BE1370W Manual

B.E.
1370-W – WALKING DRAGLINE

Maintenance and Mechanical Procedures
CONTENTS
CHAPTER 1 – MECHANICAL MAINTENANCE..............................................................................................6

SECTION 1 - MAINTENANCE PROCEDURE....................................................................................................6
GENERAL...........................................................................................................................................................6
MAINTENANCE SCHEDULES AND REPORTS...............................................................................................6
SAFETY...............................................................................................................................................................7
GENERAL......................................................................................................................................................................... 7
IN-OPERATION MAINTENANCE.................................................................................................................................7
PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK..........................................................................7
SECTION 2— LOWER WORKS..........................................................................................................................9
BASE...................................................................................................................................................................9
Repair........................................................................................................................................................................... 10
SWING RACK...................................................................................................................................................10
Repair........................................................................................................................................................................... 10
ROLLER CIRCLE.............................................................................................................................................10
Repair........................................................................................................................................................................... 11
LIFTING HOOK AND HOOK PATH...............................................................................................................13
Repair........................................................................................................................................................................... 13
CENTRE PINTLE.............................................................................................................................................14
SECTION 3— ROTATING DECK......................................................................................................................15
REVOLVING FRAME.......................................................................................................................................15
MACHINERY UNITS........................................................................................................................................15
HOIST AND DRAG MACHINERY...............................................................................................................................16
Repair........................................................................................................................................................................... 16
SWING MACHINERY....................................................................................................................................................23
Repair........................................................................................................................................................................... 23
Swing Cushion Adjustment.........................................................................................................................................29
Swing Timing...............................................................................................................................................................29
Procedure..................................................................................................................................................................... 30
PROPEL MACHINERY..................................................................................................................................................32
BRAKES.......................................................................................................................................................................... 39
BRAKE STYLES 3, 4 & 5...............................................................................................................................................40
Adjustment...................................................................................................................................................................43
BRAKE STYLE 1............................................................................................................................................................43
Adjustment (Figure 41)................................................................................................................................................45
BRAKE STYLE 2 (FIGURE 42).....................................................................................................................................45
Adjustment...................................................................................................................................................................47
DRAG ROPE SUPPORT..................................................................................................................................48
DRAG ROPE DIRT TROUGH CLEANING SYSTEM......................................................................................48
SELSYN-TIE......................................................................................................................................................51
RETRACTABLE LADDER — OPTIONAL.......................................................................................................51
MACHINERY HOUSE AND CABS..................................................................................................................51
STRUCTURAL MEMBERS AND PANELS.................................................................................................................51
DYNAVANE AIR CLEANER........................................................................................................................................52
Page
Rev – 0
22/07/99
JLC
B.E. 1370-W – WALKING DRAGLINE
Inspection.....................................................................................................................................................................52
HOUSE FANS.................................................................................................................................................................52
Inspection.....................................................................................................................................................................52
Lubrication...................................................................................................................................................................52
Bearings....................................................................................................................................................................... 53
HOUSE FANS (PROPELLAIR).....................................................................................................................................53
Inspection.....................................................................................................................................................................53
HOUSE FANS (CHICAGO BLOWER)..........................................................................................................................53
Inspection.....................................................................................................................................................................53
Maintenance.................................................................................................................................................................53
AUXILIARY HOISTS AND OVERHEAD CRANE......................................................................................................54
Adjustment of Load Brake...........................................................................................................................................54
Adjustment of Clapper Type Electric Brake................................................................................................................54
Lubrication...................................................................................................................................................................54
Frequency.....................................................................................................................................................................55
WALKWAYS AND STAIRWAYS................................................................................................................................56
REAR DOOR OPENERS................................................................................................................................................57
Vertical Door Opener...................................................................................................................................................57
Horizontal Door Opener..............................................................................................................................................57
WINDSHIELD WIPER...................................................................................................................................................58
Wiper Travel Adjustment............................................................................................................................................59
Wiper Shutoff Adjustment...........................................................................................................................................59
OPERATOR’S SEAT......................................................................................................................................................59
SWING CONTROL UNIT..............................................................................................................................................59
Pedal Angle Adjustment..............................................................................................................................................59
SECTION 4— FRONT END EQUIPMENT........................................................................................................61
BOOM...............................................................................................................................................................61
UPPER AND LOWER DEFLECTION SHEAVES AND TOWERS.............................................................................62
BOOM POINT.................................................................................................................................................................62
MAST.................................................................................................................................................................65
A-FRAME..........................................................................................................................................................67
STRUCTURAL STRANDS................................................................................................................................68
A-FRAME SAFETY STRUCTURAL STRANDS.........................................................................................................69
UPPER, LOWER AND INTERMEDIATE STRUCTURAL STRANDS......................................................................69
HOIST AND DRAG ROPES.............................................................................................................................73
HOIST ROPE REPLACEMENT.....................................................................................................................................74
DRAG ROPE REPLACEMENT.....................................................................................................................................75
FAIRLEAD........................................................................................................................................................77
STRAIGHT THROUGH TYPE FAIRLEAD..................................................................................................................77
BUFFER CYLINDER......................................................................................................................................................79
OVER AND UNDER TYPE FAIRLEAD...........................................................................................................80
FAIRLEAD RESTRICTION BRAKE.............................................................................................................................82
Brake Discs..................................................................................................................................................................82
Piston Rings.................................................................................................................................................................83
DRAGLINE BUCKET.......................................................................................................................................83
CHAPTER 2 – AIR SYSTEM................................................................................................................................86
SECTION 1— GENERAL MAINTENANCE.....................................................................................................86
SAFETY.............................................................................................................................................................86
GENERAL.........................................................................................................................................................86
MAINTENANCE OF AIR SYSTEM..................................................................................................................86
AIR COMPRESSOR........................................................................................................................................................86
AIR LINES.......................................................................................................................................................................86
AIR TANK.......................................................................................................................................................................88
AIR LINE LUBRICATOR..............................................................................................................................................88
AIR LINE FILTER..........................................................................................................................................................88
AIR LINE REGULATOR................................................................................................................................................88
ANTI-FREEZER — ALCOHOL TYPE (Optional)........................................................................................................88
SOLENOID VALVES.....................................................................................................................................................88
PRESSURE SWITCHES.................................................................................................................................................88
Page
Rev – 0
22/07/99
JLC
AIR DRYER.....................................................................................................................................................................89
SECTION 2— COMPONENT MAINTENANCE...............................................................................................90
AIR COMPRESSOR (KELLOGG-AMERICAN)...............................................................................................90
DAILY MAINTENANCE...............................................................................................................................................90
WEEKLY MAINTENANCE...........................................................................................................................................90
MONTHLY MAINTENANCE........................................................................................................................................90
HEAD VALVE SERVICE...............................................................................................................................................90
PISTON RING SERVICE...............................................................................................................................................92
OVERHAUL PROCEDURE...........................................................................................................................................92
REASSEMBLY................................................................................................................................................................93
CENTRIFUGAL UNLOADER SERVICE......................................................................................................................94
AIR LINE LUBRICATORS................................................................................................................................95
MICRO-FOG LUBRICATOR.........................................................................................................................................95
OIL FOG LUBRICATOR (TYPE 10-002, 3 OZ. AND 1/3 PINT SIZE).......................................................................95
OIL FOG LUBRICATOR (TYPE 10-002, 1/2-PINT SIZE)...........................................................................................96
AUTOMATIC DRAIN FILTER.........................................................................................................................96
MAINTENANCE.............................................................................................................................................................96
ANTI-FREEZER................................................................................................................................................97
AIR REGULATOR............................................................................................................................................98
AIR DRYER.......................................................................................................................................................99
CHAPTER 3— LUBRICATION.........................................................................................................................100
SECTION 1— GENERAL MAINTENANCE...................................................................................................100
GENERAL.......................................................................................................................................................100
LUBRICATION BENCHMARKS....................................................................................................................100
LUBRICATION CHARTS...............................................................................................................................102
Swing Machinery Lube Points – Figure 96...............................................................................................................103
Propel Machinery Lube Points – Figure 97...............................................................................................................104
Fairlead Lube Points – Figure 98...............................................................................................................................105
Front End Equipment Lube Points– Figure 99..........................................................................................................106
SECTION 2— AUTOMATIC LUBE SYSTEMS..............................................................................................107
SYSTEM A.......................................................................................................................................................107
SYSTEM-B.......................................................................................................................................................107
SYSTEM-C......................................................................................................................................................108
SYSTEM-D......................................................................................................................................................108
SYSTEM-E.......................................................................................................................................................108
SYSTEM-F.......................................................................................................................................................108
SYSTEM-G......................................................................................................................................................108
SYSTEM-H......................................................................................................................................................109
SYSTEM-I........................................................................................................................................................109
SYSTEM-J.......................................................................................................................................................109
SYSTEM-K......................................................................................................................................................109
SYSTEM-L.......................................................................................................................................................110
CONTROL PANELS.......................................................................................................................................110
PUMPS...........................................................................................................................................................111
WARNING DEVICES......................................................................................................................................111
COLD WEATHER EQUIPMENT (OPTIONAL)............................................................................................111
LUBRICANT DRUM HANDLING EQUIPMENT (OPTIONAL)...................................................................111
CHAPTER 4 - TROUBLE SHOOTING.............................................................................................................111
BASE COMPONENTS....................................................................................................................................111
REVOLVING FRAME.....................................................................................................................................113
HOIST, DRAG, SWING AND PROPEL MACHINERY..................................................................................113
MACHINERY HOUSE AND CABS................................................................................................................114
LUBRICATION SYSTEMS..............................................................................................................................114
AIR SYSTEM...................................................................................................................................................115
AIR COMPRESSOR......................................................................................................................................................115
Page
Rev – 0
22/07/99
JLC
CENTRIFUGAL UNLOADER.....................................................................................................................................116
AIR LINE REGULATOR..............................................................................................................................................116
AIR LINES AND STORAGE TANK............................................................................................................................117
AIR LINE LUBRICATOR............................................................................................................................................117
AUTOMATIC DRAIN FILTER....................................................................................................................................117
DYNAVANE AIR CLEANER...........................................................................................................................117
A-FRAME........................................................................................................................................................117
MAST...............................................................................................................................................................117
BOOM.............................................................................................................................................................118
DRAGLINE BUCKET.....................................................................................................................................118
DRAG AND HOIST ROPES...........................................................................................................................119
FAIRLEAD......................................................................................................................................................119
APPENDICES.......................................................................................................................................................120
APPENDIX AL — GEAR INSPECTION..........................................................................................................120
APPENXIX A2 – BOLT TORQUING...............................................................................................................122
BOLT TORQUE VALUES FOR STATIC JOINTS.....................................................................................................122
APPENDIX A3 – ADJUSTMENTS...................................................................................................................123
BOOM STRUCTURAL STRAND ADJUSTMENTS..................................................................................................123
BRAKE ADJUSTMENT TABULATION....................................................................................................................123
Hoist Brake................................................................................................................................................................123
Drag Brake.................................................................................................................................................................123
Swing Brake...............................................................................................................................................................123
Propel Brake...............................................................................................................................................................123
APPENDIX A4 — PINION AND COUPLING INSTALLATION...................................................................124
REMOVAL FROM MOTOR SHAFT...........................................................................................................................124
MOUNTING PINION OR COUPLING ON SHAFT...................................................................................................124
APPENDIX A5 — MAINTENANCE WELDING............................................................................................127
SECTION 1— REPAIR WELDING OF BASE, REVOLVING FRAME, A-FRAME, WALKING SHOES AND
DRAG BUCKET..............................................................................................................................................127
GENERAL..................................................................................................................................................................... 127
RECOMMENDED ELECTRODES AND PREHEAT.................................................................................................127
WELDING ELECTRODES...........................................................................................................................................128
REPAIR WELDING PROCEDURES...........................................................................................................................128
General Procedure for Repair of Cracks....................................................................................................................128
GENERAL PROCEDURE FOR REPAIR OF CRACKS.............................................................................................129
PRE-HEAT.....................................................................................................................................................................129
WELDING TECHNIQUES...........................................................................................................................................129
GENERAL PROCEDURE FOR REPAIR OF BROKEN PARTS...............................................................................130
ROCEDURE FOR THE REPAIR OF CRACKED OR BROKEN DRAGBUCKET LIPS..........................................131
STRESS RELIEVING...................................................................................................................................................132
PROCEDURE FOR REPLACEMENT OF BUCKET LIP SHROUDS.......................................................................133
DRAG BUCKET TOOTH REPAIR..............................................................................................................................133
DRAG BUCKET CLEVIS PLATES.............................................................................................................................134
SECTION 2— REPAIR WELDING SWING RACK TEETH...........................................................................137
PREPARATION............................................................................................................................................................137
WELDING ELECTRODES...........................................................................................................................................139
PREHEAT...................................................................................................................................................................... 139
WELDING..................................................................................................................................................................... 139
SECTION 3— WELDING AND CUTTING EQUIPMENT............................................................................141
SECTION 4— STRESS RELIEVING AND TEMPERATURE MEASURING EQUIPMENT..........................142
APPENDIX A6 — LUBRICATION BENCHMARKS.....................................................................................143
MPG — MULTIPURPOSE TYPE GREASE...............................................................................................................143
Scope.......................................................................................................................................................................... 143
Application.................................................................................................................................................................143
General Requirements................................................................................................................................................143
Compounding.............................................................................................................................................................143
Specific Requirements...............................................................................................................................................144
Notations....................................................................................................................................................................144
Page
Rev – 0
22/07/99
JLC
ACPL — AIR COMPRESSOR (PISTON TYPE) LUBRICANT.................................................................................144

Scope.......................................................................................................................................................................... 144
Application.................................................................................................................................................................144
MWCL – MONIGHAN WALKING CAM LUBRICANT...........................................................................................146
Scope.......................................................................................................................................................................... 146
Application.................................................................................................................................................................146
Compounding.............................................................................................................................................................146
Timken Retention Test, 4 Grams...............................................................................................................................147
Low Temperature Properties......................................................................................................................................147
MPO — MULTI-PURPOSE OIL..................................................................................................................................147
Scope.......................................................................................................................................................................... 147
Application.................................................................................................................................................................147
Viscosity Recommendations......................................................................................................................................147
OGL – OPEN GER LUBRICANT................................................................................................................................148
Scope.......................................................................................................................................................................... 148
Application.................................................................................................................................................................148
Methods of Application.............................................................................................................................................148
Types of Lubricants...................................................................................................................................................148
Compounding.............................................................................................................................................................149
Specific Requirements for All Type of Lubricant.....................................................................................................149
RGL – REGULAR TYPE GEAR LUBRICANT..........................................................................................................149
Scope.......................................................................................................................................................................... 149
Application.................................................................................................................................................................150
Compounding.............................................................................................................................................................150
Viscosity and Viscosity Index...................................................................................................................................150
Notations....................................................................................................................................................................151
Walking Dragline.......................................................................................................................................................151
RCRL – ROLLER CIRCLE RAIL LUBRICANT.........................................................................................................152
Scope.......................................................................................................................................................................... 152
Application.................................................................................................................................................................152
Method of Application...............................................................................................................................................152
Types of Lubricants...................................................................................................................................................153
Compounding.............................................................................................................................................................153
Specific Requirements for All Types of Lubricant....................................................................................................153
Special Instructions....................................................................................................................................................154
RWRL – RUNNING WIRE ROPE LUBRICANT........................................................................................................154
Scope: A....................................................................................................................................................................154
Application.................................................................................................................................................................154
Compounding.............................................................................................................................................................155
Special Requirements.................................................................................................................................................155
Scope: B....................................................................................................................................................................155
Application.................................................................................................................................................................155
Compounding.............................................................................................................................................................156
SWRL – STRUCTURAL STRAND AND STAIONARY WIRE ROPE LUBRICANT.............................................156
Scope.......................................................................................................................................................................... 156
Page
Rev – 0
22/07/99
JLC
maintenance or repair. The following points

should be considered during the evaluation.
CHAPTER 1 – MECHANICAL
1. Is the problem one of normal wear?
MAINTENANCE
2. Is the problem caused by machine
application?
SECTION 1 - MAINTENANCE
3. Is the problem a result of operator error?
PROCEDURE
4. Is the problem a result of unavoidable
circumstances?
GENERAL
5. Is the problem of a repetitive nature?
This section of the manual describes those
aspects of maintenance such as schedules, 6. By leaving repairs to a later date, will
reports, and safety as related to the Model any other component be affected?
1370W Walking Dragline.
7. Can repairs be accomplished
immediately?
MAINTENANCE SCHEDULES AND 8. Will the cost of repairs immediately,
REPORTS rather than later, be worthwhile?
Ideally, all maintenance should be approached 9. How long will the machine be down?
from the preventive standpoint and on a
regularly scheduled basis. Obviously, this Once maintenance or repair has been
approach keeps downtime to a minimum and scheduled, take the following points into
results in reduced maintenance costs. To consideration to minimize downtime and
establish a preventive up keep program- expense.
scheduled inspections, and an operator’s daily
reports are the most useful tools avail able. 1. Are all tools and equipment needed to
Scheduled inspections should be conducted by accomplish maintenance or repair available on
the Mine Mechanical and Electrical Maintenance the job, and are they in good repair?
Departments since they are the most qualified.
Either department should generate a certain 2. Are all replacement parts on hand and
amount of paperwork, such as inspection readily available?
records that become a part of the mine’s
permanent file on the machine. The inspection 3. Is replacement of auxiliary parts, such
records should be explicit, complete, and cover as seals and bearings, necessary to accomplish
every part of the machine. Each machine repair, and have they been ordered?
operator should complete a daily record of the
machine’s performance. This record should 4. Is all disassembly and re-assembly data
include time worked, time down, reasons for all available?
delays, and observations on any unusual
conditions encountered during operation. From 5. Have repair crews been scheduled?
these records, items that can potentially, cause
machine down time can be corrected or 6. Will there be adequate supervision on
prevented immediately, or scheduled for a future hand for the repair crews?
date when the machine availability can be
coordinated with the other mine activities. 7. Has the manufacturer been consulted
for Service or Engineering assistance?
Each problem should be thoroughly reviewed
and evaluated before scheduling any 8. How long will the machine be down?
Page
Rev – 0
22/07/99
JLC
Once repair has been accomplished, the should be determined if a safety problem exists.
problem should again be reviewed with the Remember that maintenance is vital to safe
following things in mind. operation. It should be performed systematically
by competent personnel.
1. Was the cause of the problem
permanently corrected or just patched? From an economic standpoint, it is advisable to
perform as much of the upkeep as can be safely
2. What guarantee is there that the same accomplished while the dragline is running.
problem will not occur again? Obviously, there are maintenance procedures,
such as gear tooth inspection and replacement,
3. Is consultation with the manufacturer for which require machine shutdown. However,
design improvement necessary’? many support duties can be safely and
effectively handled at shift change when the
4. What costs, were incurred in downtime, dragline is still activated.
parts, tools and labour?
Automatic lubrication systems function through
5. Could the problem have been prevented out the operational cycles of the machine. These
by
prior action? systems release pre-measured lubricant which
lengthen the wear life of the machinery units.
SAFETY Other parts of the machine may be manually
lubricated in a safe manner through extended
grease or oil fittings designed to keep the
GENERAL
operator’s hands at a safe distance. Where this
is not possible, the machine must be shut down
The importance of overall safety in the during the required lubrication.
maintenance of a dragline should always be
emphasized; excavating operations may involve A repair or maintenance job on dragline
a variety of hazardous conditions. Many critical equipment is not complete until guards, plates
dragline components are subject to wear and and other safety devices have been replaced
other deterioration, which limits their useful life; before the equipment is restored to operation.
thus they are expendable. When new, all such
parts have built-in reserve strength, against PRECAUTIONS BEFORE AND DURING
unknown factors and reasonable loss of MAINTENANCE WORK
durability from gradual wear. If, however,
inspection and adjustment are neglected, these The operator must be sure the dragline
parts eventually reach a condition where they equipment is in a safe position before repairs or
become a safety problem. Similarly, failure to adjustments are made. Falling rock or a yielding
replace various mechanisms to insure proper support surface should not endanger the
performance of the dragline also constitutes a machine. Before beginning repair or adjustment,
safety problem. Study this manual care fully and the operator shall:
follow all recommended procedures to avoid
unsafe conditions. Review the manual  Set the bucket on the ground.
periodically to refresh your knowledge of these  Set all brakes.
procedures. Supervisors, operators and  De-energize control functions.
maintenance men should continuously follow  Do whatever else is necessary to
safe practices. prevent accidental movement of the
machine.
IN-OPERATION MAINTENANCE
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
deficiencies should be carefully investigated. It
Page
Rev – 0
22/07/99
JLC
NOTE: IF POWER IS ESSENTIAL CAUTION: MANY OF THE

TO THE REPAIR, IT SHOULD ONLY BE COMPONENT PARTS OF THE 1370W
ENERGIZED WHEN ALL PERSONNEL ARE HEAVY, BULKY ITEMS. EXTREME
ARE CLEAR OF ELECTRICAL AND CAUTION SHOULD BE USED WHEN
MECHANICAL HAZARDS. THE POWER LIFTING THESE ITEMS. PERSONNEL
SHOULD ONLY BE ENERGIZED SHOULD BE CERTAIN OF THE
DURING THE REQUIRED PERIOD AND WEIGHTS OF COMPONENTS BEFORE
NOT WHEN REPAIR WORK IS BEING ATTEMPTING TO LIFT THEM, EITHER
DONE. MANUALLY OR WITH SOME LIFTING
DEVICE. ALL APPLICABLE SAFETY
Prior to undertaking any work, maintenance RULES SHOULD BE FOLLOWED
personnel should notify the operator about the WHEN USING CRANES OR OTHER
nature and location of the job. If work is to be LIFTING EQUIPMENT. BE SURE OF
done on or near moving parts, the starting THE LOAD, LIFTING HEIGHT AND
controls should be locked in the “off” position RADIUS, AND CAPACITY OF THE
and tagged. Only the maintenance people who MACHINE BEFORE LIFTING A LOAD.
installed them or other authorized personnel FAILURE TO FOLLOW ALL
should remove the lock and tag. During all APPLICABLE SAFETY RULES WHEN
phases of maintenance, use extreme caution LIFTING HEAVY PARTS CAN CAUSE
when working near electrical equipment. Never SERIOUS OR FATAL INJURY.
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.
Page
Rev – 0
22/07/99
JLC
SECTION 2— LOWER WORKS BASE
The lower works (figure 1) of the 1370W Inspect the entire base structure (figure 1) for
dragline should be checked periodically for wear cracked or buckled plates and cracked welds at
and damage. The base structure should be regularly scheduled intervals, no less than one
checked monthly for cracking or buckling month apart. Carefully check the interior
especially in the areas of the centre pintle and surfaces of the top plate welds that join the top
the roller circle diaphragms. The roller circle rails plates to the roller circle rail pads. Check them
and rollers should be checked weekly for proper both inside and out. Observe the condition of all
lubrication, pitting, spalling, and galling of the welds and plates of the interior with special
wear surfaces. The rail clamp bolts and chocks attention given to the vertical diaphragm plates
should be checked for tightness. The swing rack and welds underneath the roller circle path.
should be checked weekly for proper lubrication, Examine the welds that join the centre pintle
cracked or broken teeth and pitting, spalling or section to the intermediate sections. Check all
galling of the teeth. The swing pinions should bottom plates for buckling and indentations to
also be inspected at this time paying close make sure no localized high ground loading is
attention to the condition of the pinion teeth and occurring. Watch all vertical diaphragms, both
that the pinion retainer bolts are in place and radial and circumferential, for paint cracking or
tight. checking in lines. This condition indicates high
stress pattern development.
Page
Rev – 0
22/07/99
JLC
Repair CIRCLE. Install ramps sloping down from the rail

pad toward the damaged rack section (figure 2).
The basic repair procedure for the base is repair
welding of cracked or damaged welds or plates. CAUTION: EACH RACK SEGMENT IS
Use welding procedures as outlined in appendix. EXTREMELY HEAVY, SO BE SURE
When repairing cracks do not add reinforcing THE EQUIPMENT USED TO HANDLE
plates unless so advised by Bucyrus-Erie THE SEGMENT HAS SUFFICIENT
Service Department. CAPACITY TO SAFELY PERFORM THE
REPAIR.
SWING RACK
4. Unbolt the rack segment from the base
and with the selected equipment pull it over the
Inspect the swing rack and pinion weekly to ramps and off the base.
insure there are no bare metal spots or contact
points, broken tooth ends, loose bolts or broken 5. Repair or replace the damaged rack
welds at back of rack. In particular, check for pit segment. Reset the ramps and pull the new or
ting, abrasion, scratching, spalling, and galling repaired rack segment into place. Remove the
as shown in appendix under the topic, GEAR ramps.
INSPECTION. All teeth should carry a good
coating of protective lubricant. 6. Insert 1 x 4 UNC capscrews in the
tapped holes in the rack segment. Use the
If during inspection a broken tooth is noted shut capscrews to level the rack segment. Insert
down the machine immediately and do not shims, as needed, between the rack segments
operate the machine until the tooth has been and rack pad. Install the rack bolt and snug up.
repaired. For repair instructions for broken or Check for proper alignment of the rack section to
cracked teeth, refer to appendix. the mating sections. When properly aligned back
off on the leveling capscrew and torque the rack
WARNING: CONTINUED OPERATION bolts.
OF THE MA CHINE WITH ONE OR
MORE BROKEN TEETH IN THE SWING 7. Weld the rack segment to the pad and
RACK COULD RESULT IN then to the mating sections. The rack to pad
ADDITIONAL DAM AGE TO THE weld is a ¾ inch fillet weld. Be sure the vertical
SWING RACK, SWING PINIONS AND leg of the fillet weld is ¾ inch as shimming could
SWING MACHINERY UNITS. affect the weld height. The inside vertical joint
weld is a convex butt weld.
Repair
8. Replace the roller circle section as
Although uncommon, if complete cracking of a described in the topic ROLLER CIRCLE.
swing rack segment is noted, the rack segment
can be replaced using the following procedure. 9. Lubricate the teeth of the rack segment
Prior to initiating the repair, contact the Bucyrus- and check the segment for proper operation by
Erie Service Department so that the cause of the swinging the machine.
cracking can be traced.
ROLLER CIRCLE
1. Move the machine to a safe area with
adequate space to perform the repair. Inspect the roller circle weekly for severe pitting
or spalling, which generally indicates non-
2. Swing the machine so the damaged uniform loading. Small incipient pitting on the
rack segment lies behind a roller circle section rollers however, is not unusual. Also check for
not having an upper rail. Shut down the machine destructive roller wear in the contact area of the
and tag the controls. inside flange. If rollers are damaged, they should
be removed immediately. If the roller cannot be
3. Remove the roller circle section replaced at the time of removal, the good rollers
completely as described under topic ROLLER should be redistributed so that they are equally
spaced around the roller circle. Generally, 10%
Page
Rev – 0
22/07/99
JLC
of evenly distributed rollers may be missing and NOTE: IF AN UPPER RAIL

not significantly effect the operation of the SECTION IS TO BE REPLACED, THE
dragline. Also, the roller frames should be MACHINE WILL HAVE TO BE JACKED
checked for warping or bending. Examine the UP SLIGHTLY TO REMOVE IT.
upper and lower rails for pitting and spalling and CONTACT THE BUCYRUS-ERIE
that the chock and clamps are in place and tight. SERVICE DEPARTMENT FOR THE
Check that the rails and rollers are being CORRECT PROCEDURE.
properly lubricated.
3. Remove the roller lube fittings and roller

Repair pin retaining bolts. Remove the outer and inner
frame splice plate bolts. With a torch, break the
To replace a roller, frame section or rail section weld at the top of the splice plate. Follow all
(figure 3), proceed as follows: safety rules when using the torch.
1. Move the machine to a safe area with NOTE: THE INNER AND OUTER
adequate space to perform the repair. FRAME SPLICE JOINTS ARE NOT IN
LINE BUT ARE STAGGERED.
2. Swing the machine so the damaged part
is located under roller circle not having an upper 4. Remove the splice plates and inner and
rail. Shut down the machine and tag the outer frames. With suitable equipment, lift the
controls. rollers from the lower rail. Remove the pin and
bushings from the roller.
Page
Rev – 0
22/07/99
JLC
5. With a torch, break the welds securing match the existing rollers. Refer to appendix for
the chocks to the base top plate. Remove the procedure for matching rollers.
rail clamps and chock. Remove the rail section.
8. Be sure the rail chocks and clamp are in
6. Repair or replace all worn or damaged place and the chocks are welded. Also be sure
parts and reassemble in reverse of disassembly. the splice plates are welded to the roller frames.
Shim the rail ends if required, gaining a solid rail

7. If a new rail section is being installed, circle.
the rail section must be machined to match the
rails on either side. If a new roller is being 9. Lubricate the roller circle and rails and
installed, the roller flange must be machined to test.
Page
Rev – 0
22/07/99
JLC
LIFTING HOOK AND HOOK PATH 4. Slide the pin toward the base and out of
the bracket and hook. Remove the washers and
slide the hook sideways out of the bracket.
Inspect the lifting hook (figure 4) monthly to see
that there is 3/8-inch clearance between the
5. If the bracket is to be removed, remove
hook shoe and the hook path on the base
the weld using air-arc. Be sure to follow all
flange. Check the supporting, bracket and hook
safety precautions when using air-arc. Unbolt
for cracking. If cracking appears, replace or
the bracket and remove it.
repair the weld immediately. Refer to appendix
for repair welding procedure. Check the
6. Check the pin, bushings and hook shoe
adjusting nuts for ¼ inch clearance. Also check
for wear. Replace all worn parts. Check the
the pin bushings and washers for wear.
lifting hook and bracket for any cracking. Repair
all cracks using welding procedures as outlined
in appendix.
Repair
7. Reinstall the lifting hook using the
Repair of the lifting hook will consist mainly of reverse of removal. Refer to Figure 4 for welding
replacement of worn parts or repair welding of of bracket to revolving frame. Use shims to
cracks. To disassemble the lifting hook, proceed obtain proper clearance with the base. Adjust
as follow s: the nuts on the adjusting rod to obtain ¼ inch
clearance between each nut and the hook.
1. Move the machine to a safe area with When completely installed there should be 3/8-
adequate space to perform the repair. Shut inch clearance between hook shoe and hook
down the machine and tag the controls. path.
2. Block under the lifting hook securely.

