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Technical Manual

BI005345

BUCYRUS

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Bucyrus International, Inc. ----- BUCYRUS '","$ WALKING DRAGLINE MECHANICAL

BUCYRUS '","$ BI005345

MAINTENANCE MANUAL

The purpose of this manual is to provide information concerning the mechanical maintenance of the 680W Walking Dragline.

The Model 680W 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 fairleacL mast, boom, running ropes, boom structural strands, and dragline bucket.

This manual consists offive chapters, each divided into sections. A table of contents is located in the front of the manual.

base, rack and roller circle. The deck includes the frame and house. The machinesystems to an system build-up the machinery house. elevated cab mounted the house provides the machinery station. The cab contains machine controls. The front end is of the fairleacL mast, of the manual.

Throughout this manual references are made to lot 1, lot 2 and lot 3 and future. Lot 1 is serial #139865, 10t:2 is serial #140799, lot 3A is serial #140844, and lot 3B is serial #140845.

#140799, #140844,

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.

occur the are not followed or maintenance. read the note extreme that

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.

followed.

NOTE is used to stress a point or to give additional information concerning the procedure being discussed.

NOTE is used to stress a or to additional information the 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.

know, evaluate. and advise maintenance and service conceivable service of

These CAUTION's and WARNING's are not all-inclusive. is for to operation might performed resulting possible consequences therefore extremely important that anyone who uses a service procedure or tool which is recommended his own the of others, or cause machine or

E to at Bucyrus-Erie Company reserves right continually improve products. reason changes not in

E very 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

MACHINE SERIAL

BUCYRUS-ERIE COMPANY

General Offices: South Milwaukee, Wisconsin, U.S.A 1M SPS 786

FOREWORD

<;) BUCYRUS-ERIE COMPANY, 1986

FOREWORD

COMPANY COMPANY, lot lot:2 particular

BUCYRUS-ERIE

machine

______________________

BUCYRUS·ERIE BI005345

important procedure

Wisconsin,

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 Roller Circle and Rails. .................................................................. .. 5 Swing Rack 6 Illustrations for Chapter 1, Section 2 , 1-2-1 Section 3- ROTATING DECK Rotating Deck. ............................................................... .. . .. ...... .. 9 Revolving Frame. 9 Hook Rollers 9 Hook Rollers Adjustment 9 Main Machinery 10 Hoist Drum Assembly , 11 Drag Drum Assembly 12 Hoist or Drag Motor. 12 Main Machinery Gearcase Assembly , 12 Interlock Clutch , , 16 Inspection ,, 16 Repair 17 Rotary Seal , 17 Clutch Discs 17 Piston Rings. ....................................................................... .. 17 Hoist or Drag Brake , 18 Adjustment 18 Drag Rope Support , 19 Swing Machinery 20 Swing Timing , 22 Swing Brake '............................ 23 Brake Removal , 23 Disc Repair , 24 O-Ring Repair , 24 Expansion Spring Repair 24 Propel Machinery , 25 Propel Brake , 31 Brake Removal , 31 Disc Repair. 32 O-ring Repair. 32 Expansion Spring Repair 32 Illustrations for Chapter 1, Section 3 1-3-1 11 - MAINTENANCE General Maintenance Schedules and Safety ..................................................................................... 2 ................................................................................. 2 ............................................................... Precautions Before and Maintenance Work Section 2 - LOWER WORKS Roller Circle and Rails. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Illustrations for 1, Section 3 - ROTATING DECK Rotating Deck __ 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 Hook Rollers Adjustment ......................................................................... Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11 .................................................................. 12 Hoist Assembly. Clutch 16 Repair ................................................................................ Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17 Piston 17 Drag .................................................................... Adjustment Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22 .................... . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ............................ . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. O-Ring Repair ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Expansion Spring Repair 1, BI005345

