Cat Bucyrus W2000 Walking Dragline Service Manual BI010548 – PDF DOWNLOAD

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Cat Bucyrus W2000 Walking Dragline Service Manual BI010548 – PDF DOWNLOAD

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Cat Bucyrus W2000 Walking Dragline Service Manual BI010548 – PDF DOWNLOAD

Language : English
Pages : 208
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Cat Bucyrus W2000 Walking Dragline Service Manual BI010548 – PDF DOWNLOAD

Operating Precautions:
• Wear hearing protection when exposed to the following noise levels in excess of the
period indicated:

8 hours at 90 dBa
4 hours at 95 dBa
2 hours at 100 dBa
1 hour at 105 dBa
30 minutes at 110 dBa
15 minutes at 115 dBa
• When in doubt about the noise level, wear approved hearing protection.
• Do not attempt to get on or off the machine while it is in operation. Notify the operator
prior to any attempt to board/exit the machine.
• Do not move or operate the machine without first knowing the location and purpose of
all personnel and test or support equipment on or near the machine.
• Do not allow unauthorized personnel on board the machine while in operation.
• Use audible signals to warn of machine movements. A signal horn button is provided
for this purpose.
• Do not propel until the travel route has been cleared of obstructions.
• Prevent trail cable from being dragged on the ground for long distances or at high
speeds.
• Limit the amount of cable being pulled by the machine. Pulling too much cable will
damage both the cable and the machine.
• Check to ensure all control panel cabinets are closed and secure.

About This Manual:
1.1.1 Purpose:
This manual is designed to assist in the operation and maintenance of your Bucyrus machine. Inside,
you will find the following information: guidance on machine operation, disassembly
procedures, and maintenance procedures.
NOTE: This is not a parts book and cannot be used to order parts. A separate, detailed parts
book for this machine has been supplied with the machine.
1.1.2 Organization:
• A main table of contents (TOC) is your guide to topics and subtopics. It is located at the
front of the manual. Main topics are listed as numbered Sections, with subtopics listed beneath
(and indented). Subtopics include the main topic’s section number.
• Additionally, each section contains its own TOC.
• In the electronic version, all TOC items are hyperlinked to their respective topics.

TABLE OF CONTENTS:

