be brought into the dragline. The trail cable leads through the Qenter pintle to a collector ring arrangement. This arrangement _ allows power to be transmitted to the revolving frame above the

Figure 1·1

The internal structure of the base is made up of a series of compartments formed by an array of radial and circumferential diaphragms. Port holes in the' diaphragm facilitate entry into the compartments for inspection purposes. Port holes which provide access to the compartments having external trail cable to internal cable connections, are furnished with locked doors, minimizing electrical hazards. Steel wear plates, welded to the bottom surface of the base at the outer edge, prevent excessive wear of the base during the walking mode. A machined flange on the base outer diameter engages lifting hooks mounted on the revolving frame while the machine is in the propel motion.

The top of the base includes covered manholes. They are used for admission into the internal compartments. The upper surface (figure 1-3) provides amounting deck for a circular swing rack and roller circle assembly. Both of them

overlay the radial and circumferential diaphragms. The swing rack is secured to the base by body fit and loose fit bolts; it meshes with the swing pinions of the swing machinery. The roller circle assembly consists of tapered and flm)ged rollers mounted on tapered lower rails and held spaced apart by inner and outer frames. The tapered lower rails rest directly upon base rail pads. They are firmly secured to the base by clamps and chocks. The tapered rollers permit an even distribution of roller loads on both the base and revolving frame. Furthermore, the action of the tapered rollers on the tapered rails enables a smooth swing of the machine with a minimum of roller skidding. The rollers are fitted with polyurethane bushings, which require no lubrication, under normal conditions. For adverse conditions the rollers may require additional lubrication. A lubrication fitting is provided for such special applications. Automatic lubrication for servicing the roller and rail surfaces

Figure 1-2

LUBE FITTING

t1H_- BOLT

_____ ROLLER

Figure'1-3

SIDE GIRDER FRONT LH

HOIST GIRDER LH

OUTER CAM ___ -+. GIRDER LH

CENTER PINTLE GIRDER

HOIST GIRDER RH

FRONT FAIR LEAD GIRDER RH

FRONT A-FRAME FOOT

FRONT CAM GIRDER SUPPORT RH

SIDE BALLAST BOX LH REAR BALLAST BOX

is standard on all machines. Optional grease drains are distributed throughout the base to lead excess lubricants from the top to the bottom of the structure.

REVOLVIN,G FRAME

The revolving frame is a completely welded unit; It is comprised of a series of box girders welded together to form a single unit. Openings in the vertical diaphragms and deck of the structure provide access to each <:;ompartment for inspection purposes. Electrical wiring, lubrication lines and air lines run along and through the deck to various components on the machine.

The structure is divided into four major support groups. Group 1 (figure 1-4) comprises front and central girders directly overlying. the base. In addition to supporting the swing and main machinery, these sections serve as mounting stations for the front end equipment and operator cabs (figure 1-5). Group 2 includes re;u girders JlPon which the transformer and high voltage rooms,

SIDE BALLAST BOX RH

auxiliary winches, MG sets exciters and drag machinery are anchored. The MG sets are secured upon a support ,girder which functions as a ballast box to offset the heavy loads imposed on the front end equipment during the digging cycle. Group 3 includes the t1ateral cam girders which house the cam and frame arrangment and the propeJ machinery. Hoists (figure 1-6) are located over the cam girders for servicing the propel machinery. Group 4 includes four deck extension girders.

The revolving frame rides, upon the rollers mounted on the base. It is secured to the base by the large \ diameter pi11tie clamp collar. The upper roller rails are secured to the bottom of the revolving frame with chocks and clamps (see figure 1-7). Lifting hooks atta,ched to the bottom of the revolving frame are employed to raise the base off the ground during the walking cycle. An overhead crane travels along a monorail assembly at the front of the structure to service. the swing and center pintle units.

GROUP 1

....r----REAR CAM GIRDER

REAR CAM GIRDER SUPPORT LH SUPPORTRH

Figure 1-4

LIFTING HOOK SUPPORT LH

DRAG MACHINERY GIRDER RH

REAR CROSS GIRDER

Figure 1-5

Figure 1·6

SPLICE RAI L RAI L (/ JOINT CLAMPS

Figure 1·7

MAIN MACHINERY

HOIST MACHINERY

The hoist machinery is powered by eight D.C. motors (figure 1-8). These motors drive through flexible couplings to eight motor pinion shafts

Since the hoist machinery is located forward on the machinery deck the hoist line has nearly a straight line lead to the boom point sheaves. '

Each motor is equipped with a spring-set, airrelease post brake (figure 1-12) which, when set, holds the bucket in a fixed position when the machine is idle or in an emergency situation.

and four intermediate shaft gears (figure 1-9). The motor pinion shafts and intermediate pinion shaft gears have machine-cut, herringbone teeth which run in oil in enclosed gear cases. The motor pinion shafts and intermediate pinion shafts are mounted on anti-friction bearings. The two intermediate pinion shafts have machine-cut helical teeth and mesh with common hoist gears. The intermediate pinion shafts and hoist gears are protected by a steel guard. A hoist gear is mounted to each end of the drum. The ends of the drum are mounted to integral spider and stub shafts. The hoist drum does not have a through drum shaft. The entire assembly is supported in the machinery side frames by self-aligning anti-friction bearings. The drum has machine-cut, flame-hardened grooves and will accommodate twin hoist ropes.

The twin hoist ropes lead from the top of the drum over large diameter idler sheaves .and boom point sheaves to an equalizer on the· dragline bucket.

DRAG MACHINERY

The drag machinery is powered by eight D.C. motors (figure 1-8). These motors drive through flexible couplings to eight motor pinion shafts and four intermediate pinion shaft gears (figure 1-10). The motor pinion shafts and intermediate pinion shaft gears have machine-cut herringbone teeth which run in oil in enclosed gear cases .. The motor pinion shafts and intermediate pinion shafts are mounted on anti-friction bearings. The four intermediate pinion shafts have machine-cut helical teeth and mesh with common drag gears. The intermediate pinion shafts and drag gears are protected by a steel guard. A drag gear is mounted on each end of the drum_ The ends of the drum are mounted to integral spider and stub shafts. The drag drum does not have a through drum shaft. The entire assembly is supported in the machinery side frames by self-aligning anti-friction bearings. The drum has machine-cut, flame-hardened grooves and will accommodate twin drag ropes, figure 1-11.

Figure 1-8

Figure 1-9

The twin drag ropes lead directly off of the bottom of the drum, through the fairlead to the drag chains on the dragline bucket. Since the drag machinery is located well to the rear of the center line of rotation there is only a small fleet angle between the drum and the fairlead sheaves.

Each motor is equipped with a s'pring-set, airrelease post brake (figure 1-13) which, when set, holds the bucket in a fixed position when the machine is idle or in an emergency condition.

SWING MACHINERY

The swing machinery consists of four swing units mounted near the front of the revolving frame. Each unit is powered by a vertically mounted D.C. motor (figure 1-14). The motor shaft is joined to a motor pinion shaft through a flexible coupling (figure 1-15). The motor pinion shaft, which has a herringbone pinion machined integral with the shaft, extends through upper and lower

Figure 1-10

Figure 1-11

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