Cat Bucyrus 680W Walking Dragline Mechanical Maintenance Manual BI005073 – PDF DOWNLOAD

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Cat Bucyrus 680W Walking Dragline Mechanical Maintenance Manual BI005073 – PDF DOWNLOAD

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Cat Bucyrus 680W Walking Dragline Mechanical Maintenance Manual BI005073 – PDF DOWNLOAD

Language : English
Pages : 213
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat Bucyrus 680W Walking Dragline Mechanical Maintenance Manual BI005073 – PDF DOWNLOAD

FOREWORD

• The purpose ofthis manual is to provide information concerning the mechanical maintenance ofthe 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 fairlead,
  mast, boom, running ropes, boom structural strands, and dragline bucket.
• This manual consists offive chapters, each divided into sections. A table ofcontents is located in the front
  of the manual.

TABLE OF CONTENTS:

Cat Bucyrus 680W Walking Dragline Mechanical Maintenance Manual BI005073 – PDF DOWNLOAD

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 1
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 2
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
BI 5 73
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 ” 4
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 ” 5
CHAPTER 3 – ELECTRICAL CABINET COOLING SYSTEM
CHAPTER 4 – LUBRICATION
Section 1- LUBRICATION PROCEDURES
General 53
Lubrication Cleanliness 53
BI 5 73
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 7
Main Machinery Gearcase 7
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
BI 5 73
Section 5 – LINCOLN AUTOMATIC LUBE SYSTEM
Air Locks 79
Injectors 79
Pumps 8
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 5A
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 I – Repair Welding of Base, Revolving Frame, Walking
Shoes and Drag Bucket IIA
General IIA
Recommended Electrodes and Preheat IIA
Welding Electrodes IIA
Repair Welding Procedures I2A
General Procedure for Repair of Cracks ” I2A
Preheat 13A
Welding Techniques ” I3A
General Procedure for Repair of Broken Parts I3A
Procedure for the Repair of Cracked or Broken Bucket Lips 14A
Stress Relieving ” I6A
Procedure for Replacement of Bucket Lip Shrouds 16A
Drag Bucket Tooth Repair I 7A
Drag Bucket Clevis Plates o oI8A
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 27A
ACPL – Air Compressor (Piston Type) Lubricant ” 28A
MWCL – Monighan Walking Cam Lubricant o29A
MPO – Multi-purpose Oil 3 A
OGL – Open Gear Lubricant 3IA
RGL – Regular Type Gear Lubricant 32A
RCRL – Roller Circle Rail Lubricant 36A
RWRL – Running Wire Rope Lubricant 38A
BI 5 73
SWRL Structural Strand and Stationary Wire Rope Lubricant 39A
ECO Electrical Cooling Oil Specification 4 A
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 5 A
Monthly 5lA
Quarterly 53A
2 Hour 54A
Semi-Annual 55A

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