Cat Bucyrus W2000 Walking Dragline Service Manual BI010548 – PDF DOWNLOAD

Table of Contents................................................  3
Revision History................................................. 11
Safety........................................................... 15
S.1 Safety Symbols............................................... 15
S.2 Safety Precautions........................................... 16
	S.2.1 General Precautions.................................... 18
	S.2.2 Maintenance Precautions................................ 19
	S.2.3 Operating Precautions.................................. 21
	S.2.4 Fire Prevention........................................ 22
Introduction..................................................... 23
1.1 About This Manual............................................ 25
	1.1.1 Purpose................................................ 25
	1.1.2 Organization........................................... 25
	1.1.3 Terminology............................................ 25
	1.1.4 Revisions.............................................. 26
	1.1.5 Precautions and Disclaimers............................ 26
	1.1.6 Contact................................................ 26
1.2 Machinery Details............................................ 27
	1.2.1 General Arrangement.................................... 27
		1.2.1.1 Base............................................. 27
		1.2.1.2 Rotate Frame..................................... 30
		1.2.1.3 Fairleads........................................ 32
		1.2.1.4 Superstructure................................... 32
		1.2.1.5 House and Cabs................................... 34
	1.2.2 Machinery.............................................. 35
		1.2.2.1 Hoist and Drag................................... 35
		1.2.2.2 Swing Gear....................................... 37
		1.2.2.3 Walk Gear........................................ 39
		1.2.2.4 Ventilation...................................... 41
1.3 Air System................................................... 42
	1.3.1 Compressor............................................. 43
Operation........................................................ 45
2.1 Motion Controls, Instruments, and Indicators................. 49
	2.1.1 Motion Controls........................................ 49
	2.1.2 Operator’s Seat........................................ 50
		2.1.2.1 Hoist Control Joystick........................... 50
		2.1.2.2 Drag/Propel Joystick............................. 51
		2.1.2.3 Swing Control Pedals............................. 51
	2.1.3 Operator Control Panels................................ 51
		2.1.3.1 Controls on the Left Panel....................... 52
			2.1.3.1.1 Earth Continuity Lockout................... 52
			2.1.3.1.2 Window Washer Pushbutton................... 52
			2.1.3.1.3 Windshield Wiper Selector Switch........... 52
			2.1.3.1.4 Fault Reset................................ 52
			2.1.3.1.5 Grease Spray Fault Light................... 53
			2.1.3.1.6 Auto-Park Pushbutton....................... 53
			2.1.3.1.7 Propel Excess Error Override Pushbutton.... 53
			2.1.3.1.8 Rope Limit Bypass Pushbutton............... 53
			2.1.3.1.9 Boom Lights Selector Switch................ 53
		2.1.3.2 Controls on the Right Panel...................... 54
			2.1.3.2.1 Machine Shutdown........................... 54
			2.1.3.2.2 Excitation Stop Switch..................... 54
			2.1.3.2.3 Excitation Start Pushbutton................ 55
			2.1.3.2.4 Propel Transfer Switch..................... 55
			2.1.3.2.5 Air Compressor Switch...................... 55
			2.1.3.2.6 Swing Brake Selector Switch................ 55
			2.1.3.2.7 Drag/Propel Brake Selector Switch.......... 55
			2.1.3.2.8 Hoist Brake Selector Switch................ 55
			2.1.3.2.9 Propel Mode Light.......................... 55
			2.1.3.2.10 Drag Mode Light........................... 55
			2.1.3.2.11 Propel Brake Light........................ 55
			2.1.3.2.12 Swing Brake Light......................... 55
			2.1.3.2.13 Drag Brake Light.......................... 56
			2.1.3.2.14 Hoist Brake Light......................... 56
			2.1.3.2.15 Emergency Stop Pushbutton................. 56
2.2 Operator Interface Panel..................................... 57
	2.2.1 Basic System Description............................... 57
		2.2.1.1 Rope Travel Limits............................... 57
		2.2.1.2 Boom Protection.................................. 57
		2.2.1.3 Propel Control................................... 57
		2.2.1.4 Fault Annunciation............................... 58
		2.2.1.5 Fault Logging.................................... 58
	2.2.2 Operator’s Screens, Switches and Buttons............... 58
		2.2.2.1 Limit Bypass Pushbutton.......................... 58
		2.2.2.2 Calibrate Pushbutton............................. 58
		2.2.2.3 Limit Set Buttons................................ 59
		2.2.2.4 Operator's Screen................................ 59
			2.2.2.4.1 Main Screen................................ 59
			2.2.2.4.2 Propel Screen.............................. 61
			2.2.2.4.3 New Active Alarms or Faults................ 61
		2.2.2.5 Active Alarm Screen.............................. 62
		2.2.2.6 Alarm History Screen............................. 63
		2.2.2.7 Calibration Select Screen........................ 64
		2.2.2.8 Temperature Select Screen........................ 74
		2.2.2.9 Permissives Status Screen Selection.............. 81
2.3 Starting and Stopping Procedures............................. 93
	2.3.1 Introduction........................................... 93
	2.3.2 Starting Procedure..................................... 93
	2.3.3 Stopping Procedure..................................... 99
	2.3.4 Security Procedure..................................... 99
2.4 Alarm and Emergency Procedures...............................100
	2.4.1 Action for Individual Alarm Conditions.................101
	2.4.2 Reset Pushbutton.......................................102
	2.4.3 PCC Alarm Display......................................103
2.5 Operating the Machine........................................109
	2.5.1 Walking................................................109
	2.5.2 Preparation for Walking................................109
	2.5.3 Walk Procedure.........................................109
	2.5.4 Direction of Walking...................................110
		2.5.4.1 Hoist............................................110
		2.5.4.2 Drag.............................................110
		2.5.4.3 Swing Motion.....................................111
			2.5.4.3.1 Swing Procedure............................111
2.6 Operating Precautions........................................112
2.7 Digging Cycle................................................113
2.8 Operating Techniques.........................................115
Ropes............................................................117
3.1 Rope Handling................................................119
	3.1.1 General................................................119
		3.1.1.1 Correct Handling.................................119
		3.1.1.2 Gauging Rope Size................................119
		3.1.1.3 Corrosion........................................120