Remove the adjusting stud and nuts.
3. With a torch, remove the hook pin

retainer bar. Be sure to take all safety measures
when working with the torch. Remove the pin-
retaining bolt.
Page
Rev – 0
22/07/99
JLC
CENTRE PINTLE
CAUTION: EXTREME CARE MUST BE

EXERCISED AT ALL TIMES WHEN
PERFORMING MAINTENANCE IN THE
AREA OF THE CENTRE PINTLE DUE
TO THE PRESENCE OF HIGH
VOLTAGE, WHICH CAN CAUSE
SERIOUS OR FATAL INJURY. ALWAYS
DISCONNECT ELECTRICAL POWER
BEFORE TOUCHING ANY PART IN
THE CENTRE PINTLE AREA. ONLY
QUALIFIED PERSONNEL SHOULD
PERFORM MAINTENANCE OR
INSPECTION IN THIS AREA.
The centre pintle is the centre structure of the

base and is secured to the revolving frame by
means of a clamp collar (figure 5). The centre
pintle rides in a bushing mounted in the lower
plate of the revolving frame.
When the base is inspected for cracking or

buckling, the centre pintle should also be
checked. Any failures in the structure should be
repaired immediately.
The bushing in the revolving frame should be

checked weekly for proper lubrication. Monthly,
check the clamp collar bolts for tightness.
The maximum recommended bushing to pintle

diametral clearance is .300 inch. The vertical
gap between the bottom of the clamp collar and
the top of the bushing flange should always be
greater than the lifting hook gap.
If the bushing or centre pintle must be replaced,

contact Bucyrus-Erie Service Department for the
proper procedure.
Page
Rev – 0
22/07/99
JLC
SECTION 3— ROTATING DECK MACHINERY UNITS
REVOLVING FRAME The machinery units (figure 6) of the 1370W

Walking Dragline consist of the Hoist Machinery,
Drag Machinery, Swing Machinery and Propel
Inspect the entire structural makeup of the
Machinery. All machinery units are mounted on
revolving frame (figure 6) at least once a month
the revolving frame. Each machinery unit will be
for cracked and buckled plate and cracked
described separately in the following
welds. Check in particular, interior areas, such
paragraphs.
as vertical diaphragms above the roller circle,
reinforcement diaphragms in the areas of the
boom and mast feet and areas of the fairlead
and lifting hook attachments. Also examine
under the machinery frames and around the
bottom bearing casting for the lower swing shaft
bearing and rear A-frame leg connections. If a
structural crack is detected, it will be necessary
to repair weld immediately. Repair weld to
original design, do not add reinforcement plate
unless authorized by Bucyrus-Erie Service
Department. Refer to appendix for welding
procedures.
Page
Rev – 0
22/07/99
JLC
daily for cracking, wear and lube film. The first

reduction gearcases should be checked daily for
HOIST AND DRAG MACHINERY proper lube level. The second reduction gearing
should be checked every shift for tooth wear and
The hoist and drag machinery (figure 7) are proper lubrication. All bearings should be
almost identical units, except for the orientation checked daily to see that they are receiving
of the units in the machine, the height of the proper lubrication and that the seals are not
pedestals and bases and the design leaking.
characteristics of the drums and spiders. All
bearings, gears, pinions and seals are
interchangeable between the hoist and drag
machinery units.
The bases and pedestals should be checked Repair

periodically for tightness of hardware and
cracking, especially in the area where the Repair of the hoist or drag machinery will consist
pedestals and base are welded or bolted to the of replacement of worn or damaged parts.
revolving frame. The drums should be checked
Page
Rev – 0
22/07/99
JLC
Proceed as follows to disassemble the hoist or 3. Remove the brakes from the motors
drag machinery gear train. Repair procedures using the procedure as outlined in the topic
for the brakes are listed separately. Motor repair MOTOR BRAKES.
will be found in the Electrical Manual.
4. Remove the coupling guard and
CAUTION: THE FOLLOWING separate the coupling.
PROCEDURE IS FOR COMPLETE
DISASSEMBLY OF THE HOIST OR 5. Have an electrician disconnect the
DRAG MACHINERY. IF ONLY motor from the power source and tape and tag
PORTIONS OF THE UNIT ARE TO BE the cable ends.
REMOVED, ADDITIONAL
PRECAUTIONS MUST BE TAKEN TO 6. The units of the hoist and drag
INSURE AGAINST UNWANTED machinery will be handled with the overhead
MOVEMENT OF PARTS NOT BEING crane. Unbolt the motors and remove them from
DISASSEMBLED. the base.
1. Move the machine to a safe area with 7. Remove the lube lines to the first
sufficient room to perform the maintenance. reduction gearcase, second reduction guards
and drum pedestal. Remove the second

2. Set the walking shoes and bucket on the reduction guards. If so equipped, remove the
ground. Set all brakes and turn the controls to shock pulse monitoring equipment.
the “off’ position and lock and tag them. Remove
the hoist and drag ropes as described in the
topics HOIST ROPE and DRAG ROPE.
Page
Rev – 0
22/07/99
JLC
NOTE: IF THE DRAG DRUM IS e. Remove the rod bolts and dowel bolts
EQUIPPED WITH A DIRT SHIELD, securing the gearcase cover to the gearcase.
REMOVE THE DIRT SHIELD BEFORE Remove the gearcase cover.
REMOVING THE SECOND REDUCTION
GUARDS. 10. With the overhead crane, lift the motor
input shaft from the gearcase.
8. Drain the first reduction gearcase.
11. To disassemble the motor input shaft
9. To remove the first reduction gearcase (figure 8), remove the half-coupling and key from
cover: the shaft. Remove the bearing spacer.
a. Remove the motor shaft end cover bolts
and end cover (figure 8). Remove the 0-ring 12. Slide the bearing retainer assembly from
from the end cover. the shaft. Remove the 0-ring, seal retainer and
b. Remove the bolts securing the bearing oil seal from the retainer.
retainer, on the coupling end, to the gear case.
c. Remove the intermediate shaft end 13. Remove the bearing retainer from the
cover bolts and remove the end cover from the other end of the shaft. Remove the bearings
gearcase (figure 9). Remove the 0-ring from the from both ends of the shaft.
cover.
d. Remove the bolts securing the inner
seal retainer to the gearcase.
Page
Rev – 0
22/07/99
JLC
NOTE: THE BEARINGS ARE

PRESS FIT TO THE SHAFT AND WILL 17. Remove the bearing inner retainer from
REQUIRE A PULLER TO REMOVE the pinion end of the shaft. Remove the seal
THEM. retainer and oil seal from the inner retainer.
14. To remove the intermediate shaft (figure 18. Remove the bearing inner retainer and
9), remove the end cover at the pinion end of the seal retainer from the gear end of the shaft.
shaft. Remove the 0-ring from the end cover. Remove the oil seal from the retainer.
Remove the bearing cap from the pinion end of
the shaft. 19. Remove the gear and key from the
intermediate shaft.
15. With the overhead crane, lift the
intermediate shaft from the gearcase. NOTE: THE GEAR IS PRESS FIT TO
THE SHAFT AND WILL REQUIRE A
NOTE: THE DRUM AND DRUM PULLER TO REMOVE IT.
GEAR MUST BE FREE TO ROTATE TO
ALLOW SHAFT REMOVAL. 20. Remove the inner seal retainer and oil
seal from the shaft. Remove the oil seal from the
16. Remove the bearing retainers from each retainer.
end of the shaft and remove the bearings.
21. After all first and second reduction
NOTE: THE BEARINGS ARE shafts have been removed, the drum assemblies
PRESS FIT TO THE SHAFT AND WILL (figure 10) can be removed as follows. Because
REQUIRE A PULLER TO REMOVE of the weight of the drum assemblies, they can
THEM. not be removed as complete assemblies.
Page
Rev – 0
22/07/99
JLC
a. Have an electrician disconnect and tag m. Take up the 25-ton hoist and release the
the power lines to the rotary limit switch and welded beam from the drum. Note that any time
selsyn generator. If so equipped, remove the the raising procedure is stopped the gear and
shock pulse monitors from the drum shaft drum must be secured.
bearing caps. n. When the gear has been rotated until
b. If so equipped, remove lube lines to the splice is horizontal, securely block and chock
bearing caps. the drum and gear. Reposition the 25-ton hoist,
c. Uncouple and remove the rotary limit remove the remaining drum to gear bolts and
switch and selsyn generator. remove the gear.
d. Remove the bolts securing the shaft end o. Remove the bearing cap from gear end
covers. Remove the end covers and gaskets. of the drum assembly. Crib securely under the
e. Remove the bolts securing the inner drums. Attach the 25-ton hook to the spider on
labyrinth seals and slide them toward the drum. the gear side of the drum assembly and remove
f. Rotate the drum gear until the splice the spider to drum bolts.
bolts are in a horizontal plane. Securely block p. Shift the spider outward to clear the
the drum and gear. drum shoulder fit and remove the spider. A jack
g. Remove all the drum-to-gear bolts, or a come-along will be required to disengage
except six equally spaced, three on each gear the spider from the drum.
half.
h. Secure the 25-ton overhead crane to the NOTE: A BLOCK AND TACKLE CAN
upper gear half. Remove the eight gear splice BE ATTACHED TO THE BOTTOM OF
bolts and three gear-to-drum bolts from the THE SPIDER TO HOLD IT VERTICAL
upper half of the gear. Remove the upper gear AS IT IS LIFTED CLEAR OF THE
half. DRUM.
CAUTION: THE REMAINING STEPS TO q. When the spider is completely removed,

RE MOVE THE OTHER HALF OF THE the bearing can be removed from the spider.
GEAR MUST BE DONE WITH Remove the bearing retainer. Attach hydraulic
EXTREME CARE AS THE DRUM lines in the end of the spider stub shaft and
ASSEMBLY WILL BE SEVERELY apply 10,000-PSI pressure with a grease gun
UNBALANCED. with No. 2 grease while applying pressure with a
bearing puller.
i. Attach the 25-ton hook of the overhead r. Secure the 25-ton hoist to the drum half
crane to the remaining gear half. Attach the 5- on the gear side. Air-arc out the weld between
ton hook to the drum by means of a rod slipped the drum halves. Be sure to follow all safety
in between rope lugs. The 25-ton hook will be precautions. When the weld has been removed,
used to rotate the gear half and the 5-ton hook remove the bolts and dowel pin from the center
will be used to restrain the drum. flange. Use jacks between the rope anchor
j. Slowly take up on the 25-ton hoist and blocks to separate the drum halves.
slack off on the- 5-ton hoist. Only lift the gear s. Test the crane by raising the drum half 2
two or three feet at a time. Securely block the inches, two or three times, and then holding for
gear and reposition the weight of the gear. a couple of minutes. Check that the rigging is
k. When the gear has been rotated 90º, secure. When everything checks out, remove
securely block the drum gear half. A heavy the drum half.
beam welded between the drum rope lugs and t. Be sure the remaining drum spider is
machinery deck is recommended. securely blocked; then remove the remaining
l. Reposition the hooks so that the gear drum half. Use the same procedure as listed for
can be rotated the final 90o to the horizontal the gear side drum half.
position. u. Secure the remaining spider to the over
head crane and remove the bearing cap.
CAUTION: THE DRUM IS HIGHLY Remove the spider from the pedestal. Remove
UNSTABLE NOW SO BE EXTREMELY the bearing from the spider stub shafts as
CAREFUL AND GO SLOWLY. described in step q.
Page
Rev – 0
22/07/99
JLC
22. The drum assembly is reinstalled in reverse 23. The rest of the main machinery is also
of disassembly, noting the following: rein stalled in reverse of disassembly, noting the
a. The bearing should be heated in an oil following:
bath prior to installation on the stub shafts. a. Replace all seals if damaged or worn
and also replace all 0-rings and gaskets. Be
CAUTION: USE SUITABLE sure all oil seal lips face in the correct direction.
PROTECTIVE EQUIPMENT WHEN b. All bearings must be heated in an oil
HANDLING THE HEATED ITEMS. bath prior to installation.
c. The intermediate gear is interference fit
b. The bolts holding the drum to the to the shaft and the bore must be preheated
spiders and gear should have the long threaded prior to assembly.
end facing outwards. The bolts holding the two d. Use Permatex 42 or Silicone rubber
drum halves together should have the long between the gearcase and cover flanges when
threaded end towards the gear. All bolt threads reassembling.
should be coated with Locktite 4271-31 and e. Be sure all bolts are torqued, all
torqued to 4.515-ft. lbs. minimum, using a electrical connections made, all lube lines are in
Hydro-Torque tool. stalled, all gearcase filled to proper level, all
c. The gear splice bolts should have the monitor equipment installed and all guards
threads coated with Locktite 4271-81 and replaced. Be sure all bearings are lubed.
torqued to 2,740 ft lbs. minimum.
d. The gib keys should be fit to the bearing
caps so that they have an 80% contact on all
surfaces.
Page
Rev – 0
22/07/99
JLC
Page
Rev – 0
22/07/99
JLC
4. Remove all of the lube lines and drain

the gearcase.
SWING MACHINERY 5. Remove inspection covers to expose

the motor coupling and remove the coupling
There are four swing units on 1370W Walking bolts. Re move the motor mounting bolts and lift
Dragline (figure 11). The level of lubricant in the the motor and brake from the gearcase.
gearcase should be checked daily and lubricant
added as required. All manually lubricated points 6. With a puller, remove the coupling half
should be lubricated daily. The daily inspection from the motor pinion shaft. Remove the
should also include checking for leaking seals or coupling key.
gaskets. Weekly, check that the oil cup, which
lubricates the vertical shaft upper seal, is full. NOTE: PRESSURE REQUIRED TO
Periodically check the movement of the motor REMOVE COUPLING HALF WILL BE IN
pinion shaft. Undue movement may indicate EXCESS OF 45 TONS, THEREFORE, IN
adjustment of the cushion may be required. ADDITION TO THE PULLER, THE
Monthly, check the condition of the swing pinion COUPLING WILL HAVE TO BE
retainer bolts. HEATED WITH A TORCH. WHEN
USING THE TORCH, BE SURE ALL
Repair SAFETY PRECAUTIONS ARE
FOLLOWED.
Repair of the swing machinery (figure 12) will 7. Remove the double row of bolts
consist mainly of replacement of worn or securing the motor shaft, upper bearing retainer
damaged parts. Proceed as follows to to the gear case cover and bearing carrier.
disassemble the gear train. Repair procedure for Remove the retainer from the shaft. Remove the
the brakes is listed separately. Motor repair will oil seal retainer and oil seal from the bearing
be found in the Electrical Manual. retainer. Remove the bearing retainer gasket.
Remove the coupling spacer from the shaft.
CAUTION: THE FOLLOWING
DISASSEMBLY OF A SWING UNIT. IF
ONLY PORTIONS OF THE UNIT ARE
TO BE REMOVED, ADDITIONAL
PRECAUTIONS MUST BE TAKEN TO
INSURE AGAINST UNWANTED
MOVEMENT OF PARTS NOT BEING
DISASSEMBLED.
1. Move the machine to a safe area with

sufficient room to perform the maintenance.
2. Set the walking shoes and bucket on the

ground. Set all brakes. Turn the controls to the
‘‘off’ position and lock and tag them.
CAUTION: AT LEAST ONE SWING

BRAKE SHOULD BE SET AT ALL
TIMES TO PREVENT UNWANTED
MOVEMENT OF THE MACHINE.
3. Have an electrician disconnect and tag

the motor electrical connections. Also have him
remove any monitoring equipment. 8. Screw two eyebolts into the bearing
carrier 180º apart. Use the eyebolts to lift the
bearing carrier from the shaft. Remove the
Page
Rev – 0
22/07/99
JLC
bearing cage, spacer and oil seals from the

carrier. The bearing inner race and lower spacer
will re main on the shaft. These items should be
removed only if the bearing needs to be
replaced, as the inner race will most likely be
damaged during removal.
9. If the swing unit is equipped with a

swing recorder (figure 13), remove the recorder.
Re move the fork drive from the recorder drive 16. Install special clamps at the top of the
shaft, then remove the recorder and base. If the lower bearing carrier to hold it in place while the
unit is equipped with a position sensor (figure cushion housing is removed. Place a jack under
14) unbolt and remove the bracket and sensor the housing and remove the double row of bolts
as an assembly. securing the housing to the gearcase and
bearing carrier. Remove the housing assembly
10. Remove both rows of bolts securing the and gasket.
intermediate shaft, upper bearing end caps to
the gearcase cover and bearing carriers. 17. Remove the two-large pipe plugs from
Remove the bearing end caps and gaskets. the bottom of the cushion housing and install
special rod bolts. Tighten the nuts on the rod
11. Remove the vertical shaft upper retainer bolts to remove the pressure on the dowel bolts.
bolts and remove the retainer and gasket from Re move the dowel bolts. Back off on the rod
the gearcase cover. The vertical shaft, upper bolt nuts until all tension is removed from the
bearing cage will be removed with the retainer. spring. Remove the rod bolts, upper spring
Remove the bearing cage from the retainer. guide, spring, lower spring guide and adjusting
screw. Remove the 0-ring from the adjusting
12. Remove the cover to gearcase screw. Remove the cushion bearing outer race
attachment bolts and alignment, dowel bolts and from the upper spring guide.
remove the cover from the gearcase. Remove
the 0-ring from the gearcase flange surface. 18. Support the bearing carrier with a jack
and remove the clamps. Lower the bearing
13. Screw an eyebolt into the upper end of carrier and bearing out of the gearcase (figure
the motor shaft and support shaft with rigging 12). Separate the bearing cage from the bearing
connected to the eyebolt. carrier.
14. Remove the bolts and dynaseal 19. Disengage the motor shaft from the
washers from the sides of the cushion housing mesh with the intermediate gears and lift the
(figure 15). Remove the pipe cap, lock wire and shaft out of the gearcase.
lock bar from the bottom of the cushion. Remove
the small pipe plug from the bottom of the 20. Remove the nut (figure 16) securing the
housing and drain any accumulated oil from the cushion bearing cage to the lower bearing
housing. Reinsert the pipe plug when the retainer and remove the bearing cage. Remove
housing is completely drained. the bearing retainer from the shaft. The bearing
inner race and spacer will remain on the shaft.
15. Turn the adjusting screw These items should be removed only if the
counterclockwise to compress the spring and bearing is to be replaced, as the inner race will
raise the upper spring guide. Raising the shaft most likely be damaged during removal.
slightly will help.
21. Match mark the teeth on the
When the holes in the housing and upper spring intermediate shaft pinions and the swing gear
guide align, insert the special dowel bolts. This (figure 12) so that the gearing will not have to be
will lock the spring in the housing. After the re-timed at re-assembly.
dowel bolts have been inserted, back off on the
adjusting screw (turn clockwise) to its full limit.
Page
Rev – 0
22/07/99
JLC
27. Remove the other intermediate shaft

22. Support the intermediate shaft that has assembly repeating steps 22 through 26.
the gear in the upper position (Y Shaft), with the
hoist. Install a jack under the lower bearing end
cap and remove the outer row of bolts, which
secure the end cap to the gearcase. Lower the
end cap assembly from the gearcase.
The bearing carrier and bearing cage will be

removed with the end cap. Separate the bearing
cage and carrier and gasket from the end cap.
23. Move the shaft pinion out of mesh with

the vertical shaft gear and remove the shaft
assembly.
24. Remove the lower bearing and bearing

inner race from the shaft.
25. Remove the upper bearing retainer.

Install a hydraulic pump capable of 10,000 PSI
to the tub holes in the upper end of the shaft.
Apply pressure with the pump to remove the
bearing from the shaft. Separate the bearing oil
seal retainer and oil seal from the bearing
carrier. Remove the bearing spacer from the
shaft.
26. With a puller, remove the gear from the

shaft. Remove the gear key and spacer from the
shaft.
Page
Rev – 0
22/07/99
JLC
duo-cone seal and 0-rings from the retainers.

These retainers are not used on all machines.
34. Remove the vertical shaft lower bearing

sleeve seal retainer and oil seal.
35. Remove the sleeve upper retainer and

28. Remove the upper bearing retainer and lube fitting. Remove the bearing upper retainer
outer race from the vertical shaft gear. Remove and gasket. Remove the seal retainer and oil
the gear bore cover and gasket. seal from the upper retainer. Set the field
assembly spacer on the sleeve so bores are
29. Securely crib the swing pinion and aligned.
remove the pinion retainer.
36. Reinstall the vertical shaft and lower it
30. Remove the oil pan, oil slinger, and through the spacer and bearing sleeve (figure
gasket from the vertical shaft. 17). Bolt the pinion retainer to the end of the
shaft. Remove the bearing lower retainer and
31. Attach an eyebolt to the upper end of gasket. Remove the seal retainer and oil seal
the shaft and support the shaft with the from the retainer.
overhead crane. Remove the split retainer,
spacer and shims. Note the thickness of the 37. Raise the vertical shaft with bearing and
shims. Match-mark the splines of the shaft and sleeve high enough to install the field removal
gear for ease of re-assembly. With the crane, fixture to the bearing carrier. Lower the bearing
slowly lift the shaft out of the gearcase. onto the fixture.
32. Attach two eyebolts to the pinion 180º 38. Attach a grease gun and fitting, capable
apart. Attach a sling to the eyebolts. Run a cable of 10,000 PSI with #2 grease, to the two
from the overhead crane down through the gear hydraulic pressure holes in the sleeve.
and pinion bore and attach it to the sling. Raise
the pinion just enough to remove the cribbing. NOTE: INSERTING A ROD IN THE
Lower the pinion into the pinion basket and HOLES CAN IDENTIFY THE
disconnect and remove the sling and cable. HYDRAULIC PRESSURE HOLES; THE
DEEPEST HOLES ARE THE
33. The group of retainers mounted to the PRESSURE HOLES. THE SHORTER
bottom of the vertical shaft gear. Remove the HOLES ARE FOR LUBRICATION.
Page
Rev – 0
22/07/99
JLC
APPLY MAXIMUM PRESSURE WITH

THE GREASE GUN AND RELAX THE 1. Vertical Shaft Gear (figure 12)
STRAIN ON THE SHAFT SUPPORTING a. The gear upper bearing outer race is
CABLE. THE WEIGHT OF THE SHAFT interference fit to the gear and must be cooled
AND THE PRESSURE FROM THE with dry ice or the bore heated prior to
GREASE GUN SHOULD RELEASE THE installation.
BEARING FROM THE SLEEVE.
b. The gear lower bearing is interference fit
to the gear end and must be heated in an oil
CAUTION: CONTROL THE TENSION bath to 250ºF prior to installation. Be sure the
ON THE SUPPORTING CABLE SO upper retainer is positioned on the gear before
THAT THE SHAFT DOES NOT DROP installing the bearing.
AS THE BEARING IS RELEASED c. Be sure the lower bearing oil seal lips
FROM THE SLEEVE. face toward the bearing and are separated by
the spacer.
NOTE: IF THE WEIGHT OF THE SHAFT d. When installing the group of lower
IS INSUFFICIENT TO RELEASE THE retainers, be sure all O-rings are installed.
BEARING FROM THE SLEEVE,
INSTALL ROD BOLTS THROUGH THE 2. Vertical Shaft Lower Bearing
FIXTURE AND INTO THE THREADED a. Use the following procedure for
HOLES IN THE BEARING SLEEVE. installing the vertical shaft lower bearing (figure
WHILE CONTINUING THE ABOVE 18).
PROCEDURE, TIGHTEN THE ROD b. Install the bearing carrier in the girder.
BOLT NUTS TO HELP PULL THE Be sure it is positioned as match marked during
SLEEVE FROM THE BEARING. disassembly.
c. Bolt field assembly fixture to bearing
39. Remove the pinion retainer sleeve and carrier and set lower bearing on fixture.
spacer and lift the shaft out of the gearcase. d. Install the vertical shaft in the gear and
lower part way to the bearing. Install the field
40. Remove the rod bolts, field assembly assembly spacer and bearing sleeve on the
spacer, sleeve and bearing from the fixture. shaft and secure with the pinion retainer.
Unbolt and remove the fixture from the bearing
carrier. Match mark the bearing carrier to girder, NOTE: THE BEARING SLEEVE
then remove the bearing carrier. MUST BE ASSEMBLED UPSIDE DOWN
ON THE SHAFT.
41. Remove the bolts securing the gear e. Pack the bearing sleeve on the shaft in
lower bearing upper retainer (figure 12). Access dry ice until it cools to a minus 100ºF At the
to the bolts is gained through the elongated same time, heat the bearing bore to 250ºF,
openings in the gear. using heating blanket (20 minutes for each inch
of bore).
42. With the overhead crane, lift the vertical CAUTION: USE SUITABLE
shaft gear from the gearcase. Remove the PROTECTIVE EQUIPMENT WHEN
bearing lower retainer, the bearing and the HANDLING THE ITEMS BECAUSE OF
upper retainer from the gear. THE EXTREME COLD AND HEAT
APPLIED TO THEM.
43. Remove the seal retainer, oil seals and f. When the desired temperatures have
spacer from the gearcase bore. been reached, lower the shaft assembly until the
bearing sleeve shoulder is tight against the
44. Clean and inspect all parts. Inspect all bearing.
parts for wear or damage and replace or repair g. When the temperatures return to
all damaged or worn parts. Replace all 0-rings, ambient, remove the pinion retainer and lift the
gaskets and oil seals. shaft clear of the sleeve. Remove the field
assembly spacer. Turn the bearing sleeve with
45. Reassemble in reverse of disassembly bearing right side up.
noting the following:
Page
Rev – 0
22/07/99
JLC
NOTE: ADDITIONAL LUGS AND b. If the shaft safety bolt was removed,
PORTABLE HOIST WILL HAVE TO BE install it at this time.
RIGGED TO TURN THE BEARING AND c. When installing the shaft pinion, torque
SLEEVE AS THE APPROXIMATE the bolts until the belleville washers are flat, then
WEIGHT IS 2,000 LBS. back off ¼ turn. Lockwire the bolts.
h. Reinstall the field assembly spacer on
the shaft and lower the shaft through the sleeve. 4. Intermediate Shafts (figure 12)
Secure the sleeve on the shaft with the pinion a. The lower bearing inner race is
retainer. Raise the shaft and lift the bearing and interference fit and must be heated in an oil bath
sleeve out of the fixture. Remove the fixture from to 250ºF prior to assembly.
the bearing carrier. b. Check the fit of gear key to gear and
i. Install the bearing lower retainer and shaft. The gear is interference fit and the bore
gasket on the bearing carrier. Lower the shaft must be heated to 250ºF prior to installation. For
until the bearing rests on the retainer. Remove the “Y” shaft, be sure the spacer is installed
the pinion retainer and lift the shaft high enough before installing the gear.
to remove the field assembly spacer. c. The upper bearing is interference fit to
j. Reinstall the remaining retainers, seals the shaft. Assemble the bearing spacer (and
and gaskets on the lower bearing (figure 12). gear spacer on “Z” shaft) on the shaft. Assemble
When installing the bearing upper retainer, the upper bearing to the bearing carrier and
check the gap between the retainer and the assemble the seal and seal retainer to the
carrier. If the gap exceeds .005 inches add an carrier. Be sure the seal lip is facing toward the
additional gasket. bearing. Cool the shaft upper end with dry ice
prior to installing bearing assembly.
3. Vertical Shaft (figure 12) d. When installing the gears on the shafts,
a. When replacing the vertical shaft, use they should be so positioned that the long hub
sufficient shims at the top of the shaft to obtain fits against the gear spacer. That is on the “Y”
¼ inch pinion to rack overlap. shaft the long hub faces down and on the “Z”
shaft the long hub faces up.
Page
Rev – 0
22/07/99
JLC
e. When installing shaft assemblies, they 3. Lower the shaft by backing off on the
must be installed, as match marked during adjusting screw (turn clockwise) until the shaft
disassembly or the gearing will have to be re- stops descending. Move the gear train to reduce
timed. For timing of gearing, see separate topic. the effects of friction. Note and mark this
position on the indicator.
5. Motor Shaft (figure 12)
a. The motor shaft, bearing inner races are 4. Measure the difference between the
interference-fit to the shaft and must be heated high and the low positions. Mark the midpoint on
in an oil bath to 250ºF before assembly. Be sure the indicator. Turn the adjusting screw to move
spacers are installed. the shaft so that the notch on the upper spacer
b. The cushion bearing outer race is aligns with the midpoint.
interference fit to the upper spring guide.
c. Check fit of coupling hub key to hub and 5. Compare the measured midpoint with
shaft. The hub is interference fit to the shaft and the mid-point inscribed by the factory on the
will require heating in an oil bath to 250ºF prior indicator. The factory inscribed midpoint is
to assembly. theoretically 1-1/2 inch from the notch on the
d. Be sure all 0-rings and gaskets are in upper spacer to the top of the upper bearing
place and all oil seal lips face in the correct cover. The cushion is properly adjusted if the
direction. measured midpoint falls within the range of 1/2
e. Adjustment of the cushion is covered in inch above or below the inscribed midpoint.
a separate topic.
6. If the measured midpoint does not fall
6. Gearcase Cover (figure 12) within this range, the gearing must be re-timed.
Refer to separate topic for SWING TIMING.
a. When installing the gearcase cover, be
sure the mounting flanges are clean. In stall the 7. When the cushion has been properly
0-ring in the gearcase flange groove if used, and adjusted, reinstall the lockbar, lockwire and pipe
apply a sealant to the flange. cap.
b. Install the cover on the gearcase and
insert the four centering dowel bolts and torque Swing Timing
tight. Install the remaining cover to case bolts
and torque. The purpose of swing timing is to center the
motor input pinion to the intermediate gears.
7. Check motor coupling alignment. This will enable the proper axial movement to be
accomplished without damage to the motor
Swing Cushion Adjustment coupling and bearing, or the motor input pinion
support bearings. Restricting this axial floatation
After the disassembly of the gearcase or by improper assembly can result in bearing
removal of the motor pinion shaft, the cushion damage or unequal intermediate gear loading.
must be adjusted to hold the shaft in its working
position. Adjust the cushion (figure 19) as The necessity for this instruction is due to an
follows: accumulation of machinery tolerances in the
gear case structure and the relationships of
1. Remove the pipe cap, lockwire and keyways to tooth axis. Unequal wear of the
lockbar from the bottom of the cushion. intermediate gear meshes is an indication of the
need for adjusting the swing timing.
2. Raise the shaft to its maximum by
tightening the adjusting screw (turn There have been two sizes of swing units used
counterclockwise). During this step move the on 1370W draglines. To determine which size is
gear train to reduce the effects of friction. Note on the machine, measure the distance from the
the position of the pinion and mark on the pinion centreline of either intermediate shaft to the
indicator this position. Use the upper spacer centerline of the vertical swing gear. A distance
notch as a reference. of 46.914 inches indicates the larger swing unit
and a distance of 40.375 inches indicates the
smaller swing unit. For the larger unit, use figure
Page
Rev – 0
22/07/99
JLC
21 for calculating timing corrections and for the

smaller units use figure 22. For the following
procedure, figure 21 will be used.
Page
Rev – 0
22/07/99
JLC
Procedure gear and mark the eleventh space with an (X)

with a marking pen.
1. Check the (Y) and (Z) pinion shafts to
verify the eleventh space with an (X) with a
marking that the (S) mark has been stamped on
the upper pinion face in line with the keyway for
locating the intermediate gear. If the pinions do
not have the (S) mark, then mark this on the
tooth in line with the centre line of the keyway
(using a steel stamp). See figure 20.
2. Install the (Z) shaft so that the (S) mark lines

up with the tooth space on the swing gear (figure
21). If there is no (S) mark on the swing gear,
stamp one at the tooth space aligned with the
(S) mark on the (Z) shaft pinion tooth. This point
will remain constant during the rest of the timing.
Repositioning the “Y” shaft will make all
corrections.
3. Count eleven tooth spaces

counterclockwise from the (S) mark on the swing
Page
Rev – 0
22/07/99
JLC
NOTE: WHEN COUNTING TEETH OR 6. Check the overlap of the motor pinion to
TOOTH SPACES, THE TOOTH OR intermediate gears. The overlap should be as
TOOTH SPACE MARKED WITH (S) IS indicated on figure (23). Manually move the gear
ALWAYS ZERO (0). train and observe the movement of the pinion
shaft. Note the relationship of the motor pinion
indicator to the groove in the coupling spacer. In
the stationary position with overlaps as indicated
on figure (23), the groove in the coupling spacer
should align with the point on the indicator.
When the gear train is moved, the pinion shaft
should not rise or lower more than ½ inch in
either direction if the unit is properly timed.
NOTE: THE GAP AND OVERLAP

OF THE MOTOR INPUT PINIONS WILL
VARY DEPENDING ON THE TYPE OF
TOOTH CUT. FOR MAAG CUT
PINIONS, THE CENTER GAP AND
OVERLAP WILL BE 5/8 INCH; FOR
SYKES CUT PINIONS, THE CENTER
GAP WILL BE 1/4 INCH AND THE
OVERLAP WILL BE 13/16 INCH.
7. If the measurement exceeds the

maximum in either direction, the gearcase cover
and motor input pinion shaft will have to be
removed and the (Y) shaft repositioned. Prior to
disassembly, record the actual movement of the
pinion shaft so the correct axial movement
necessary to achieve proper timing can be
determined.
8. As an example, if the measured mid-

point of the spacer notch was 21/32 inch below
the mid-point of the indicator, the pinion shaft
must be raised 21/32. Refer to chart figure (21).
According to the chart, 21/32 inch is closest to ½
inch, therefore, to correct the pinion shaft error,
the (Y) shaft will have to be rotated 3 teeth
4. On the (Y) shaft pinion, count three counterclockwise.
teeth counterclockwise from the (S) marked
tooth and mark this tooth with an (X) with a
marking pen. Install the (Y) shaft so that the (X)
mark on the pinion tooth aligns with the (X) mark
on the swing gear tooth space. This is the initial
positioning for the gear train.
5. Install the motor input pinion shaft and

pinion shaft lower bearing. Hold the lower
bearing in place with the special clamps. Install
the gear case cover and lock in place with the
four dowel bolts. Install the motor input pinion
shaft upper bearing and coupling spacer.
Page
Rev – 0
22/07/99
JLC
Each unit consists of two gear trains driving the

cam. In the front gear train, the motor input
shaft, first, second and third intermediate shafts
and gears are mounted above deck (figure 25).
In the rear gear train, the motor input shaft, first
intermediate shafts and gears are above deck
and the remainder of the gear train is below
deck. The cams, cam frames and shoes are
mounted to the exterior of the machinery house.
All gear train parts are identical in makeup and
all parts are interchangeable.
9. Mark the pinion tooth of the (Y) shaft

with an (X) as determined in Step 8 and remove
the old mark. Reassemble the gearcase and
recheck the movement of the pinion shaft. If the
movement falls within the allowable range,
complete the assembly of the swing unit. Install
and adjust the swing cushion per the topic
SWING CUSHION ADJUSTMENT.
PROPEL MACHINERY The gears and pinions should be checked

weekly for pitting, galling and unusual wear
The propel machinery consists of two identical patterns. Refer to GEAR INSPECTION in
units, one on each side of the machine (figure Appendix. The gears and pinions should also be
24). checked for proper lubrication. The bearings and
Page
Rev – 0
22/07/99
JLC
bushings should be checked daily for excessive

heat and proper lubrication. CAUTION: THE FOLLOWING
The motor bases, gearcase, shaft pedestals, DISASSEMBLY OF A PROPEL UNIT. IF
shaft support structures, cam frame, guides and ONLY PORTIONS OF THE UNIT ARE
shoes should be checked monthly for any signs TO BE REMOVED, ADDITIONAL
of cracking. All cracks noted should be repaired PRECAUTIONS MUST BE TAKEN TO
immediately using welding procedures as INSURE AGAINST UNWANTED
outlined in Appendix. MOVEMENT OF PARTS NOT BEING
DISASSEMBLED.
The oil in the gearcase should be checked
regularly and replaced at least once a year or To disassemble the propel machinery, proceed
more often if indicated during regular checks. as follows:
The following disassembly procedure refers only 1. Move the machine to a safe area with
to the gear trains. For maintenance procedures adequate room to perform the maintenance.
for the motor, refer to the Electrical Maintenance
Manual and for maintenance procedure for the
brakes, refer to the topic BRAKES.
Page
Rev – 0
22/07/99
JLC
2. Set the bucket and shoes on the ground 8. Remove the rod bolts, capscrews and
and set the propel brakes. Shut off and tag all aligning dowel bolts, which secure the cover to
controls. the gear case. Remove the gearcase cover.
3. Have an electrician disconnect and tag 9. Lift the motor input shaft from the
the electric leads to the motors and any gearcase and disassemble as follows:
monitoring equipment to the gear train. a. Remove the coupling half from the shaft
using a coupling puller. Remove the key from
4. Drain the gearcases. the shaft. Remove the coupling spacer.