Section 4- FRONT END EQUIPMENT Front End Equipment 33 Boom 33 Boom Deflection Sheave and Tower 33 Boom Point 34 Mast 35 Hoist Rope Guide Roller 35 Structural Strands '. ..................... .. 35 Upper, Lower and Intermediate Structural Strands 36 Hoist and Drag Ropes 37 Hoist Rope Replacement. 38 Drag Rope Replacement 39 Fairlead. ............................................................................... .. 39 Dragline Bucket. ....................................................................... .. 40 Illustrations for Chapter 1, Section 4 " 1-4-1 CHAPTER 2- AIR SYSTEM Section 1- GENERAL MAINTENANCE Saftey 43 General 43 Maintenance of Air System 43 Air Compressor 43 Air Lines. ............................................................................ .. 43 Air Tank 43 Air Line Lubricator. 43 Air Line Filter - '. 43 Air Line Regulator 44 Anti-Freezer - Alcohol Type 44 Solenoid Valves 44 Pressure Switches .................................................................... .. 44 Illustrations for Chapter 2, Section 1 2-1-1 Section 2- COMPONENT MAINTENANCE Air Compressor (Kellogg-American Mod. K25) 45 Daily Maintenance. 45 Monthly Maintenance 45 Quarterly Maintenance. .............................................................. .. 45 Disassembling Pump - 45 Fitting and Reassembling Pump 47 Anti-Freezer 50 CHAPTER 3- ELECTRICAL CABINET COOLING SYSTEM CHAPTER 4- LUBRICATION Section 1- LUBRICATION PROCEDURES General 53 Lubrication Cleanliness 53 Section 4- FRONT END EQUIPMENT Front End Equipment 33 Boom 33 Boom Deflection Sheave and Tower 33 Boom Point 34 Mast 35 Hoist Rope Guide Roller 35 Structural Strands '. ..................... .. 35 Upper, Lower and Intermediate Structural Strands 36 Hoist and Drag Ropes 37 Hoist Rope Replacement. 38 Drag Rope Replacement .............................................................. .. 39 Fairlead. 39 Dragline Bucket. 40 Illustrations for Chapter 1, Section 4 " 1-4-1 CHAPTER 2- AIR SYSTEM Section 1- GENERAL MAINTENANCE Saftey 43 General 43 Maintenance of Air 43 Air Compressor 43 Air Lines. ............................................................................ .. 43 Air Tank 43 Air Line Lubricator. 43 Air Line Filter - '. .................... .. 43 Air Line Regulator 44 Anti-Freezer - Alcohol Type 44 Solenoid Valves 44 Pressure Switches 44 Illustrations for Chapter 2, Section 1 2-1-1 Section 2- COMPONENT MAINTENANCE Air Compressor (Kellogg-American Mod. K25) 45 Daily Maintenance. .................................................................. .. 45 Monthly Maintenance 45 Quarterly Maintenance. .............................................................. .. 45 Disassembling Pump - 45 Fitting and Reassembling Pump 47 Anti-Freezer 50 CHAPTER 3- ELECTRICAL CABINET COOLING SYSTEM CHAPTER 4- LUBRICATION Section 1- LUBRICATION PROCEDURES General 53 Lubrication Cleanliness 53 4.................................................................... ....................................................... .............................................................................. .................................................................. Structural ................................................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............. " ..................................... 21 - GENERAL .................................................................................... .................................................................................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Filter " . . . . . . . . . . . . . . . . . . . . ..................................................................... ............................................................. .................................................. Section 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................... '............................... 341.................................................................. BI005345

