Cat Bucyrus 7450 Walking Dragline Operation & Maintenance Manual BI006202 - PDF DOWNLOAD

Technical Manual

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TABLE OF CONTENTS

WARNING

DUE TO THE DANGERS INHERENT IN THE OPERATION OF ANY HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM SHOULD INCLUDE GROUND CONDUCTORS IN THE CABLE, A NEUTRAL RESISTOR AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.

In the event you doubt, for anyREASON, your ability to safely perform any of the enclosed maintenance and operational procedures as they refer to your machine; please contact your Local Service Representative or Service Department at Marion, Ohio 43302.

READ AND OBSERVE ALL warning signs, they're placed for your health and safety.

This manual has been prepared for the standard production machine. Any deviation due to advanced engineering design, optional equipment or the particular requirements of this machine may not be covered.

Additional information that is required will be furnished as soon as such information is available.

STANDARD WARRANTY

All goods are sold and delivered subject to standard manufacturing and variations and practices customary in the trade. Seller warrants manufactured by Seller to be free from defects in material and wprkmanship ynder normal use and service for a period of six (6) months from the date of delivery, provided that the goods have, since the date of delivery, been properly used, maintained and stored, and no repairs 9r alterations thereon have been carried out without Seller's consent in writing. Liability of Seller for goods found to be defective or not in ac;cordance with agreed specifications or for other breach of contract, negligence, strict liability or otherwise shall be limited to replacement of goods F .O,B. Seller's plant or return of goods and refund Of the purchase price therefor as the Seller shall elect. Goods which have not been manufactured by Seller shall be subject only to such warranty as may be made by the manufacturer thereof. TH E GOODS

AAE SUaJECT TO NO OTHER WARRANTIES, EXPRESS OR 1M· PLIED. SELLER DISCLAIMS AND BUYER WAIVES ANY IMPLIED OF MERCHANTABILITY OR FITNESS OTHER THAN THE eXPRESSED SIX MONTHS WARRANTY SET FORTH ABOVE.

Marion Shovel Division shall not be held responsible or liable in any event for special or consequential damages, arising from any cause and Buyer agrees to indemnify and save Marion Power Slhovel Division harmless therefrom.

Marion Power Shovel Division reserves the right to improve or change the design of its products and specifications thereof and the Marion Power Shovel Division shall incur no liability thereby or any obligations to install such improvements on products previously sold. 1-..-

SECTION 1

INTRODUCTION

This manual is designed to be informative and helpful during the operation and preventive maintenance of this 'equipment. Great care has been taken to provide you, the with the most comprehensive, up-to-date material available from our engineering, service and training departments. Following the easy to understand step-by-step procedures, the maintenance crew will be able to perform their duties without sacrificing safety or production. When a systematic and thorough maintenance/service procedure (a responsibility' of the maintenance superintendent) is instituted for the Equipment, quality maintenance and operation will result.

THIS MANUAL JS NOT A PARTS BOOK, nor is it to be used to order parts. You have supplied with a separate, de,tailed Parts Book. Please carefully read the instructions in the front of it. All parts are listed by group numbers with item/part numbers for THIS SPECI FIC MACHINE. Order parts in exact quantity. Parts ordered by mistake and returned, are subject to a charge. RIGHT and LEFT HAND PARTS on the upper frame correspond to the operator's hands at the controls; that is, facing forward and looking out the cab front window. Please state the correct machine SERIAL NUMBER (located on a plate in the operator's cab) when corresponding or conversing with us. Our records on each maChine are filed by serial number and when given this number, your specific design and original equipment is both accurate and quick .

When required,ADPED INFORMATION not published in this Manual or the Parts Book, may be obtained from your local service representative or send correspondence to:

Technical Services

Marion Power Shovel Division

Dresser Industries, Inc.

617 West Center Street

P.O. Box 505

Marion, Ohio 43302

or:

Telephone 614/383·5211

Ext. 2454 or 2359

Telex 24-5307

TWX 810/487-2772

Telecopier 614/383·5211

Ext. 2275

Service and labor charges not accepted unless previously' authorized, in writing, by Marion Power Shovel Division.

SAFETY TIPS

Safety, the main factor and CONSTANTLY in mind, prevents accidents and near mishaps.

- Cleanliness and $afety go hand in hand, thus making the machine easier to operate, inspect and maintain. A safety conscious crew will carefully read this manual and -:

Create a systematic maintenance schedule and STICK to it.

Develop good, habi,s and erase the bad ones qu ickly.

Observe and ALL warning signs. Ignoring one of these signs could not only be but fatal.

Keep safe operating procedures in mind at ALL times.

Never take a "short cut" that could jeopardize a life or limb.

Know the location of fire extinguishers.

Never board an operating machine.

Keep away from moving parts.

Never wear 190se clothing, Wear requil'td safety equipment.

Keep floors/walkways/ladders clear and -free of oil or grease.

THINK

OPERATOR TIPS

The operator, c'ontrolling the machine for maximum efficiency and production, can "feel" when something Is or is not functioning properly. An efficient operator will.:

Have a full tank of air pressure before starting machine.

Keep safe procedures in mind at all times.

Know lopation of fire extinguishers.

Operate mach ineon level ground.

Watch air system performance.

Watch clearance in the swing mode.

Never set swing brakes while machine is in swing mode, except in an emergency situation.

Never hold load longer than needed in the dump cycle.