b. Slide the bearing retainer from the shaft.
5. Separate the motor coupling and Remove the seal retainer, oil seal and 0-ring
remove the motor and brake as an assembly. from the bearing retainer. Slide the bearing outer
Note the thickness of shims removed from under race and cage from the shaft. The inner race
the motor mounting pads. Remove only the front will remain on the shaft.
side chocks and a wedge from the front motor c. Remove the bearing retainer from the
and the rear side chocks and wedges from the pinion end of the shaft. Remove the bearing
rear meter. Remove the first intermediate shaft, outer race and cage from the shaft. The inner
pinion guard. race will remain on the shaft.
d. Use a bearing puller or heat the races to
6. Remove the motor input shaft and first 250ºF to remove them from the shaft.
inter mediate shaft end covers (figure 26).
Remove the 0-rings from the end covers. 10. Lift the first intermediate shaft from the
gear case and disassemble as follows:
7. Remove the capscrews from the bearing
retainers on the coupling end of the motor shaft
and pinion end of the first intermediate shaft.
Page
Rev – 0
22/07/99
JLC
NOTE: TO REMOVE THE FIRST

INTERMEDIATE SHAFT FROM THE 11. Remove the guards for the front gear
FRONT GEARCASE, THE SECOND train and the guard and deck plate to gain
INTERMEDIATE SHAFT GEAR GIB access to the rear gear trains.
KEYS MUST BE REMOVED AND THE
GEAR MOVED OUT OF ENGAGEMENT 12. Remove the gib keys from the second
WITH THE PINION PRIOR TO LIFTING intermediate gear spider so that the gear can be
THE FIRST INTERMEDIATE SHAFT rotated (figure 27). Rotate the gear so that the
FROM THE GEARCASE. gear splice is parallel to the deck. Securely block
the gear in this position. Secure the upper half of
a. Remove the gear end-bearing retainer. the gear to the hoist and then remove the splice
Remove the bearing cup, cones and spacer bolts and bolts securing the upper gear half to
from the shaft. Remove the inner retainer, oil the spider. Remove the upper gear half.
seal and seal retainer.
b. Use a puller to remove the gear from the 13. Remove the blocking and with a pry bar
shaft. Remove the key from the shaft. and come-along, rotate the remaining gear half
c. Remove the pinion end bearing inner to the top of the shaft. Securely block the gear
seal retainer, oil seal and retainer. half. Secure the hoist to the gear half and
d. Use a puller to remove the bearing. remove the spider to gear bolt. Remove the gear
e. Slide the outer retainer assembly from half.
the shaft and disassemble by removing the 0-
ring, labyrinth seal, and oil seal.
Page
Rev – 0
22/07/99
JLC
14. Support the second intermediate shaft secure the outside crane to the gear and slide
with the hoist. Remove the bolts securing the the gear from the shaft. Remove the gear from
gear end-bearing sleeve to the bearing cap and the area. On the rear gear train, securely block
base. Remove the bearing cap and bearing the gear and pull the shaft from gear. Attach the
sleeve with bushing. Remove the gear end outside crane to the gear and lift the gear from
thrust washer from the shaft. the girder.
NOTE: Secure the gear thrust washer with a

sling or it will drop as the shaft is pulled from
the gear.
NOTE: For removal of the third intermediate

shaft mounted in the girder, the cam frame
must be removed, or the cam rotated so that
the frame moves forward to allow access to
the shaft.
15. Slide the gear spider toward the pinion,

then pull the shaft outward until the pinion
disengages from the third intermediate gear and
end of the shaft is out of the bushing. Lift the
shaft clear of the pedestal or out of the girder.
Remove the thrust washer and spider from the
shaft.
16. Remove the bushings and dowels from

the bearing sleeve and girder only if they must 19. Remove the third intermediate shaft
be replaced. To remove the bushings, cut in half cover plate. Remove the shaft clamp collar and
to relieve press fit and also to make removal of remove the bolts securing the bearing sleeve to
dowels easier. the pedestal or girder.
17. To remove the remainder of the propel 20. Attach an eyebolt to the shaft. Attach an
gear trains, will require an outside crane as the auxiliary line to the eyebolt and to a ground
hoist is insufficient to lift most of the major vehicle. Use a jack between the girder bulkhead
components. Removal of appropriate roof or pedestal to break the shaft loose, then pull
sections is also required. the shaft from the bore with the ground vehicle.
18. Remove the third intermediate gear

retainer (figure 28). On the front gear train,
Page
Rev – 0
22/07/99
JLC
NOTE: CRIB UNDER THE INNER 29. Secure an outside crane to the cam to
END OF THE SHAFT TO PREVENT IT support the cam and shaft as they are pulled
FROM DROPPING AS IT IS PULLED. from the girder. Secure a cable to the cam and
WHEN THE SHAFT IS PARTIALLY shaft assembly and to a ground vehicle, which
REMOVED, SUPPORT IT WITH A will be used to pull the assembly from the girder.
SLING ATTACHED TO THE OUTSIDE Use a jack on the gear end of the shaft to assist
CRANE TO PREVENT IT FROM in breaking it free.
DROPPING WHEN IT IS REMOVED.
NOTE: AS THE SHAFT IS BEING
21. Remove the inner and outer thrust REMOVED, CHECK THAT THE
washers. THRUST WASHERS DO NOT COME
LOOSE AND DROP INTO THE CLAMP
22. Remove the bushings from the girder or COLLAR GROOVE.
pedestal only if they must be replaced. To
remove the bushings, cut in half to relieve press 30. With the outside crane, lift the cam shaft
fit, then remove bushing sections and dowels. gear out of the girder.
23. Have an electrician disconnect and tag 31. Clean and inspect all parts. Repair or
the wires to the synchro-tie and remove the replace all damaged or worn parts. Use all new
synchro-tie as a unit. oil seals, O-rings, and gaskets.
24. Be sure the walking shoe is set firmly on 32. Reassemble in reverse of disassembly,
the ground (figure 25). Unbolt and remove the noting the following:
cam guides from the cam frame. Support the
lower cam frame; then unbolt and remove the a. Cam Shaft (figure 29)
upper cam frame.
1. When installing the bushings in the
25. Remove the cam guide roller lube girder ensure that the lube holes in the hub
fittings and retainer plate (figure 29). Remove align with the outer grooves in the bushing.
the roller and thrust washer. Remove the If the dowel holes are difficult to align the
bushing from the roller. bushing may be rotated 15º and new holes
drilled. The bushings must be shrunk fit to
26. Remove the roller pin nut lock bar and the hubs. Be sure all dowels are flush with
remove the nut. Use a jack to break the pin or slightly below the face of the bushings
loose from the cam. Remove the pin. and thrust washers.
NOTE: WHEN USING THE JACK, 2. Install the cam shaft gear in the girder
YOU MUST BE CAREFUL NOT TO so that the bore of the gear aligns with the
DAMAGE THE THREAD ON THE END bores in the girder. Securely crib and block
OF THE PIN. the gear. Coat all bores with a thin film of
Molykote type “G”. The bore of the gear
27. Secure a crane to the cam at the roller must be heated with heating blankets to
pinhole and rotate the cam ¼ turn to disengage 250ºF and the square surface of the shaft
it from the lower frame (figure 25). Secure a cooled to minus 100ºF with dry ice prior to
second crane to the lower cam frame. Remove assembling the shaft.
the trunnion caps, which hold the frame to the
shoe, and with the second crane lift the lower CAUTION: USE SUITABLE
cam frame off the shoe and out of the way. PROTECTIVE EQUIPMENT WHEN
Lower the cam back to low position. HANDLING THE ITEMS BECAUSE OF
THE EXTREME COLD AND HEAT
28. Securely crib under the cam-shaft gear APPLIED TO THEM.
and block to prevent any movement. Remove
the clamp collar and thrust washer from the gear 3. When installed, the cam guide rollers
end of the shaft (figure 29). should have an axial movement of .240
inches to .304 inches.
Page
Rev – 0
22/07/99
JLC
the gear aligns with bushing bores prior to

4. Clean and apply the Molykote rubbing installing the shaft. Also, the gear thrust
well into the bearing surfaces of the cam washer must be supported in place prior to
and frames, then apply special cam grease, positioning the gear.
such as Keystone 30B Extra Heavy mixed
with Molykote c. Second Intermediate Shaft (figure 27)
b. Third Intermediate Shafts (figure 28) 1. If an outside crane is available for

1. When installing the bushing in the girder assembly, the second intermediate gear
or pedestal and bearing sleeve, ensure that can be assembled and mounted to the
the lube holes in the hub align with the shaft prior to installing the shaft. If not, then
outer grooves in the bushings. If dowel the gear rim will have to be installed after
holes are difficult to align the bushing may the shaft has been installed.
be rotated 15º and new holes drilled. The
bushings must be shrunk fit to the hubs and 2. The gib keys should be checked as to fit
bearing sleeve. Be sure all dowels are flush to the shaft and the gear. There should be
with or slightly below the face of the at least 80% contact on all surfaces.
bushings. Coat the bushing bores with a
film of Molykote Type “G”. 3. When installing the bushings in the
girder or pedestal and the bearing sleeve,
2. On the front gear train, the shaft may be new dowel holes will have to be drilled.
inserted and then the gear installed, but on Since the dowels fit in the end of the
the rear gear train, the gear must be bushings, check for 10,020 minutes
positioned and cribbed so that the bore of
Page
Rev – 0
22/07/99
JLC
running clearance. If necessary, scrape 2. Install oil seal in coupling end bearing
high points. retainer and lock in place with seal retainer.
Be sure seal lip faces toward bearing.
4. When installing the gear or spider on the Install 0-ring in bearing retainer groove.
shaft, insert the gib keys but do not drive Slide coupling spacer and bearing retainer
them tight. The keys are driven tight only assembly onto shaft.
after the gear and shaft are completely
assembled in the pedestal or girder. In the 3. Heat coupling half in oil bath to 250ºF
case of the second intermediate shaft and install key and coupling half on shaft
pedestal mounted, the keys cannot be tight against spacer.
driven in until the first intermediate haft has
been mounted in the gear case. f. Gearcase (figure 26)
5. After complete assembly of shaft, move 1. When installing shaft assemblies in

the gear tight against the thrust washer gearcase, be sure they turn freely.
then drive the keys in tight. After keys are
tight, remove bearing sleeve bolts and add 2. Clean flanges of gearcase and cover
shims under sleeve flange to obtain 1/8- and apply a coating of silicone sealant to
inch clearance on thrust washers. flanges. Install the four aligning dowel bolts
and tighten. Install remaining capscrews
d. First Intermediate Shaft (figure 26) and rod bolts.
1. Assemble the pinion and bearing 3. When mounting bearing retainers and
retainer and slide onto shaft. Be sure the end covers to gearcase, be sure 0-rings
seal lip faces toward bearing and the 0-ring are properly installed.
is in the groove of the retainer.
4. Fill the gearcase with the correct type
2. Heat the bearing in an oil bath to 250º F and amount of oil.
and install on shaft tight against shoulder.
g. Propel Motor (figure 25)
3. Install oil seal in inner retainer. Be sure
seal lip faces toward bearing, then install 1. When replacing the motor, be sure that
both inner retainers on shaft. the same amount of shims removed during
disassembly are used under the motor
4. Heat the bore of the gear to 250ºF and mounting pads to maintain motor
install gear and key on shaft. Be sure gear alignment. Also, be sure the motor chocks
is tight against shaft shoulder. and wedges are installed and driven tight.
Also check coupling alignment to verify
5. Install gear end bearing oil seal into correct shimming.
inner bearing retainer. Be sure seal lip
faces toward bearing. Install both inner 33. Reinstall all guards and other
retainers on the shaft. miscellaneous equipment removed during
disassembly.
6. Heat the gear end bearing in oil bath to
250ºF and install on shaft tight against 34. Have an electrician reconnect all
shoulder. Be sure spacer is in place electrical leads and test the unit.
between bearing cones. Install bearing
outer retainer. BRAKES
e. Motor Input Shaft (figure 26) The brakes on the 1370W for the hoist, drag,
1. Heat bearings to 250ºF in oil bath and swing and propel units are shoe type spring set,
install on shaft tight against shoulders. air released brakes (figure 30). The brakes
Install bearing retainer on pinion end of should be checked daily for proper adjustment
shaft. and lining wear. The lube points should be
greased weekly.
Page
Rev – 0
22/07/99
JLC
To disassemble brakes style 3, 4 and 5 proceed

There have been five different styles of brakes as follows:
used on the 1370W for the hoist, drag, swing
and propel units. Refer to appendix for the style 1. Remove all guards.
brake for each unit and for the adjustment
dimensions for A-mm, A-max, B-mm, and B- 2. Activate the air cylinder to compress the
max. spring (figure 31). While the spring is
compressed, screw nuts onto the two spring
retaining rod bolts and tight against the spring
guide. This will lock the spring in the
compressed state when the air cylinder is
deactivated.
Brakes style 1 and 2 are covered under

separate topics.
BRAKE STYLES 3, 4 & 5
Brake styles 3, 4 and 5 are similar, the main

difference being the method of removal and
installation of the spring assembly.
CAUTION: PRIOR TO WORKING ON

ANY BRAKE, OBSERVE THE
FOLLOWING PRECAUTIONS:
1. Place walking shoes and the bucket on

ground.
2. De-energize, lock out and tag all

controls.
3. Set all brakes except those being

worked on. A minimum of one brake per unit
should always be set.
Page
Rev – 0
22/07/99
JLC
3. When the spring is secured and the

cylinder deactivated, unpin and remove the air
cylinder and spring assembly from the brake
arms.
4. To disassemble the spring assembly

(figure 32), back off on the rod end jam nut and
remove the rod end and jam nut. Back off on the
spring locking rod bolt nuts until spring tension is
removed or the remaining tension is secured by
the spring adjusting rod bolt. Remove any
remaining spring tension by backing off on the
adjusting rod bolt nuts. Separate all items once
the spring tension is removed.
5. Remove the shoe adjusting bolts from

the side of the brake support (figure 33).
6. Remove the brake arm fulcrum pin

retainers and pins. Rotate the arm and shoe
assemblies out of the brake support.
7. Back off on the shoe to arm pin locking

screw and separate the shoe from the arm by
NOTE: IF THE BRAKE SPRING removing the pin.
ASSEMBLY IS NOT EQUIPPED WITH
THE TWO SPRING LOCKING ROD 8. Unbolt and remove the brake support
BOLTS, THE SPRING ADJUSTING ROD from the motor noting the position of any shims
BOLT NUTS WILL HAVE TO BE or spacers (figure 34).
BACKED OFF UNTIL THE SPRING
TENSION IS REMOVED. AN 9. To remove the brake drum from the
ALTERNATE METHOD IS TO motor, bend down the locking ear of the nut lock
ACTIVATE THE AIR CYLINDER TO plate and unscrew the nut about two full turns.
COMPRESS THE SPRING, THEN Do not remove the nut. Use a puller to break the
INSERT A STEEL BLOCK BETWEEN drum loose from the motor shaft. Remove the
THE SPRING GUIDE END PLATE AND nut, lock plate, drum and key from the motor
THE ANCHOR. USE THE ALTERNATE shaft.
METHOD ONLY IF THE SPRING
ASSEMBLY IS NOT TO BE 10. Clean and inspect all parts. Repair or
DISASSEMBLED. replace all damaged or worn parts.
Page
Rev – 0
22/07/99
JLC
On brakes with spring locking rod bolts, tighten

11. Reassemble in reverse of disassembly the nuts on the rod bolt to compress the spring
noting the following: to the A-min dimension. Then tighten the
adjustment rod bolt nuts to obtain the B-max
dimension. Screw the rod end onto the spring
guide rod to the measured distance. Lock the
rod end with the jam nut.
a. Mount the brake drum using the

procedure as outlined in appendix as listed for
pin-ions under the topic PINION AND
COUPLING INSTALLATION.
b. Spread the brake arms to their 2. On brakes without spring locking rod
maximum and measure distance between bolts, tighten the adjusting rod bolt nuts to
cylinder mounting pinholes (figure 35). Activate obtain B-max dimension, then screw the
the air cylinder to its maximum extension. Screw rod end onto the spring guide rod to the
the rod end onto the cylinder rod until the measured distance. Lock the rod end with
distance between pinholes is the measured the jam nut.
distance plus one-inch. Lock the rod end on the
rod with the jam nut. d. Mount the cylinder and spring assembly
to the brake arms with the mounting pins (figure
c. Close the brake arms and measure the 37).
distance between the spring assembly mounting 1. On brakes with spring locking rod bolts,
pinholes (figure 36). remove the nuts from the long end of the
rod bolt. Check the A-min and B-max
dimensions and adjust as required.
Page
Rev – 0
22/07/99
JLC
1. When the spring length reaches A-max

2. On brakes without spring locking rod dimension with the brake set, tighten the
bolts, adjust the adjusting rod bolt nuts to obtain adjusting
the A-min and B-max dimensions.
e. On brakes with spring locking rod bolts

paint a bright yellow strip on the rod bolts from
the spring guide out to 3/8 inch. When the yellow
disappears into the spring guide the spring must
be readjusted to A-min dimension.
Also, on all brakes, whether equipped with

spring locking rod bolts or not, paint a yellow
strip on the adjusting rod bolts from the anchor
plate outward towards the spring guide a
distance equal to B-min dimension. When the
spring guide approaches the painted line, with
the spring adjusted to A-min dimension, the
linings must be replaced.
12. Activate cylinder to release brake and

adjust set screws on the sides of the support to
obtain 1/16 inch clearance at the top and bottom
between the lining and drum.
13. Install all guards and lubricate all of the BRAKE STYLE 1
lube points.
CAUTION: PRIOR TO WORKING ON
ANY BRAKE, OBSERVE THE
Adjustment FOLLOWING PRECAUTIONS
There are two adjustments on the brakes (figure 1. Place walking shoes and bucket on
38) as follows: ground.
2. De-energize, lock out, and tag all

controls.
Page
Rev – 0
22/07/99
JLC
3. Set all brakes, except those being 7. Unbolt and remove the brake support
worked on. A minimum of one brake per unit mounting plate from the motor. Separate the
should always be set. brake support from the mounting plate.
Disassemble style 1 brake (figure 39) as follows:
1. Remove all guards.
2. Activate the air cylinder and install the

air cylinder assembly pin (figure 40). Remove
the cylinder mounting pins and remove the
cylinder.
NOTE: IF THE CYLINDER

ASSEMBLY PIN CANNOT BE
INSERTED BY ACTIVATING THE
CYLINDER, THE PRESSURE ON THE
SPRING WILL HAVE TO BE RELIEVED
BY BACKING OFF ON THE 8. To separate air cylinder assembly, back
ADJUSTING ROD BOLT NUTS. off on the spring adjusting rod bolt nuts until all
the tension has been removed from the spring,
3. Remove the brake arm retaining bolts. then remove the nuts, spring retainer, rod bolts
and spring.
4. Remove the brake shoe adjusting studs
and springs. Remove the cylinder assembly pin and slide the
piston from the cylinder. Remove the nuts from
5. Remove the arm to shoe pins. Back off the end of the piston rod and remove the
on the arm to support pin retaining set screws. follower and piston cup.
Remove the pins and arms. Rotate the shoes
out of the support. 9. Clean and inspect all parts. Repair or
replace all damaged or worn parts.
6. To remove the brake drum from the
motor, bend down the locking ear of the nut lock 10. Reassemble in reverse of disassembly
plate and unscrew the nut about two full turns. noting the following:
Do not remove the nut. Use a puller to break the
drum loose from the motor shaft. Remove the a. Mount the brake drum using the
nut, lock plate, drum and key from the motor procedure as outlined in appendix as listed for
shaft.
Page
Rev – 0
22/07/99
JLC
pin ions under the topic PINION AND e. Release the brake and adjust spring
COUPLING INSTALLATION. stud nuts to gain equal clearance between drum
and lining at top and bottom of brake. The spring
b. Assemble the piston cup and follower to should be adjusted to an approximate height of
the piston. Lubricate the piston cup and the 1-5/8 inches.
cylinders bore and then slide the piston into the
cylinder. Install the cylinder assembly pin, then CAUTION: WHEN INSERTING THE
install the adjusting rod bolts, spring and spring STUD INTO THE BRAKE SHOE, BE
retainer. Tighten the rod bolts nuts to compress SURE NOT TO SCREW THE STUD
the spring to approximate A-max dimension. INTO THE LINING.
NOTE: DO NOT REMOVE

ASSEMBLY PIN UNTIL CYLINDER HAS Adjustment (Figure 41)
BEEN MOUNTED IN BRAKE AND
LEVER STOP BOLTS HAVE BEEN a. When brake wears and “A” dimension
INSTALLED. approaches A-min length, the spring rod bolts
will have to be adjusted to A-max. Also, the lever
stop bolts will have to be readjusted for 1/16
inch drum to lining clearance when brake is
released. Adjust stud nuts for equal lining
clearance.
b. After several adjustments check the

distance between the cylinder anchor pins,
dimension “B”. When this dimension approaches
c. Adjust lever stop bolts so that there is a
B-Mm, the linings must be replaced.
1/16 inch clearance between lining and drum
when brake is released. There should be no
clearance between head of stop bolt and
BRAKE STYLE 2 (FIGURE 42)
trunnion when brake is released.
d. After cylinder has been installed and CAUTION: PRIOR TO WORKING ON

lever stop bolts adjusted, adjust spring rod bolts ANY BRAKES, OBSERVE THE
for initial height of A-max. FOLLOWING PRECAUTIONS:
Page
Rev – 0
22/07/99
JLC
1. Place the walking shoes and the bucket 6. Unpin and remove the brake lever
on ground. adjusting screw assembly from the brake lever
and brake jaw (figure 44).
2. De-energize, lock out and tag all
controls.
NOTE: ON SOME BRAKES ONLY

ONE ROD END IS USED AND THE
OTHER END OF THE ADJUSTING
SCREW IS THREADED DIRECTLY
INTO THE ANCHORING PIN. IN THIS
CASE THE ADJUSTING SCREW MUST
3. Set all brakes except those being BE REMOVED FROM THE PIN AND
worked on. A minimum of one brake per unit THEN THE PIN REMOVED.
should always be set.
7. Unpin and remove the brake lever from
To disassemble style 2 brakes (figure 43) the brake jaw.
proceed as follows:
8. Turn the brake jaw adjusting screws all
1. Remove the brake guard. the way in, then remove the jaw to bracket pins
and remove the jaw and shoe as an assembly.
2. Remove the spring rod bolt pin nut. Separate the jaw and shoe by removing the
Back off on the rod bolt special nut until all mounting bolt.
tension is removed from the spring.
NOTE: WHEN REMOVING THE
3. Unbolt the brake support bracket and JAW TO BRACKET PINS, NOTE THE
slide the complete brake assembly from the THICKNESS AND POSITION OF THE
brake drum. Note, if used, the thickness and SPACER WASHERS SO THAT WHEN
location of the shims under the bracket, so that THE BRAKE IS REASSEMBLED THE
when the bracket is remounted, the brake will JAWS WILL BE CENTERED.
align properly with the brake drum.
9. To remove the brake drum from the
4. Remove the spring rod bolt special nut, motor (figure 45), bend down the locking ear of
rod bolt, and spring. the nut lock plate and unscrew the nut about two
full turns. Do not remove the nut. Use a puller to
5. Unpin and remove the air cylinder from break the drum loose from the motor shaft.
the brake. On some brakes the cylinder to brake Remove the nut, lock plate, drum and key from
lever pin retainers are tack welded. the motor shaft.
Page
Rev – 0
22/07/99
JLC
10. Reline or replace the brake shoe. Clean assembly to the brake drum. Shim under the
and inspect all parts. Repair or replace all worn bracket as required to center the brake
or damaged parts. assembly on the drum.
f. Adjust the spring length to A-min

dimension (figure 46).
g. Actuate the cylinder to release the

11. Reassemble in reverse of disassembly brake. Insure both linings are off the drum, then
noting the following: adjust jaw set screws so that they are within
1/64 inch of the brake bracket.
a. Mount the brake drum using the
procedure as outlined in appendix as listed for
pinions under the topic PINION AND Adjustment
COUPLING INSTALLATION.
As the brake linings wear, the brake will have to
b. When bolting brake jaws to brake shoes be adjusted to maintain proper braking. After
(figure 46), brake shoe is to clamp against brake several adjustments or as the thickness of the
jaw flange sufficiently tight so that the shoe can shoe lining approaches 5/16 inch, the linings will
adjust itself to the brake drum and still not drag have to be replaced. The brake is adjusted as
on the drum when the brake is released. follows:
c. When installing the brake jaw fulcrum 1. When the spring length reaches A-max
pins, be sure to insert the spacer washers of the loosen the jam nut and tighten the special nut
same thickness so that the brake jaws are until the spring length reaches A-mm dimension.
properly aligned.
2. Also adjust the adjusting screw to
d. Assemble the adjusting screw so that shorten the B dimension 3/8 inch each time the
the screw is about the same distance in each spring is readjusted. This will prevent the
rod end. The distance from pinhole to pinhole cylinder from bottoming out and possibly
should be approximately 15 inches. preventing the brake from setting.
e. When the brake is completely

assembled (figure 43), mount the brake
Page
Rev – 0
22/07/99
JLC
3. Release brake, check for equal b. Remove the bearings from the sheave.
clearance of lining to drum, and readjust jaw set The bearings are interference fit to the sheave
screws for 1/64 inch clearance. and will require a bearing puller for removal.
4. Reassemble the sheave by pressing the

DRAG ROPE SUPPORT bearings into the sheave. Be sure the bearings
are tight against the shoulder in the sheave.
Install new wipers in the retainers and bolt the
Periodically inspect the base and shaft
retainers to the sheave.
mountings of the drag rope support (figure 47).
Check for cracks in the supports as well as the
5. Check the sheave shaft and clean up all
dirt deflectors and repair weld as required.
nicks or burrs with a fine tooth file.
Lubricate all grooves and bearings of the
sheaves to insure smooth rotation and sliding
6. Position the sheave on the cribbing and
movement. If it is necessary to replace the
install the shaft. Install the shaft retainer.
bearings of a sheave, use the following
Release the drag rope.
procedure.
1. Secure the drag rope so that it does not

rest on the sheave. Securely crib under the DRAG ROPE DIRT TROUGH
sheave. CLEANING SYSTEM
2. Remove the sheave shaft retainer and
pull the shaft from the supports and sheave. The cleaning system (figure 48) should be
checked periodically to see that it is functioning
3. Remove the sheaves from the cribbing properly. During wet weather it should be
and dismantle as follows: checked daily. Check the condition of the ropes,
drums, turnbuckles, runners, guides and wipers.
a. Remove the bearing retainers from each Excess slack in the ropes should be taken up
end of the sheave. Remove the wipers from the with the turnbuckles.
retainers.
To disassemble the trough cleaning system,
proceed as follows:
Page
Rev – 0
22/07/99
JLC
1. Set the bucket on the ground and 7. Remove the reach rod, rod ends, and
secure the drag ropes against unwanted equalizers from the cleaner. Unbolt and remove
movement. Shut off and tag the controls. the runners, guides, and wipers from the
cleaner.
2. Back off on the turnbuckle to remove
tension on the turnbuckle-anchoring pin. 8. Loosen the limit switch unit mounting
Remove the pin. bolts and slide the switch unit toward the drum
to relax the tension in the chain. Separate and
3. Remove the rope clips securing the remove the chain. Remove the switch unit
turnbuckle to the rope and remove the mounting bolts and switch unit.
turnbuckle.
9. Loosen the bolts securing the gear
4. Remove the pin anchoring the rope reducer unit and back off on the adjusting bolts.
socket to the equalizer. Remove the wedge and Move reducer unit toward the drum to put slack
socket -from the rope. in the drive chain. Separate and remove the
chain. Unbolt and remove the reducer unit.
5. Spool the rope from the drum, then
remove the rope clips which secure the ropes to 10. Remove the sprockets and keys from
the drum. both ends of the drum shaft.
6. Pull the cleaners toward the drum until 11. Support the drum with blocking or the
they are clear of the guides, then lift them out of overhead crane and remove the bolts securing
the troughs. the pillow block bearings to the drum supports.
Page
Rev – 0
22/07/99
JLC
Remove the bearing retaining nut and washers. e. Have an electrician adjust the limit
Remove the bearings from the drum shaft. switch for the correct rearward most and forward
most positions.
12. Clean and inspect all parts. Repair or
replace all damaged or worn parts. f. Install all guards and lubricate all
lubrication points.
13. Re-assemble in reverse of disassembly
a. When installing the bearings on the

drive shaft, be sure they are tight against the
shoulders of the shaft. Install the washers and
tighten the nuts sufficiently to hold the bearings
in place but do not bind the hearings. Lock the
nuts in place by bending one of the tabs of the
washer tight against a flat on the nuts.
b. When installing the sprockets on the

reducer unit and drum shaft, check the fit of the
gib keys. There should be a minimum of 80%
contact on all surfaces. On the reducer unit, the
face of the sprocket hub should be even with the
end of the shaft. On the drum shaft, the sprocket
should be tight against the shaft shoulder.
c. The chains should he snug on the

sprocket but do not over tighten chains or there
will be premature wear or possible failure of the
chains.
d. When installing the Ropes, position the

cleaner in its most rearward position closest to
the drum. Reeve the outer drum ropes from the
drum, forward around the guide sheave and
back to the cleaner. Attach the ropes on the
topside of the drum with the rope clips. Rotate
the drum in reverse until two wraps of the ropes
is on the drums. At the cleaner end of the rope,
install the rope socket and connect the socket to
the equalizer on the cleaner.
Install the turnbuckles on the inner drum ropes

and secure with rope clips. Attach the turnbuckle
to the cleaner equalizers. Run the cleaner in the
clean out mode to move the cleaner to the front
of the machine while spooling out the inner drum
ropes. When the cleaner is at its forward most
position, stop the unit. Hand wrap, from the
bottom of the drum, two wraps of the inner drum
ropes on the drum and secure the ropes to the
drum with rope clips. Take up any slack in the
ropes with the turnbuckles.
Page
Rev – 0
22/07/99
JLC
SELSYN-TIE It should be checked rnechanically to see that all

mounting bolts are secure and the couplings
between units are in good shape. Also check the
The selsyn-tie (figure 49) is supplied to monitor
oil level in the right angle drive.
the position of’ each shoe during the walking
mode of the machine. If the shoe becomes out
of sync during the walking mode, the selsyn-tie RETRACTABLE LADDER —
will indicate on the dials, on the operator left OPTIONAL
hand control stand, the degree of misalignment
of the shoes. If the shoes become 10 inches Periodically inspect the retractable ladder (figure
apart in angular displacement, a warning alarm 50) for signs of cracking or other damage. Pay
will sound. If the shoes become more than 15º special attention to the rungs of the ladder that
apart, propel motion will be stopped. they are not broken or loose. If repair welding is
required, follow the welding instructions in the
appendix.
Also check the condition of the ladder rope for

fraying, rusting, etc., and that the rope clips are
secure.
Periodically lubricate the sheaves, ladder

guides, and rope.
MACHINERY HOUSE AND CABS
STRUCTURAL MEMBERS AND PANELS
Frequently inspect all internal and external

house panels and structural members for
cracking. Include a close examination of all
sheets, aprons and purlins in the roof structure.
Also check the panels which form the walls of
the lubrication, filter and transformer rooms.
Examine all struts, columns, beams and braces
used to reinforce the machinery house. Be sure
there are no cracks in the rails along which the
service crane travels. Always restore defective
structural members to their original state by
repair welding.
Periodically observe the hinges and closure

mechanisms on all doors and windows to insure
they will remain closed during machine
operation. Verify the installation sealing of the
leg closures of the A-frame. Search thoroughly
for all loose or missing bolts. The absence of
these fasteners can result in excessive vibration
and wear of house components. Individually,
these faults can be considered minor; but taken
collectively, they represent a major exposure of
the electrical and mechanical elements of the
house to dust and water.
The selsyn-tie should be checked periodically by
an electrician to see that it is adjusted properly.
Page
Rev – 0
22/07/99
JLC
Check the condition of the house paint; paint is HOUSE FANS

not impervious to deterioration. A well-painted
ma chine is less susceptible to rust, corrosion Be sure the pressurization system is functioning
and progressive failure. properly to keep the house well ventilated and at
a pressure higher than atmospheric pressure.
DYNAVANE AIR CLEANER Service the house fans (Axial Flow, Series 300)
as follows:
Inspection
Inspection
Check the blades for grease and or dirt

accumulation. Clean if necessary. Blades should
rotate freely without binding.
If vibration is detected, check the following:
1. Bearing and drive alignment,
2. Shaft straightness,
3. Wheel or sheaves loose on shaft,
4. Loose or worn hearings,
5. Loose mounting bolts,
6. Motor out of balance,
7. Sheaves out of balance,
8. Nose cap loose on wheel
The air entrance of the cells must be free of 9. Worn or corroded wheel,
leaves, paper, rags, etc., to assure a free flow of
air. 10. Accumulation of material on the wheel.
Equipment exposed to this type of obstruction Lubrication

during application should have the intakes
(figure 50A) covered by a coarse mesh (5 mesh) All bearings are pre-lubricated and sealed at the
screen to prevent the entry of material larger factory. Under normal temperature conditions,
than the bleed slot. which are -20º to 150ºF, when the fans are
circulating clean air, the bearings are considered
Periodically inspect the bleed system to make lubricated for life and re-greasing is
sure nothing is impairing the flow of bleed air. unnecessary.
Check the cells for a build-up of deposits on the If the fans are circulating contaminated air, or
blades at the same time. A light coating of dust operating at elevated temperatures, periodic
is normal and will not impair the operation or the lubrication is required.
efficiency of the cell. If a heavier accumulation of
deposits occurs, clean the cells by brushing, by For normal temperatures, a high quality, light
the use of compressed air or, where there is neutral mineral grease of about 1 ½ to 2 pounds
adequate drainage, by washing with water or consistency is used. It is free of abrasive fillers
some suitable solvent. and highly resistant to oxidation.
Page
Rev – 0
22/07/99
JLC
When fans are operating at elevated First check supporting members to see that
temperatures (166ºF or higher), silicone or there will be no distortion or twisting of operating
lithium soap base grease should be used. This equipment (figure 51). Correct any inaccuracies
high temperature grease should have a by shimming before tightening the fan bolts.
breakdown point above
350ºF.
Use a lower pressure grease gun for fan

bearings. It is preferable that either the gun or
the fittings be vented. To prevent overfilling,
apply only a small amount of grease. This is
especially important when extended lubrication
piping is used and the bearing cannot be
observed.
Integral horsepower Westinghouse motor

bearings are factory pre-lubricated, which is
considered a lifetime lubrication.
Bearings
Bearing alignment is critical; therefore,

whenever bearings are removed, carefully check
alignment.
Bearings for the Series 300 fans are furnished

with an eccentric type, locking collar, which Carefully check shaft and bearing alignment
mounts on the outside of each bearing. To before operation. The bearings must be properly
remove, loosen the setscrews and turn the collar locked to the shaft. Certain bearings use
in the direction opposite wheel rotation. This setscrews, tighten them. Some bearings use an
releases the eccentric and the bearing will slide eccentric locking collar, which should be driven
along the shaft. To install the bearings, reverse on in the direction of fan rotation and then held,
the procedure. in position with setscrews.
HOUSE FANS (PROPELLAIR) Turn the wheel over by hand to make sure it
runs free and clear. Reposition by shifting and or
Inspection shimming, if necessary.
Periodically check the propeller for accumulated Be sure all anchor bolts, bearings, motor bolts
dirt and clean, if necessary. and setscrews are tight. Make certain the
bearings have ample lubrication.
Check all the bolts and set screws periodically to
ensure they are tight. Maintenance
Motors are equipped with double shielded, pre- Maintenance, basically, consists of applying
lubricated bearings. Under normal operating proper lubricants in bearings. Check lubrication
conditions, the motors should require no once each week under normal conditions.
attention.
It is preferable to add grease while the shaft is
HOUSE FANS (CHICAGO BLOWER) slowly turned. Add grease until it starts to ooze
through the bearing seals. Wipe excess grease
Inspection off. Exercise care when lubricating with a high-
pressure type gun or the bearing seals may be
Page
Rev – 0
22/07/99
JLC
ruined. The bearing should run warm after being exceed the maximum shown on the nameplate.
filled with grease. It is preferable to keep the air gap considerably
below maximum.
AUXILIARY HOISTS AND OVERHEAD CRANE
To reduce the air gap, remove the pin and turn
Adjustment of Load Brake the rod counterclockwise until the minimum air
gap is restored.
The multiple discs of the brake work at about
one fourth the pressure of the surface screw Lubrication
type brakes; therefore, adjustment is seldom
required. If adjustment becomes necessary,
lower the block to the floor, loosen lock nut C
and tighten adjusting with about a sixth-inch
wrench until moderate resistance is felt (figure
52). Back out the adjusting screw one-half turn
and tighten lock nut C. Check the adjustment by
removing air vent plug A and observing the
movement of the compound internal gear when
approximately full load is lifted from the floor.
This movement should be about three-eighths
inch.
Adjustment of Clapper Type Electric Brake

