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The purpose of this manual is to provide information concerning the mechanical maintenance of the li300W Walking Dragline.
The Model li300W 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 req uired 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 A-frame, fairlead, 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.
This section of the manual describes those aspects of maintenance such as schedules, reports, and safety as related to the Model Walking Dragline.
Ideally, all maintenance should be approached from the preventive standpoint and on a regularly scheduled basis. Obviously, this approach keeps downtime to a minimum and results in reduced maintenance costs. To establish a preventive upkeep program, scheduled inspections and an operator's daily report are the most useful tools available. Scheduled inspections should be conducted by the Mine Mechanical and Electrical Maintenance Departments since they are the most qualified. Either department should generate a certain amount of paperwork, such as inspection records, that become a part of the mine's permanent file on the machine. The inspection records should be explicit, complete, and cover every part of the machine. Each machine operator should complete a daily record of the machine's performance. This record should include time worked, time down, reasons for all delays, and observations on any unusual conditions encountered during operation. From these records, items that can potentially cause machine downtime can be corrected or prevented immediately, or scheduled for a future date when the machine availability can be coordinated with the other mine activities.
Each problem should be thoroughly reviewed and evaluated before scheduling any maintenance or repair. The following points should be considered during the evaluation.
1. Is the problem one of normal wear?
2. Is the problem caused by machine application? Is the problem a result of operator error?
4. Is the problem a result of unavoidable circumstances?
;). Is the problem of a repetitive nature?
6. By leaving repairs to a later date, will any other component be affected?
7. Can repairs be accomplished immediately?
H. Will the cost of repairs immediately, rather than later, be worthwhile?
9. How long will the machine be down?
Once maintenance or repair has been scheduled, take the following points into consideration to minimize downtime and expense.
1. Are all tools and equipment needed to accomplish maintenance or repair available on the job, and are they in good repair?
2. Are all replacement parts on hand and readily available?
3. Is replacement of auxiliary parts, such as seals and bearings, necessary to accomplish repair, and have they been ordered?
4. Is all disassembly and reassembly data available?
5. Have repair crews been scheduled?
6. Will there be adequate supervision on hand for the repair crews?
7. Has the manufacturer been consulted for Service or Engineering assistance?
H. How long will the machine be down?
Once repair has been accomplished, the problem should again be reviewed with the following things in mind.
1. Was the cause of the problem permanently corrected or just patched?
2. What guarantee is there the same problem will not occur again?
3. Is consultation with the manufacturer for design improvement necessary?
4. What costs were incurred in downtime, parts, tools and labor?
5. Could the problem have been prevented by prior action?
The importance of overall safety in the maintenance of a dragline should always be emphasized; excavating operations may involve a variety of hazardous conditions. Many critical dragline components are subject to wear and other deterioration which limits their useful life; thus they are expendable. When new, all such parts have a builtin reserve strength against unknown factors and reasonable loss of durability from gradual wear. If, however, inspection and adjustment are neglected, these parts eventually reach a condition where they become a safety problem. Similarly, failure to replace various mechanisms to insure proper performance of the dragline also constitutes a safety problem. Study this manual carefully and follow all recommended procedures to avoid unsafe conditions. Review the manual periodically to refresh your knowledge of these procedures. Supervisors, operators and maintenance men should continuously follow safe practices.
Safety requirements dictate that all draglines in active service be inspected at regular intervals for proper adjustment of operating mechanisms, excessive wear of components, system cleanliness and any other defects. In-operation deficiences should be carefully investigated. It should be determined if a safety problem exists. Remember, maintenance is vital to safe operation. It should be performed systematically by competent personnel.
From an economic standpoint, it is advisable to perform as much of the upkeep as can be safely accomplished while the dragline is running. Obviously, there are some maintenance procedures, such as gear tooth inspection and replacement, which require machine shutdown. However, many support duties can be safely and effectively handled at shift change when the dragline is still activated.
Automatic lubrication systems function throughout the operational cycles of the machine. These systems release premeasured lubricant which lengthen the wear life of the machinery units. Other parts of the machine may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the operator's hands at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.
A repair or maintenance job on drag line equipment is not complete until guards, plates and other safety devices have been replaced before the equipment is restored to operation.
The operator must be sure the dragline equipment is in a safe position before repairs or adjustments are made. The machine should not be endangered by falling rock or a yielding support surface. Before beginning repair or adjustment, the operator shall:
• Set the bucket on the ground.
• Set all brakes.
• De-energize control functions.
• Do whatever else is necessary to prevent accidental movement of the machine.
NOTE: If power is essential to the repair, it should only be energized when all personnel are clear of electrical and mechanical hazards. The power should only be energized during the required period and not when repair work is being done.
Prior to undertaking any work, maintenance personnel should notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the starting controls should be locked in the "off' position and tagged. The lock and tag should be removed only by the maintenance people who installed them or other authorized personnel. During all phases of maintenance, use extreme caution when working near electrical equipment. Never work near exposed, energized high voltage connections.
Approved protective equipment such as gloves and insulated hooks or tongs should always be used when high voltage electrical cables are handled. Only qualified electricians are permitted to directly maintain electrical equipment such as motors, transformers, and switches.
While performing maintenance, the awkward positions assumed often increase injuries due to handling heavy parts. As a precautionary measure, use mechanical handling equipment whenever possible. The mining foreman can facilitate safer and easier maintenance work by providing blocking materials. Service crews should have a fundamental knowledge of lifting practices so their knees and legs are used rather than their backs.
A CAUTION: Many of the component .. parts of the 1300W 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.
The lower works (figure 1) of the 1:300W dragline should be checked periodically for wear and damage. The base structure should be checked monthly for cracking or buckling, especially in the areas of the center pintle and the roller circle diaphragms. The roller circle rails and rollers should be checked weekly for proper lubrication, pitting, spalling, and galling of the wear surfaces. The rail clamp bolts and chocks should be checked for tightness. The swing rack should be checked weekly for proper lubrication, cracked or broken teeth and pitting, spalling or galling of the teeth. The swing pinions should also be inspected at this time pay ing close attention to the condition of the pinion
teeth and that the pinion retainer bolts are in place and tight.
Inspect the entire base structure (figure 1) for cracked or buckled plates and cracked welds at regularly scheduled intervals, no less than one month apart. Carefully check the interior surfaces of the top plate welds that join the top plates to the roller circle rail pads. Check them both inside and out. Observe the condition of all welds and plates of the interior with special attention given to the vertical diaphragm plates and welds underneath the roller circle path. Examine the welds that join
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