FOREWORD
The purpose of this manual is to provide information concerning the mechanical maintenance of the 1260-W Walking Dragline.
The Model 1260-W 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 of the 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 buildup 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 A-frame, fair lead, mast, boom, running ropes, boom structural strands, and dragline bucket.
This manual consists of four chapters, each divided into sections. A table of contents is located in the front of the manual.
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.
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.
NOTE is used to stress a point or to give additional information concerning the procedure being 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.
Every effort has been made to make this manual as complete and accurate as possible at the time of publication. Bucyrus-Erie Company reserves the right, however, to continually improve its products. Therefore changes to the equipment herein may have been made that are not reflected in this manual.
MACHINE SERIAL NUMBER ________________
BUCYRUS-ERIE COMPANY
General Offices: South Milwaukee, Wisconsin, U.S.A. S/N 140884 and up
Lit. S386 BECOM 592
BI615832
BI615832
PAGE CHAPTER 1 MECHANICAL MAINTENANCE SECTION 1 - MAINTENANCE PROCEDURE General ................................................................................................................................... 1-1-1 Maintenance Schedules and Reports ................................................................................. 1-l-1 Safety ...................................................................................................................................... 1-1-2 General ......................................................................................................................... 1-1-2 In-Operation Maintenance ......................................................................................... 1-1-2 Precautions Before and During Maintenance Work .............................................. 1-1-2 SECTION 2 - LOWER WORKS Lower Works ......................................................................................................................... 1-2-1 Base ........................................................................................................................................ 1-2-1 Repair ........................................................................................................................... 1-2-2 Center Pintle ......................................................................................................................... 1-2-2 Swing Rack ............................................................................................................................ 1-2-3 Repair ........................................................................................................................... 1-2-4 Roller Circle .......................................................................................................................... 1-2-5 Repair ........................................................................................................................... 1-2-5 Lifting Hook and Hook Path .............................................................................................. 1-2-6 Repair ........................................................................................................................... 1-2-6 SECTION 3 - ROTATING DECK Revolving Frame ................................................................................................................... 1-3-1 Machinery Units ................................................................................................................... 1-3-1 Hoist and Drag Machinery ........................................................................................ 1-3-2 Swing Machinery ...................................................................................................... 1-3-10 Propel Machinery ...................................................................................................... 1-3-20 Brakes ......................................................................................................................... 1-3-32 Drag Rope Support Rollers ............................................................................................... 1-3-38 Machinery House and Cab ................................................................................................ 1-3-38 Structural Members and Panels ............................................................................. 1-3-38 Dynavane Air Cleaner .............................................................................................. 1-3-39 House Fans ................................................................................................................ 1-3-39 House Fans (Chicago Blower) ................................................................................. 1-3-40 Auxiliary Hoists and Overhead Crane .................................................................. 1-3-40 Walkways and Stairways ........................................................................................ 1-3-41 Windshield Wiper ..................................................................................................... 1-3-42 Operator's Seat .......................................................................................................... 1-3-43 Swing Control Unit .................................................................................................. 1-3-43 SECTION 4 - FRONT END EQUIPMENT Boom ....................................................................................................................................... 1-4-1 Upper and Lower Deflection Sheaves and Towers ................................................ 1-4-3 Boom Point ................................................................................................................... 1-4-3 Hoist Rope House Deflector Rollers ......................................................................... 1-4-7 Mast ........................................................................................................................................ 1-4-8 A-Frame ................................................................................................................................. 1-4-9 Structural Strands ............................................................................................................. 1-4-11 A-Frame Safety Structural Strands ....................................................................... 1-4-12 Upper, Lower And Intermediate Structural Strands .......................................... 1-4-12 Hoist and Drag Ropes .............................................................................................. 1-4-16
TABLE OF CONTENTS
BI615832 Hoist Rope Replacement .......................................................................................... 1-4-16 Drag Rope Replacement ........................................................................................... 1-4-18 Fairlead ................................................................................................................................ 1-4-19 Repair ......................................................................................................................... 1-4-19 Buffer Cylinder .......................................................................................................... 1-4-27 Dragline Bucket .................................................................................................................. 1-4-27 CHAPTER 2 AIR SYSTEM SECTION 1 - GENERAL MAINTENANCE Safety ...................................................................................................................................... 2-1-1 General ................................................................................................................................... 2-1-1 Maintenance of Air System ................................................................................................ 2-1-1 Air Compressor & Air Dryer .................................................................................... 2-1-1 Air Lines ...................................................................................................................... 2-l-1 Air Tank ....................................................................................................................... 2-1-1 Air Line Lubricator .................................................................................................... 2-1-1 Air Line Filter ............................................................................................................. 2-l-1 Air Line Regulator ...................................................................................................... 2-1-1 Solenoid Valves ........................................................................................................... 2-1-1 Pressure Switches ....................................................................................................... 2-1-1 Air Dryer ...................................................................................................................... 2-1-5 SECTION 2 - COMPONENT MAINTENANCE Air Line Lubricators ............................................................................................................ 2-2-1 Type L12 & Ll 7 Micro-Fog Lubricators ................................................................. 2-2-1 Air Regulator ......................................................................................................................... 2-2-1 Air Line Filters ..................................................................................................................... 2-2-2 Type F12 & F17 Auto Drain Filters ....................................................................... 2-2-2 Air Dryer ................................................................................................................................ 2-2-3
