Bucyrus-Erie 25-B User manual

INSTRUCTION
MANUAL
INTRODUCTION 1
OPERATION 2
ADJUSTMENT 3
BUCYRUS-ERIE
lUBRICA TION
REEVING
5
MODEL
25-8 CONVERSION
6~
40-T
DISASSEMBLY
7~
"
SHOVEL-CLAMSHELL
WELDING
8~
DRAGLINE-HOE-CRANE
AIR' SYSTEM
9~
CRAWLER & TRANSIT®
VENDORS
10~
BOOK I
Applicable to SPECIFICATIONS
11~
Serial No. 121994 thru 133888
ADDITIONAL MANUALS $2.00 EACH
TABLE OF CONTENTS
25 RS
4
BUCYRUS-ERIE COMPANY
GENERAL OFFICES: SOUTH MILWAUKEE, WISCONSIN, U.S.A.
X·222S
Rev. 7-73 0·1

25 B Crawler Machine
Clamshell
Dragline
Hoe
u
..... :..,....
Crane
rON 6051

25B Transit Machine
Clamshell
Hoe
Crane
F01'll 6051
~--~~~~~~-- - - _. - ----

INTRODUCTION
Subject Page
GENERALINSTRUCTIONS • • • • • • • • • • • • • • •• 1-2
Read Instruction Manual and Safety Rule s Carefully. 1-2
To the Owner. • • • • • • • • • • 1-2
Machine Inspection and Maintenance ••••
Machine Application and Operation • • • • • • . . •
Rope Inspection, Replacement, and Maintenance
Handling the Load • • • • • • • •
Safety Precautions • • • • •
Hand Signals •••
. . . .
1-3
1-4
1-4
1-7
1-9
1-11
1-13
1-15
Warranty • • • . . . . . . . . . . . • • .
Terms and Definitions •••••••••••.
25-B
X-2172
1-1
Rev. 7-73

GENERAL INSTRUCTIONS
I. Read Instruction Manual and Safety Rule s Carefully
This manual has been compiled to give the owner, operator, and mechanic,
information as to the care, operation, and maintenance of the machine. For
convenience this Instruction Manual has been written in sections. The first
page of each section lists the heading s contained in that section. Familiarize
yourself with the Instruction Manual so that you can easily locate the particu-
lar information you may need.
A capacity plate which shows the lifting limitations of the machine is mounted
inside the operator' s cab. Never exceed the loads and/or conditions stated.
The safety rule s included with this manual repre sent a minimum set of stan-
dards for safe machine operation, and every operator should be familiar with I
and follow them at all times.
Each machine has a specific serial number assigned to it so that it can be
readily identified. The serial number of your machine is stamped on a plate
which is mounted on the right hand machinery side frame. This serial number
should always be included in any correspondence with Bucyrus-Erie Company
or any of its distributors.
Every effort has been made to have this manual as complete as possible at
the time of printing. However, since Bucyrus-Erie Company reserves the
right to improve its products continually I change s may have been made that
will not be covered in this manual.
WHEN ORDERING PARTS, ALWAYSUSE THE PARTSCATALOG TO INSURE GET-
TING THE CORRECT PARTFOR YOUR SPECIFIC SERIALNUMBERED MACHINE.
REFERTO THE PARTSCATALOG FOR CORRECT PROCEDURE IN ORDERING
PARTS.
II. To the Owner
As an owner of a Bucyrus-Erie Company machine, you are entitled to all the
high performance, quality, low-cost operation, and long life that is built into
said machine.
Your machine has been carefully checked and put through an operational test
at the factory. In addition, your Bucyrus-Erie Company Distributor has per-
formed rigid inspections and made final adjustments before placing machine
into service. To further guard your interests as a Bucyrus-Erie Company
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25-8
X-2172