Inspect the machines daily (figure 53).
Refer to figure 52.
Braking power may be varied, by moving the

fulcrum Y. No. 1 position gives maximum
power, No. 6 position minimum power. The
factory setting is shown on the nameplate
attached to the brake
Adjust bridge and trolley brakes as desired; hoist

brakes should never be reduced in power from
the factory setting.
As the friction surfaces wear, the air gap G will

increase. The air gap should never be allowed to
Page
Rev – 0
22/07/99
JLC
Oil level should be maintained as close as after approximately 1500 hours of operation.
possible to the top of the oil gauges (figure 54). Use a good grade of ball bearing grease.
An excess or deficiency of oil could damage the
machine. Anti-friction bearings, shafts, axles, sheaves,
etc. should be checked monthly. Use a good
Oil should be sufficiently fluid to flow freely into grade of ball bearing grease.
the openings provided and rise within the
enclosure to a level corresponding with the top Check gearboxes for leaks and proper oil levels
of the oil gauge. after 50 hours operation. After this, a semi-
annual check should be sufficient. If the
To assure correct oiling, the oil gauge should be equipment is subject to extreme weather
left open for several minutes after filling to verify conditions, a lighter weight oil should be used in
the oil does not overflow the oil gauge or sink winter and a heavier weight for the summer.
below the correct level. Heavy oil will increase the load on the motor in
cold weather. Use a good grade of gear oil
When servicing oil gauge B, a good grade of (S.A.E. 30 for 1 HP, S.A.E. 50 for 35 HP, S.A.E.
auto mobile engine oil is preferred (S.A.E. 40 for 90 to 600 for over 35 HP).
winter and S.A.E. 50 for summer). For grease
connection C, apply a good grade of solidified oil Open gearing should be checked at least once a
with a viscosity of 400 at 100ºF. Oil should be month, more often if conditions warrant it. Use a
drawn off and cases refilled as often as good grade of adhesive gear compound.
necessary to keep the oil in good condition.
Remember this when drain plug D is pulled. Use The proper oil level of lubricated electric brakes
an extremely light automobile oil (about S.A.E. should be checked after 50 hours of operation.
10) for oil gauge E. Check it at least once a month thereafter. If the
oil is dirty from wear particles, flush the case and
Frequency fill it with fresh oil. A non-adhesive S.A.E. 10
weight, non-detergent oil is satisfactory.
Anti-friction bearing motors require minimum
lubrication. Motors provided with external means Check the cables monthly. Use a lubricant that
of lubrication should be re-lubricated sparingly will penetrate to the inner core and is adhesive
enough to prevent dripping. Hot or cold
Page
Rev – 0
22/07/99
JLC
applications are required, depending on the (figure 55). The maintenance crew that uses
lubricant chosen. A cold application is more these access ways should be the inspectors
convenient, but it may have to be applied more since the walkways are provided for their safety
often. Refer to Appendix for lubrication data. and convenience. Should a structural member
become damaged, repair or replacement may
WALKWAYS AND STAIRWAYS be necessary. Replace nuts and bolts where
required or repair weld to restructure individual
Each day inspect all handrails, walkways, access members such as steps and railings.
platforms and stairways on the machinery house
Page
Rev – 0
22/07/99
JLC
Eliminate accumulations of wiping rags, oil and Vertical Door Opener

grease, dust and dirt, and mislaid maintenance
tools. They can create a safety hazard. Keep 1. Remove the coupling half and key from
new and used wiping rags in barrel containers the end of the screw.
rather than draped or tied to railings. Clean off
excess oil and grease in the prominent walking 2. Unbolt and remove the end plate from
and working areas to prevent workers from the opposite end of the screw. Remove the
slipping. Maintain a tool bench and rack for the bushing from the end plate.
storage of all tools used in the dragline upkeep.
Do not let tools lie scattered about the machine. 3. Slide the screw and roller unit from the
guide. Separate the screw from the roller unit.
REAR DOOR OPENERS Separate the screw nut from the roller unit.
Remove the cotter pins and remove the washers
The rear of the machinery house is equipped and rollers from the roller unit.
with doors to allow the overhead crane to exit
the house. There are three doors, two of which 4. Remove the coupling end bearing
are vertical and one, which is horizontal. retainer cap screws and remove the retainer.
The doors and operating mechanisms (figure 5. Remove the bearing carrier lock nut and
56) should be checked monthly for cracking, lock washer and then remove the carrier and
buckling and correct operation. All hinge points bearing from the guide. Separate the bearing
should be lubricated with multipurpose oil and all from the carrier.
grease points should be lubricated with
multipurpose grease. Any cracking noted should 6. Inspect all parts and repair or replace all
be repair welded using the procedures outlined dam aged or worn parts.
in the appendix.
7. Reassemble in reverse of disassembly
The parts, which would most likely require repair and lubricate the screw, bearing and bushing.
at some time, are the operating mechanisms. To
repair the operating mechanism, proceed as NOTE: WHEN REASSEMBLING
follows: THE BEARING, TIGHTEN THE
1. Shut down the machine and tag the CARRIER NUT ONLY ENOUGH TO
controls. REMOVE ALL ENDPLAY. DO NOT
BIND THE BEARING.
2. Have an electrician disconnect and tag
the electrical lines to the gear motor and the limit Horizontal Door Opener
switch.
1. Remove the coupling half and key from
3. Separate the coupling at the gear motor. the end of the screw.
Unless the gear motor needs repair, it need not
be removed. 2. Remove the lock nut and lock washer
from the opposite end of the screw.
4. Support the operating mechanism frame
with adequate rigging and remove the pin that 3. Remove the bolts securing the end plate
secures the lift arm to the roller unit. Secure the to the guide and remove the end plate. Separate
arm out of the way. Remove the operating the labyrinth seal and bearing from the end
mechanism frame support bolts and lower the plate.
frame to the floor of the machine.
The operating mechanisms for the vertical and

horizontal doors, though similar, have specific
differences so each unit will be described
separately in the following paragraphs.
Page
Rev – 0
22/07/99
JLC
NOTE: WHEN REASSEMBLING

4. Remove the nut and lock washer from THE UNIT, TIGHTEN THE LOCK NUTS
the coupling end of the screw. ONLY ENOUGH TO REMOVE ALL END
PLAY. DO NOT BIND THE BEARINGS.
5. Slide the screw and roller unit from the
guide. Separate the screw from the roller unit. WINDSHIELD WIPER
Separate the screw nut and flange from the
roller unit. Remove the cotter pins and remove The windshield wiper (figure 57) on the front
the washers and rollers from the roller unit. window of the cab has an adjustable crank
which will vary the horizontal length of travel of
6. Remove the capscrews securing the the wiper. Make sure the crank is set so the
bearing housing to the guide and remove the wiper will swing freely across the window
bearing housing from the guide. Separate the without interference with the window frame.
labyrinth seal, bearing carrier and bearing from Check the wiper blades, linkage and spring for
the housing. proper operating condition.
7. Inspect all parts and repair or replace all The wiper assembly also includes a limit switch,
dam aged or worn parts. which positions the wiper in the extreme right
position (as viewed from inside the cab) upon
8. Reassemble in reverse of disassembly shut off. Because the wiper will coast after
and lubricate the screw and bearings. power is turned off, the limit switch must be
adjusted to disconnect power when the wiper
blade is vertical on the return stroke.
Page
Rev – 0
22/07/99
JLC
Wiper Travel Adjustment all pivot points and bearings to maintain smooth
movement of the seat. Check the condition of all
There are holes at various radii in the crank, seat plungers, retainers, and lock seats as well
which will vary the horizontal length of travel of as the seat cushions.
the wiper. For initial operation, the rod end (7)
should be assembled in the smallest radius hole
and the hole positioned 10º CCW of horizontal.
The center distance of connecting rod (6) must
be 16-11/16 inches in all cases. Adjust wiper
arm to extreme right position (as viewed from
inside cab). Loosen mounting hub bolts slightly
so that, in case of interference of the blades to
the window frame, the hub case slips. After
initial setting, one of the following conditions will
exist:
1. Interference of wiper blade and window

frame.
a. Move the rod end (7) to a smaller radius

hole and recheck for proper operation.
2. No interference.
a. If travel is short of interference by less

than 1-1/2 inches, center wiper path by
adjustments of wiper arm on shaft and
tighten hub bolts securely. SWING CONTROL UNIT
b. If travel is short of interference by more The swing control unit (figure 59) consists of the
than 1-1/2 inches, move rod end (7) to the right and left swing pedals and the swing control
next larger radius hole on the crank. Centre gearbox. Each pedal is pinned to a shaft of the
wiper path by adjustment of wiper arm on gearbox. The shafts rotate the horizontal bevel
shaft and tighten hub bolts securely. gears, which transfer the horizontal rotation of
the pedal shafts into vertical rotation of a shaft
Wiper Shutoff Adjustment connected to the swing rotary switch. Setscrews
mounted on posts beneath the pedals serve as
The function of the limit switch is to position the stops for the pedals.
wiper arm in the extreme right position (as
viewed from inside cab) upon shutoff. The limit Check the electrical resistance of the swing
switch should be set to turn off the wipers switch rheostat with either pedal depressed to
approximately when the blade is vertical on the full swing position. A zero ohms reading is
return stroke. Because the blade has a tendency required between the wiper arm and the end
to coast after power is turned off, this will be terminal toward which it has been turned. Zero
enough travel to allow the blade to stop at the ohms should be obtained with at least 5 percent
window edge. This adjustment should be done of the switch travel left. Adjust the pedal stop
with a semi-damp window, as the blade will screws to obtain the correct pedal travel.
travel a greater distance on a very wet window.
Check the operation of the swing pedals. If any
OPERATOR’S SEAT binding or difficulty in moving the pedals is
encountered, disassemble the gearbox to check
the gears and bearings.
The individual operator may adjust the
operator’s seat as desired with respect to height,
Pedal Angle Adjustment
tilt, and swivel travel (figure 58). Periodically oil
Page
Rev – 0
22/07/99
JLC
The pedal angle may be adjusted to suit the

operator using the following procedure.
1. Drain the oil from the gearbox.
2. Remove the gearbox side plates and re-

index the mating bevel gears.
3. Reassemble gearbox.
4. Fill gearbox with oil to check plug level.

Use W S.A.E. 90 gear oil.
Page
Rev – 0
22/07/99
JLC
SECTION 4— FRONT END weld as out lined in Appendix and Tubular Boom
EQUIPMENT Manual. Lubricate all manual lube points and
The front-end equipment of the 1370W walking check that all points lubed by the automatic
dragline, (figure 60) consists of the boom, boom system are receiving the proper amount of
deflecting sheaves, and boom point sheaves. grease.
Mast and mast deflecting sheaves; fairlead and
fairlead buffer cylinder; running ropes — hoist All boom chord members should be visually
and drag; suspension ropes — upper, lower and inspected especially in the area of weld joints
intermediate and intermediate rope take-up and peripheral surfaces of the chords.
mechanism; A-frame; bucket and bucket rigging.
The boom point and deflection sheaves should
also be inspected at this time. Refer to the topics
BOOM
on these items for inspection procedures.
The boom (figure 60) should be inspected daily. To assist in locating cracks in the boom, the
In the area of the boom feet, check for a sound main longitudinal chords and apex chords are
connection between the boom and the revolving filled with pressurized dry air. The air pressure in
frame. the chords is monitored by gauges and pressure
switches. If the pressure drops below 75 PSI the
Check for cracking in all plate to plate and plate pressure switch will close and activate a warning
to chord weld joints. Examine reinforcing device in the operator’s cab. If the warning
gussets, which run along side the chord ends. device sounds the machine should be stopped
Check the fabricated plate structure of the boom and the source of the leak located and repaired
feet for plate fracture. If cracks are found repair before further operation of the machine.
Page
Rev – 0
22/07/99
JLC
The sheaves, sheaves bushings and thrust

If any cracks are noted in the boom refer to the washers can be replaced with the boom in the
Tubular Boom Manual for the correct repair working position. Replacement of tower bushing
procedures. or thrust washers requires the lowering of the
boom onto cribbing.

UPPER AND LOWER DEFLECTION SHEAVES
AND TOWERS BOOM POINT
Check all structural members of the deflection Examine all upper, boom structural strand
sheave towers (figures 61 and 62) daily for weld connections at the boom point box. Attend to all
cracking. Inspect all support structural strands structural cracking immediately using the field
anchoring the towers to the boom chords. repair welding techniques as described in
Sheave brackets in both the upper and lower Appendix. Daily inspect the boom point sheaves
tower structures must be examined and adjusted and swivel yoke, for wear and proper lubrication.
so there is proper spacing between the sheaves If so equipped check daily the structural
and the rope guides. Inspect all sheaves and members of the auxiliary and boom point jibs for
bushings to insure they rotate freely. Apply cracking. Repair weld as required. Inspect and
lubrication where required. lubricate all pivot and swivel connections.
The normal wear items on the sheave towers Repair of the boom point sheaves or swivel yoke
will be the sheaves, sheave bushings and thrust will require the lowering of the boom unless the
washers, and tower bushings and thrust machine is equipped with auxiliary and boom
washers. point jibs (figure 63). The following procedure
describes the removal of the swivel yoke and
Page
Rev – 0
22/07/99
JLC
point sheaves using the auxiliary and boom 5. Install a lifting sling through each
point jibs. sheave and attach the slings to the lifting
bracket. Maintain a distance of 8 to 18 inches

1. Secure the machine from all unwanted between the sheaves and the lifting bracket.
movement. Shut off and tag the controls.
6. Attach a come-a-long to sheaves at
2. Release the hoist ropes from the hoist point A and come-a-long support lugs at point B.
drum and use the auxiliary winch to lower the
hoist ropes off the machine.
3. With the auxiliary winch pull a 1-1/8 inch

x 650-foot long, 6 x 37 classification, right lang
lay, fibre core, preformed with ends tapered rope
onto the machine and over the large sheave on
the auxiliary jib (figure 64). Secure the 1-1/8 inch
rope to the hoist drum with special anchors.
CAUTION: BE SURE SPECIAL

ANCHORS ARE USED TO SECURE
THE 1-1/8 INCH ROPE TO THE DRUM
SO THAT THE ROPE WILL NOT COME
LOOSE FROM THE DRUM DURING
THE MAINTENANCE PROCEDURE.
4. Use the boom point jib to hoist the lifting

bracket up to the boom point. Attach the lifting
bracket to the 1-1/8 inch rope.
Page
Rev – 0
22/07/99
JLC
9. Take-up on the come-a-long until the

7. Attach the deck winch rope to the swivel swivel is removed from the lower bearing and
frame at point C. the edge of the crossbeam is resting on the
support platforms on the front of the point box.
8. With the swivel assembly supported as Make certain that the 1-1/8 inch rope is taut.
noted in step 5, 6 and 7, burn off the chock bars
in front of the crossbeam. Remove the bolts 10. Take-up on the 1-1/8 inch rope until the
securing the crossbeam. crossbeam is setting flat on the support
Page
Rev – 0
22/07/99
JLC
platforms, then bolt the cross beam to the

platforms. 15. Remove the lube piping from the
bearing retainer. Remove the bearing retainers.

11. With the 1-1/8 inch rope and deck winch
rope taut, relax the come-a-long until the swivel 16. Slide the sheave assemblies from the
is out of the upper bearing and crossbeam. swivel stub shafts. Remove the bearing inner
spacers from the stub shafts.
12. Relax the deck winch rope until the
swivel contacts the lifting bracket bumper. It may 17. Remove the bearing retainers and
be necessary to take-up of the 1-1/8 inch rope to bearings from the sheaves.
prevent interference between the swivel and
point box. 18. Inspect all parts for wear or damage and
repair or replace all damaged or worn parts.
13. Detach the deck winch rope from the Reassemble in reverse of disassembly.
swivel at point C. Slowly lower the swivel
assembly while using the come-a-long to keep MAST
the sheaves from contacting the point box.
When the swivel has cleared the point box,
Each week inspect the mast structural members.
detach the come-a-long and continue lowering
In particular, check for weld and plate failures in
the swivel assembly to the ground.
the head area around the boom structure strand
anchors and links. Also, check the ladders,
14. To dismantle the swivel assemblies
railings and platforms for missing hardware or
(figure 65) remove the bushing and thrust
cracking and repair immediately.
washer from the lower end of the swivel and the
bushing from the upper end of the swivel.
Page
Rev – 0
22/07/99
JLC
Check the hoist rope, deflection sheaves on the and mast. Repair or replacement deflection
mast for freedom of movement and proper sheave parts can be accomplished with the mast
lubrication. Also, check the thrust washers for and boom in their working position.
wear.
The main items of the mast, which would at
Any major repair or parts replacement on the some time require replacement are the sheave,
masthead will require the lowering of the boom links, bushings and thrust washers at the
Page
Rev – 0
22/07/99
JLC
masthead and the deflection sheaves, bushings

and thrust washers. Refer to figure 66 for a Inspect the rear legs of the A-frame at least
description of the parts of the mast. once each week. They are major tension
elements. Look closely for cracked welds and
plates. Check for structural failure around the pin

A-FRAME connections and in members lying crossways to
the major axis of the leg beams.
Inspect the front legs and diagonal braces of the
The rear legs of the A-frame are filled with
A-frame once each month for cracked weld
pressurized air, which is part of a warning
joints and plates (figure 67). Important areas to
system. A separate supply system with a
be checked include boom structural strand links
pressure gauge and pressure switch is secured
and major welds in the head area. Also examine
to each of the rear legs.
pin hub to plate welds in the head area. Check
carefully for cracks in members that lie
If either rear leg should crack, a pressure drop
transverse to the longitudinal axis of the leg
will register on the appropriate monitoring
beams.
gauge. When the pressure falls below 15 psi,
Page
Rev – 0
22/07/99
JLC
the switch automatically closes. This, in turn,

activates an audible-visible warning device in Once the rear leg defect has been located, field
the operator’s cab. The gauge reveals which leg, repair welding of the A-frame must be
is cracked. Machine shutdown and examination accomplished. Refer to the repair welding
should commence at once. Pulling the pipe information in Appendix.
plugs in each rear leg may periodically test the
pressurization system. Such action deliberately Major repairs to the A-frame or repair or
causes a pressure drop. When the alarm device replacement of suspension links or head pin will
is triggered, the plugs may be replaced and the require the lowering of the boom and mast.
supply valve activated to re-pressurize the leg to
25 psi. Repair or replacement of the boom hoist
sheaves bushings or thrust washers can be
When a pressure drop occurs during either accomplished without lowering the boom and
testing or digging, first inspect all joints and mast.
piping from each gauge to each back leg. This
area is thus eliminated as a possible source of Refer to figure 63 for a description of the
the problem. It may be necessary to repair or components of the A-frame.
replace the connection points and piping since
they are liable to loosen. If these areas are free STRUCTURAL STRANDS
of damage, check all weld joints and back leg
surfaces for cracking.
The structural strands of the 1370W Walking
Dragline (figure 68), consist of the upper

To help in locating leaks, a sonic detection unit structural strands connecting the boom point to
is provided with tools and supplies. The sonic the mast head. The upper and lower
detection unit is a sensitive portable instrument, intermediate structural strands which connect
which picks up the sound of a leak. the boom at intermediate points to the mast
Page
Rev – 0
22/07/99
JLC
head; the lower structural strands connecting the

mast head to the A-frame head; the A-frame
safety structural strands connecting the A-frame
head to the rotating deck.
The purpose of these structural strands is to

support the boom in its working position.
All structural strands should be inspected weekly

for deterioration. Deterioration will usually show
up in the form of broken outer wires, the
presence of rust, or reduction in rope diameter.
The area most susceptible to these problems is
at the rope sockets.
All broken wires should be tied down to prevent

further unraveling or wear to the strands of the
rope. To prevent rusting periodic applications of
good penetrating oil at the rope socket is
required. This oil should have high penetrating
properties and contain about 50% lubricating oil
as well as a penetrating solvent. The oil should
be able to displace water on the surface of steel
in such a way as to positively prevent corrosion
from moisture already present within the strand
at the time of application, or moisture that might
accumulate later.
The typical life span of structural strands is

approximately 8 years, however, this does not
void the requirement of periodic inspection and NOTE: TO PREVENT TWISTING
replacement at shorter intervals if necessary. OF A NEW STRAND DURING
INSTALLATION, BE SURE THAT THE
PAINTED STRIP ON THE STRAND IS
A-FRAME SAFETY STRUCTURAL STRANDS IN A STRAIGHT LINE.
To replace the A-frame safety structural strands 5. Install the new strand in reverse of
(figure 69) proceed as follows: removal. When the strand is pinned to the A-
frame and rotating deck, pre-load the strand by
1. Move the machine to an area sufficient tightening the adjusting nut to a torque of 800 to
to perform the repair. Set the bucket on the 1600 ft. lbs.
ground. Shut off the controls and tag them.
6. Remove and replace the rest of the A-
2. Remove the cowling around the strands frame safety strands in the same manner.
on the machinery house.
3. Back off on the strand adjustment nuts UPPER, LOWER AND INTERMEDIATE
at the rotating deck and unpin the strand. STRUCTURAL STRANDS
4. Secure a crane to the upper end of one To replace the upper, lower or intermediate
of the strands just below the socket and unpin strands proceed as follows:
the socket. With the crane remove the strand
from the machine.
Page
Rev – 0
22/07/99
JLC
CAUTION: TO REPLACE THE THE NUMBER OF INTERMEDIATE

STRUCTURAL STRANDS (EXCEPT STRUCTURAL STRANDS
FOR THE LOWER STRUCTURAL DETERMINES THE SECOND SUPPORT
STRANDS) THE BOOM MUST BE POSITION. FOR MACHINES HAVING
LOWERED. WHEN THE BOOM HAS UPPER AND LOWER INTERMEDIATE
BEEN LOWERED IT MUST BE STRUCTURAL STRANDS, THE
SUPPORTED AT A MINIMUM OF TWO CRIBBING SHOULD BE PLACED
POSITIONS. THE FIRST SUPPORT UNDER THE LOWER STRAND
POSITION (FIGURE 70) IS THE BOOM SUSPENSION POINT. FOR MACHINES
POINT. THE BOOM POINT SHEAVES HAVING ONLY ONE SET OF
CAN BE PLACED ON THE GROUND IN INTERMEDIATE STRUCTURAL
WHICH CASE THE SWIVEL MUST BE STRANDS, THE CRIBBING SHOULD
BLOCKED TO PREVENT MOVEMENT, BE PLACED IN APPROXIMATELY THE
OR THE BOOM POINT CAN BE CENTER OF THE BOOM.
PLACED ON CRIBBING.
Hoisting equipment used to maneuver the boom

must not be relaxed until the boom is properly
cribbed.
1. Remove the roof section above the drag

drum.
Page
Rev – 0
22/07/99
JLC
2. Check the boom hoist sheaves at the mast and boom slightly then set the drag brakes.
masthead and A-frame head to assure that they Allow the drag brakes to hold the mast and
work freely and are well lubricated. boom for about one hour to check that they work
properly. After the brakes have been checked,
3. Check the pre-load on the intermediate take-ups on the boom hoist rope, only enough to
structural strands and adjust as required. remove the tension on the lower structural
strands. These are the strands that run between
4. Remove the drag ropes from the drag the A-frame head and masthead.
drum and secure the ropes out of the way.
5. Check the drag motor brakes for lining

wear and proper adjustment. Repair or adjust as
required.
6. Position the reel of boom hoist rope at

the rear of the machine in line with the drag
trough clean out hole on the left side of the
machine (figure 71).
7. Position a reel of auxiliary wire rope 5/8-

inch x 1200 foot at the rear of the machine in
line with the right cleanout hole.
8. Pull the auxiliary rope through the

cleanout hole, under the right side of the drag
drum, up and over the A-frame right centre
sheave; then continue reeving the line as shown
in figure 71. Bring the rope from the left centre
A-frame sheave, down under the left side of the
drag drum, and out the left side cleanout hole.
9. Connect the auxiliary rope to the boom 13. Secure one of the structural strands at
hoist rope and with the auxiliary rope pull the the A-frame with a block and tackle. Remove the
boom hoist rope onto the machine and through pin securing the strand to the A-frame. With the
the reeving points. block and tackle, lower the strand to the vertical
position. Remove the remaining strands from the
10. Starting from the fourth from the last A-frame in the same manner.
rope groove on the right drag drum, wrap the
boom hoist rope on the drum (9 wraps) and 14. Carefully lower the boom and mast until
anchor it to the drum with the special boom hoist the boom is resting on the cribbing. After the
rope clamps. Do not use the drag rope clamps boom is secure on the cribbing lower the mast
to anchor the boom hoist rope to the drums. enough to remove the tension in the upper and
inter mediate structural strands (approximately
11. Pull the remaining end of the boom hoist 22º from the horizontal).
rope into the machinery house and starting with
the fourth groove from the end of the left drag 15. Use a crane to handle the structural
drum, wrap the rope onto the drum 9 ½ wraps). strands, as they are unpinned from the mast and
Anchor the rope to the drum with the special, boom.
boom hoist rope clamps.
16. Check all the pinholes for elongation or
12. Take up on the boom hoist rope by wear. Also check the links and Rugs for damage
activating the drag machinery. Watch closely or wear. Repair or replace all damaged or worn
that the boom hoist rope rides properly in the links or lugs.
sheaves at the reeving points. Make sure there
are no kinks in the boom hoist rope. Raise the
Page
Rev – 0
22/07/99
JLC
17. Use a crane and block and tackle to

install the new structural strands. When e. Install the hydraulic rams (11) on the rod
installing the strands be sure they are not bolts and secure the rams with washer
twisted. The painted line on the strand will help (10), full nut (9) and jam nut (8).
you assure that the strand is not twisted.
f. Connect the piping from the hydraulic

18. After all the strands have been pinned to pump (1 2) to the rams (11) as shown in
the mast and boom, take up on the boom hoist figure 72.
ropes to raise the mast so that the strands are
tight but the boom is still resting on the cribbing. g. Operate the hydraulic pump to actuate
Adjust the intermediate strands to their correct the hydraulic rams. Check the pressure
pre-load value as follows (figure 72): gauge reading for the correct value. Refer
to Appendix for correct value for strands for
a. Replace the top socket nuts from the your machine.
legs of the bridge socket with special nuts
(2). NOTE: IF RAM STROKE IS
INSUFFICIENT TO OBTAIN CORRECT
NOTE: ON SAME MACHINES THE VALUE, INSERT SPACERS (3), (4)
LOWER NUTS ARE ALSO REPLACED AND/OR (5) BETWEEN SUPPORT
WITH A SPECIAL SPHERICAL END PLATE AND SPACER (6).
NUT (19) AND CONICAL WASHER (20).
NOTE: THE PRESSURE GAUGE
b. Screw rod bolt (7) into each special nut READING INDICATES 1/2 THE
2). PRELOAD VALUE IN TONS. MULTIPLY
THE PRESSURE GAUGE READING BY
c. Insert the spacer (6), which has a 2 TO OBTAIN THE CORRECT TOTAL
recessed face against the bridge to clear PRELOAD IN EACH STRAND.
the zinc adhesive on the structural strand.
h. When the correct pre-load has been
d. Slide the support plate (1) over the rod obtained tighten the lower socket nut
bolts (7) and up against the spacer (6). against the bridge. Do not remove the take-
Page
Rev – 0
22/07/99
JLC
up material, as the strand pre-load will have rope in which one strand makes a complete
to be re checked after the boom is secured revolution around the rope.)
in its working position.
2. Abrasion, scrubbing or peening which
19. After the initial pre-loading of the causes the loss of more than 1/3 of the original
intermediate structural strands, raise the mast diameter of the outside wires.
and boom beyond the working angle so the
lower main structural strands can be attached to 3. Evidence of severe corrosion.
the A-frame.
4. Evidence of severe kinking, crushing, or
20. Using a crane, pick up the loose end of other damage, which results in distortion of the
each lower main structural strand, one at a time, rope structure.
and raise it into position on the A-frame. Pin
each strand to the links on the A-frame. Make 5. Evidence of heat damage from any
sure the strands are not twisted. A painted line cause.
on the strand is provided for this purpose.
6. Evidence of reduction in rope diameter,
21. When all the main lower structural which indicates deterioration of the core. This
strands have been pinned to the A-frame links, will result in lack of proper support for load
slowly lower the mast and boom until the mast carrying strands. Excessive rope stretch or
and boom are supported completely by the elongation may also be an indication of internal
structural strands. deterioration.
22. Recheck the pre-load on the 7. Evidence of “bird caging” or other

intermediate structural strands and readjust if distortion, which results in some members of the
necessary, as outlined in step 18. Remove the rope structure carrying more load than the
take-up material and replace the top socket nuts others.
and lock them in place.
8. Noticeable rusting or development of
23. Remove the boom hoist rope from the broken wires in the vicinity of attachments.
reeving points and drag drum and store the rope
for future use. NOTE: IF THIS CONDITION IS
LOCALIZED AND THE SECTION IN
24. Reattach the drag rope to the drum. Be QUESTION CAN BE ELIMINATED BY
sure to use the drag lope clamps and not the MAKING A NEW ATTACHMENT, DO
boom hoist rope clamps. THIS RATHER THAN REPLACING THE
ENTIRE ROPE.
HOIST AND DRAG ROPES
Lubricate the hoist and drag ropes at least twice
every eight-hour shift with running wire rope
The hoist and drag ropes should be visually
lubricant (RWRL) as listed in Appendix. Give
inspected daily. A thorough inspection of the
special attention to “bright spot” areas. These
ropes should be made weekly and dated records
spots generally appear where the rope travels
should be kept as to the condition of each rope.
around a drum or over a sheave.
Any deterioration, which results in appreciable
loss of original rope strength, should be closely
When the use of wire rope is temporarily
observed and a determination made as to
discontinued, lubricate the rope thoroughly and,
whether further use of the rope constitutes a
if possible, place it on a reel and store it in a dry
safety hazard. Conditions such as those listed
place. If the wire rope is left on the drum,
below should be sufficient reason for
thoroughly grease that part of the rope
questioning rope safety and or cause for rope
remaining on the drum.
replacement.
1. Six randomly distributed broken wires in

one rope lay, or three broken in one strand in
one rope lay. (A rope lay is the length along the
Page
Rev – 0
22/07/99
JLC
HOIST ROPE REPLACEMENT