		3.1.1.4 Deformation By Kinking...........................120
		3.1.1.5 Rope Sheaves.....................................122
	3.1.2 Unloading..............................................122
		3.1.2.1 Reels............................................122
		3.1.2.2 Spiders..........................................123
	3.1.3 Storage................................................123
	3.1.4 Uncoiling..............................................124
	3.1.5 Unreeling..............................................124
	3.1.6 Uncoiling A Spider.....................................125
3.2 Rope Fittings................................................126
	3.2.1 Rope Sockets...........................................126
	3.2.2 Rope Grips.............................................126
		3.2.2.1 Rope Safety......................................128
3.3 Rope Renewal.................................................129
	3.3.1 General................................................129
	3.3.2 Rope Reeving Winch and Control Panel...................130
	3.3.3 Hoist Rope Renewal.....................................131
	3.3.4 Drag Rope Renewal......................................133
	3.3.5 Checks After Removing/Replacing Ropes..................134
	3.3.6 Limit Switch Settings..................................134
Preventive Maintenance...........................................135
4.1 Introduction.................................................139
	4.1.1 General recommendations................................139
	4.1.2 Planned maintenance....................................140
	4.1.3 Housekeeping...........................................141
4.2 Routine Maintenance Schedule.................................142
	4.2.1 Daily Inspections......................................142
	4.2.2 Every 150 Hours Inspection.............................142
	4.2.3 Every 300 Hours Inspection.............................143
	4.2.4 Every 600 Hours Inspection.............................143
4.3 Mechanical Components and Assemblies.........................144
	4.3.1 A-Frame Front and Rear Legs............................144
		4.3.1.1 Lubrication......................................144
		4.3.1.2 Pressurization...................................144
	4.3.2 Base...................................................145
	4.3.3 Boom...................................................145
		4.3.3.1 Lubrication......................................145
		4.3.3.2 Pressurization...................................146
	4.3.4 Bucket.................................................146
		4.3.4.1 Lubrication......................................146
	4.3.5 Front and Rear Hooks...................................147
	4.3.6 Hoist and Drag Gear and Drums..........................148
	4.3.7 Hoist and Drag Ropes...................................148
		4.3.7.1 Broken Wires.....................................148
		4.3.7.2 Lubrication......................................149
4.4 Brakes.......................................................150
	4.4.1 Brake Adjustment.......................................153
	4.4.2 Replacement of Friction Discs on Single Disc Brakes....156
	4.4.3 Replacement of Friction Discs on Dual Disc Brakes......157
4.5 House Ventilation Filters....................................160
	4.5.1 Air Inlet Filters......................................160
	4.5.2 Mast...................................................162
		4.5.2.1 Pressurization...................................162
	4.5.3 Rotate Frame...........................................162
	4.5.4 Rotate Gearing.........................................163
	4.5.5 Rotate Rack and Pinions................................163
		4.5.5.1 Lubrication......................................163
	4.5.6 Rotate Rails and Rollers...............................163
		4.5.6.1 Lubrication......................................163
	4.5.7 Suspension Ropes.......................................163
	4.5.8 Walk Gear..............................................163
	4.5.9 Walk Shoes.............................................164
4.6 Air System...................................................165
	4.6.1 Circuit Details........................................165
	4.6.2 Adjustments and Settings...............................166
	4.6.3 Routine Inspection and Servicing.......................166
		4.6.3.1 Condensation Collectors..........................166
		4.6.3.2 Compressor Air Receivers.........................166
		4.6.3.3 Compressor Crankcase.............................166
4.7 Electrical Systems...........................................167
	4.7.1 Routine Maintenance....................................167
		4.7.1.1 Electrical Equipment Manual......................167
		4.7.1.2 Regular Inspection...............................167
		4.7.1.3 H.T. Equipment...................................167
		4.7.1.4 Contactors.......................................168
		4.7.1.5 Resistors........................................168
		4.7.1.6 Master Switches (Operator's Console).............168
		4.7.1.7 Commutation......................................168
			4.7.1.7.1 Commutator Brush Wear......................168
			4.7.1.7.2 Commutator Film............................169
		4.7.1.8 Trailing Cable...................................170
		4.7.1.9 Drive Motors and Vent Fans.......................170
		4.7.1.10 Vibration.......................................170
Boom.............................................................171
5.1 Boom Angle...................................................173
	5.1.1 Introduction...........................................173
5.2 Changing the Boom Angle Without Boom Hoist Unit..............174
	5.2.1 Introduction...........................................174
	5.2.2 Changing the Boom Angle................................174
	5.2.3 Boom Hoist Reeving.....................................176
	5.2.4 Changing the suspension ropes..........................180
	5.2.5 Dismantling the Boom Hoist Rope........................184
	5.2.6 Hoist Rope Reeving.....................................185
	5.2.7 Checks After Changing the Boom Angle...................186
5.3 Changing the Boom Angle With Boom Hoist Unit.................187
	5.3.1 Introduction...........................................187
	5.3.2 Changing the Boom Angle................................188
	5.3.3 Changing the Suspension Ropes..........................190
	5.3.4 Checks After Changing the Boom Angle...................193
	5.3.5 Boom Hoist Reeving.....................................193
	5.3.6 Checks After Reeving...................................195
5.4 Hydraulic Tensioning Equipment...............................197
	5.4.1 Introduction...........................................197
	5.4.2 Fitting Hydraulic Tensioning Equipment.................197
5.5 Operating the Tensioning Equipment...........................200
Schematics.......................................................203
6.1 Schematics...................................................205
6.2 Side View....................................................  0
6.3 Deck Plan....................................................  0

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