FOREWORD
The purpose of this manual is to provide information concerning the mechanical maintenance of the 1300W Walking Dragline.
The Model 1300W 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 sysf;fms 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 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 WARN IN G'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.
MACHINE SERIAL NUMBER ______________________
BUCYRUS-ERIE COMPANY General Offices: South Milwaukee, Wisconsin, U.S.A
1M SPS 1284
BI615838 \
@ BUCYRUS-ERIE COMPANY,
1984
BI615838 \ TABLE
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 l Section 2 - LOWER WORKS Base ...................................................................................... 5 Center Pintel .............................................................................. 6 Swing Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Roller Circle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Lifting Hook and Hook Path .............................................................. 10 Section 3- ROTATING DECK Revolving Frame ......................................................................... 11 Machinery Units ......................................................................... 12 Hoist and Drag Machinery ............................................................ 12 Swing Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Propel Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Brakes - Style 4 and 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Brakes - Style 1 ........................................................................ 47 Brakes - Style 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Drag Rope Support ....................................................................... 51 Selsyn-Tie ................................................................................ 52 Machinery House and Cabs . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Structural Members and Panels . . . . . . . . . . . . . . . . . . . . 53 Dyna vane Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 House Fans ........................................................................... 53 House Fans (Propellair) ............................................................... 54 House Fans (Chicago Blower) .......................................................... 55 Auxiliary Hoists and Overhead Crane ................................................. 55 Walkways and Stairways .............................................................. 57 Rear Door Openers .................................................................... 57 Windshield Wiper ...................................................... : . . . . . . . . . . . . . . 59 Operator's Seat ........................................................................ 61 Swing Control Unit ................................................................... 61 Section 4 - FRONT END EQUIPMENT Boom .................................................................................... 63 Upper and Lower Deflection Sheaves and Towers ...................................... 64 Boom Point ........................................................................... 66 Hoist Rope House Deflector Rollers . . . . . . . . . . . . . . . . . . . . . . . 68 Mast ..................................................................................... 68 A-Frame ................................................................................. 68
OF CONTENTS
BI615838 \ Structural Strands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 A-Frame Safety Structural Strands .................................................... 71 Upper, Lower and Intermediate Structural Strands ..................................... 72 Hoist and Drag Ropes ..................................................................... 78 Hoist Rope Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Drag Rope Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Fairlead .................................................................................. 81 Buffer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Dragline Bucket .......................................................................... 88 CHAPTER
Section 1 - GENERAL MAINTENANCE Safety ........................................................... l •••••••••••••••••••••••• 91 General .................................................................................. 91 Maintenance of Air System ............................................................... 91 Air Compressor ....................................................................... 91 Air Lines .............................................................................. 91 Air Tank .............................................................................. 91 Air Line Lubricator .................................................................... 93 Air Line Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Air Line Regulator .................................................................... 93 Anti-Freezer - Alcohol Type (Optional) ................................................. 93 Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Section 2 - COMPONENT MAINTENANCE Air Compressor (Kellogg-American) (B352) ................................................ 95 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Reassembly ........................................................................... 96 Lubrication Specifications ............................................................. 97 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Air Compressor (Kellogg-American) (B462) ................................................ 98 Daily Maintenance .................................................................... 99 Weekly Maintenance .................................................................. 99 Monthly Maintenance ................................................................. 99 Head Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Piston Ring Service .................................................................. 100 Overhaul Procedure .................................................................. 101 Reassembly .......................................................................... 101 Centrifugal Unloader Service ................................................ , ........ 103 Air Line Lubricators ..................................................................... 103 Micro-Fog Lubricator ................................................................. 103 Oil Fog Lubricator (Type 10-002, 3 oz. and 1/3 pint size) ................................ 104 Oil Fog Lubricator (Type 10-002, 1/2 pint size) ......................................... 104 Automatic Drain Filter .................................................................. 104 Anti-Freezer - Alcohol Type .............................................................. 106 Air Regulator ........................................................................... 107 Air Dryer ............................................................................... 108