Lubrication Points 53 Lubricant Benchmarks , 54 Lube Charts. 54 Section 2- LINCOLN AUTOMATIC LUBE SYSTEM General 63 System D Operation , 63 System F Operation (Optional) , 63 System H Operation ,..................................................... .. 64 System I Operation (Optional) 64 System J Operation (Optional) 64 System L Operation , 64 Control Panels : ,........................... 64 Pumping Stations : , 64 Lube System Air System 64 Section 3- GEARCASE OIL FILTRATION AND PRESSURIZATION SYSTEMS General 65 Maintenance , , 65 CHAPTER 5- TROUBLESHOOTING Section 1- LOWER WORKS Base 67 Swing Rack and Pinions , 67 Roller Circle , 68 Hook Rollers 68 Center Pintle 68 Section 2- ROTATING DECK Revolving Frame 69 Hoist and Drag Machinery 69 Hoist and Drag Brakes 70 Main Machinery Gearcase , 70 Interlock Clutch 71 Propel Brake , 71 Propel Gearcase ........................................................................ .. 72 Swing Machinery 73 Swing Brake 73 Section 3- FRONT END EQUIPMENT Boom 75 Mast : 75 Structural Strands , 75 Fairlead. 76 Drag and Hoist Ropes 76 Dragline Bucket , 76 Section 4- AIR SYSTEM Air Compressor '" 77 Air Line Regulator 78 Air Line Lubricator , 78 Air Lines and Air Tank , 78 Lubrication Points 53 Lubricant Benchmarks , 54 Lube Charts. ........................................................................... .. 54 Section 2- LINCOLN AUTOMATIC LUBE SYSTEM General 63 System D Operation , 63 System F Operation (Optional) ", 63 System H Operation ,..................................................... .. 64 System I Operation (Optional) 64 System J Operation (Optional) 64 System L Operation , 64 Control Panels : ,........................... 64 Pumping Stations : , 64 Lube System Air System 64 Section 3- GEARCASE OIL FILTRATION AND PRESSURIZATION SYSTEMS General 65 Maintenance , , 65 CHAPTER 5- TROUBLESHOOTING Section 1- LOWER WORKS Base , 67 Swing Rack and , 67 Roller Circle , 68 Hook Rollers 68 Center Pintle 68 Section 2- ROTATING Revolving Frame 69 Hoist and Drag Machinery 69 Hoist and Drag Brakes 70 Main Machinery Gearcase , 70 Interlock Clutch 71 Propel Brake , 71 Propel Gearcase 72 Swing Machinery 73 Swing Brake ........................................................... .. 73 Section 3- FRONT END EQUIPMENT Boom 75 Mast : 75 Structural Strands , 75 Fairlead. 76 Drag and Hoist Ropes 76 Dragline Bucket , 76 Section 4- AIR SYSTEM Air Compressor '" 77 Air Line Regulator 78 Air Line Lubricator , 78 Air Lines and Air Tank , 78 .................................................................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.................................................................................. 63 ..................................................... " .... , .............. , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I ..................................................................... 64 3...................... ..................................................... 51................................................................. ............................................................................. Center 2......................................................................... Main ............................................................... .......................................................................... ............................................................................ ........................................................................ ................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,' ...................................................... .............................. ....................................................................... Bucket 76 4 . AIR SYSTEM '" ...................................................................... BI005345

Section 5- LINCOLN AUTOMATIC LUBE SYSTEM Air Locks 79 Injectors 79 Pumps 80 APPENDICES Appendix Al - GEAR INSPECTION IA Appendix A2 - BOLT TORQUING Torque Wrench Method 3A Turn of Nut Method 4A Appendix A3 - ADJUSTMENTS Boom Structural Strand Adjustment SA Appendix A4 - PINION, BRAKE DRUM AND COUPLING INSTALLATION Removal From motor Shaft 7A Mounting Pinion, Brake Drum or Coupling on Shaft 7A Appendix A5 - MAINTENANCE WELDING Section 1- Repair Welding of Base, Revolving Frame, Walking Shoes and Drag Bucket IIA General IIA Recommended Electrodes and Preheat IIA Welding Electrodes llA Repair Welding Procedures 12A General Procedure for Repair of Cracks 12A Preheat I3A Welding Techniques 13A General Procedure for Repair of Broken Parts 13A Procedure for the Repair of Cracked or Broken Bucket Lips 14A Stress Relieving ...............................................•.................. '" I6A Procedure for Replacement of Bucket Lip Shrouds I6A Drag Bucket Tooth Repair 17A Drag Bucket Clevis Plates I8A Section 2- Repair Welding of Swing Racks 2IA Crack Repair Welding 2IA Broken Tooth Repair Welding , 22A 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 MWCL - Monighan Walking Cam Lubricant 29A MPO - Multi-purpose Oil 30A OGL - Open Gear Lubricant 3IA RGL - Regular Type Gear Lubricant 32A RCRL - Roller Circle Rail Lubricant 36A RWRL - Running Wire Rope Lubricant 38A Section 5- AUTOMATIC LUBE Air Locks Injectors Pumps Appendix Al - INSPECTION IA AppendixMethod 3A Method 4A AppendixStrand SA A4 - BRAKE DRUM INSTALLATION Removal From motor Shaft 7A Mounting Brake Drum or on Shaft 7A A5 - WELDING Repair Base, Revolving Frame, Shoes and Bucket IIA Preheat Welding llA Procedures 12A for of Cracks 12A 13A for Repair Broken 13A for Repair of Bucket Lips 14A Stress Relieving I6A Procedure for Replacement of Bucket Lip Shrouds I6A Drag Plates 2- of Swing 2IA Crack Repair Welding Welding 22A 3- Welding 25A Section Relieving and Measuring Equipment ' A6 Multi-purpose Type A ACPL Air 28A MWCL Cam 29A Multi-purpose Oil 30A - Lubricant 3IA RGL Regular Gear Lubricant 32A Circle Rail 36A RWRL Running Rope Lubricant 38A 5Air Pumps ................................................................................... Al .............................................................. IA Appendix: ...................................................................... Appendix...................................................... From _ 7A ....................................... MAINTENANCE WELDING Shoes and ................................................................................. ................................................... ...................................................................... ........................................................... 13A ............................................ for of ...............................................•......................... Procedure for ............................................................... I 7A ............................................................... 2 - ....................................................... Welding ......................... .................................. 3 - ...................................................... 25A 4 - ' BENCHMARKS Multi-purpose Type ........................................................ A ACPL· .......................................... - Cam .............................................. 29A Multi-purpose Oil Open ...................................................... ................................................... BI005345