LUBRICATION SECTION 1- GENERAL MAINTENANCE General ................................................................................................................................... 3-1-1 Lubrication Benchmarks ..................................................................................................... 3-1-1 Lubrication Charts ............................................................................................................... 3-1-2 SECTION 2 - AUTOMATIC LUBE SYSTEMS System-A ................................................................................................................................ 3-2-1 System-B ................................................................................................................................ 3-2-1 System-C ................................................................................................................................ 3-2-1 System-D ................................................................................................................................ 3-2-2 System-E ................................................................................................................................ 3-2-2 System-F ................................................................................................................................ 3-2-2 System-G ................................................................................................................................ 3-2-2 System-H ................................................................................................................................ 3-2-2 System-I ................................................................................................................................. 3-2-2 System-J ................................................................................................................................. 3-2-3 System-K ................................................................................................................................ 3-2-3 System-L ................................................................................................................................ 3-2-3 Control Panels ....................................................................................................................... 3-2-3 Pump Control Stations ........................................................................................................ 3-2-3 Pumps ..................................................................................................................................... 3-2-3 Warning Devices ................................................................................................................... 3-2-3
CHAPTER 3
BI615832 Cold Weather Equipment (Optional) ................................................................................. 3-2-4 Lubricant Drum Handling Equipment (Optional) ........................................................... 3-2-4 CHAPTER 4 TROUBLESHOOTING Base Components ................................................................................................................. 4-1-1 Revolving Frame ................................................................................................................... 4-1-2 Hoist, Drag, Swing and Propel Machinery ..................................................................... .4-1-2 Machinery House and Cab .................................................................................................. 4-1-3 Lubrication Systems ............................................................................................................. 4-1-4 Air Line Regulator ............................................................................................................... 4-1-5 Air Lines and Storage Tank ............................................................................................... 4-1-5 Air Line Lubricator .............................................................................................................. 4-1-6 Automatic Drain Filter ........................................................................................................ 4-1-6 Dynavane Air Cleaner ......................................................................................................... 4-1-6 A-frame ................................................................................................................................... 4-1-6 Mast ........................................................................................................................................ 4-1-7 Boom ....................................................................................................................................... 4-1-7 Dragline Bucket .................................................................................................................... 4-1-7 Drag and Hoist Ropes .......................................................................................................... 4-1-8 Fairlead .................................................................................................................................. 4-1-8 APPENDICES APPENDIX Al - GEAR INSPECTION ............................................................................................... Al-1 APPENDIX A2 - BOLT TORQUING .................................................................................................. A2-1 APPENDIX A3 - BOOM INTERMEDIATE STRUCTURAL STRAND ADJUSTMENT A3-1 APPENDIX A4 - PINION AND COUPLING INSTALLATION ...................................................... A4-1 APPENDIX A5 - MAINTENANCE WELDING SECTION 1 - Repair Welding of Base, Revolving Frame, A-Frame, Walking Shoes and Drag Bucket ................................................................................................................ A5-1-1 General ....................................................................................................................... A5-1-1 Recommended Electrodes and Preheat ................................................................. A5-l-1 Welding Electrodes ................................................................................................... A5-l-1 Repair Welding Procedures .................................................................................... A5-1-2 General Procedure for Repair of Broken Parts ................................................... A5-1-4 Procedure for the Repair of Cracked or Broken Drag Bucket Lips ................ A5-1-4 Stress Relieving ........................................................................................................ A5-1-6 Procedure for Replacement of Bucket Lip Shrouds ............................................ A5-1-6 Drag Bucket Tooth Repair ...................................................................................... A5-1-6 Drag Bucket Clevis Plates ...................................................................................... A5-1-8 SECTION 2 - Repair Welding Swing Rack Teeth ....................................................... A5-2-1 Preparation ................................................................................................................ A5-2-1 Welding Electrodes ................................................................................................... A5-2-2 Preheat ....................................................................................................................... A5-2-2 Welding ...................................................................................................................... A5-2-2 SECTION 3 - Welding and Cutting Equipment ......................................................... A5-3-1 SECTION 4 - Stress Relieving and Temperature Measuring Equipment A5-4-1 APPENDIX A6 - LUBRICATION BENCHMARKS ........................................................................... A6-1 APPENDIX A7 -TAPERED ROLLER REPLACEMENT ................................................................. A7-1 APPENDIX AS - RAIL CHOCKING TIGHTNESS ............................................................................ AS-1
BI615832 APPENDIX A9 - PREVENTIVE MAINTENANCE CHECKLISTS ............................................. A9-1 APPENDIX Al0 - BRAKE OR CLUTCH MAINTENANCE CHECKLIST .............................. Al0-1 Brake Lining Burnish-In Procedure Al0-2 APPENDIX All - TYPICAL PART WEIGHTS All-1
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