2 - AIR SYSTEM
BI615838 \ CHAPTER 3 - LUBRICATION Section 1 - GENERAL MAINTENANCE General ................................................................................. 109 Lubrication Benchmarks ................................................................ 109 Lubrication Charts ...................................................................... 110 Section 2 - AUTOMATIC SYSTEMS A System ............................................................................... 117 B System ................................................................................ 117 C System : ...................................................................... 117 D System ............................................................................... 117 E System ...................................................................... .., ......... 118 F System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 G System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 H System .................................................. ,............................. 118 I System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 J System ................................................................................ 119 K System ............................................................................... 119 L System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Control Panels .......................................................................... 119 Pumps .................................................................................. 119 Warning Devices ........................................................................ 119 Cold Weather Equipment (Optional) ...................................................... 120 Lubricant Drum Handling Equipment (Optional) ......................................... 120 CHAPTER 4 - TROUBLESHOOTING Base Components ....................................................................... 121 Revolving Frame ........................................................................ 122 Hoist, Drag, Swing and Propel Machinery ................................................ 122 Machinery House and Cabs .............................................................. 123 Lubrication Systems ..................................................................... 124 Air System .............................................................................. 125 Air Compressor ...................................................................... 125 Centrifugal Unloader ................................................................. 127 Air Line Regulator , . . . . . . . . . . . . . . . . . . . . . . . . . 127 Air Lines and Storage Tank .......................................................... 127 Air Line Lubricator ................................................................... 127 Automatic Drain Filter ............................................................... 127 Dynavane Air Cleaner ................................................................... 127 A-Frame .................................................................. : ............. 127 Mast .................................................................................... 128 Boom ................................................................................... 128 Dragline Bucket ......................................................................... 128 Drag and Hoist Ropes ................................................................... 129 Fairlead ................................................................................. 129
BI615838 \
l Appendix Al - GEAR INSPECTION .............................................................. lA Appendix A2 - BOLT TORQUING Bolt Torque Values for Static Joints ......................................... Bulletin 6-82-1 Appendix A3 - ADJUSTMENTS Boom Structural Strand Adjustments ................................................... 5A Brake Adjustment Tabulation .......................................................... 5A Appendix A4-PINION AND COUPLING INSTALLATION ...................................... 7A Appendix A5 - MAINTENANCE WELDING Section 1 - Repair Welding of Base, Revolving Frame, A-Frame, Walking Shoes and Drag Bucket ... llA General ...................................................., ....................... 1 lA Recommended Electrodes and Preheat ............................................. 1 lA Welding Electrodes ................................................................ 1 lA Repair Welding Procedures ........................................................ 12A General Procedure for Repair of Cracks ............................................ 12A Preheat ........................................................................... 13A Welding Techniques ............................................................... 13A General Procedure for Repair of Broken Parts ...................................... 13A Procedure for the Repair of Cracked or Broken Drag Bucket Teeth .................. 14A Stress Relieving ................................................................... 16A Procedure for Replacement of Bucket Lip Shrouds .................................. 16A Drag Bucket Tooth Repair ......................................................... 16A Drag Bucket Clevis Plates ......................................................... 18A Section 2 - Repair Welding Swing Rack Teeth .................................................. 21A 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 .......................................... 29A MPO - Multi-purpose Oil ............................................................. 30A OGL - Open Gear Lubricant .......................................................... 31A RGL - Regular Type Gear Lubricant .................................................. 32A RCRL - Roller Circle Rail Lubricant .................................................. 36A RWRL - Running Wire Rope Lubricant ............................................... 38A SWRL - Structural Strand and Stationary Wire Rope Lubricant ....................... 39A Appendix A7 -TAPERED ROLLER REPLACEMENT ................................. Bulletin 2-76-1 Appendix A8 - RAIL CHOCKING TIGHTNESS ................................................. 41A Appendix A9 - PREVENTIVE MAINTENANCE CHECKLISTS Daily ................................................................................. 43A Weekly ............................................................................... 45A Monthly .............................................................................. 48A Quarterly ............................................................................. 51A Semi-Annual .......................................................................... 53A
APPENDICES
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