CAUTION: THE CONDITION OF THE
(Refer Figure 73) ROPES MAY MAKE IT NECESSARY TO
MODIFY THE PROCEDURE OUTLINED

There are several methods of removing and HERE, ESPECIALLY IF THE ROPE IS
installing new hoist ropes. The procedure BROKEN OR SEVERELY DAMAGED.
outlined in this manual assumes that the old BE SURE TO ALWAYS FOLLOW
hoist ropes are not broken or severely frayed, SAFETY PRECAUTIONS WHEN
that the machine is equipped with deck rope BURNING OR CLIMBING. ALWAYS
winches, and that all of the tools and supplies KEEP THE ROPES UNDER COMPLETE
specified are on hand. This method was CONTROL.
developed to keep the hoist rope under
complete control at all times. All applicable 1. Move the machine to an area sufficient
safety regulations should be followed. Only to perform the repair and set the bucket on the
personnel directly connected with replacing the ground about halfway between the base and the
ropes should be allowed on or near the boom point. Allow enough slack in the hoist rope
machine. so that the hoist socket is lying on the ground.
CAUTION: METHODS, WHICH ALLOW 2. Disconnect the hoist ropes from the
THE ROPE TO BECOME hoist sockets and then secure the ropes to a
UNCONTROLLED AT ANY TIME ground vehicle.
DURING THE OPERATION, SHOULD
BE AVOIDED. THE HOIST ROPES ARE 3. Position a signalman in the machinery
VERY HEAVY AND DEATH, house in a position to observe the hoist drum
SERIOUSINJURY, OR SERIOUS and ropes. Activate the hoist drum slowly in the
DAMAGE TO THE DRAGLINE COULD lowering mode to spool the ropes from the drum.
RESULT SHOULD A ROPE BECOME At the same time, pull the hoist ropes from the
UNCONTROLLED. boom with the ground vehicle. Stop the hoist
Page
Rev – 0
22/07/99
JLC
machinery and ground vehicle, as the last CAUTION: WHEN REMOVING THE
winding or rope starts to spool from the drum. STAPLES, BE SURE TO STAND TO
Then very slowly rotate the drum until the left THE SIDE, AS THE ROPE WILL SNAP
hoist rope is completely off the drum and only DOWNWARD WHEN THE STAPLES
secured to the drum with the rope clamps. The ARE REMOVED.
right hoist rope will have one half wrap on the
drum. 11. With the deck winch, pull the right hoist
rope up over the boom point sheave and down
CAUTION: THROUGHOUT THIS to the right side of the hoist drum. Secure the
OPERATION, A SIGNALMAN IS rope to the drum with the rope clamps and
NECESSARY TO COMMUNICATE disconnect the deck winch line from the hoist
DRUM OR ROPE POSITIONS TO THE rope.
OPERATOR. MAKE SURE THAT A
SYSTEM OF SIGNALS IS WORKED 12. Rotate the hoist drum 180º to put the left
OUT IN ADVANCE AND THAT THE hoist rope drum sockets in position for installing
LINE OF COMMUNICATION IS the rope.
UNBROKEN.
13. With the deck winch, pull the left hoist
4. Run the left deck winch line under the rope up over the boom point sheave and down
drag drum and securely attach it to the left hoist to the left side of the hoist drum. Secure the
rope, then remove the left hoist rope drum rope to the drum with the rope clamps and
clamps. disconnect the deck winch line from the hoist
rope.
5. Slowly rotate the drum so that the right
hoist rope is completely off the drum and only 14. Take up on the hoist machinery to reel
secured to the drum with the rope clamps. Run the hoist rope onto the drum. Make sure the
the right deck winch line under drag drum and rope seats properly in the drum rope grooves.
securely attach it to the right hoist rope, then Stop the hoist machinery when the ropes are off
remove the right hoist rope drum clamps. the reels. Disconnect the ropes from the reels
and remove the reels from the area.
6. Using the deck winches to control the
hoist ropes, pull the hoist ropes from the boom 15. Connect the hoist ropes to the bucket
with the ground vehicle. hoist sockets.
7. Pull the hoist ropes and attached deck
winch line over the boom point sheaves and DRAG ROPE REPLACEMENT
down to the ground.
(Figure 74)
8. Separate, the deck winch lines from the
old hoist ropes and remove, the old hoist ropes Refer to cautions at the beginning of the topic
from the area. HOIST ROPE REPLACEMENT.
9. Check the condition of the drum rope 1. Move the machine to an area sufficient
grooves, rope clamps, deflection and boom point to perform the repair and set the bucket on the
sheaves. ground under the boom point. Allow enough
slack in the drag ropes so that the drag sockets
10. Position the reels of new hoist ropes in are on the ground.
front of the machine beyond the boom point.
Attach the deck winch lines to the new hoist 2. Disconnect the drag ropes from the drag
ropes. Remove the staples securing the new sockets and then secure the ropes to a ground
rope to the reel. vehicle.
Page
Rev – 0
22/07/99
JLC
3. Position a signalman in the machinery

house in a position to observe the drag drum 5. Rotate the drag drum one half turn in
and ropes. Activate the drag drum slowly in the the pay out direction. Run the right deck winch
pay out mode to spool the ropes from the drum. line under then over the right side of the drag
At the same time, pull the drag ropes from the drum and securely attach it to the right drag
machine with the ground vehicle. Stop the drag rope. Remove the rope clamps and with the
machinery and ground vehicle as the last winch line lower the drag rope to the deck.
winding of rope starts to spool from the drum.
Then very slowly rotate the drum until the left 6. With the ground vehicle, pull the drag
rope is completely off the drum and only secured ropes from the machine. The deck winch line will
to the drum with the rope clamps. The right drag control the drag ropes as they are removed and
rope will have one half wrap on the drum. will also be reeved in position to pull the new
ropes onto the machine. Disconnect the old drag
CAUTION: THROUGHOUT THIS ropes from the winch line and remove the old
OPERATION, A SIGNALMAN IS ropes from the area.
NECESSARY TO COMMUNICATE
DRUM OR ROPE POSITIONS TO THE 7. Check the condition of the drum rope
OPERATOR. MAKE SURE THAT A grooves, rope clamps, guide sheaves and
SYSTEM OF SIGNALS IS WORKED fairlead sheaves.
OUT IN ADVANCE AND THAT THE
LINE OF COMMUNICATION IS 8. Position the reels of new drag rope in
UNBROKEN. front of the machine. Attach the deck winch lines
to the new drag ropes. Remove the staples
4. Run the left deck winch line under then securing the new rope to the reels.
over the left side of the drag drum and securely
attach it to the left drag rope. Remove the rope
clamps and with the winch line, lower the drag
rope to the deck.
Page
Rev – 0
22/07/99
JLC
CAUTION: WHEN REMOVING THE STRAIGHT THROUGH TYPE FAIRLEAD

STAPLES, BE SURE TO STAND TO
THE SIDE AS THE ROPE WILL SNAP To repair the straight through type fairlead
DOWNWARD WHEN THE STAPLES (figure 75), proceed as follows:
ARE REMOVED.
1. Position the machine in a safe,
9. With the right deck winch pull the right adequate area to perform the repair. Remove
drag rope onto the machine and into the rope the drag ropes as described in the topic DRAG
clamp sockets on the drum. Secure the rope to ROPE REPLACEMENT and shut down the
the drum with the rope clamps and disconnect machine, lockout and tag the controls.
the winch line from the drag rope.
2. To remove the guide rollers, working on
10. Rotate the drag drum 180º to put the left one roller at a time, secure the roller with rigging
drum drag rope clamp sockets in position for to a crane. Remove the capscrew securing the
installing the rope. lower pin retainer to the frame and pin. Remove
the retainer and shim set. Screw an eyebolt into
11. With the deck winch pull the left drag one of the pin screw holes and pull the pin from
rope onto the machine and into the rope clamp the roller and frame.
sockets on the drum. Secure the rope to the
drum with the rope clamps and disconnect the 3. Remove the upper roller pin using the
winch line from the drag rope. same procedure as for removing the lower pin.
12. Take up on the drag machinery to reel 4. Lift the roller out of the frame. Remove
the drag rope onto the drums. Make sure the the covers, bearings and inner seals from both
ropes seat properly in the drum rope grooves. ends of the roller.
Stop the drag machinery when the ropes are off
the reels. Disconnect the ropes from the reels 5. Remove the other rollers from the frame
and remove the reels from the area. repeating steps 2, 3 and 4 for each roller.
13. Connect the drag ropes to the bucket 6. To remove the upper vertical sheave,
drag sockets. secure the sheave with rigging to a crane.
Remove the sheave pin retainer wedge, retainer
FAIRLEAD bolts and retainer.
There are two types of fairlead, which are used 7. Remove the sheave pin from the frame
on the model 1370W Walking Dragline—the and sheave sleeve. With the crane, lift the
straight through type and the over and under sheave from the frame. Remove the key from
type. the sleeve.
The mountings and frames should be checked 8. Remove the labyrinth seal capscrews
weekly for cracking or other signs of structural and remove the labyrinth seal, oil seal retainer
damage. The condition of the limiting ropes or and oil seal from the sheave.
chains should also be checked. Check all
sheaves for wear or damage. On the straight 9. Remove the sleeve retainer capscrews
through type fairlead, check the buffer cylinder and remove the retainer and shims from the
for proper operation. Also check the buffer sleeve. Slide the sleeve out of the bearings.
cylinder support. Remove the bearings from the sheave.
Check that all pins are secure and that all lube 10. Remove the swivel frame spreader bolts
points are receiving the proper amount of and spreader.
lubricant. On the over and under type fairlead,
the restriction brakes should be checked for, air 11. To remove the lower vertical sheave,
leaks and correct air pressure. use the same procedure as described for the
upper vertical sheave in steps 6 through 9.
Page
Rev – 0
22/07/99
JLC
13. Attach rigging to the sheave and attach

12. To remove the outer horizontal sheaves, the rigging to a crane. With the crane, lift the
remove the capscrews, which secure the dirt sheave from the pin.
shield to the pin and sleeve and remove the dirt
shield. 14. Unbolt and remove the labyrinth seals
from the sheave.
Page
Rev – 0
22/07/99
JLC
15. Remove the sleeve lock nut lock bar 28. Remove the upper pin dirt shield and
screw and remove the lock bar and lock nut. screw an eyebolt into the pin. Secure the eyebolt
Slide the sleeve from the bearings. Remove the to a come-along and remove the pin retainer.
bearings from the sheave. Pull the pin from the frame.
16. Screw an eyebolt into the top of the 29. With the crane, lift the swivel frame from
sheave pin and secure the eyebolt to a crane. the fairlead frame. Remove the bushings and
Remove the pin retainer capscrew and retainer. thrust washers from the swivel frame.
With the crane, lift the pin from the frame.
30. Inspect all parts for wear or damage and
17. To remove the center set of horizontal repair or replace all damaged or worn parts.
sheaves, remove the capscrews, which secure Clean all parts thoroughly, then reassemble in
the dirt shield to the pin and remove the dirt reverse of disassembly.
shield.
NOTE: BE SURE ALL OIL SEAL LIPS
18. Secure the sheaves to a crane with FACE IN THE CORRECT DIRECTION.
rigging and with the crane lift the sheaves from ALSO, BE SURE ALL SHIMS ARE
the pin. INSTALLED.
19. Remove the sleeve lock nut bar screws 31. After the fairlead is completely
from both ends of the sleeve. Remove the lock assembled, lubricate all lube points. Install the
bars and lock nuts. drag ropes per topic DRAG ROPE
REPLACEMENT. Remove the outer horizontal
20. Slide the sheaves off the sleeve. sheaves dirt shield. Screw two 3/4 inch eyebolts
Remove the labyrinth seals and bearings from into the sleeve 180o apart. Use the eyebolt to
the sheaves. rotate the sleeve on the pin until all clearance is
gone between rope and sheaves. Match holes in
21. Screw an eyebolt into the end of the pin pin and sleeve to line up with holes in dirt shield,
and secure the eyebolt to a crane with rigging. then install capscrews. Tighten and lockwire cap
Remove the pin retainer capscrews and retainer. screws.
With the crane, lift the pin out of the frame.
BUFFER CYLINDER
22. Remove the limiting ropes from each
side of the fairlead. To repair the buffer cylinder (figure 76), proceed
as follows:
23. Remove the swivel frame dire troughs.
1. Remove the buffer cylinder from the
24. Remove the buffer cylinder support and fairlead as described in step 25 of topic
oil piping. STRAIGHT THROUGH TYPE FAIRLEAD.
25. Support the buffer cylinder with rigging 2. Remove the bushing spacers from the
and a crane. Remove the cylinder anchor pins piston rod and end plate.
and lift the cylinder out of the frames.
3. Remove the piston rod and end plate
26. Secure one of the swivel frames to a bushing retainers and bushings.
crane. On the lower swivel frame pin, remove
the dirt shield and gasket. Remove the pin 4. Remove the cylinder head plate bolts
retainer bolt chocks and remove the retainer and slide the piston and head plate out of the
bolt. cylinder. Remove the cylinder support plate.
27. Put a jack under the pin and remove the 5. Remove the brass plugs in the piston,
cap screws securing the pin retainer to the then remove the piston to piston rod anchor pin.
frame. Lower the pin out of the frame and Remove the piston rod from the piston and head
separate the retainer and shims from the pin. plate.
Page
Rev – 0
22/07/99
JLC
6. Remove the wiper retainer, piston rod

wiper, oil seal, and the head plate, bushing 4. Remove the sheave pin retainer bolts
retainer and bushing from the head plate. and remove the retainers. Remove the pin and,
Remove the 0-ring from the head plate. with the crane, lift sheave from the frame.
7 Remove the cylinder end plate bolts and 5. Remove the spacers from the sheave.
separate the cylinder from the end plate. Remove the labyrinth seal capscrews.
Remove the 0-ring from the end plate.
6. Remove the labyrinth seals, oil seals
8. Inspect all parts for damage or wear and and spacers from the sheave. Remove the
repair or replace all damaged or worn parts. bearings from the sheave.
Replace all seals. Clean and lightly lubricate all
parts. Reassemble in reverse of disassembly. 7. Repeat steps 3 through 6 to remove the
sheave on the other swivel frame.
OVER AND UNDER TYPE FAIRLEAD
8. Remove the limiting chains between the
swivel frames and from the swivel frames to the
To repair the over and under type fairlead (figure
revolving frame.
77), proceed as follows:
9. Install cribbing under the swivel frame
1. Position the machine in a safe,
and add any other necessary support cables or
adequate area to perform the repair. Remove
blocking to secure the swivel frames in a safe
the drag rope as described in the topic DRAG
stable condition until they can be removed from
ROPE REPLACEMENT and shut down the
the fairlead.
machine, lockout and tag the controls.
10. Remove the socket head capscrews
2. Disconnect, plug and tag all air and lube
mounting the restriction brakes to the shear cap.
lines to the fairlead.
Remove the brakes. The brake hubs, hub shafts
and keys will remain in the swivel frames.
3. To remove the swivel frame sheave on
Remove these items from the swivel frames.
one side, remove the rope guide and secure a
crane to the sheave with rigging.
Page
Rev – 0
22/07/99
JLC
11. Verify that the swivel frames are still the bracket. Remove the other swivel frame in
properly supported, then secure a crane and the same manner.
rigging to the shear cap and remove the shear
cap mounting bolts. With the crane, lift the shear 13. To remove the fairlead bracket sheave
cap from the fairlead. Remove the bushings (rear) on one side, remove the pin retainer bolts
from the shear cap. and retainer.
12. Attach a crane and rigging to one of the 14. Attach a crane and rigging to the sheave
swivel frames and release the frame so that it and slide the sheave from the pin. Remove the
can be lifted out of the fairlead bracket. Remove spacer from the pin.
the thrust washer as the frame is removed from
Page
Rev – 0
22/07/99
JLC
15. Remove the labyrinth seal capscrews

and remove the labyrinth seals, oil seals and
spacers from the sheave. Remove the bearings
from the sheave.
16. Repeat steps 13, 14 and 15 to remove

the sheave on the other side of the bracket.
17. Install cribbing in front of the bracket of

sufficient height so that when the bracket is
lowered it will be approximately level. Also crib
under the tensile arm to support it when it is
unpinned from the bracket.
18. Attach a crane and rigging to the

fairlead bracket and remove the tensile arm to
bracket pin. Lower the bracket onto the cribbing.
19. Disconnect the crane from the bracket

and connect it to the tensile arm. Remove the
pin securing the arm to the revolving frame and
remove the arm.
20. Reconnect the crane to the fairlead

bracket and remove the bracket to revolving
frame pin. Note the amount of shims removed
so that the same amount of shims will be
installed at reassembly. Remove the bushings
from the bracket.
21. Inspect all parts and repair or replace all

worn or damaged parts.
22. Reassemble in reverse of disassembly

Frequently check the air line connections for air
a. Be sure seal lips face in correct leaks. Tighten loose connections. Periodically
direction. check the brake disc wear through the openings
in the outer drive ring. The wear can be
b. When installing swivel frame sheave measured by inserting a rule in the slotted
pin, be sure end with lube hole is facing openings in the top of the cylinder. Measure the
outside of swivel frame. distance when the brake is released and when it
is set. When the difference between the two
c. When installing the bracket to the measurements equals 7/16 inch, the discs must
revolving frame pin, be sure that the lube be replaced.
holes closest to the end of the pin are on
top. Brake Discs
d. When installing sheave pins, lube holes To replace the discs:

should be to the front side of the pin.
1. Disconnect the airline to the brake.
FAIRLEAD RESTRICTION BRAKE Remove the air cylinder and piston as a unit, by
removing the nuts from the cylinder studs, and
The brake is a self-contained unit used to restrict sliding the cylinder and piston from the brake
the movement of the fairlead swivel frame. drive ring (figure 78).
Page
Rev – 0
22/07/99
JLC
4. Insert bolts in the tapped puller holes of

2. Remove the outer plate, discs and the piston and lift the piston from the cylinder.
centre plate from the drive ring. The separating Do not attempt to use air pressure to remove the
springs and push studs will come out with the piston from the cylinder as the cylinder can be
centre plate. damaged.
3. Check the disc facings for wear. If the 5. Remove and discard the piston O-ring.
facing thickness is approximately half the
thickness of the new facing, reline or replace the 6. Inspect the piston ring for scratches,
discs. gouges, and other damage. Replace the piston
ring if necessary.
4. Inspect the brake plate faces for nicks,
scratches, gouges or other surface defects, 7. Inspect the inner surface of the cylinder
which will cause unusual or rapid disc facing for any surface defects, which can damage the
wear. Replace damaged plates. piston ring or O-ring. The surface of the cylinder
should be smooth and polished. If needed, the
5. Check the brake springs for weakness bore can be re-bored to 0.015-inch oversize. If
and defects. Replace weak or faulty springs. re-bored the cylinder must be polished to a 10 to
15 microunit surface finish. Replace the cylinder
6. Install the discs and centre plate in the if it is badly damaged or worn.
drive ring. Make sure the centre plate and spring
assemblies are installed with the small ends of 8. Lightly lubricate a new 0-ring and insert
the spring studs properly entering the bores in the O-ring in the groove of the piston. If
the outer plate. Also make sure the springs removed, lubricate, and install the piston ring.
locate in the counter bored holes provided for
them in the centre plate and the drive rings. 9. Coat the bore of the cylinder lightly with
oil and carefully lower the piston into the
7. Thoroughly clean the cylinder 0-ring cylinder. Make sure the piston is not cocked in
surface with an approved solvent to remove any the cylinder.
contaminant that could damage the piston ring,
O-ring or the cylinder bore. Install the cylinder 10. Install the piston and cylinder assembly
and piston as a unit. Secure the cylinder with the on the brake. Secure the cylinder with the stud
stud nuts, making sure all nuts are snug and nuts, making sure all nuts are snug and equally
equally torqued to distribute the total load evenly torqued to distribute the load evenly to each
to each stud. stud.
8. Connect the airline to the brake. 11. Reconnect the airline to the brake and
test the brake function.
Piston Rings
DRAGLINE BUCKET
If the piston O-ring is cut or damaged from lack
of lubrication or entry of dirt, the 0-ring must be Should components break, repair all materials
replaced as follows: used in fabricating the bucket by preheating,
torching, and welding. Refer to Appendix for
1. Disconnect the airline to the brake. repair welding information.
2. Remove the cylinder stud nuts securing Inspect tooth tips frequently for abrasion,
the cylinder to the brake drive ring and remove cracking, or shearing of any nature. To replace a
the cylinder and piston as a unit. tooth, remove the wedge connection between
the tooth tip and its horn (base). Cap the horn
3. Clean the inboard side of the cylinder with a new tooth tip and apply a new wedge for
bore to remove any loose dirt or contaminants. the assembly. Then trim the protruding upper
Lightly lubricate the cylinder bore. and lower portions of the wedge flush with the
top and bottom surfaces of the tooth tip.
Page
Rev – 0
22/07/99
JLC
Carefully inspect the tooth horns (bases) each CAUTION: DO NOT APPLY HARD
time tooth points are replaced. Templates can SURFACING TO STEEL SIDE AND
be ordered for checking sides and slopes of the BOTTOM PLATES. THIS WILL
tooth horn. Rebuild worn tooth horns to prevent PROMOTE THE DEVELOPMENT OF
tooth point breakage or subsequent tooth horn CRACKS. WHERE WEAR IS
fracture. Refer to Appendix for tooth horn EXCESSIVE, MILD STEEL PLATES
rebuilding data. CAN BE WELDED IN PLACE AND
HARD SURFACING APPLIED TO
Optional reinforcing shrouds (figure 79) may be THESE ADDITIONAL PLATES WITH
provided on the corners of the bucket and on the EXCELLENT RESULTS.
bottom of the bucket between adjacent shoe
horns. Clevis plates on the sides of the bucket are
formed with lugs to which shrouds, pivot hitches
and accompanying bucket rigging are secured.

If wear or breakage necessitates shroud These lugs have a variety of directional stresses
replacement, refer to Appendix for welding inflicted on them, so the lugs are liable to
information. considerable weak ness and breakage. Should
these defects occur then refer to Appendix for
repair welding information.
The side and bottom plates provide critical
reinforcement for the bucket. Consequently, they Carefully inspect for wear such critical pivot
should be checked regularly for fatigue and connections as the rear trunnions and the
component failure. When wear spots develop in spreader bar junctions. These points are
the side and bottom plates, building up the provided with grease fittings (figure 80) at
affected area can restore the metal contour. assembly. Lubricate them at periodic operating
Refer to Appendix for welding information. intervals to promote smooth dumping action of
the bucket. Inspect for deterioration such as
anchor points distributed on the bucket and the
arch anchors and rope sockets. At times, pivot
connections can be easily restored by the
substitution of a new pin about which the
adjoining component may turn. In other
Page
Rev – 0
22/07/99
JLC
situations, complete part replacement may be

required.
The sheave upon which the dump rope travels

swivels on a pick-up link which interconnects the
hoist ropes and chains. Carefully inspect and
lubricate this swivel mounting as well as the
central pivot pin and groove of the sheave.
Lubrication insures the proper balancing action
for bucket dumping. Severe jerking or frictional
rubbing may call for pin and link repair or total
sheave replacement.
Closely examine the hoist, dump and drag

chains associated with the bucket to determine if
link replacement is warranted. All links have
zones of high stress concentration where severe
wear and breakage often occur.
Page
Rev – 0
22/07/99
JLC
CHAPTER 2 – AIR SYSTEM AIR COMPRESSOR
The following checks are for the standard

SECTION 1— GENERAL compressor supplied with the Model 1370W
MAINTENANCE Dragline which is a Kellogg-American air
compressor. If the machine is equipped with
SAFETY another compressor refer to that Manufacturer’s
manual.
Whenever work is to be done on the 1. Daily checks for any unusual noises,
compressed air system there are three important failure to compress, overheating, and vibration
safety rules to follow: or belt slippage. Adjust the belt if required. If any
of the other symptoms are found refer to the air
1. Turn the air compressor switch on the compressor troubleshooting in Section 2.
operator’s console to the “off” position and
attach a warning sign to the switch. 2. Once a week examine the intake filter
element and clean or replace if necessary.
2. Open the auxiliary power circuit breaker
and attach a warning sign to the breaker. 3. Every shift check the oil level, if required
add oil. Add only enough oil to bring the level up
3. Drain the compressed air from the air to, but not above, the mark on the oil gauge.
tank and air lines. Every three months change the oil. Refer to the
oil specification in Section 2.
GENERAL
NOTE: CONTINUOUSLY OPERATING
The air system (figure 81) on the 1370W COMPRESSORS IN DAILY USE AND UNITS
Walking Dragline consists of two air SUBJECT TO HEAVY DUTY SHOULD HAVE
compressors, driven by electric motors, which THE OIL CHANGED MORE OFTEN.
supplies air to an air tank. The air is then routed
from the air tank to the brakes, boom 4. Keep the compressor clean for efficient
pressurization system, lubrication system, propel operation as well as appearance.
transfer switch, and miscellaneous optional
components. The system is protected and 5. Once a month check and tighten, all
monitored for failure by safety valves, check bolts, as required. Section 2 contains a
valves and pressure switches. The compressed tabulation of specific bolts and their required
air as it passes through the air lines is filtered, torque values.
lubricated and regulated. In addition
electromechanical valves are located in the 6. If the compressor has been briefly shut
system to control the air to the various off and air leaks from the centrifugal unloaded
components. filter opening the compressor to air tank line
check valve is leaking. Repair or replace the
MAINTENANCE OF AIR SYSTEM check valve as necessary.
NOTE: BE SURE THE ROTATION OF

The maintenance of the air system consists of THE COMPRESSOR IS CORRECT OR
periodic checks (each shift, daily, weekly, etc.) THE WEIGHT RETAINER ASSEMBLY
to assure the system is working correctly. It also IN THE CENTRIFUGAL UN-LOADER
requires minor adjustments and repairs as WILL QUICKLY WORK LOOSE.
problems are found. The actual repair
procedures will be found in Section 2 of this AIR LINES
chapter, titled COMPONENT MAINTENANCE,
in Chapter 1 for maintenance of the various
brakes and in the case of some items separate Daily check the air lines for loose or damaged
Vendor manuals. fittings, hose and piping. Also check for leaking
Page
Rev – 0
22/07/99
JLC
of air at the fittings. Tighten loose fittings and
replace damaged or worn lines.
Page
Rev – 0
22/07/99
JLC
freezer. Lowering the rod increases the rate of

evaporation, raising the rod will decrease it.
Completely removing the rod will stop the
evaporation.
AIR TANK
Check the air tank for damage. Check all the SOLENOID VALVES
connections to the air tank. Tighten if necessary.
Electromechanical solenoid valves control the
AIR LINE LUBRICATOR brakes and air horn of the air system of the
model 1370W Dragline.
Daily check that the lubricator is full of oil and
that it is operating correctly. Add oil if required. The solenoid valves should be checked daily for
correct operation and for air leaks.
AIR LINE FILTER
PRESSURE SWITCHES
Daily check the filter for accumulation of
moisture and drain any moisture by opening the There are eight pressure switches located in the
drain cock in the bottom of the bowl. A visible air system. These switches should be checked
coating of dirt or condensation on the filter cone regularly to see that they are operating correctly.
or an excessive pressure drop indicates the filter If they do not function properly readjust them or
cone needs cleaning. have them replaced by an electrician.
AIR LINE REGULATOR The pressure switch and their correct settings
are as follows;
Daily check the regulator for reduced pressure, 1. AIR COMPRESSOR START-STOP
unsteady pressure or deviations in excess of SWITCH.
normally observed setting. If any of these
conditions exist the filter could be dirty or the The switch should close and the compressor
shutoff valve could be partially closed. Check start when the air pressure in the air tank drops
the filter and valve. If this does not solve the to 145 psi or below. The switch should open and
problem, repair or replace the regulator. shut off the air compressor when the air tank
reaches 160 psi.
ANTI-FREEZER — ALCOHOL TYPE
(OPTIONAL) 2. PROPEL TRANSFER SWITCH
SHUTDOWN SAFETY SWITCH.
Before freezing weather sets in the wicks of the
anti-freezer should be checked and cleaned or This switch will open and shut down the transfer
replaced as required. During freezing weather switches if line pressure drops below 95 psi.
keep the level of the alcohol at a maximum. When air pressure reaches 110 psi the switch
Check level at dipstick and fill as required using will close and the propel transfer switch can be
dipstick hole. The container holds about one operated.
quart. Before filling the anti-freezer stop the
compressor. 3. BOOM PRESSURIZATION SWITCHES.
CAUTION: WHEN FILLING THE ANTI These four switches are set so that the normally
FREEZER WITH ALCOHOL NO OPEN closed contacts will open at 55 psi on falling
FLAME OR SMOKING IS ALLOWED IN pressure and the normally open contacts will
THE AREA. ALCOHOL IS HIGHLY close at 70 psi on rising pressure.
FLAMMABLE AND IF IGNITED COULD
CAUSE SERIOUS BURNS. 4. A-FRAME PRESSURIZATION
SWITCHES.
The rate of evaporation is changed, by raising or
lowering the control rod in the top of the anti
Page
Rev – 0
22/07/99
JLC
These two switches are set to close contacts

when pressure drops to 15 psi or less.
AIR DRYER
The boom and A-frame rear legs are

pressurized with dry air. The dry air is obtained
by passing the air through a desiccant before it
enters the boom or A-frame rear legs.
When pressurizing the boom and A-frame rear

legs the desiccant should be constantly
monitored and when the color in the inspection
window turns pink the desiccant cartridge should
be changed. Refer to Section 2 of this chapter
for cartridge change out procedure.
Page
Rev – 0
22/07/99
JLC
SECTION 2— COMPONENT
MAINTENANCE 3. Clean the exterior of the compressor
AIR COMPRESSOR (KELLOGG-

AMERICAN)
NOTE: IF YOUR MACHINE IS

EQUIPPED WITH AN AIR
COMPRESSOR OF A DIFFERENT
MANUFACTURER, REFER TO THE
MANUFACTURER’S MANUAL FOR
MAINTENANCE AND REPAIR
PROCEDURES.
DAILY MAINTENANCE
1. Inspect the compressor (figure 82) for

belt slippage, vibration, and unusual noise,
overheating or failure to compress. with a rag or compressed air.
2. Drain condensate from the air storage MONTHLY MAINTENANCE

tanks.
1. Check all bolts. If necessary, tighten
WEEKLY MAINTENANCE them to comply with the following recommended
values.
1. Examine the air filter element (figure Foot Pounds
83). If it is dirty, remove it and wash it in
kerosene or in hot water containing any Head bolts 40
commercial grease solvent. Low pressure valve hold-down 15
Base bolts 43
CAUTION: DO NOT USE GASOLINE. High pressure valve hold-down 8
End cover bolts 20
Dry the air filter and dip it in new clean oil. Allow Pulley bolts 43
the excess oil to drain off. Then reinstall the air
filter element in the air system.
2. Check all of the air connections and
2. Check the oil level at the visual oil joints for leaks. Tighten as necessary.
gauge in the compressor base. Add oil if
necessary to bring the oil level to the full mark 3. Drain the oil from the base and refill with
on the visual oil gauge. new oil.
HEAD VALVE SERVICE
1. To reseat or replace head valves (figure

84) take off the head and head plate by
removing the hold-down bolts.
WARNING: DO NOT TEAR THE HEAD

GASKET.
NOTE: FOR OPERATION IN DAMP OR
HUMID LOCATIONS, ADDITION OF A Then proceed to lift out hold-down rings and
RUST INHIBITOR IS RECOMMENDED. valves.
Page
Rev – 0
22/07/99
JLC
3. Reinstall the elements of each head
2. Clean all parts thoroughly including the valve in the sequence shown in figure 84.
head and the top of the pistons. Valves and
seats must be smooth and flat. If possible, NOTE: DO NOT CATCH THE VALVES
resurface the valves and seats by rubbing on BETWEEN THE EDGES OF THE
fine (No. 400) emery cloth held on a smooth flat SEATS AND RETAINERS. VALVES
surface. Badly worn parts, including springs, MUST MOVE FREELY IN THE
which lose tension after considerable use, RETAINER WHEN ASSEMBLED.
should be replaced.
Page
Rev – 0
22/07/99
JLC
The nut holding the valve assembly must be PISTON RING SERVICE
locked with the cotter pin.
1. To replace worn or stuck piston rings,
remove the head bolts and disassemble the
head, head plate and cylinder. Take out the oil
rings (figure 86) and clean the grooves in the
piston.
2. Check the end gap of the new rings in

the cylinder, and, if necessary, file ends to give a
clearance of 0.010 inch to 0.015 inch for high
pressure and 0.010 inch to 0.025 inch for low
pressure.
3. Place the oil rings with expander in the

bottom groove, followed by the stepped scraper
ring and the two bevelled compression rings.
4. Slide the cylinder down over the pistons

(starting with the large side). Be sure the base
gasket is intact.
OVERHAUL PROCEDURE
NOTE: BEFORE DISMANTLING A