SWRL - Structural Strand and Stationary Wire Rope Lubricant 39A ECO - Electrical Cooling Oil Specification 40A Appendix A7 - ROLLER CIRCLE REPAIR MODIFICATION 4lA Appendix A8 - ROLLER REPLACEMENT 43A Appendix A9 - BRAKE OR CLUTCH MAINTENANCE CHECKLIST 45A Appendix AlO - PREVENTIVE MAINTENANCE CHECKLISTS Daily 47A Weekly 50A Monthly 5lA Quarterly 53A 2000 Hour 54A Semi-Annual 55A SWRL - Structural Strand and Wire Lubricant 39A ECO Electrical Cooling Specification A7 MODIFICATION ROLLER A9 - BRAKE OR CLUTCH MAINTENANCE CHECKLIST 45A - CHECKLISTS Daily 47A Weekly Monthly Quarterly Hour and Wire Lubricant ................................................ A7 ROLLER ....................................................... Appendix A9 MAINTENANCE CHECKLIST 45A Daily ................................................................................... .................................................................................. ............................................................................... ............................................................................... BI005345

A CAUTION: Many of the component parts of the 680W 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.

safety when using other lifting equipBe radius, and capacity of the machine before or BI005345

Cj BUCYRUS-ERIE COMPANY. 1986 3 (4

"-,

blank)

A Many component .. 680W are lifting them, either with some device. COMPANY,

2 4 5 7 8 SECTION A 9 TORQUE TO 747773-02* 1

BASE CENTER SECTION

BASE OUTER SECTION

WEDGE

WEDGE RETAINER

CHOCK 6. SWING RACK 7. CENTER PINTLE 8. CLAMP COLLAR 9. COllECTOR RING SUPPORT 10. RACK HOlDOWN BOLTS 11. RACK SPLICE BOLTS 12. BASE CONNECTION BOLTS 2 2 = -t1_7

METHOD BASE FIGURE 1 BUCYRUS-ERIE COMPANY, 1986 1-2-1 2 4 8 TORQUE BASE CENTER SECTION 2. CHOCK 7. CENTER PINTLE 11. __-rt_7

METHOD COMPANY, 0 0 0 = 7 12 3 5 WEDGE 11. BI005345

·SEE APPENDIX A2

A4 FOR "TURN-OF·NUr

·SEE PG FOR "TURN-OF·NUr

1. UPPER RAIL - END

2. UPPER RAIL - END

3. UPPER RAIL-CENTER

4. RAIL CLAMP

5. CHOCK

6. REVOLVING FRAME

7. LOWER RAIL

8. RAIL CLAMP

9. RAILSHIM

10. OUTER FRAME

11. SPLICE PLATE

12. INNER FRAME

13. SPLICE PLATE

14. ROLLER

12. ROLLER

15. ROLLER BUSHING

15.

16. ROLLER PIN

17. THRUST WASHER

18. PIN BOLT

19. SWING RACK

(EVERY OTHER JOINT) 6 16

2 1-2-2 1-2-2 9 OTHER

UPPER

CHOCK

ROLLER CIRCLE AND RAILS FIGURE

UPPER END

RAIL-CENTER

LOWER