IEDIII
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customer I you are entitled to rece ive two (2) after-delivery serv ice calls.
These calls are at 30 days or 200 hours and 60 days or 400 hours. Contact
your Bucyrus-Erie Company Distributor for a mutually agreeable time to receive
this service.
To keep your machine at its maximum efficiency I and to avoid dangerous and
costly accidents I a great deal depend s on the operator and maintenance per-
sonnel. Insist that this manual be read by those responsible for operation of
your machine and that all recommended services be performed.
III. Warranty
Reproduced below in its entirety is the standard BUCYRUS-ERIEWarranty cov-
ering all construction machines and spare parts manufactured by the Company.
r
BUCYRUS-ERIE COMPANY
GUARANTY:We warrant the machinery,and all spares,replccemenrsand auxiliary
equipment,nowor hereafterfurnishedby ustherefor,to be built in a workmanlikemanner
of sound high-grade material, and, under normal useand proper attention,to operate
properly. Any claim made under this warranty mustbe presentedto us in writing at
Evansville,Indiana,within six monthsafter final shipmentor, in the caseof TransitCrane
carrier unitswhetheror not sold separately,or any parts thereof,within six monthsafter
shipmentor 4,000 miles travel, whicheverfirst occurs. We are to have the option of
replacingf.o.b. works any elementproved to be defectiveor of remedyingany proved
defect, but our liability in any event shall not exceed the replacementvalue of the
defectiveelementf.o.b. works, and in the caseof unitsor parts purchasedby us,our
liability shall not exceed the settlementwhich we are able to obtain from our supplier.
We are to havea reasonablelengthof time,after recognitionof claim,in whichto exercise
our above option, and shall have the right to require the return of the alleged defective
element,transportationchargesprepaid, beforerecognizingany claim. No allowancewill
be made for repairsor alterationsundertakenwithout our written consent. If partsother
than of the original manufacturerare usedin replacementwithoutour written consent,or
if you fall in arrearsir. makingany paymenthereinprovided,or if the machinerywithout
our written consentis repaired or altered in sucha way as in our judgmentto reduceits
stabilityor reliability, or if the machineryissubjectedto misuse,negligenceor accident,all
warrantiesare therebywaived. The foregoing warranty is in lieu of all tort liability and
all otherwarrantiesor representationsor rightsof rejection,expressor implied,by law or
by contract. Morespecifically,but without restrictionthereto,there isno representationor
expressor impliedwarranty that the machinerycomplieswith the lawsof any state.
\.. ..J
"
25-B 1-3
X-2172 Rev. 7-73

NOTE: Warranty claims on Bucyrus-Erie Company machines are processed
through your authorized Distributor. This Distributor will submit
the formal claim, in writing, to Bucyrus-Erie Company.
Although this manual may give disassembly and rebuilding instructions for
various components, no component which fails within the warranty period is
to be opened or disassembled by the customer or distributor, and must be
returned intact to Bucyrus-Erie Company for factory inspection and liability
consideration.
DISASSEMBLYOR TAMPERINGWITH COMPONENTS DURING THE WARRANTY
PERIOD, WILL VOID THE WARRANTY.
IV. Terms and Definitions
"Basic Machine" is the machine without front end equipment attached.
"Lower Works" is that section of the machine which includes the truck frame,
propel machinery, crawlers, and the swing rack. It does not revolve.
"Lower Works" for TRANSITmachine is the transit carrier.
"Upper Works" is that section which revolves and to which the front end
equipment is attached.
"Right Side" of machine is at observer's right when standing at the power unit
and facing the boom.
"Left Side" is opposite to the right side.
"Rear" of the lower works is the end where the propel drive chains are
located.
"Front End Equipment" include s the boom, dipper handle, and dipper.
V. Machine Inspection and Maintenance
There is no substitute for preventive maintenance. A regular schedule of pre-
ventive maintenance should be set, so that any apparent troubles are found
before extensive damage is done to the machine.
Many critical components on the machines are subject to wear and other de-
terioration or damage which limit their useful life; thus, they are expendable.
When new, all such parts have a built-in reserve strength against unknown
conditions and reasonable loss of strength due to gradual deterioration. How-
ever if replacement is neglected, these parts can eventually reach a condition
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25-B
X-2172