PUMP FOR OVER HAUL, IT IS
ADVISABLE TO OBTAIN A SET OF
VALVES AND SPRINGS, PISTON
RINGS AND GASKETS AS WELL AS
OTHER REQUIRED PARTS.
1. Loosen the motor, slide it toward the

pump and remove the belts. Drain oil from the
crankcase and, if desired, remove the complete
pump from the platform.
2. Loosen the pulley bolts and remove the

pulley. Use a wheel puller or a wedge in the split
hub, if necessary.
3. Disassemble heads, head plate and

cylinder by removing the head bolts. Mark the
4. Install the head and head plate on the top of each piston on the side nearest the pulley
cylinder using a thin film of oil on the head and so they can be reinstalled in the same position.
cylinder gaskets. The condition of the cylinder, pistons, rings and
bearing fits can then be checked.
NOTE: DO NOT USE SHELLAC.
4. Remove the side plates.
Blow loose dirt out of the inter-coolers with
compressed air before replacing them. 5. To remove the pistons, drive the
lockpins into the wrist pins with a drift or pin
punch and punch out wrist pins.
Page
Rev – 0
22/07/99
JLC
6. To remove the connecting rods, remove 2. Wrist pin — piston should be “tap” fitted
the rod bolts. Keep the rods and caps in by hammer (figure 86). Be sure the lockpin holes
matched sets. Note the position of the are in line.
identification marks on one side of each so the
connecting rod can be replaced in the same 3. Wrist pin — needle bearing (figure 86):
position it originally occupied. the wrist pin should fit the needle bearing in
connecting rod so the pin can be pushed
7. To remove the crankshaft, take out the through the bearing with moderate pressure.
key, remove the end cover and slide the (Hold rod in both hands with thumbs pressing on
crankshaft out of the base. Be careful not to the end of the pins). The pin should not fall
damage the “V” oil feeder ring. through the bearing of its own weight. If
adjusting screws are provided, tighten or loosen
8. If the oil seal is to be replaced, drive it to provide the proper fit. When the piston is
out of the base with evenly spaced blows assembled to the connecting rod, drive the
applied to the seal inside the base. lockpin into the wrist pin until it is flush with the
boss. If a needle bearing needs replacement,
REASSEMBLY make sure the small hole through the casing of
the new bearing lines up with the oil hole in the
NOTE: CLEAN ALL PARTS rod. The wrist pin should also be replaced.
THOROUGHLY BEFORE
ASSEMBLING. 4. Crankshaft — base (figure 85): Be sure
the pulley, bearing end of the crankshaft is
1. Piston-cylinder: Check fit before smooth and clean. Slide the assembly into the
assembling the pistons to the connecting rods. base and tighten the end cover bolts evenly.
Pistons without rings should slide through the End cover gaskets or shims are furnished in
cylinder of their own weight. When holding the three thick nesses. The proper combination
skirt of the piston with the two thumbs, there must be selected so the crankshaft can be spun
should be no appreciable side motion at any in the bearings without endplay. If the oil seal
point of piston travel. Scored cylinders or pistons needs replacing, slide the replacement seal on
should be replaced. the pulley end of crankshaft and press into place
in the base with the lip or seal side toward the
Page
Rev – 0
22/07/99
JLC
pulley. Do not hammer the seal directly. Make Position rings on the high-pressure piston so the
sure the “V” ring is free and located between the gaps are staggered around the piston. Insert the
base floor guides. piston and rod assembly into the cylinder bore
taking care to compress the rings so that the
ends cannot catch and score the cylinder or
break the ring. Assemble the cylinder to the
base gasket. Assemble the cylinder and high-
pressure piston and the rod assembly to the
base and crankshaft assembly. Tighten the base
bolts with lock washers in place. Insert the low-
pressure rod assembly through the cylinder bore
following previous precautions to compress the
rings. Coat the bearing journals of the crankshaft
with heavy oil. With the crankshaft installed in
the base, install the connecting rod and piston
assemblies to the crankshaft. During installation,
the connecting rod bolts, with lock washers in
place, should be tightened until they just start to
compress the lock washers. Then lightly tap the
cap to help align the bearing. The bolts should
be drawn up tight (torque 90 foot pounds). Never
file the rod or cap and never use shims to adjust
the bearing clearance.
NOTE: “RUNNING IN” FOR A FEW

HOURS WITHOUT THE HEAD IS
RECOMMENDED IF A PUMP HAS
BEEN COMPLETELY OVERHAULED —
ESPECIALLY IF NEW PISTONS
AND/OR CYLINDERS HAVE BEEN
INSTALLED.
6. Oil: fill the base with oil to level on the oil

gauge before operating or “running in.”
7. Install the key and pulley after the head,

inter cooler and after cooler are connected.
CENTRIFUGAL UNLOADER SERVICE
5. Connecting rod — cylinder — The centrifugal unloader provides the

crankshaft: the lower connecting rod bearing compressor with “loadless” starting. When the
consists of two identical inserts, which are current to the motor is interrupted or the pump
interchangeable in rod and cap. When installing stops, the centrifugal unloader removes the air
the bearings, make sure that the bore and in the aftercooler and head. When the unit
bearing insert are free of any foreign material. resumes operation, the unloader valve closes to
Install the inserts in the rod and cap, fitting the allow a build up of tank pressure.
locating projections into the grooves provided.
The ends of the inserts extend slightly above the NOTE: WHEN USING THE THREE-
parting line of the rod and cap. PHASE MOTORS BE SURE OF
PROPER ROTATION OR THE WEIGHT
WARNING: DO NOT FILE THESE RETAINER ASSEMBLY WILL QUICKLY
ENDS OF THE INSERTS. WORK LOOSE. TEST MOTOR
ROTATION WITHOUT THE BELTS
ASSEMBLED.
Page
Rev – 0
22/07/99
JLC
If the compressor has been briefly shut off and WARNING: THE PLASTIC PARTS OF
air leaks from the unloader filter opening, a THE LUBRICATOR WILL BE DAMAGED
check valve is leaking. Inspect the spring, ball BY ACETONE, METHYL ALCOHOL,
and seating surface of the retainer. Repair or BENZENE, DIOXONE, ETHYL
replace parts as necessary (figure 87). ACETATE, LACQUER THINNERS,
TOLUENE, CARBON TETRACHLORIDE

AIR LINE LUBRICATORS AND OTHER AROMATIC
HYDROCARBONS, CHLORINATED
HYDROCARBONS OR STRONG
MICRO-FOG LUBRICATOR
ALKALINE SUBSTANCES.
Shut off the air pressure and remove the sight OIL FOG LUBRICATOR (TYPE 10-002, 3 OZ.
feed dome gasket and the lock washer. See AND 1/3 PINT SIZE)
figure 88. Use a 3/32-inch Allen wrench to
remove the oil feed adjustment screw (left-hand
To disassemble, shut off the air pressure, relieve
thread).
line pressure and remove clamp ring (18). See
figure 89. After removing bowl (16) unscrew
Remove the reservoir and unscrew the constant
siphon tube assembly (13) and check valve
oil feed assembly. Remove the venturi plug and
assembly (14).
unscrew the siphon tube.
Remove needle valve assembly (1), and
NOTE: DO NOT LOSE THE BALL,
unscrew drip gland (5) with an Allen wrench.
WHICH RESTS ABOVE THE SIPHON
Then remove venturi tube (9) from below.
TUBE. CLEAN THE REMAINDER OF
THE DISASSEMBLED PARTS, USING
Carefully clean and inspect all parts.
SOAP AND WATER OR A PETROLEUM
SOLVENT SUCH AS KEROSENE.
REPLACE DAMAGED PARTS AND
REASSEMBLE THE LUBRICATOR.
Page
Rev – 0
22/07/99
JLC
AUTOMATIC DRAIN FILTER
MAINTENANCE
Shut off the air pressure before disassembly.
On the one-quarter, three-eighths and one-half

inch models remove the clamp ring. See figure
91.
Remove the bowl and unscrew the baffle, thus

releasing the filter element.
OIL FOG LUBRICATOR (TYPE 10-002, 1/2-

PINT SIZE)
To disassemble, shut off the air pressure, relieve

line pressure and remove screws (12, figure 90).
Remove clamp ring (19). Remove the bowl (17)
and unscrew siphon tube assembly (14) and
check valve assembly (15).
Remove needle valve assembly (1) and unscrew

drip gland (5) with an Allen wrench. Push out
venturi tube (9) from below.
Before assembling, check each part carefully

and replace any damaged parts, ordering from
the repair kit or replacement parts as listed.
To disassemble the three-quarters and one-inch

models, remove the clamp ring and separate the
Page
Rev – 0
22/07/99
JLC
body from the intermediate body. Remove the When the bowls of automatic drain models 12-
filter element by inserting a 1/4-inch x 1-1/4 inch 052 and 12-062 are removed and turned upside
x 4inch long metal bar into the slots in the down the strainer and float drop out. Loosen the
underside of the baffle and unscrew it with a knurled ring to remove the automatic drain
wrench. To remove the bowl from the assembly. When reassembling, make certain the
intermediate body, take out the snap ring and gasket is installed on the bottom of the
the baffle. automatic drain assembly before placing the
assembly in the bowl. If the strainer has a
flanged end, the flanged end should face down.
The float and the automatic drain assembly are
not considered repairable items.
Inspect each part carefully for wear or damage

and cleanse all parts with clean, warm water or
kerosene.
NOTE: DO NOT ATTEMPT TO CLEAN

THE AUTOMATIC DRAIN OR FLOAT
ASSEMBLY.
Replace any worn or damaged parts.
ANTI-FREEZER
Clean the wicks (figure 92) with a nonflammable

After cleaning the filter element in a cleaning solvent before freezing weather sets in. During
solvent, blow it out with compressed air. Keep freezing weather keep the level of the alcohol at
the filter element clean. a maximum. The chamber holds about one
quart. Before filling the Anti—Freezer, vent the
Page
Rev – 0
22/07/99
JLC
line for the pressure line type. Stop the CAUTION: BEFORE TURNING ON
compressor for the atmospheric type. THE AIR SUPPLY, TURN THE
ADJUSTING SCREW, COUNTER
CLOCKWISE UNTIL COMPRESSION IS
RELEASED FROM THE PRESSURE
SPRING.
The regulator then acts as a shut-off valve. Turn

on air pressure and adjust to the desired
downstream pressure by turning the adjusting
screw clockwise. This allows pressure to slowly
build up which pre vents any unexpected
operation of devices in the line. Be sure all
controls are in off or neutral position before
opening air regulator.
The wick carries the alcohol by capillary action

into the air passage where it evaporates into the
air stream. The alcohol vapor is then distributed
to all parts of the system.
The rate of evaporation is changed in the

atmospheric type by raising or lowering the
control rod in the top of the Anti-Freezer.
Lowering the control rod increases the rate of
evaporation. With the control rod completely
removed, the evaporation stops.
To increase regulator pressure, turn the
adjusting screw clockwise. Adjustment can be
AIR REGULATOR made with or without air flowing. Make the
adjustment to the required pressure under
Adjusting to the desired downstream pressure typical operating conditions. When the desired
can be done only with live pressure applied to setting has been reached, securely tighten the
the regulator (figure 93). locknut.
The regulator is self-venting unless specifically

ordered otherwise; therefore, it is not necessary
to “blow down” the secondary lines by
exhausting them. To lower a setting, always
reset from a pressure lower than the fine setting
Page
Rev – 0
22/07/99
JLC
desired. For example, lowering the secondary

pressure from 80 psi to 60 psi is best
accomplished by dropping the secondary
pressure to 55 psi, or less, then adjusting
upward to 60 psi.
To facilitate servicing, the cartridge assembly

can be removed and a spare assembly installed.
CAUTION: DO NOT ATTEMPT TO

DISASSEMBLE THE UNIT WHILE THE
LINE IS UNDER PRESSURE.
At the same time, carefully inspect the other

internal parts (diaphragm, gaskets, etc.) for
possible replacement.
The cartridge assembly removed can be

cleaned and repaired for later use as a spare.
If leaking should occur at points between the

body and the bonnet, tighten the screws. If
leaking persists, check the gaskets and
diaphragm.
AIR DRYER
The air dryer is used to dry the air used to

pressurize the boom and A-frame rear legs.
Using 100ºF-inlet air at 100 psig, the dryer
cartridge will process approximately 800 SCF of
air at 100% relative humidity before becoming
saturated. It takes about 10 cartridges to
pressurize the boom and A-frame rear legs.
To replace a saturated cartridge proceed as

follows (figure 94):
1. Shut off the globe valve in the dryer inlet

line and open the manual depressing valve.
2. Loosen the quick-connect clamp

securing the housing to the head and remove
the housing.
3. Pull the old cartridge off the boss and

replace it with a fresh cartridge.
4. Reposition the housing over the

cartridge and on the head. Secure the housing
to the head with the quick-connect clamp.
5. Close the manual depressing valve and

open the inlet line globe valve.
Page
Rev – 0
22/07/99
JLC
CHAPTER 3— LUBRICATION
The most common cause of overheating of an
anti friction bearing is churning of the grease.
SECTION 1— GENERAL This happens when the bearing is packed too
MAINTENANCE full. If grease leaks out of an anti-friction bearing
it is almost a sure sign that too much grease
was added to the bearing. Continue to grease it
GENERAL as often as before, but use less grease.
Lubrication is often considered the most Even the best lubricant is useless in preventing
important part of preventive maintenance. Do wear if it has become dirty by careless handling
not allow anything to interfere with the and storage. The manufacturer usually packs
lubrication of the dragline. It may require some the lubricant in tight containers to keep it clean.
study and on-site experience to determine the It is the job of the operator (and the oiler, if there
correct amount of lubricant to use at each is one assigned to the machine) to be sure that
servicing. However, you will be rewarded for the no dirt gets into the lubricant. Follow these
effort by having a smooth running machine with points of good practice:
less component wear.
1. Keep all oil and grease in tightly covered
There is no way to say definitely how much containers.
grease to add to any particular bearing. It
depends on how hard the machine is being 2. Wipe off covers before opening
worked, how much the bearing is worn, and the containers.
grade of grease being used. Watch all the
bearings closely until you are sure the grease 3. Keep funnels, oilcans, grease guns,
added at one servicing, is enough to last until etc., in a clean place and wipe them off before
the next servicing. using them.
Most wearing parts need lubricants applied 4. Wipe off, each grease fitting before
regularly in small quantities, instead of large attaching the grease gun.
amounts applied only occasionally. Make regular
inspections of the machine and watch for signs 5. Wipe off, oil filler caps and the
of incorrect lubrication, such as an accumulation surrounding area before removing them.
of excess grease. Make sure the grease has not
come from a broken or disconnected line or
grease pipe. Usually, it is futile to pump grease
into a plain bearing once the grease starts to
come out. However, certain bearings, which may
collect dirt should have extra grease added to
force out all the old grease. The old grease may
have collected abrasive dirt.
New bushings sometimes overheat because

they are too tight to allow normal distribution of
grease. Old bushings may overheat because
they are so worn grease will not stay in until the
next time of servicing. In the case of the new LUBRICATION BENCHMARKS
bearing, it may be necessary to give it more
frequent greasing until it is worked in. It may be Lubrication benchmarks are the performance
necessary to do the same for the old bearing, requirements for the various lubricants identified
until it can be replaced. It is much better to lose in the lubrication charts of this section. These
a little time on a shift to give extra grease to a performance requirements are not
point, which needs it, instead of trying to run it to specifications, but rather boundaries within
the end of the shift. which the lubricant properties must fall. Meeting
Page
Rev – 0
22/07/99
JLC
these limits, as described for each lubricant original specifications, the oil in the gearcases
does not relieve the supplier of the responsibility should be drained and the gearcases refilled.
associated with brand name products. (See
Appendix for lubrication benchmarks.) When manually lubricating lube points, the
handgun will deliver .06 to .08 cubic inches of
NOTE: THROUGHOUT THIS lubricant per pumping stroke.
MANUAL, LUBRICATION
INSTRUCTIONS SET FORTH FOR All components not manufactured by
VENDOR-SUPPLIED ITEMS ALWAYS BUCYRUS-ERIE COMPANY such as air
TAKE PRIORITY OVER BUCYRUS- compressors, electric motors, winches, hoists,
ERIE COMPANY LUBRICANT etc. are to be lubricated per manufacturer’s
RECOMMENDATIONS. recommendations.
Samples of oil should be taken from each All structural strands should be lubricated
gearcase once every month and analyzed for periodically with stationary wire rope lubricant,
contaminates, water, oxidative material and (SWRL) at the base of each socket for a
viscosity. If there is a significant change from the minimum distance of three feet.
Page
Rev – 0
22/07/99
JLC
LUBRICATION CHARTS
The lubrication charts included in this section

indicate the major service locations which
require periodic lubrication (figures 95 through
99). Heavy lines run from the chart to the
specific lubrication points on the machinery
groups illustrated. The letters in the chart
columns relate to the type of lubricant or
centralized lubrication system used at each
point. The various lubricants such as MPG,
MPO, OGL, RGL, RWRL, MWCL and RCRL are
fully explained under LUBRICATION
BENCHMARKS, which can be located in
Appendix. The service area and frequency of
optional centralized lubrication systems A, B, D,
E, F, G, H, I, J, K and L are described in Section
2 of this chapter.
The lubrication charts are easily used to supply

the location and number of service points, the
lubrication cycle and the type of lubricant or
system employed. For example, figure 95 shows
the two local service points for greasing the hoist
drum shaft bearings. Reading vertically and to
the right across the column, one sees that MPG
(multi purpose grease) can be utilized once
every six eight-hour shifts if lubrication is applied
manually. The chart further shows that
centralized automatic lubrication system D,
designed for anti friction bearings, may operate
automatically once every 30 minutes at the two
service points.
The frequency of lubrication on figures 95

through 99 is intended only as a guide. Under
unusual operating conditions, some points may
necessitate more frequent lubrication or other
special attention. Use good judgment in
lubricating the dragline. If a bearing shows signs
of trouble, such as overheating or peculiar noise,
give it immediate attention. Make sure the
grease was not dirty or of the wrong grade.
When the dragline is operated, for more than
one shift daily, all the crews must pool their
lubricating efforts. This practice insures that no
lubrication points are missed and none over
lubricated. Generally, it is a good maintenance
policy, to perform as much of the lubrication as
possible at the beginning of each shift.
Page
Rev – 0
22/07/99
JLC
Swing Machinery Lube Points – Figure 96
Page
Rev – 0
22/07/99
JLC
Propel Machinery Lube Points – Figure 97
Page
Rev – 0
22/07/99
JLC
Fairlead Lube Points – Figure 98
Page
Rev – 0
22/07/99
JLC
Front End Equipment Lube Points– Figure 99
Page
Rev – 0
22/07/99
JLC
SECTION 2— AUTOMATIC LUBE

SYSTEMS This system has one control panel, and pump
station and will pre-lube the bushings prior to
propel ling and once every step thereafter. The
Though the automatic lubrication system on the injectors should be adjusted to maximum
1370W dragline is considered optional delivery. This system will also lubricate only the
equipment almost all machines are equipped center pintle bushing during the dig cycle with
with an automatic system. The automatic lube the frequency of lubrication controlled by an
system covered in this manual is that electric timer.
manufactured by Lincoln St. Louis.
The following text describes each automatic sys

SYSTEM-B
tem including application, service points,
operation and control. This system will lubricate the following bearings
and bushings of the fairlead.
For repair of the components of the lube
systems refer to the manufacturer’s (Lincoln St. Straight through type fairlead:
Louis) manual.
1. Vertical roller bearings
Table 1 lists the type of injectors used, the
amount of lubricant they can disperse, and the 2. Vertical sheave bearings
system operating and venting pressures.
3. Horizontal sheave bearings
4. Swivel frame upper pin bushings
5. Swivel frame lower pin bushings
6. Swivel frame lower pin thrust washer
7. Buffer cylinder hanger pin
8. Buffer cylinder anchor pin bushings.
Over and under type fairlead:

SYSTEM A
1. Front sheave bearings.
This system will lubricate the following bushings
of the propel machinery, walking equipment and 2. Rear sheave bearings.
center pintle.
3. Shear cap bushings.
1. Propel 2nd intermediate shaft inner and
outer bushings. 4. Fairlead bracket, lower swivel bushings.
2. Propel 3rd intermediate shaft inner and 5. Fairlead bracket, lower swivel thrust
outer bushings. washers.
3. Propel cam shaft, inner and outer 6. Tensile arm rear pin bushing.
bushings.
7. Tensile arm front pin bushing.
4. Propel cam roller pin bushings.
This system has one control panel and pump
5. Walking shoe trunnions. station and will be activated once every 30
minutes. For bushings and thrust washers the
6. Center pintle bushings. injectors should be set to maximum delivery. For
bearings the injectors should be set to 1/2
Page
Rev – 0
22/07/99
JLC
maximum delivery. An electric timer controls the hours during propelling. The injectors should be
frequency of the system. set for maximum delivery.
The SYSTEM-B also serves as a control and SYSTEM-E

pumping station for systems C, E, F and G.
This system will lubricate the following sheave
and link bushings in the masthead.
SYSTEM-C 1. Boom hoist sheave bushings.
This system lubricates the house roller 2. Structural strand link bushings.
bushings. It is a satellite of SYSTEM-B and is
semi-automatic. The system should be activated 3. Mast head cross tie.
semi-annually and the injectors set at maximum
delivery. 4. Intermediate structural strand anchor lug
bushings.
SYSTEM-D
This system is connected to the control panel
and the timer of SYSTEM-B regulates pumping
This system will lubricate the following bearings
station of SYSTEM-B and the frequency of
of the hoist, drag, swing and propel machinery.
lubrication. The injectors should be set for
maximum delivery for the bushings.
1. Hoist intermediate shaft bearings.
2. Hoist drum shaft bearings. SYSTEM-F
3. Drag intermediate shaft bearings. This system will lubricate the following bushings,
bearings and thrust washers at the boom point.
4. Drag drum shaft bearings.
1. Boom point sheave bearings.
5. Swing motor pinion shaft, upper
bearings. 2. Swivel trunnion bushings.
6. Swing intermediate shaft upper 3. Swivel trunnion thrust washers.

bearings.
7. Swing vertical shaft lower bearings. and the timer of SYSTEM-B regulates pumping
station of SYSTEM-B and the frequency of
8. Propel motor input shaft seals. lubrication. The injectors should be set for
maximum delivery for bushings and thrust
9. Propel 1st intermediate shaft bearings. washers and 1/2 maximum delivery for bearings.
This system has one control panel and pump SYSTEM-G

station. The control panel has two electric timers
to control frequency, one for the hoist, drag and
This system will lubricate the following bushings
swing machinery and one for the propel
in the A-frame head.
machinery. For the hoist, drag and swing
machinery the system will be activated once
1. Boom hoist sheave bushings.
every 4 hours. The injectors should be set for
maximum delivery.
2. Structural strand link bushings.
For the propel machinery when activated, the
3. A-frame rear leg pin.
system will pre-lube the bearings before the start
of the walking cycle and then once every four
and the timer of SYSTEM-B regulates pumping
Page
Rev – 0
22/07/99
JLC
station of SYSTEM-B and the frequency of Adjusting the air pressure to the pump can
lubrication. The injectors for the bushings should regulate the volume of lubricant delivered by the
be set for maximum delivery. pump. Every four hours manually operate the
OFF-ON switch of the system during three
SYSTEM-H lowering cycles of the hoist ropes.
This system is a gear spray system for the SYSTEM-J

following gear reductions of the hoist, drag,
swing and propel machinery. This system will spray lubricant on the drag
ropes at the fairlead. The system has one
1. Hoist drum, gear and pinions (2nd control panel and one pumping station.
reduction).
Adjusting the air pressure to the pump can
2. Drag drum, gear and pinions (2nd regulate the volume of lubricant delivered by the
reduction). pump. Every four hours manually operate the
OFF-ON switch of the system during three
3. Swing pinions and rack (3rd reduction). payout cycles of the drag rope.
4. Cam gears and pinions (4th reduction). SYSTEM-K

5. Propel (3rd reduction).
This system will apply lubricant to the surface of
the house rollers and rails at a minimum of four
6. Propel (2nd reduction).
different locations.
This system will have one control panel and
The points of application will be located at each
pumping station. An electric timer will activate
of the four ends of the upper rail circle. There
the system so it will spray the gear at
will be three nozzles at each point. One will
predetermined intervals of time and only when
apply lubricant at the contact point between the
the machinery is in motion.
inner flange of the roller and the rail. The other
two will apply lubricant to the main surface of the
When the machine is in propel this system will
rail.
give an initial lubrication cycle on the propel
gearing and will re-lubricate at 30 minute
The system will have one control panel and one
intervals. During propel cycle hoist, drag and
pumping station.
swing open gearing are not lubricated.
The frequency of application will be as follows:
When the machine is digging the system will
lubricate the hoist, drag and swing open gears at
1. Once every 30 minutes with the
30-minute intervals. During the dig cycle the
injectors adjusted to maximum delivery.
propel open gearing, is not lubricated.
2. Once every four hours the machine
The injectors should be adjusted to give the
should make one complete rotation while the
desired quantity of lubricant to be applied and
system is being repeatedly cycled by means of
the air regulator adjusted to the lowest possible
the manual over-ride switch.
air pressure that will produce the desired
atomization of the lubricant.
3. Actual field operational conditions may
dictate lubrication frequencies and injector
SYSTEM-I adjustments different than those above. If so,
change the lubrication frequency and/or injector
This system will spray lubricant on the hoist adjustment accordingly.
ropes at the boom point. The system has one
control panel and one pumping station.
Page
Rev – 0
22/07/99
JLC
SYSTEM-L regulate each rotation of the cam. The pump

delivers 6.5 cubic inches of lubricant per cycle.
This will supply lubricant to the walking
equipment at points between the cam and cam CONTROL PANELS
frame, and between the cam roller and guides.
The system will only operate when the machine Typical control panels for systems A, B, D, H
is in propel. There will be two control panels and and K will have operating indicator lights, an air
two pumping stations, one for each cam. filter, lubricator, regulator, gauge, 7-day
pressure recorder, required valves and electrical
The lubrication cycle starts as soon as the cam components for operating the system (figure
begins to rotate, and re-lubricates every step 100). The panel also will have an override
there after. switch for manual operation of the system.
Adjusting the air pressure to the pump can Typical control panels for the systems J and I
regulate the amount of lubricant delivered by the will have an OFF-ON switch, air filter, lubricator,
pumps. The number of lubrication cycles (one and regulator, gauge and solenoid air valve. The
up and down motion of the pump piston per frequency of lubrication will be controlled
cycle) for adjusting the impulse counter can manually by the OFF-ON switch.
Page
Rev – 0
22/07/99
JLC
Typical control panel for system L will have 1. Insufficient air or lubrication pressure.
operating indicator lights, an air filter, lubricator,
regulator, gauge, required valves and electrical 2. Empty drum.
components for operating the system. An
override switch is provided for manual operation 3. Monitor broken supply lines and shut-off
of the system. systems if such should occur.
Systems C, E, F and G do not have their own 4. A vent monitor, in systems A and L will
control panels but are controlled by system B give warning if the system does not vent
panel. properly.
The alarm system will be both visible and

PUMPS audible at the control panel and in the operator’s
cab.
Systems A, B, C, D, E, F, G, H and K have 50:1
ratio air operated pumps which mount to 400 COLD WEATHER EQUIPMENT
pound drums. (OPTIONAL)
Systems J and I have 24:1 ratio air operated As optional equipment for cold weather radiant
pumps, which mount to 400-pound drums. heater can be supplied for use at the control
panels and pumping stations, and
System L has 64:1 ratio air operated pumps, thermostatically con trolled heating tape can be
which mount to 400-pound drums. supplied which can be wrapped around the
lubrication lines.
NOTE: ANY VARIATIONS FROM THE
ABOVE PUMP RATIOS OR PROPOSED LUBRICANT DRUM HANDLING
SUBSTITUTION OF ELECTRIC PUMPS
FOR THE AIR OPERATED PUMPS EQUIPMENT (OPTIONAL)
MUST BE SUBMITTED TO THE
BUCYRUS-ERIE COMPANY As optional equipment an electric hoist can be
ENGINEERING DEPARTMENT FOR supplied to lift lubricant drums from the ground
APPROVAL. onto the machinery deck. Also air operated
elevator hoists can be supplied at each pumping
WARNING DEVICES station to facilitate the changing of drums of
lubricant.
A failure alarm system is provided to give a
warning if the following conditions exist:
CHAPTER 4 - TROUBLE SHOOTING
PROBLEM CAUSE CORRECTIVE ACTION
BASE COMPONENTS
1. Cracks in plates, stress Stress due to eccentric loading. Repair weld to mend cracks. (Consult
lines in paint, Bucyrus-Erie before attempting
diaphragms and other independent repairs on the base.) Refer
major structural to Appendix for repair welding
members. information.
2. Pitting, spalling, Misalignment, foreign materials between Check alignment, clean abrasives from
Page
Rev – 0
22/07/99
JLC
abrasion, scratching or teeth or inadequate lubricant. teeth, and use proper lubricant. Severe
galling on swing rack or wear of rack or pinions necessitates
pinions. replacement.
3. Bare metal spots or Lack of lubricant on gear teeth. Apply correct lubricant.
contact points on swing
rack or pinions.
4. Broken gear teeth on Misalignment. Repair weld to rebuild the worn or
swing rack or pinions. broken teeth to original shape. Refer to
Appendix for repair welding information.
Install new pinion. Do not repair weld
pinion. Check electrical system for
motoring and braking.
5. Complete cracking in a Severe unbalanced loading or unlevel Replace rack segment.
swing rack segment. ground position.
6. Damaged rollers in Non-uniform loading or foreign objects in Replace damaged rollers. Before
roller circle, roller circle, installation replacement rollers must be
matched as closely as possible with the
adjacent rollers. Use a template to
match up inner flanges.
7. Skidding, warping or Concentrated load condition. Check that upper and lower rails are
bending on roller circle. properly clamped and chocked. Inspect
roller pins and roller frames; replace, if
necessary. Check roller flanges.
8. Lifting hook ineffective. Cracks in lifting hook or bracket. Repair by welding or replace. Refer to
Appendix for repair welding information.
Improper mounting. Verify a 3/8-inch
clearance between the hook shoe and
base lifting rail. Make sure the bracket
supporting the lifting hook is securely
welded to the revolving frame. Maintain
proper adjustment of adjusting bolts
between hook and hook bracket. Check
the wear of the washers between the
bracket and the lifting hook.
Page
Rev – 0
22/07/99
JLC
REVOLVING FRAME
1. Centre pintle, bushing Lack of lubricant. Check that lubrication systems,
rubbing. including grease ways of bushing, are
operating properly.
2. Centre pintle cracks. Centre pintle rather than hook shoes are Repair per directive of Bucyrus-Erie
absorbing load. Service Department.
3. Cracked and buckled Overload. Field repair weld to mend cracks.
plates and welds on Consult Bucyrus-Erie Service
revolving frame. Department before adding reinforcing
members or attempting modification.
Refer to Appendix for repair welding
information.
4. Boom, mast or A-frame Overload. Field repair weld to secure mounting
mounting lugs cracked. lugs to revolving frame. Contact
Bucyrus-Erie Service Department
before proceeding with this repair.
HOIST, DRAG, SWING AND

PROPEL MACHINERY
1. Overheating in anti Anti-friction bearings are excessively or Make sure correct type of lubricant is
friction bearings. inadequately lubricated. used. Remove relief plugs during
lubrication.
2. Severe wear in gear Loose parts, lack of lubrication, or Dirt or water in gearcase. Tighten all
trains. incorrect lubrication. gear train elements; check lubrication
systems and gear cases. Heavy pitting
or spalling necessitates gear overhaul
or replacement.
3. Worn shoes or linings Maladjusted brakes – shoes dragging. Repair, replace, or adjust as required.
on brakes. See instructions. Excessive usage.
4. Slow release on brake Faulty quick release valve on hoist drag Replace.
cylinders. and propel.
Leaks in air piping. Insufficient air Repair piping.
pressure.
5. Sticking of mechanical Lack of proper lubricant or misalignment. Make sure all pivot points are well
linkages on brakes. lubricated with MPO or MPG.
6. Noise of vibration in Loose parts. Check anchor bolts, drum spiders and
hoist or drag couplings and repair as needed.
machinery. Unbalanced brake housings.
7. Deformed rope Lack of proper lubricant. Lubricate grooves with RWRL.
grooving on drums.
8. Swing shaft, bearing or Prolonged high loading, misalignment or Replace.
pinion breakage. wear.
Vertical motion adjustment incorrect. Adjust vertical motion cushion.
9. Propel cams, frames Eccentric loading and bridging due to Field repair weld. Contact BE Service
and shoes cracked. walking on uneven ground. Department before proceeding with this
repair.
10.Propel error alarm Shoes are out of synchronisation or Check Selsyn-tie.
system activated. electrical control malfunctions. Check ground conditions.
Page
Rev – 0
22/07/99
JLC
MACHINERY HOUSE AND CABS

1. Structural members fail. Stress concentrations. Examine and repair all struts, columns,
braces, purlins and panels. Search
thoroughly for all missing fastening
elements and replace where necessary.
2. Vibration in house fans. Components misaligned, imbalanced or Check shaft straightness, bearing and
dirty. Worn bearings. drive alignment, loose or worn shafts,
bearings or bolts; determine if the motor
is in balance, and check the fan blades
for dirt and grease accumulation.
3. House fans operating Bearings are not adequately lubricated. Use recommended grease with vented
at elevated grease gun or fittings. Add grease as
temperatures. shaft is turned.
4. Brakes on auxiliary Normal wear patterns. Adjust to obtain proper braking or
hoists and overhead replace linings. Lubricate brake pivot
crane fade. points properly. Grease on linings.
5. Handrails, catwalks, Cracked welds or missing fasteners. Repair by welding or replace nuts and
platforms and bolts. Refer to Appendix for repair
stairways, inside or welding information.
outside machinery
house fail.
6. Rope support sheaves a. Failed bearing or worn shaft. a. Replace.
do not move freely on b. Cracked rope support shaft. b. Field repair weld. Refer to Appendix
support shafts of drag for repair welding information.
rope supports.
LUBRICATION SYSTEMS
1. Air locks in pump. System is not primed properly. Open vent plug during pump operation
and allow air to escape.
2. Air locks in supply System in not primed properly. Loosen pipe plugs on each line; allow
lines. lubricant with entrapped air to escape.
3. Air locks in injectors. System is not primed properly. Open lube fitting, allow lubricant and air
to escape.
4. Air locks in feed lines. System is not primed properly. Loosen feed line at bearing inlet. Allow
lubricant and air to escape as system
cycles.
5. Injector or vent valve Dirty supply lines or worn injectors. Disassemble and clean or repair.
malfunctions.
6. Injectors will not move Bearings are not receiving lubricant or Adjust pressure switch to higher
to discharge position. system not venting. developed pressure. (3500 psi
maximum for high pressure systems.
1000 psi maximum for low pressure
systems.)
7. Injector stems on Restriction on supply. Check lubricant. Use low temperature
injectors do not return additives. Use specified lubricant. See
to normal position after instructions.
venting.
Page
Rev – 0
22/07/99
JLC

