Cat Bucyrus 1260-W Walking Dragline Mechanical Maintenance Manual BI005568 – PDF DOWNLOAD

• The lower works provides a foundation for the revolving frame and contains the base, swing rack
and roller circle.

• The rotating deck includes the revolving frame and machinery house. The machinery
house encloses all of the hoist, swing, drag and propel machinery, and the electrical systems
required to control machine functions. It also contains an air filtration system to minimize heat
and dirt build­ up in the machinery house. An elevated cab mounted on the house
provides the machinery operator’s station. The cab contains all machine operating controls.

• The front end equipment is comprised of the A-frame, fairlead, mast, boom, running ropes, boom
structural strands, and dragline bucket.
This manual consists of four chapters, each divided into sections. A table of contents is located
in the front of the manual.

CHAPTER 1 MECHANICAL MAINTENANCE
SECTION 1 – MAINTENANCE PROCEDURE
General 1-1-1
Maintenance Schedules and Reports 1-1-1
Safety 1-1-2
General 1-1-2
In-Operation Maintenance 1-1-2
Precautions Before and During Maintenance Work 1-1-2
SECTION 2 – LOWER WORKS
Lower Works 1-2-1
Base 1-2-1
Repair 1-2-2
Center Pintle 1-2-2
Swing Rack 1-2-3
Repair 1-2-4
Roller Circle 1-2-5
Repair 1-2-5
Lifting Hook and Hook Path 1-2-6
Repair 1-2-6
SECTION 3 – ROTATING DECK
Revolving Frame 1-3-1
Machinery Units 1-3-1
Hoist and Drag Machinery 1-3-2
Swing Machinery 1-3-10
Propel Machinery 1-3-20
Brakes 1-3-32
Drag Rope Support Rollers 1-3-38
Machinery House and Cab 1-3-38
Structural Members and Panels 1-3-38
Dynavane Air Cleaner 1-3-39
House Fans 1-3-39
House Fans (Chicago Blower) 1-3-40
Auxiliary Hoists and Overhead Crane 1-3-40
Walkways and Stairways 1-3-41
Windshield Wiper 1-3-42
Operator’s Seat 1-3-43
Swing Control Unit 1-3-43
SECTION 4 – FRONT END EQUIPMENT
Boom 1-4-1
Upper and Lower Deflection Sheaves and Towers 1-4-3
Boom Point 1-4-3
Hoist Rope House Deflector Rollers 1-4-7
Mast 1-4-8
A-Frame 1-4-9
Structural Strands 1-4-11
A-Frame Safety Structural Strands 1-4-12
Upper, Lower And Intermediate Structural Strands 1-4-12
Hoist and Drag Ropes 1-4-16
BI005568
Hoist Rope Replacement 1-4-16
Drag Rope Replacement 1-4-18
Fairlead 1-4-19
Repair 1-4-19
Buffer Cylinder 1-4-27
Dragline Bucket 1-4-27
CHAPTER 2 AIR SYSTEM
SECTION 1 – GENERAL MAINTENANCE
Safety 2-1-1
General 2-1-1
Maintenance of Air System 2-1-1
Air Compressor & Air Dryer 2-1-1
Air Lines 2-1-1
Air Tank 2-1-1
Air Line Lubricator 2-1-1
Air Line Filter 2-1-1
Air Line Regulator 2-1-1
Solenoid Valves 2-1-1
Pressure Switches 2-1-1
Air Dryer 2-1-5
SECTION 2 – COMPONENT MAINTENANCE
Air Line Lubricators 2-2-1
Type L12 & L17 Micro-Fog Lubricators 2-2-1
Air Regulator 2-2-1
Air Line Filters 2-2-2
Type F12 & F17 Auto Drain Filters 2-2-2
Air Dryer 2-2-3
CHAPTER 3 LUBRICATION
SECTION 1 – GENERAL MAINTENANCE
General 3-1-1
Lubrication Benchmarks 3-1-1
Lubrication Charts 3-1-2
SECTION 2 – AUTOMATIC LUBE SYSTEMS
System-A 3-2-1
System-B 3-2-1
System-C 3-2-1
System-D 3-2-2
System-E 3-2-2
System-F 3-2-2
System-G 3-2-2
System-H 3-2-2
System-I 3-2-2
System-J 3-2-3
System-K 3-2-3
System-L 3-2-3
Control Panels 3-2-3
Pump Control Stations 3-2-3
Pumps 3-2-3
Warning Devices 3-2-3
BI005568
Cold Weather Equipment (Optional) 3-2-4
Lubricant Drum Handling Equipment (Optional) 3-2-4
CHAPTER 4 TROUBLESHOOTING
Base Components 4-1-1
Revolving Frame 4-1-2
Hoist, Drag, Swing and Propel Machinery 4-1-2
Machinery House and Cab 4-1-3
Lubrication Systems 4-1-4
Air Line Regulator 4-1-5
Air Lines and Storage Tank 4-1-5
Air Line Lubricator 4-1-6
Automatic Drain Filter 4-1-6
Dynavane Air Cleaner 4-1-6
A-frame 4-1-6
Mast 4-1-7
Boom 4-1-7
Dragline Bucket 4-1-7
Drag and Hoist Ropes 4-1-8
Fairlead 4-1-8
APPENDICES
APPENDIX Al – GEAR INSPECTION A1-1
APPENDIX A2 – BOLT TORQUING A2-1
APPENDIX A3 – BOOM INTERMEDIATE STRUCTURAL STRAND ADJUSTMENT A3-1
APPENDIX A4 – PINION AND COUPLING INSTALLATION A4-1
APPENDIX A5 – MAINTENANCE WELDING
SECTION 1 – Repair Welding of Base, Revolving Frame, A-Frame, Walking Shoes
and Drag Bucket A5-1-1
General A5-1-1
Recommended Electrodes and Preheat A5-1-1
Welding Electrodes A5-1-1
Repair Welding Procedures A5-1-2
General Procedure for Repair of Broken Parts A5-1-4
Procedure for the Repair of Cracked or Broken Drag Bucket Lips A5-1-4
Stress Relieving A5-1-6
Procedure for Replacement of Bucket Lip Shrouds A5-1-6
Drag Bucket Tooth Repair A5-1-6
Drag Bucket Clevis Plates A5-1-8
SECTION 2 – Repair Welding Swing Rack Teeth A5-2-1
Preparation A5-2-1
Welding Electrodes A5-2-2
Preheat A5-2-2
Welding A5-2-2
SECTION 3 – Welding and Cutting Equipment A5-3-1
SECTION 4 – Stress Relieving and Temperature Measuring Equipment.. A5-4-1
APPENDIX A6 – LUBRICATION BENCHMARKS A6-1
APPENDIX A7 – TAPERED ROLLER REPLACEMENT A7-1
APPENDIX A8 – RAIL CHOCKING TIGHTNESS A8-1
BI005568
APPENDIX A9 – PREVENTIVE MAINTENANCE CHECKLISTS A9-I
APPENDIX AIO – BRAKE OR CLUTCH MAINTENANCE CHECKLIST AlO-I
Brake Lining Burnish-In Procedure AIO-2
APPENDIX All – TYPICAL PART WEIGHTS All-I