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X:aTS "I" ~"U"c "I" XC» l.V 1v.I:.A.l.V"U".A.::L BUCYRUS-ERIE
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where they become a safety hazard. Failure to maintain correct adjustments
of the various mechanisms to assure proper performance of the machine also
can be a safety hazard.
SINCE THE MACHINE MANUFACTURERHAS NO DIRECT CONTROL OVERTHE
FIELD INSPECTION AND MAINTENANCE, SAFETYIN THIS AREAIS THE RESPON-
SIBILITYOF THE USER.
Inspection - All machines in active service should be inspected at regular
intervals for proper adjustment of operating mechanisms, excessive wear or
deterioration of components, accidental damage and any other defects which
might be questionable as to safety. Any deficiences noted should be care-
fully inve stigated and determination made as to whether they constitute a
safety hazard. Inspection is vital to safe operation. It should be performed
by competent personnel and on a regular and systematic basis.
Inspection Frequency - Frequency requirements of inspection depend upon
numerous factors such as machine activity, severity of service, vulnerability
of parts to wear and damage and the extent to which parts may be deemed
critical in relation to safety. Inspection frequency can be divided into two
general categories as follows:
1. Daily to monthly intervals including observation during operation for any
defects which might appear between regular inspections.
a. All control mechanisms for maladjustment interferring with proper
operation.
b. All control mechanisms for excessive wear of components and con-
tamination by lubricants or other foreign matter.
c. All safety device s for malfunction.
d. Deterioration or leakage in air system.
e. Crane hooks with deformations or cracks.
f. Rope reeving for noncompliance with crane manufacturer's recommen-
dations.
g. Electrical apparatus for malfunctioning. signs of excessive deteriora-
tion, dirt, and moisture accumulation.
2. One to twelve month intervals. A complete machine inspection including
items as in 1 above and in addition the following:
a. Deformed, cracked, or corroded members in the crane structure ancl
boom.
b. Loose bolts or rivets.
c. Cracked or worn sheaves and drums.
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X-2172
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d. Worn, cracked or distorted parts such as pins, bearings, shafts,
gears, rollers and locking device s ,
e. Excessive wear on brake and clutch system parts, linings, pawls,
and ratchets.
f. Load, boom angle, and other indicators over their full range, for any
significant inaccuracies.
g. Gasoline I die sel, electric, or other power plants for improper perfor-
mance or noncompliance with safety requirements.
h. Exce ssive wear of chain-drive sprockets and excessive chain stretch.
j. Crane hooks. Magnetic particles or other suitable crack detecting
inspection should be performed at least once each year.
k, Travel steering, braking, and locking device s, for malfunction.
Maintenance - Preventive maintenance programs based on the recommenda-
tions contained in this manual should be established. However, due to the
wide variation in job applications, severity of service, machine activity and
environment it is impossible for us to develop a single, complete standard
procedure which will fit all applications. Therefore such programs should be
developed by trained and experienced personnel, responsible for maintenance
of the machine, by adjustment and extens ion of our general recommendations,
to suit the particular needs.
Adjustments, Replacements & Repairs - Any conditions, disclosed by the
inspection requirements above, which are considered to constitute safety
hazards should be corrected before operation of the machine is resumed, to
assure that the equipment will always be operated in a safe condition.
Replacement Parts - It is recommended that all replacement parts be obtain-
ed from the original equipment manufacturer in order that the strength and
quality of the original machine may be maintained.
Lubrication - Regular and systematic lubrication should be maintained on
the machine, in accordance with the lubrication charts and general recom-
mendations contained in this manual. All machinery should be stopped while
lubricating except in cases where the lubrication system is designed for safe
application while the machinery is in motion. Any guards or panels which
must be removed for access to some points for lubrication or inspection
should always be replaced before resuming operation.
Maintenance Tools - Routine maintenance tools should be available at all
times.
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Rev. 7-73
25-8
X-2172

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1[3
II
Fire Extinguisher - A carbon dioxide or dry chemical hand fire extinguisher
should be kept in the operator's cab at all times.
Remember that the matter of keeping bolts and nuts tight is just as much an
item of maintenance as lubricating or adjusting the machine. A bolted connec-
tion which is not quite tight will quickly pound itself into a loose and danger-
ous connection.
A weld which has cracked due to excessive strain can be easily repaired by
"V-ing" it out and rewelding, but if the crack is allowed to go, it may spread
so much that proper alignment of the parts is lost. A satisfactory repair is
then hard to make.
An item of maintenance not to be overlooked is cleanliness. Clean and paint
the machine as part of your regular preventive maintenance schedule.
Operation - In general, established operating safety rule s where applicable
should be observed in performing operating functions. Operating safety rule s
are found in sources such as the following:
CLEAN IT FIRST - KEEPCLEAN FROM STARTTO FINISH.
VI. Machine Application and Operation
General - This is probably the most important area relative to safety since
it involves the greatest frequency of exposure to hazards. The operator
should be fully competent physically, mentally and emotionally to unders tand
and apply established operating safety rules. He should be able to exercise
good judgment in dealing with the many situations which cannot be anticipa-
ted and covered herein. SINCE THE MANUFACTURERHAS NO DIRECT CONTROL
OVERMACHINE APPLICATION AND OPERATION, CONFORMANCE WITH GOOD
SAFETYPRACTICE IN THIS AREAIS THE RESPONSIBILI'IY OF THE USER OR HIS
OPERATING PERSONNEL.
Application - Only machine s of proper rated capacity and type should be
assigned to the job to be done. Anything less constitutes a safety hazard.
1. Occupational Safety and Health Act of 1970, as amended.
2. ANSI Standard Safety Code for Crawler, Locomotive and Truck Cranes,
ANSI 830.5.
3. Power Crane and Shovel Association - "60 Rules on Safety" •
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Rev. 7-73