Lubrication Systems (continued)
8. Failure of pump to build a. Air locks in pump. a. Open vent plug during pump
pressure. operation and allow air to escape.
b. Pump outlet checks fail to hold b. Disassemble and clean check seat.
pressure in supply line.
9. Sluggish pump Inadequate power supply. Check air hose assembly. Make sure
operation. inner diameter is fully open.
10.Low pressure rise. Loose supply connections. Check lubricant and air leakage. Use
higher ratio pump.
11.Injectors leak at outlet. Bushing and plunger not tightened Tighten to obtain gasket seal in body.
sufficiently.
12.Seepage of lubricant Plunger or piston stop packing worn. Replace packing.
indicator stem.
13.Excessive lubricant Piston and plunger packings worn. Replace packing.
output through injector.
14.Reduced pressure a. Diaphragm swollen or stiff. a. Replace diaphragm.
through air line b. Inner valve disc dirty or worn, or seat b. Clean and / or replace.
regulator. scored. c. Clean filter and open supply valve.
c. Restricted air flow.
15.Excessive pressure Dirty air filter cone. Clean.
drop through air line
filter.
16.Clogging of air line Over-lubrication. Reduce oil feed rate by turning knob to
lubricator. lower setting.
17.Restricted air flow Flattened or kinked lines. Bend or twist lines carefully to relieve
through air lines. restriction.
Make sure all plugs, sockets, nipples
and tees are free from restrictive
defects.
18.Power loss in controls. Electrical failure. Examine all relays, timing units,
disconnect switches and limit switches,
verify all electrical connections and
check wiring insulation.
AIR SYSTEM
AIR COMPRESSOR
1. No air pressure. a. Leaks in system. a. Check for leaks and repair.
b. Defective compressor or switch. b. Repair or replace.
c. Overload tripped. c. Inspect compressor and motor,
correct the cause, reset.
2. Frequent starting and a. Leaks in system. a. Check for leaks and repair as
stopping of necessary.
compressor. b. Frozen lines. b. Clear frozen lines; make sure anti-
freezer is operating correctly.
c. Switch set incorrectly. c. Check setting, adjust as necessary.
Check valve leaking internally.
Page
Rev – 0
22/07/99
JLC

Air System – Air Compressor
(continued)
3. Compressor a. Pump running backwards. a. Check motor rotation and change
overheating. connections if necessary.
b. Head valves not seating. b. Reseat or replace valves.
c. Blown head gasket. c. Replace. (Remove all traces of old
gaskets.)
d. Restriction in head, coils, or check d. Remove and clean.
valve.
e. Lack of oil. e. Maintain and correct oil level.
Ensure oil feeder rings turn freely.
f. Dirt in coil and cylinder fins. Poor f. Clean.
cooling air circulation.
4. Noisy operation. a. Loose external parts. a. Tighten only loose parts.
b. Pulley striking coils. b. Ensure pulley is located on shaft
correctly and is tight. Bend coils to
clear.
c. Foreign matter such as carbon, metal, c. Remove head and clean.
chips, etc. in pistons striking head at
top of stroke.
d. Retainer or seat not tightened flush d. Remove head and tighten.
with head and allowing piston to strike
it.
e. Piston extends above cylinder at top e. Remove cylinder and add base
of stroke. gasket (not head gasket).
f. End play in crankshaft. f. Remove end cover, take out one
end cover gasket or shim and
replace. Do not remove too many
gaskets or binding may result.
g. Loose or worn internal parts (pistons, g. Overhaul pump.
connecting rods, wrist pins, insert
bearings.)
5. Slow pumping. a. Clogged filter element. a. Clean.
b. Leaks in air line valves or fittings. b. Replace or tighten threaded parts.
c. Compressor too small. c. Add to compressor capacity.
d. Leaky head valves. d. Reseat or replace valves.
6. Excessive oil Worn or inferior grade of oil. Use correct oil.
consumption.
CENTRIFUGAL UNLOADER
1. Leakage of air through Check valve leak. Repair or replace check valve. Inspect
unloader filter opening. the spring, ball and seating surface of
the retainer.
AIR LINE REGULATOR

1. Leakage of air between a. Loose mounting. a. Tighten screws.
the body and bonnet. b. Faulty gaskets and diaphragm. b. Replace.
Page
Rev – 0
22/07/99
JLC
AIR LINES AND STORAGE TANK

1. Reduced air flow a. Defective air compressor or pressure a. Inspect and service compressor
through air lines. switch. and pressure switch.
b. Restricted air lines. b. Check all lines and valves to ensure
free flow throughout system.
c. Cracks in storage tank. c. Inspection by authorised personnel.
AIR LINE LUBRICATOR

1. No air pressure. Clogging of air line lubricator. Dirty Disassemble and clean using soap or a
internal components. petroleum solvent such as kerosene.
AUTOMATIC DRAIN FILTER

1. No air pressure. Clogging of automatic drain filter, dirty Disassemble, clean and replace worn
filter element, bowl, or damaged float and parts.
drain assembly.
DYNAVANE AIR CLEANER

1. Impaired flow of air. Dirt deposits at air and bleed exit. Clean with compressed air or by
washing with soap and water.
A-FRAME
1. Cracks in legs, Overloads and wear. Repair weld. Refer to Appendix for
diagonal braces, rope repair welding information.
anchors or leg
mountings.
2. Activation of Crack in rear legs of A-frame. Trace air leak from rear legs with sonic
pressurised warning detector and repair weld.
system.
3. Safety structural Excessive strain on structural strands due Replace structural strands and adjust.
strands break or show to incorrect adjustment. Place bucket on the ground. Pre-load
significant deterioration. the structural strands to an adjusting nut
torque of 800 to 160 ft lbs. Apply
SWRL to protect the coating on the
structural strands.
4. Handrails, platforms, Damaged welds or missing fasteners. Repair weld or replace parts. Refer to
catwalks or stairways. Appendix for repair welding information.
MAST
1. Cracks in the masthead Overloads and wear. Consult Bucyrus-Erie Company Service
and foot areas, chords, Department before undertaking repair
sheaves, caged ladders welding.
or railings.
2. Broken or damaged Overload. Replace boom structural strands.
lower boom structural Ensure to apply SRWL or RWRL to
strands. protect the coating on the boom
structural strands.
Page
Rev – 0
22/07/99
JLC
BOOM
1. Cracks in boom foot, Overload Consult BE Company Service
chords, lacings, Department before undertaking repair
deflection sheave welding.
towers or boom point.
2. Activation of Crack in main longitudinal or apex chords. Track air leak from chord with sonic
pressurised warning detector and consult BE Company
system. Service Department before undertaking
repair welding.
3. Deflection and boom Lubrication deficiency and part failure. Check all manual and automatic
point sheaves do not lubrication systems. Inspect all
rotate freely. bushings, bearings, shafts, and
spacers. Replace if necessary.
4. Broken or damaged Excessive loading. Replace. Ensure to apply SRWL to
upper boom structural protect the coating on the support or
strands or tower structural strands. If intermediate boom
support structural structural strands are replaced load
strands. them with the take-up device. Refer to
Appendix for values.
5. Handrails, platforms, Damaged welds or missing parts. Repair weld or replace parts.
catwalks, or stairways.
DRAGLINE BUCKET
1. Cracks in shroud, clevis Overloads, shock. Preheat, torch, and repair weld. Refer
plates, side and bottom to Appendix for repair welding
plates, lip and arch. information.
2. abrasion, cracking or Excessive wear patterns. Hardsurface or replace.
shearing of tooth tips.
3. Worn tooth horns. Wear. Check sides and slopes of tooth horn
with template and rebuild if necessary.
Refer to Appendix for repair welding
information.
4. Sever wear or Overload. Use repair links.
breakage of chain links
in rigging.
5. Pivot and swivel Overload. Severe jerking and frictional Restore mountings and lubricate at
mounting on rigging rubbing. periodic intervals.
break.
Page
Rev – 0
22/07/99
JLC
DRAG AND HOIST ROPES

1. Damaged or broken Kinking, crushing, rusting, heat damage Replace and lubricate with RWRL. Re-
drag and hoist ropes. or excessive loading. socket as required. Turn both the hoist
and drag ropes end for end to obtain
maximum life out of these ropes. Keep
machine positioned properly to avoid
excessive pulling of drag ropes through
the dirt. Lubricate the hoist and drag
ropes with RWRL at intervals specified
under lubrication.
FAIRLEAD
1. Crack in tensile arm, Excessive loading due to swinging of drag Repair the weld or replace. Refer to
mountings, swivel ropes. Appendix for repair welding information.
bracket and sheaves. Excessive loading due to bucket tight Repair the weld or replace.
lining.
Page
Rev – 0
22/07/99
JLC
smooth, quiet operation can no longer be

expected. This type of surface failure may be
directly attributable to overloading, overheating,
APPENDICES shock, abrasives, chips, improper alignment,
loose bearings or deflection of shafts or
housing. These conditions lead to various types
APPENDIX Al — GEAR INSPECTION of surface failures.
Many terms are employed to graphically

An important factor of dragline maintenance is describe the appearance of damaged tooth
regular inspection of gears. This should include surfaces. The terms pitting, abrasion,
the hoist, drag, swing and propel gears and scratching, spalling and galling, are the major
pinions as well as the swing rack. types of failures under which all of the other
failures can be grouped as sub-divisions.
It should be second nature to listen for any Furthermore, it can be shown that these five
unusual noises or vibrations, which would types of failures have different basic causes. Of
indicate excessive, wear patterns of gears and course, from the lubrication point of view, the
pinions. Usually, this would necessitate prompt cause of the failure is of major interest rather
attention before complete failure occurs. than the appearance of the surfaces. For the
purpose of this publication, therefore, gear
Of primary importance in proper gear operation tooth failures are classified under the headings
is correct lubrication. Always check to see that of PITTING, ABRASION, SCRATCHING,
all the gears are adequately lubricated. See the SPALLING and GALLING. These gear-tooth
Lubrication Section for further information on failure classifications are called out in figure
correct lubricants and their application. 101.
When gears do not operate at excessive loads Gears and pinions may show some minor
or temperatures, and correct lubricants are pitting which is usually normal. However, any
used, a condition of normal wear should result. heavy pitting or spalling or any abnormalities as
shown in figure 101 will necessitate replacing
Gears are designed to function satisfactorily gears. Any such problems should be thoroughly
during the entire life of the machine of which investigated with the Bucyrus-Erie Company
they are a part, and their failure to do this Service Department.
indicates some unusual condition of operation.
However, regardless of gear design, size or
construction, Correct Lubrication is essential to
assure minimum wear quiet operation and long
service life. During manufacture, tooth shapes
are very accurately developed; nevertheless,
no matter how accurately and smoothly the
teeth are finished, there will always be some
microscopic surface irregularities which cause
frictional resistance if they are allowed to meet.
With the gears in proper mechanical condition
and with Correct Lubrication, friction is reduced,
wear is practically eliminated, and gears should
operate efficiently for years. However, even
with correct lubricants properly applied, certain
mechanical or operating conditions can cause
wear and destruction of teeth. Destruction
seldom takes the form of tooth breakage, but
usually shows up as damage to the rubbing
surfaces.
Such surface failure may rapidly destroy the

original tooth contour, and once this occurs,
Page
Rev – 0
22/07/99
JLC
Page
Rev – 0
22/07/99
JLC
APPENXIX A2 – BOLT TORQUING
BOLT TORQUE VALUES FOR STATIC JOINTS
Page
Rev – 0
22/07/99
JLC
APPENDIX A3 – ADJUSTMENTS
BOOM STRUCTURAL STRAND ADJUSTMENTS
PRELOAD INSTRUCTIONS
DRAWING PRELOAD OF EACH UPPER PRELOAD OF EACH LOWER
INTER. BOOM STRUCTURAL INTER. BOOM STRUCTURAL
STRAND STRAND
BOOM WORKING BOOM BOOM BOOM BOOM BOOM BOOM
LENGTH ANGLE HORIZ. O-S.L. 100% S.L HORIZ. O-S.L. 100% S.L
DRAWING PRELOAD OF EACH UPPER PRELOAD OF EACH LOWER

INTER. BOOM STRUCTURAL INTER. BOOM STRUCTURAL
STRAND STRAND
BOOM WORKING BOOM BOOM EMPTY BOOM BOOM EMPTY
LENGTH ANGLE HORIZ. O-S.L. BUCKET HORIZ. O-S.L. BUCKET
S.L – Suspended Load

O-S.L – Bucket is on ground (Non-suspended Load)
100% S.L – Fully loaded bucket
BRAKE ADJUSTMENT TABULATION
Hoist Brake
STYLE DRAWING A-min A-max B-min B-max
Drag Brake
Swing Brake
Propel Brake
Page
Rev – 0
22/07/99
JLC
APPENDIX A4 PINION AND

— NOTE: SUCCESSFUL
COUPLING INSTALLATION OPERATION OF THE GEARING
LARGELY DEPENDS ON THE
PROPER MOUNTING OF THE PINION
REMOVAL FROM MOTOR SHAFT OR COUPLING ON THE SHAFT.
MOUNTING PINIONS OR COUPLING
CAUTION: A PROPERLY MOUNTED BY HEATING THEM IN BOILING
PINION OR COUPLING WILL HAVE WATER AND DRIVING THEM ON THE
AN INTERFERENCE FIT WITH THE SHAFT WITH A BLOW FROM A
SHAFT CAUSING IT TO RELEASE HEAVY SLEDGE HAMMER IS NOT
SUDDENLY AND VIOLENTLY WHEN RECOMMENDED BECAUSE IT
BROKEN LOOSE. LOOSE THE RESULTED IN UNCONTROLLED
SHAFT-NUT JUST ENOUGH TO ADVANCE OF THE PINION OR
ALLOW THE PINION OR COUPLING COUPLING ON THE SHAFT. TOO
TO FREE ITSELF. THE SHAFT NUT GREAT AN ADVANCE CAN CAUSE
WILL STOP THE PINION OR BREAKAGE OF THE PINION OR
COUPLING AND AVOID INJURY TO COUPLING CORE. WHILE
PERSONNEL. INSUFFICIENT ADVANCE CAN
CAUSE SLIPPAGE AND WEAR IN
NOTE: WHEN REMOVING THE SPITE OF THE PRESENCE OF THE
PINION OR COUPLING FROM A KEY. IN ADDITION, HAMMER BLOWS
MOTOR SHAFT, ALWAYS USE A CAN INJURE THE FINISHED
SUITABLE PULLER TO AVOID SURFACE OF THE ANTI-FRICTION
CAUSING DAMAGE TO EITHER THE BEARINGS.
PINION, COUPLING, MOTOR FRAME,
BEARINGS OR SHAFT. DO NOT HEAT Pinions or coupling must he mounted to a
THE PINION OR COUPLING BEFORE definite advance on the shaft, without hammer
PULLING AND DO NOT USE WEDGES blows. This requires heating them to a higher
BETWEEN THEM AND THE BEARING temperature than is obtainable with Boiling
CAP. TO PREVENT DAM AGE TO THE water, and is based on a difference in
ANTI-FRICTION BEARINGS, AVOID temperature between them and shaft. Following
THE USE OF A SLEDGEHAMMER ON is the recommended method for mounting
THE PULLER. pinions or couplings:
1. Thoroughly clean the pinion or coupling

MOUNTING PINION OR COUPLING ON seating surface on the shaft and the bore of the
SHAFT pinion or couplings using toluol or
percholoethylene; do not use kerosene.
CAUTION: SOLVENTS MAY BE

TOXIC OR FLAMMABLE. ADEQUATE
VENTILATION MUST BE PROVIDED
TO MINIMIZE FIRE AND HEALTH
HAZARDS CAUSED BY USING
SOLVENTS FOR CLEANING. USE
AWAY FROM SPARKS, HEAT OR
FLAME TO PREVENT FIRE OR
EXPLOSION. FOLLOW THE
MANUFACTURERS’ INSTRUCTIONS.
Remove any scoring from either part. Spot the

cold pinion or coupling on the shaft by hand to
obtain at least a 75 percent fit. Check the fit
with bluing. Remove the pinion or coupling.
Page
Rev – 0
22/07/99
JLC
uniform at the required number of degrees

2. Break all sharp edges of the key and above the shaft temperature. For example, if
the keyway with a fine file, so there will be a the shaft temperature is 25ºC (77ºF) and the
radius of about 1/64-inch at each edge. Fit the estimated difference is 125ºC (225ºF), heat the
key to the shaft, taking care to avoid upsetting pinion or coupling to 150ºC (320ºF) for
the metal of the shaft adjacent to the key. If mounting.
previously upset, file lightly, checking the fit
with bluing until a 75 percent fit results. Try the WARNING: PINION OR COUPLING
pinion, or coupling on the shaft to make certain TEMPERATURE MUST NEVER
it does not bind on the key. EXCEED 190ºC.
Some accurate method must be provided for

measuring the pinion or coupling and shaft
temperatures quickly before mounting the
pinion. This is best done with a hand pyrometer
(figure 103). When a hand pyrometer is not
available, placing putty over the bulb to hold it
against the pinion or coupling can use a
centigrade thermometer. Heat the pinion or
coupling a few degrees above the desired
temperature before removing it from the oven.
Wait until it has cooled to the temperature
desired, remove the thermometer and quickly
mount the pinion or coupling as described
below.
3. Mount the pinion or coupling cold by

placing it on the shaft and snapping it into
position by hand. Measure the “cold” position of
the pin ion or coupling, using a micrometer
depth gauge. Figure 102 illustrates the method
of using the depth gauge.
Mark the places where the depth gauge was

resting so measurements can be made from
the same position after the pinion or coupling
has been mounted.
4. Remove the pinion or coupling from the 5. After making sure the bore is clean,
shaft and heat it in a suitable oven to the quickly mount the hot pinion or coupling on the
temperature specified. If the pinion or coupling shaft. When it is nearly engaged with the taper
is heated in oil, the bore must be thoroughly fit (but not actually in contact), snap it forcible
cleaned before mounting; to avoid this into place with a quick push. It is important that
complication, the use of an oven is the hot pinion or coupling be instantly snapped
recommended. into position before it has cooled appreciably;
otherwise it will immediately “freeze” to the
The pinion or coupling temperature is indicated shaft and cannot be adjusted further.
as a temperature difference between the shaft
and pinion; this temperature difference is 6. Check the “hot” or shrunk-on position
estimated only and can be adjusted to maintain of the pinion or coupling on the shaft, using the
the specified advance. Heat the pinion or micrometer depth gauge. The actual advance is
coupling in the oven until the temperature is the difference between depth gauge readings
Page
Rev – 0
22/07/99
JLC
at the hot and cold positions. To control the

stresses in the pinion or coupling the advance
must be within the limits specified in Table 3.
If the advance is not within the limits given, the

pinion or coupling should be pulled and
remounted.
7. Assemble the lock washer and nut,

tighten firmly and lock.
WARNING: THE LOCK WASHER

MUST BE IN PLACE AND THE NUT
FIRMLY TIGHTENED, THEN THE TAB
ON THE LOCK WASHER MUST BE
BENT AGAINST THE FLAT OF THE
NUT. THIS IS REQUIRED TO
PREVENT THE NUT FROM WORKING
LOOSE DURING OPERATION.
Page
Rev – 0
22/07/99
JLC
APPENDIX A5 MAINTENANCE
— Maintenance welding is applied to the repair of
WELDING cracked, broken or bent structural components.
Reconditioning of failed members requires
attention to a number of details and careful
application of the repair procedure. Only in
SECTION 1— REPAIR WELDING OF certain cases is it necessary to strengthen
BASE, REVOLVING FRAME, A- members by added reinforcement.
FRAME, WALKING SHOES AND
WARNING: BUCYRUS ERIE
DRAG BUCKET
COMPANY SHOULD MAKE SUCH
MODIFICATIONS ONLY UPON
RECOMMENDATION. IMPROPERLY
APPLIED REINFORCEMENTS CAN
HAVE AN ADVERSE EFFECT ON THE
PERFORMANCE AND LIFE OF THE
STRUCTURE.
A broken member is best repaired by making a

complete penetration weld, preferably by
welding from both sides, using the correct
welding electrode and observing all
precautions, such as pre-heat, back-gouging,
etc. The complete penetration groove weld
should be ground flush with the base metal on
both sides to remove all surface irregularities.
An alternate procedure incorporates back-up
bars to ensure sound, complete penetration
welds in the repair area. Be sure to follow all
applicable safety measures and federal, state
and local regulations.
The reason for favoring a complete penetration

weld repair conditioned by grinding, instead of
adding reinforcement, is to maintain the original
pattern of stress flow, designed into the
GENERAL
structural members. Addition of reinforcement,
which is not part of the design, can reduce
These recommendations for repair welding fatigue strength because of the change in
apply to the major structural members of the geometry from the original structure.
machine including the base, revolving frame, A-
frame walking shoes, and drag bucket. RECOMMENDED ELECTRODES AND
PREHEAT
The high cyclic loading characteristics of the
walking dragline is considered in the design
and material selected for the construction of the Effective repair welding of cracked, broken or
machine. However, due to unusual operational bent structural members of the machine
conditions that may be encountered and to the involves knowledge of the types of steel used,
great number of cyclic loading that may be proper welding electrodes and recognized good
applied to the machine, fatigue cracks or other welding practice. The chemical composition,
abnormalities may occur. Early detection of mechanical properties and thickness of the
these conditions through regular machine steel determine the welding electrode to be
inspection helps to avoid problems or used and the preheat temperature required.
emergency breakdowns. Refer to Table 1 for types of steel used in the
structures and recommended electrode and
preheat.
Page
Rev – 0
22/07/99
JLC
WELDING ELECTRODES SMALL PORTABLE ROD OVENS AT

THE WELDER’S SIDE ARE IDEAL.
With the exception of the boom and mast, weld USE OF DRY LOW HYDROGEN
repairs on the various structures of the machine ELECTRODES CANNOT BE OVER-
can be made with two basic classifications of EMPHASIZED.
shielded metal arc electrodes, namely E7018
and E8018-C1. Both are low hydrogen Cracks caused by hydrogen are extremely fine
electrodes, which deposit weld metal having and occur invisibly below the surface in the
excellent properties at strength levels with base metal heat affected zone, as shown in
70,000 to 80,000 pounds per square inch, and figure 104. Therefore, they are not detectable
impact properties from -20 degrees Fahrenheit at the time of welding.
to -75 degrees Fahrenheit. These are all
position electrodes, which produce high quality These cracks can propagate in service and
welds for repairing the structural components of lead to ultimate failure to the part. It is
heavy machinery. necessary to adhere strictly to recognise good
welding practice regarding the handling,
NOTE: ALTHOUGH THESE storage and use of low hydrogen electrodes.
ELECTRODES ARE OF SUPERIOR To avoid under-bead cracks, remove all oil or
QUALITY, CARE MUST BE grease or other contaminates from the surface,
EXERCISED IN THEIR APPLICATION. and is sure that all the steel is dry.
LOW HYDROGEN ELECTRODES ARE
HIGHLY SUSCEPTIBLE TO Preheat to the required temperature. Use only
MOISTURE PICK-UP AFTER dry electrodes taken from the electrode oven.
REMOVAL FROM SEALED After exposure to the air, the electrodes must
CONTAINERS. be returned to the oven. Time limit outside the
TO MAINTAIN LOW HYDROGEN, oven is four hours for E7018 and two hours for
THAT IS, CRACK RESISTANT E8018-C1 electrodes.
PROPERTIES, THEY MUST BE
STORED IN ELECTRODE OVENS AT REPAIR WELDING PROCEDURES
250 DEGREES FAHRENHEIT UP TO
THE TIME OF USE. General Procedure for Repair of Cracks
Page
Rev – 0
22/07/99
JLC
GENERAL PROCEDURE FOR REPAIR OF suggested since the heat source can be left
CRACKS operating during welding to maintain the
minimum preheat temperature. Pre-heat
(Refer to Figure 105) temperatures up to 400 degrees Fahrenheit
depending upon the steel analysis, are
Remove the entire crack by arc air gouging or adequate under most conditions for major
grinding. Prepare a V-groove of approximately repairs. As previously stated, preheat
45-60 degrees included angle for re-welding. If temperatures are determined by the type of
cracked through the full thickness and if it is steel in the structure. Temperatures should be
possible to make the repair from both sides, a measured with temperature indicating crayons.
double V preparation is preferred. When
welding from both sides, back gouging for
complete penetration is always recommended. WELDING TECHNIQUES
(Refer to Figure 106)
When it is not physically possible to back
gouge and weld the second side, an alternate
approach must be taken. Sometimes it is
possible to gouge through to completely
remove the crack, then fit a back-up bar on the
underside to facilitate making a complete
penetration weld.
NOTE: THE BACK-UP BAR MUST FIT

TIGHTLY TO THE UNDERSIDE
OTHERWISE POOR WELDING
CONDITIONS CONDUCIVE TO
CRACKING MAY OCCUR.
When it is not possible to fit a back-up due to

limited accessibility to the underside, it is
advisable, if possible, to remove a portion of
the defective plate and weld in a new piece,
using back-up bars on all sides to ensure
complete penetration welds.
A further alternative is to gouge through,

removing the crack, and then weld small
stringer beads to close the gap and prepare a
groove for a repair weld. In this case, the repair
weld will be essentially full penetration, but will
be less than perfect on the underside. The Maximum electrode sizes are 1/4 inch for flat
other methods are preferred in the order position, 3/16 inch for horizontal position and
described, that is, welding both sides, welding 5/32 inch for vertical and overhead positions.
against a back-up bar, or completely replacing Use a split weave as soon as bead width is
a section of plate. large enough to accommodate beads side by
side. Throughout all welding be certain
PRE-HEAT thorough fusion with the base metal and
(Refer to Table 1) adjacent weld beads is obtained on all weld
passes. Clean off all slag between passes and
When preheating, apply heat to a broad, all craters before starting the next electrode.
general area surrounding the repair location. A
soaking heat, which thoroughly penetrates the Inspect closely for cracks, undercut or overlap
material through the full thickness, is preferred of beads, and gouge out or grind flaws where
to high surface temperature quickly applied. they occur before continuing. It is very
Electrical resistance or radiant heating is important on highly loaded parts, particularly
Page
Rev – 0
22/07/99
JLC
members subject to cyclic or dynamic stresses, simultaneously on opposite sides, etc. All of
to obtain sound repair welds. these precautionary measures are intended to
minimize shrinkage stresses and subsequent
The presence of any stress risers on the distortion or cracking during welding. The
surface of a part is detrimental to fatigue life, method to follow should be determined after a
which can result in future cracking. Therefore, it careful analysis of the situation and by
is essential that the finished repair be smooth approaching the problem with common sense.
and well blended into the base metal. Repair by Generally a procedure which has proven
welding any undercuts, grind off overlapped successful in previous experience could
weld beads and blend out any notches or logically be applied in most cases.
gouges. Grinding the repair smooth and flush
with the surface of the base metal provides the Use of doubling plates, stiffeners or other
best condition in a repair weld location. Final reinforcements to strengthen a member, which
grinding direction is to be identical with the has cracked in service, must be carefully
direction of applied load in the structure. considered before that repair measure is
decided upon. Additional material added for
GENERAL PROCEDURE FOR REPAIR OF strengthening alters the configuration and
BROKEN PARTS geometry of the member, possibly with a
(Refer to Figure 107) pronounced effect on the fatigue life of that
structure. Many times, such attempts at
All recommendations given for repair of cracks strengthening by added plates only serves to
apply to repair of broken parts, with additional ‘‘chase the crack someplace else.’’ The stress
suggestions. flow in the part has been altered, creating a
location for stress concentration. Attachments

Depending upon the size and cross-section of requiring fillet welds across a tension member,
the part, a specific sequence of welding for example, are poor repair methods. A sound
procedures may be required in making the repair weld, carefully made and smoothly
repair. These techniques include, back-step blended into the base metal on all sides, is
welding sequence, block welding sequence, preferable to additional reinforcements. Any
alternating from side to side, welding application of reinforcements requires careful
Page
Rev – 0
22/07/99
JLC
consideration regarding total overall effect on deposit tough nickel steel weld metal, are used
the structure during service, and should be for repair welding of large drag bucket lips.
done only after consulting Bucyrus-Erie
Company. Successful repair of cracked or broken cast lips
requires removal of the cracks and restoration
ROCEDURE FOR THE REPAIR OF to sound metal. In all cases where cracking
CRACKED OR BROKEN DRAGBUCKET LIPS extends through the thickness of the lip, the
repair weld must be made from both sides of
(Refer to Figure 108) the lip. This requires that the bucket be turned
over at least once during repair.
Large dragline bucket lips are made of Ni-Cr-

Mo alloy steel, heat treated by quenching and Arc-air gouging is recommended for removal of
tempering for high strength and maximum cracks. However, before gouging is started, the
toughness. cast lip must be preheated to a minimum
temperature of 400 degrees Fahrenheit. This
Cast lips, which have broken in service, are temperature must be maintained until gouging
generally repairable by welding, provided has been completed.
correct repair procedures are carefully followed.
When the crack has been completely removed,
Because of their alloy content, cast lips require or when half the thickness has been gouged,
thorough preheating for welding or arc-air the gouged area should be shaped to a V
gouging. A minimum base metal temperature of groove with a minimum included angle of 20
400 degrees Fahrenheit must be maintained degrees and 1/4 inch radius at the bottom. The
throughout all welding. Stress relief heat arc-gouged groove, must be ground to clean
treatment is recommended to restore the metal.
casting to best condition for service after repair
welding. NOTE: IF SHROUDS MUST BE
REMOVED IN ORDER TO MAKE THE
Shielded metal arc welding using low hydrogen, REPAIR, PROCEED AS FOLLOWS:
low alloy steel electrodes is recommended for
field repairs. AWS E8018-C1 electrodes, which
Page
Rev – 0
22/07/99
JLC
ARC-AIR GOUGE TO REMOVE removing residual weld stresses, reducing

SHROUD WELD. GRIND OFF THE hardness in the weld area, and restoring
REMAINDER OF THE WELD AND ductility and aids in removal of hydrogen from
INSPECT THE LIP FOR SOUNDNESS. the metal.
AFTER THE LIP REPAIR HAS BEEN
MADE, REINSTALL THE SHROUD
ACCORDING TO INSTRUCTIONS
GIVEN IN PROCEDURE FOR
REPLACEMENT OF BUCKET LIP
SHROUDS.
When possible, weld in the flat position, by

turning the bucket over as required. For repair
of the side (vertical) portion of the lip casting,
horizontal or vertical position welding may be
necessary. In that case, open up the prepared
welding groove to a minimum of 45 degrees
included angle with 1/4-inch radius at the root.
Maintain 400 degrees Fahrenheit minimum.

Preheat throughout welding.
Use E8018-C1 electrodes as follows:
Use only oven dried electrodes. See section on

WELDING ELECTRODES. Electrical resistance heating with thermocouple
temperature control is recommended. The area
Hold a short arc and deposit stringer beads to be heated should include several inches on
only. When depositing weld beads to the side either side of the repair and should extend the
walls of the groove, direct the arc to the side to full depth of the lip from leading edge to the
obtain good fusion to the base metal. basket. Heating elements, however, should not
Thoroughly clean each pass to remove all slag be placed over the plate of the basket.
before continuing. Grind to remove any Thermocouples should be placed over the weld
undercut or other defects, which occur during in the area of the thickest and thinnest portions
welding. of the lip.
Maintain the pre-heat until arc gouging and Rate of heating and cooling must be controlled
welding has been completed. Arc-air gouge to to avoid drastic temperature differences in the
the half thickness. Prepare a V groove for metal. Up to 600 degrees Fahrenheit, the lip
welding. Weld this half completely. Thin bucket can be heated at the maximum rate attainable
over. Arc-air gouge to completely remove the with the equipment. Over 600 degrees
crack from the second side and prepare a V Fahrenheit, the rate of heating should be
groove for welding as before. restricted to 100 degrees Fahrenheit per hour
up to a temperature at 1050 degrees
STRESS RELIEVING Fahrenheit. The thermocouple readings should
be within a range of 1025 to 1075 degrees
On major repairs, such as a broken lip or one, Fahrenheit for a period of time based on the
which has cracked through the thickness, thickness of the casting. To calculate the time
thermal stress relieving is recommended after in hours, multiply the average thickness of the
welding. Stress relieving is beneficial in lip in the repair area in inches by two. At the
Page
Rev – 0
22/07/99
JLC
end of the holding time, the rate of cooling to “Procedure For The Repair Of Cracked Or
600 degrees Fahrenheit should be restricted to Broken Drag Bucket Lips”.
100 degrees Fahrenheit per hour, after which
air cooling is permissible. NOTE: NO WELDING IS TO BE
APPLIED TO THE EDGE OF THE LIP
PROCEDURE FOR REPLACEMENT OF WHEN ATTACHING SHROUDS. ALL
BUCKET LIP SHROUDS WELD ENDINGS ARE TO BE AWAY
FROM THE EDGE BY THE AMOUNT
(Refer to Figures 109 and 110) SPECIFIED IN FIGURES 109 AND 110,
AND BLENDED AS SHOWN.
Arc-air gouge to remove the shroud welds.
Grind off the remainder of the weld and inspect DRAG BUCKET TOOTH REPAIR
the lip for soundness.
Install center shrouds according to welding

details to welding details shown in figure 109.
Install corner shrouds, and shroud plates
according to welding details shown in figure
110.
400 degree Fahrenheit, minimum preheat is

required, for shroud welding. Use only oven dry
E8018-C1 low hydrogen electrodes and follow
applicable welding recommendations given in
Page
Rev – 0
22/07/99
JLC
As wear patterns develop on the tooth the Adhere to the following instructions for
effective life of the tooth can be increased by rebuilding tooth horns (figure 113).
applying hard surfacing beads parallel to the
lines of minimum stress. The hard surfacing
produces a slight build-up, which protects the
steel. For hard surfacing cast cap type teeth
proceed as follows (figure 111).
1. Preheat the tooth in the area to be hard

surfaced to 200-300 degrees Fahrenheit.
2. Use a 3/16 inch electrode and space

the beads 1/2 to 5/8 inch apart. Dots 3/16 to 3/8
inch in diameter, or rings one inch in diameter
can be intermixed with straight beads. 1. Place the tooth horn template in
position to determine the amount of rebuilding
3. To prevent an excess of small cracks to be done on the tooth horn. If necessary,
or undercuts along the weld, apply the hard remove the high spots by grinding. Clean all
surfacing rod at the lowest side of the current surfaces that require rebuilding.
range specified by the rod manufacturer.
Penetration of 1/64 inch or less is sufficient to 2. Preheat each tooth horn to 400
hold the hard surfacing to the tooth. degrees Fahrenheit prior to welding. Maintain
this temperature throughout the entire welding
WARNING: DEEPER PENETRATION process.
CAN DAMAGE THE HEAT TREATED
STEEL CASTING FROM WHICH THE 3. Weld with AWS E11018-M electrodes.
TOOTH IS FABRICATED.
4. Rebuild broken or worn tooth horns
To replace a worn or broken tooth, remove the slightly larger than the template cutouts.
wedge connection between the tooth tip and its
horn (base) (figure 112). Cap the horn with a 5. Grind the rebuilt section to fit the tooth
new tooth and apply a new wedge for the horn template. The height of the tooth horn at
assembly. the front edge of the wedge hold (point “A”) at
both the top and the bottom of the tooth horn
Then trim the protruding upper and lower must correspond with the scribed line on the
portions of the wedge flush with the top and template.
bottom surfaces of the tooth.
Tooth horns may be rebuilt to prevent tooth DRAG BUCKET CLEVIS PLATES
breakage or subsequent tooth horn fracture.
Templates may be ordered for checking horn Clevis plates on the sides of the bucket are
sides and slopes. formed with lugs to which shrouds, pivot
hitches and accompanying bucket rigging are
Page
Rev – 0
22/07/99
JLC
secured. To replace worn or broken clevis

plates proceed as follows.
1. Preheat that area of the clevis plate

along the burn line to 400 degrees Fahrenheit
for 4 inches about the burn line (figure 114).
2. Burn off broken or worn lugs along the

burn line with an acetylene or propane torch.
3. Deburr and grind the weld surface

clean.
4. Locate the new clevis lugs flush with

the inside bucket. Use AWS. E11018-M
electrodes.
5. Again preheat the clevis plate (to about

4 inches beyond the weld joint) and the new lug
casting to 400 degrees Fahrenheit.
6. Start the welds with 5/32-inch diameter

electrodes and finish with 3/16-inch diameter
electrodes. Use 140-150 amperes for the 5/32-
inch electrodes and 190-200 amperes for the
3/16 inch electrodes.
Page
Rev – 0
22/07/99
JLC
Page
Rev – 0
22/07/99
JLC
SECTION 2— REPAIR WELDING

SWING RACK TEETH
The following is a suggested method for the

repair of cracked or broken swing rack teeth on
walking draglines. The repair method should
produce satisfactory results and provide a
serviceable swing rack, provided the procedure
is carefully followed in all details.
Repair of cracked teeth is illustrated in figures

115 and 116, and broken teeth in figure 117.
The welding procedure is essentially the same
for the three conditions shown.
PREPARATION
1. Clean off the swing rack in the area of

the tooth to be repaired to remove all traces of
grease, oil or dirt. Wash down thoroughly with a
solvent cleaner and wipe dry with clean rags.
2. Grind to completely remove the crack

and prepare a groove for welding as shown in
figures 115 and 116.
3. Dye penetrant test for complete crack

removal.
4. In the case of a broken tooth, grind the

fracture surface on the swing rack smooth and
round off edges as shown in figure 117.
Page
Rev – 0
22/07/99
JLC
Page
Rev – 0
22/07/99
JLC
WELDING ELECTRODES 3. During welding, the repair area must be

continually checked with temperature indicating
1. All welding is to be done using oven crayons to be sure that the minimum
dry El 1018-M low hydrogen electrodes. temperature is being maintained. Do not weld
Connect an electrode drying oven as close as at temperatures below the specified minimums.
possible to the work area. Set the oven
temperature at 300ºF. As sealed containers of WELDING
electrodes are opened, place the entire
contents of the container in the oven. Remove 1. Refer to figures 115, 116 and 117
no more electrodes than can be consumed in illustrating the application of butter welding. The
one half-hour. If all electrodes are not used in purpose of the butter weld layer is to provide a
one half hour, return them to the oven. Discard buffer between the weld required to fill the
any electrodes, which have been wet. groove and the alloy cast steel. This technique
is essential in preventing heat affected zone
PREHEAT cracking in the cast steel which otherwise is
likely to occur due to the shrinkage of the weld
1. Two levels of preheat are required for as the groove is filled. Butter welding permits
tooth repair, 250ºF minimum for butter welding the repair weld to be made at the preheat
and 175ºF minimum for filling in the groove. temperatures specified. Much higher
Temperatures should be measured with temperature would otherwise be required for
temperature indicating crayons. crack free welding.
2. Preheat will be difficult to maintain

because of the mass of metal in the swing rack
to draw the heat away from the repair area. It is
recommended, therefore, to apply heat to a
large sections of the swing rack to offset this
quench effect. A section covering at least 3
teeth on either side of the tooth being repaired
should be heated so that the minimum preheat
temperature is obtained at the repair location. It
is suggested that electrical resistance heaters
be applied behind the teeth as shown in figure
118, if such physical arrangement is possible. If
the repair area cannot be heated to the
required minimum temperature by this
arrangement, supplementary heat must be
applied from the tooth side of the swing rack.
Electrical resistance heaters can be applied, or
heat provided by oxy-propane torches.
Adjacent areas of the swing rack should be
covered with heavy insulation to avoid heat
loss.
NOTE: CONTRACT SERVICES

ARE AVAILABLE FOR FIELD
APPLICATION OF RESISTANCE
HEATING EQUIPMENT. SUGGESTED 2. Butter welding is done using 1/8-inch
SOURCE: diameter E11018-M electrodes at a minimum
preheat temperature of 250ºF. (See section
Stresstech under Welding Electrodes regarding use of the
Box 11 Red Wing, MN 55066 electrode-drying oven.) Horizontal weld beads
(612) 388-7117 are applied to completely cover the cavity or
Page
Rev – 0
22/07/99
JLC
surface to be welded. The edges of the butter notch free radius may result in future cracking
weld must overlap the adjacent surface about at the root of the tooth.
1/2 inch. This is to prevent subsequent welding
from impinging upon the cast steel. 8. After the swing rack has cooled to
ambient temperature, dye penetrant test the
3. Before starting the butter weld, position repaired tooth for soundness.
a piece of thin mild steel plate under the bottom
end of the tooth. This is to provide a shelf for
starting the weld and to avoid irregular weld
beads at the bottom, which would become
stress risers to cause cracking when the tooth
is loaded in service.
4. Apply the butter weld, progressing with

horizontal beads from bottom to top. Use care
to keep the butter weld layer as smooth and
regular as possible. When finished, remove all
slag and grind high spot, which could trap slag
when welding to fill the groove. In the case of
repairing a broken tooth (figure 117), the
prepared tooth segment is butter welded
separately before positioning for final welding in
place.
5. Filling the groove is done with 1/8 inch

or 5/32-inch E11018-M electrodes at a
minimum pre-heat temperature of 175ºF. (See
section under Welding Electrodes regarding
use of the electrode-drying oven.) Weld vertical
up using a split layer technique as soon as the
groove is wide enough to accommodate 2 or
more beads. See figures 115, 116 and 117 for
approximate weld bead sequence.
6. For replacing a tooth segment as

shown in figure 117, it will be necessary to
prepare a tooth profile template as shown in
figure 119. The template must be carefully
made to fit the rack teeth as accurately as
possible. Use the template to position the tooth
segment prior to tack welding. When welding
the tooth segment in place alternate welding
from side to side to control distortion. Check
frequently with the template.
7. When groove welding is finished check

carefully for low spots and fill in as required.
Grind the weld smooth and flush with the
adjacent tooth surfaces. Use the tooth profile
template to check grinding of a welded on tooth
segment. Grinding of the radius at the root of
the tooth is very important. Avoid any nicks,
gouges or grinding marks in a vertical direction.
Grind a smooth radius using small diameter
(peanut) grinders. Failure to achieve a smooth,
Page
Rev – 0
22/07/99
JLC
SECTION 3— WELDING AND

CUTTING EQUIPMENT
The welding and cutting equipment needed for

general repair welding is listed below.
Page
Rev – 0
22/07/99
JLC
SECTION 4— STRESS RELIEVING

AND TEMPERATURE MEASURING
EQUIPMENT
The equipment recommended for stress

relieving after repair welding is listed below.
Page
Rev – 0
22/07/99
JLC
APPENDIX A6 LUBRICATION BENCHMARKS —
MPG MULTIPURPOSE TYPE GREASE

—
Scope
Lubricant performance requirements for Multi-Purpose Type Grease.
Application
For heavy-duty ball, roller and plain bearings.
General Requirements
1. HEAT RESISTANCE Shall be thermal stable.

-
2. RETENTION IN BEARINGS Shall not exhibit high leakage.

-
3. MECHANICAL STABILITY Shall work continuously with a minimum change in consistency.

-
4. WATER RESISTANCE shall withstand water wash-out or leaching.

-
5. REVERSIBILITY Shall be stable with repeated heating and cooling.

-
6. PRESSURE OIL SEPARATION Shall resist oil-soap separation.

-
7. DISPENSABILITY Shall have the ability to be pumped through automatic lubrication systems
-
without the aid of heat tracing on the lube lines at the designated ambient temperatures.
8. EXTREME PRESSURE Shall withstand heavy shock loading.

-
9. COMPATIBILITY Low temperature greases shall be compatible with mineral oil base greases
-
and their oil seal material.
Compounding
1. Suitable for producing the extreme pressure characteristics (without inert fillers) required for
heavy duty ball, roller and plain bearing lubrication.
Page
Rev – 0
22/07/99
JLC
Specific Requirements
Notations
1. AMBIENT TEMPERATURE The ambient temperature shall be the temperature at the point of
-
lubricant application.
2. LOW TEMPERATURE GREASE - For extended use in low temperature (+ 10º to -50oº) areas,
this product should be capable of slumping in containers and should be pumpable through lube lines
without the aid of heat tracing.
In order to minimize compatibility problems, it is desirable that the thickener and additive system be the
same as NLGI #1 and #2 greases.
3. PUMPABILITY TESTS - Samples of the above grades of greases must be sent by the
lubricant’s vendor to the major manufacturers of automatic lubrication systems for pumpability tests at
the designated ambient temperatures. The results of these tests should be sent to the Engineering
Department of Bucyrus-Erie Company for review.
4. SEALS AND PACKING - If a vendor should recommend a multi-purpose grease, which would
require a special type of material for seals and packing, he should contact the Bucyrus-Erie Company
Engineering Department and discuss these requirements with them.
THESE PERFORMANCE REQUIREMENTS ARE BENCHMARKS AND NOT A

SPECIFICATION. THEREFORE, MEETING THESE LIMITS AS DESCRIBED ABOVE DOES
NOT RELIEVE THE SUPPLIER OF THE RESPONSIBILITY ASSOCIATED WITH BRAND
NAME PRODUCTS.
ACPL — AIR COMPRESSOR (PISTON TYPE) LUBRICANT
Scope
These lubricant performance requirements for piston type air compressors should be used only if the
compressor manufacturer does not make a lubricant specification recommendation. The manufacturer’s
recommendations must always supercede these performance requirements.
Application
For single and multi-stage reciprocating type air compressors.
Page
Rev – 0
22/07/99
JLC
1. CORRECT VISCOSITY - At operating temperatures to assure effective oil distribution and film
formation on all surfaces that require protection.
2. HIGH CHEMICAL STABILITY - To enable the oil to resist the destructive oxidizing influence of
long exposure to heated air and thus, to resist the formation of deposits.
3. HIGH FILM STRENGTH - To enable the very thin oil films that exist between lubricated
surfaces in cylinders to support heavy loads due to high discharge pressures and, thus, to minimize
metal to metal contacts, wear and friction.
4. ADEQUATE WATER - SEPARATING ABILITY - To resist the formation of persistent emulsions

when water is present in bearing circulation systems.
5. ANTI-RUST PROPERTIES - To protect against rusting in cylinders, which may result from
condensation of moisture during idle periods.
6. PREFERENTIAL WETTING ABILITY - A property that enables the oil to wet metal surfaces in
preference to water and therefore, to resist water washing action.
7. MOTOR OIL – API service classification CC, CD, SE.
1. Air Cooled Type – Cylinders Lubricated From Crank Case
AMBIENT TEMPERATURE SAE NUMBER POUR POINT

Below 32ºF 10W -20ºF
32ºF to 90ºF 20W / 20 0ºF
Above 90ºF 30 +10ºF
Flash Point 400º or higher

Fire Point 440º or higher
Viscosity Index Range 90-105
2. Water Cooled – Cylinders Lubricated Independent of Crank Case
a. Cylinders – Using Lubricator
AIR PRESSURE SAE NUMBER

Up to 100 PSI 20W / 20
Over 100 PSI 30
b. Crank Case
AMBIENT TEMPERATURE SAE NUMBER POUR POINT

Below 32ºF 10W -20ºF
32ºF to 90ºF 20W / 20 0ºF
Above 90ºF 30 +10ºF
Flash Point 400º or higher

Fire Point 440º or higher
Viscosity Index Range 90-105
Page
Rev – 0
22/07/99
JLC
THESE PERFORMANCE REQUIREMENTS ARE BENCHMARKS AND NOT A

SPECIFICATION. THEREFORE, MEETING THESE LIMITS AS DESCRIBED ABOVE DOES
NOT RELIEVE THE SUPPLIER OF THE RESPONSIBILITY ASSOCIATED WITH BRAND
NAME PRODUCTS.
MWCL – MONIGHAN WALKING CAM LUBRICANT
Scope
Performance requirements for a hand applied or pumpable lubricant for the rolling cam walking
mechanism.
Application
Manual or automatic application between the walking cam and cam frame and between the cam roller
and its guide frame.
1. ADHESION – The protective coating must adhere to the surfaces being lubricated without
peeling or scaling. The lubricant must maintain film lubricity and be highly resistant to squeeze at
contact points at mating surfaces.
2. EXTREME PRESSURE – It must withstand high rolling contact pressures and have the ability
to flow under loads. The Hertz contact stress may reach 160,000 PSI. The lubricant must lubricate
under boundary conditions.
3. LOW TEMPERATURE PERFORMANCE — The coating on the surfaces must remain pliable at
low temperatures.
4. HEAT RESISTANT — Instantaneous temperatures between mating surfaces may reach 600ºF.
a. EFFECT OF HUMIDITY — Changes in humidity should not affect the lubricating qualities of
this lubricant.
6. WATER RESISTANT — Ability to resist being washed off with water.
7. PACKAGING FOR MANUAL APPLICATION — Packaging of one-half pound of lubricant in a

plastic bag has proven to be a very efficient and practical way of preparing it for manual application.
8. PUMPABILITY FOR AUTOMATIC LUBE SYSTEMS — Must be able to be pumped and

dispensed without the application of heat in ambient temperatures down to 50ºF. Heat will be provided
at the pumping station. Heat will be provided on the lube lines only if ambient temperatures below 50ºF
are to be encountered for any period of time.
Compounding
Suitable for producing extreme pressure lubrication for the rolling and sliding action of the rolling cam
walking mechanism.
Page
Rev – 0
22/07/99
JLC
Penetration, unworked at 77ºF, minimum 260-290

Viscosity of base oil SUS at 210ºF, minimum 3,000
Viscosity index of base oil 100
Drop point ºF, minimum 600
Type of thickener organic inorganic
Solid lubricant %, minimum 5
Timken Retention Test, 4 Grams
30 minutes, lbs., minimum 65

15 minutes, lbs., minimum 70
Low Temperature Properties
0ºF, 24 1 hours Good metal adhesion

Chip point Below 0ºF
These performance requirements are benchmarks and not a specification. Therefore, meeting these
limits as described above does not relieve the supplier of the responsibility associated with brand name
products.
MPO — MULTI-PURPOSE OIL
Scope
Lubricant performance requirements for Multi-Purpose Oil.
Application
The addition of a lubricant to the compressed air system, hand oil cans, etc.
1. Must be fluid at temperature applied.
2. Should contain rust inhibitor.
3. Motor oil - API service classification “MS”.
Viscosity Recommendations
1. Air Line Lubricant
AMBIENT TEMPERATURE SAE NUMBER

Below 10ºF 5W
Above 10ºF 10W
2. Hand Oil Can – Viscosity to be suitable for application and temperature.
Page
Rev – 0
22/07/99
JLC
products.
OGL – OPEN GER LUBRICANT
Scope
Lubricant performance requirements for the lubrication of open gearing.
Application
Lubrication between mating teeth in an open gear drive.
Methods of Application
1. Heated and either poured or hand sprayed on the gear teeth.
2. Sprayed or dripped on the gear teeth by means of an automatic lubrication system.
3. Applied by means of a cartridge gun.
The following are the requirements of the lubricant at the ambient temperature of the open gear drive.
1. ADHESIVE – Maintain film lubricity and be highly resistant to squeeze at contact points of
mating surfaces.
2. FLEXIBILITY – The coating on the surface of the gear teeth must remain pliable.
3. EXTREME PRESSURE – Must withstand the high rolling and sliding contact pressures and
have the ability to flow under loads.
4. CONSISTENCEY – Should maintain consistency.
5. WATER RESISTANCE – Ability to resist water washout.
Types of Lubricants
1. PETROLEUM RESIN AND ASPHALTIC TYPES
a. Hot Melt Type
NOTE: SINCE THIS TYPE MUST BE HEATED AND MELTED BEFORE IT IS APPLIED TO
THE GEARS, SAFETY CODES SHOULD BE CHECKED BEFORE IT IS USED.
b. Diluted Type
This should contain a fast drying diluent such as or equivalent to trichloroethelyne. The
diluted viscosity must be such that the lubricant can be applied by either spraying or
dripping at the ambient temperature of the open gear drive.
Page
Rev – 0
22/07/99
JLC
2. SEMI-SYNTHETIC TYPE
Diluted Type
This should contain a fast drying diluent such as or equivalent to trichloroethelyne. The diluted
viscosity must be such that either spraying or dripping at the ambient temperature of the open
gear drive can apply the lubricant.
3. SPECIAL GREASES
These general contain a soap type base, E.P. compounds and adhesive agents. Some contain
molydisulfied, graphite or other solid lubricants.
The consistency should be such that either dripping or cartridge gun at the ambient
temperature of the open gear drive can apply the lubricant.
Compounding
Suitable for producing extreme pressure lubrication, between the mating teeth in an open gear drive.
Specific Requirements for All Type of Lubricant
1. Must pass the United States Steel Retention Test Using Timken Tester.
2. Shell Four Ball E.P. (ASTM D-2596)

Load wear index, kg. Min 40
Load weld kg., min 250
3. Shell Four Ball Wear – (ASTM D-2266)

Wear scar diameter, mm, max 0.60
4. Timken O.K. Load lbs., min. – (ASTM D-2782) 45
5. Copper Strip Corrosion – (ASTM D-130), pass
6. Suggested Application Temperature Ranges
There should be a lubricant for each of the following temperature ranges.
110º to 30ºF 40º to 0ºF 10º to –50ºF

products.
RGL – REGULAR TYPE GEAR LUBRICANT
Scope
Lubricant performance requirements for Regular Type Gear Lubricant
Page
Rev – 0
22/07/99
JLC
Application
For enclosed helical, worm, bevel, spiral bevel and other gears or gear assemblies subjected to severe
shock loads.
PROCEDURE
PROPERTY ACCEPTANCE
ASTM
Oxidation Stability D2893 Increase in Kinematic viscosity at 210ºF should not
exceed 8%.
Rust Protection D665 No rust after 24 hours with synthetic sea water.
Corrosion Protection D130 #1b strip after 3 hours at 250ºF.
Foam Suppression D892 Test Limits
Max. Vol. Of foam (ML) after:
Seq. Temp. 5 Min. Blow 10 Min. Rest
I 75ºF 75 10
II 200ºF 75 10
III 75ºF 75 10
Demulsibility D2711-69
(Per Para. 3.2)
AGMA GRADES
Max % Water in Oil 1.0% 1.0%
Max. Cuff 2.0 ml 400 ml
Min. Free Water 60 ml 50 ml
Timken OK Load D2782 Pass typical of 55 #
EP Test-4 Ball D2783 1) Load wear index, Min. KG = 40
2) Load weld, Min. KG = 250
Wear Test-4 Ball D2266 Wear scar dia., mm. Max. = .6
1 Hr., 130ºF, 1800 RPM, 20 KG
FZG Test Stages passed = 11Min.
Resistance to Should not separate in storage and should maintain
Separation extreme pressure characteristics when subjected to
centrifugal forces in use.
Compounding
Should contain mild EP, agents of the leaded, sulphur-phosphorus or equivalen ttype.
Synthesized hydrocarbon fluids are not excluded as Regular-Type Gear Lubricants.
Viscosity and Viscosity Index
For the maximum gear life the heaviest viscosity gear oil should be used, limited by the gearcase
ambient temperature and duty cycle. The gear oil used must have a viscosity index equal to or greater
than the required minimum of this specification.
The AGMA grade is SUS (Saybolt Universal Seconds) is specified in this standard for gear oil viscosity.
This tends to overcome the confusion (motor oil and gear oil, viscosity at what temperature, etc) of
selecting a grade of oil based on SAE numbers.
Page
Rev – 0
22/07/99
JLC
Notations
1. TEMPERATURE
1.1 Ambient Temperature
The ambient temperature is defined as the air temperature in the immediate vicinity of
the gearcase. Refer to the following in determining the ambient temperature.
1.1.1 Use atmospheric temperature for gear cases in an extreme exposed location.
1.1.2 Use machinery house temperature for gearcases inside of the house. Some
machines are equipped with house heaters.
1.1.3 Use oil temperature for gearcases having either strip heaters or immersion
heaters.
1.1.4 Gearcases exposed to the direct rays of the sun will run hotter and must
therefore be given special attention.
2. REQUIREMENTS FOR SELECTING GEAR LUBRICANT
2.1 Lubrication of the gears and anti-friction bearings with the same gearcase oil.
2.2 Lubrication for the gears only whenever the bearings are sealed and lubricated
separately.
2.3 Duty Cycle

2.3.1 Semi-continuous operations such as: dragline hoist, drag and swing.
2.3.2 Intermittent operation such as propelling.
3. GUIDELINE FOR SELECTING TEMPERATURE RANGE FOR ANY GEAR OIL
3.1 Minimum Ambient Temperature

3.1.1 Use oil pour point temperature when gears only are to be lubricated.
3.1.2 Use a temperature 10ºF above pour point when gears and bearings are to be
lubricated.
3.2 Maximum Ambient Temperature

3.2.1 When oil viscosity is 2000 SUS.
3.3 Maximum Ambient Temperature

3.2.1 When oil viscosity is 2000 SUS.
3.3 Use ASTM standard viscosity – temperature chart to plot temperature range.
Walking Dragline
1. GEARCASE
1.1 Hoist, drag, swing and propel gear cases are located inside the machinery house.
2. HEATERS FOR MACHINERY HOUSE AND GEAR CASE
2.1 Machinery house heaters and/or strip heaters on the gear cases are to be standard
equipment on the following:
Page
Rev – 0
22/07/99
JLC
2.1.1 On draglines operating in climatic conditions, which would cause the ambient
temperature at the gear cases to drop to and stay below +30ºF for a period of
time.
2.1.2 Some draglines will require only strip heaters for the gear cases offered as
optional equipment on all other draglines.
2.2 Machinery house heaters and strip heaters for the gear cases are offered as optional
equipment on all other draglines.
3. SPECIAL DRAGLINE VISCOSITY AND POUR POINT REQUIREMENTS
AMBIENT 130º to 30º Below 30ºF

TEMPERATURE
Viscosity SUS ASTM D-445
@ 100ºF D-2161 Heater
Viscosity SUS ASTM D-445
@ 210ºF D-2161 220-240 Requirement
AGMA Lubricant No. Applicable #2
Viscosity Index, Min. 85
Pour Point ºF, Max. 30
1. AGMA standard gear oil specification does not include pour point temperature. Pour point as
specified is an additional Bucyrus-Erie requirement.
2. If ambient starting temperature approaches lubricant pour point, external heaters may be
required to facilitate starting and ensure proper lubrication.
3. If oil recommendation requires special seal or packing material, oil supplier should inform the
Bucyrus-Erie Company Engineering Department of the need in time to obtain suitable seals or
packings.
products.
RCRL – ROLLER CIRCLE RAIL LUBRICANT
Scope
Lubricant performance requirements for Roller Circle Rail Lubricant.
Application
Between the mating surface of the rollers and rails, and between the roller flange and rail.
Method of Application
1. Heated and either poured or hand sprayed on the roller rails.
2. Sprayed or dripped on the rollers and rails by means of an automatic lubrication system.
3. Applied by means of cartridge gun.
Page
Rev – 0
22/07/99
JLC
The following are the requirements of the lubricant at the ambient temperature at the roller circle rail.
1. ADHESIVE – Maintain film lubricity and be highly resistant to squeeze at contact points of
mating surfaces.
2. FLEXIBILITY – The coating on the surface of the roller circle rail must remain pliable.
3. EXTREME PRESSURE – Must withstand the high rolling contact pressures and have the ability
to flow under loads.
4. CONSISTENCY – Should maintain consistency.
5. WATER RESISTANCE – Ability to resist water washout.
Types of Lubricants
1. PETROLEUM RESIN AND ASPHALTIC TYPES
a. Hot Melt Type
NOTE: SINCE THIS TYPE MUST BE HEATED AND MELTED BEFORE IT IS APPLIED TO
THE RAILS, SAFETY CODES SHOULD BE CHECKED BEFORE IT IS USED.
b. Diluted Type
This should contain a fast drying diluent such as or equivalent to Trichloroethelyne.

The diluted viscosity must be such that either spraying or dripping at the ambient
temperature at the roller circle rail can apply the lubricant.
2. SEMI-SYNTHETIC TYPE
a. Diluted Type
This should contain a fast drying diluent such as or equivalent to Trichloroethelyne.

The diluted viscosity must be such that either spraying or dripping at the ambient
temperature at the roller circle rail can apply the lubricant.
3. SPECIAL GEARCASES
These generally contain a soap type base, E.P. compounds and adhesive agents. Some
contain molydisulfide, graphite or other solid lubricants.
The consistency should be such that the lubricant can be applied, by spraying, dripping or
cartridge gun, at the ambient temperature, at the roller circle rail.
Compounding
Suitable for producing extreme pressure lubrication between the mating surfaces of the rollers and rails.
Specific Requirements for All Types of Lubricant
1. Must pass the United States Steel Retention Test Using Timken Tester.
Page
Rev – 0
22/07/99
JLC
2. Shell Four Ball E.P. – ASTM D-2596)

Load Wear Index, kg., min 40
3. Shell four Ball Wear – (ASTM D-2266)

Wear scar diameter, mm., max 0.60
4. Timken O.K. Load lbs., min – (ASTM D2782) 45
5. Copper Strip Corrosion – (ASTM D130) pass
6. suggested Application Temperature Ranges
110º to 30ºF 40º to 0ºF 10 to –50ºF
Special Instructions
It may become necessary when using some of the above lubricants in cold weather to aply oil
occasionally to the lubricated rail surfaces. The oil will soften the lubricant on the rail surfaces and
minimize the tendency for the roller to snap and pop as they roll on the rails.
products.
RWRL – RUNNING WIRE ROPE LUBRICANT
Scope: A
Lubrication performance requirements for hoist rope lubricant.
Application
Primarily for hoist ropes or any other running ropes where fatigue and not wear is of prime concern.
1. Penetrate between adjacent wires in order to lubricate and protect them against wear and to
keep the rope core from drying out and deteriorating.
2. Provide a lubricant between sheaves and wire ropes.
3. Resist being washed off.
4. Protect against rusting or corrosion.
5. Form a non-sticky film so that dust and dirt will not build up on the wires.
6. Remain pliable and resist stripping at the lowest temperature to which the rope will be exposed.
7. Preferably it should form a lift control transparent film so that wear, corrosion or broken wires
can be readily detected by inspection.
Page
Rev – 0
22/07/99
JLC
8. Be capable of easy application, both manually and by devices without being heated.
Compounding
Suitable for penetration between the adjacent wires of a rope, in order to lubricate them and also, to
replenish the lubricant in the core.
Special Requirements


Scope: B
Lubrication performance requirements for drag rope lubricant.
Application
Primarily for drag ropes or any other running ropes where fatigue and not wear is of prime concern.
The following are the requirements of the lubricant at the ambient temperature to which the rope is
exposed.
1. Should form a protective coating, which must adhere to the wire rope yet remain pliable and resist
stripping at the lowest temperatures to which the rope will be exposed.
2. Should be able to withstand the heavy shock loading between the wire rope and fairlead sheaves.
3. Should not flow from the surface of wire rope during normal operation.
4. Form a non-sticky film so that dust and dirt will not build up on the wires.
5. Resist being washed off.
6. Be capable of easy application, both manually and by devices without being heated.
Page
Rev – 0
22/07/99
JLC
Compounding
Suitable for producing an extreme pressure adhesive coating of a lubricant on the drag ropes.
1. Must pass United States Steel Retention Test using a Timken Tester.


products.
SWRL – STRUCTURAL STRAND AND STAIONARY WIRE ROPE LUBRICANT
Scope
Lubrication performance requirements for bridge strand and stationary wire rope lubricants.
The following are the requirements of the lubricant at the ambient temperature at the roller circle rail.
1. Must be able to penetrate between adjacent wires in order to protect them against wear and
corrosion.
2. Must form an adhesive and durable coating, which will resist the effect of driving rain.
3. It must no drip off during application or as a result of softening under high summer temperatures.
4. It must remain pliable and not crack or peel off under low ambient temperatures.
5. Must contain a rust inhibitor.
6. Must be able to form a corrosion resistant coating over the wires
7. Must be capable of easy application, both manually and other devices without being heated.
Page
Rev – 0
22/07/99
JLC
products.
Page
Rev – 0
22/07/99
JLC

BE1370W Manual

Uploaded by

Copyright:

Available Formats

BE1370W Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BE1370W Manual

Uploaded by

Copyright:

Available Formats

B.E.

1370-W – WALKING DRAGLINE

CHAPTER 1 – MECHANICAL MAINTENANCE..............................................................................................6

ACPL — AIR COMPRESSOR (PISTON TYPE) LUBRICANT.................................................................................144

maintenance or repair. The following points

Safety requirements dictate that all draglines in

NOTE: IF POWER IS ESSENTIAL CAUTION: MANY OF THE

Approved protective equipment such as gloves

While performing maintenance, the awkward

SECTION 2— LOWER WORKS BASE

Repair CIRCLE. Install ramps sloping down from the rail

of evenly distributed rollers may be missing and NOTE: IF AN UPPER RAIL

3. Remove the roller lube fittings and roller

Shim the rail ends if required, gaining a solid rail

2. Block under the lifting hook securely.

3. With a torch, remove the hook pin

CAUTION: EXTREME CARE MUST BE

The centre pintle is the centre structure of the

When the base is inspected for cracking or

The bushing in the revolving frame should be

The maximum recommended bushing to pintle

If the bushing or centre pintle must be replaced,

SECTION 3— ROTATING DECK MACHINERY UNITS

REVOLVING FRAME The machinery units (figure 6) of the 1370W

daily for cracking, wear and lube film. The first

The bases and pedestals should be checked Repair

and drum pedestal. Remove the second

NOTE: THE BEARINGS ARE

THEM. not be removed as complete assemblies.

CAUTION: THE REMAINING STEPS TO q. When the spider is completely removed,

4. Remove all of the lube lines and drain

SWING MACHINERY 5. Remove inspection covers to expose

1. Move the machine to a safe area with

2. Set the walking shoes and bucket on the

CAUTION: AT LEAST ONE SWING

3. Have an electrician disconnect and tag

bearing cage, spacer and oil seals from the

9. If the swing unit is equipped with a

27. Remove the other intermediate shaft

The bearing carrier and bearing cage will be

23. Move the shaft pinion out of mesh with

24. Remove the lower bearing and bearing

25. Remove the upper bearing retainer.

26. With a puller, remove the gear from the

duo-cone seal and 0-rings from the retainers.

34. Remove the vertical shaft lower bearing

35. Remove the sleeve upper retainer and

APPLY MAXIMUM PRESSURE WITH

21 for calculating timing corrections and for the

Procedure gear and mark the eleventh space with an (X)

2. Install the (Z) shaft so that the (S) mark lines

3. Count eleven tooth spaces

NOTE: THE GAP AND OVERLAP

7. If the measurement exceeds the

8. As an example, if the measured mid-

5. Install the motor input pinion shaft and

Each unit consists of two gear trains driving the

9. Mark the pinion tooth of the (Y) shaft

PROPEL MACHINERY The gears and pinions should be checked

bushings should be checked daily for excessive