Checl< limit switches to assure proper "within reason" functioning.

Inform the maintenance crew on any malfunction or "odd feeling".

Never leave the contrQls until the "Excitation" button is pushed and flipping/turning all brak., switches to "Set".

MAINTENANCE TIPS

Just as the operator acquires a "feel" for the machine, the entire crew should try to sense failure before it strikes. Take that extra step to examine anything that appears out of place. H9w about a bubble or discolored crack in the paint? It is an early warning for metal stress or breakagj:!. Could that slight hiss indicate a growing air leak? After all, it is easier to tighten a packing nut than shut down for packing repairs. An alert crew will:

Check operating air pressure.

Wipe away excess lube around bearings and gears.

Maintain correct supply lubricants. reQuljJrly.

Never parts in motion, that is gears, etc.

L.ook for and any loose bolts or locking devices.

Check all wire ropes for early signs of wear or failure.

Promptly replace all guards, inspection plates, access covers or other safety devices after use EXTREME CAUTION around ANY electrical lines and equipment. This pertains to lollY well as high voltage.

Never attempt repairs, unless qualified.

Assure power source is properly grounded.

Ghecklimitswitches for proper operation.

Check overloads and thermal breakers. 1-4

SUGGESTIONS FOR INSPECTING

PREVENTIVE MAINTENANCE MEANS PEAK PRODUCTION AND LONGEVITY.

Open mining equipment undergoes tremendous shock and stress. Marion's design considers these loads. This machine, built with an ample reserve of power and strength, will . meet the demands of its task. Marion's engineers cannot foresee the conditions imposed by abuse, neglect and mismanagement. These factors damage any piece of equipment more' than yeal'lsof continuous operation and normal wear. Care, sound judgment and rea$on the economic need in the operation of power equipment.

Downtime exists, but an ongoing program of inspection and evaluation minimizes it. Awarj!ness of unusual conditions generally warns personnel before breakdowri·occurs. Normal wear of machinery parts escapes exact definition. Parts do not suddenly expire. Wear takes place at varying degrees over time. Constant checking indicates a wear pattern. An alert maintenance crew checks ALL structural members for evidence of stressed, broken or loose parts.

Minor· cracks occur in steel structures. It's true of ALL machines. This is NOT SE RIOUS when weld repaired while SMALL Cold weather causes faster expansion and br,ittleness than warm weather. Early detection and quick repair prevents failure. A stretch, bend or C1efectoften shows up in condition of surface paint. A collection of dust along a line "lay indicate a prack in the metal. Look closely at areas around openings where angles ,are cut out. Also check gusset connections and points where thin and heavy metals join. The good crew watches for loose bolts, nuts, cap screws, lock washers and. other devices. Rod bofts are important too. Signs of scuffed paint, worn or bright spots next to any part indicates movement and becomes second nature to most personnel. Retighten ALL bolts shortly after initial start-up. Grease and oil stains often indicate problems Perhaps poor housekeeping, but at least something is wrong.

Replacement and maintenance schedules may conform to planned shutdowns. Lack of proper lube, poor adjustments and abuse cause and speed up wear. These facts show up' as the MAIN reasons for breakdown. If any part shows wear or distortion beyond expected normal wear, order replacement and quickly install. The cost of parts nothing when compared to breakdown cost and loss of man hours and production.

Production machines operating 24 hours, 7 days every week deserve anB hour inspection and cleaning every 10 days. Cleaning before inspection eliminates falling in.to machinery when inspection plates and covers are removed.

On the upper frame, a solvent makes removal of the accumulation of around bearings, gears, motors and the like easier.

the machine and dig enough to warm up machinery, open the inspection cover over and pinions. Look at gear teeth as machinery slowly goes thru its paces. Broken teeth are easy to spot, but splayed or unusual wear pattern takes a closer look. ,

For a quick check, run a piece of soft wire thru the gear mesh at each side of the pinion. Measure thickness of the two adjacent loops with micrometer. The sum of the two loops indicates backlash liInd gives an indication of misalignment. If excessive backlash is suspected, measure with a dial indicator. There just isn't enough room between the gear guard and the pinion to use a feeler gauge.

rotate the upper frame several times in each direction. Look at condition ofroHer circle, ral', Q8ar and swing pinion. Sound here may indicate a flat or chipped roller or even burrser (lJlImaged teeth on the swing pinion.

cycles, check condition of sheave grooves and bearings. Test all hold down bolts with ilTlPact wrench. Check rope guides and bails for wear. Inspect all rope for broken wires ora ,IQse in diameter. When inspecting the boom point or gantry, check the auto-lube system for loose or damaged fittings. Note injector condition. Properly lube all points; IT'S

Lower bucket/dipper to the ground and shut off machine. Inspect bucket/dipper for cracks. Do not permit tooth bese exposure. Teeth may be reversed with minimal effort. Remove pucket/dipper and rebu i1d.

Check main swing gear down bolts. Use impact wrench if needed. Test all hold down bohs pn upper frame, l"peclally on swing gear case, motor mounting, machinery pedestal and base bolts. AlSO, check motor generator, air compressor mount and base bolts. Tighten r()d bQlts On be,ringho\.lSlng.

Examine and readj\,lst, if needed, all brakes, Look at the condition of brake lining. Remove Inpsection plate from swing gear case. Look at condition of gears. Use pry bar to detect any side motion of shaft indicating worn bearings.

Inspect air compressor "V" belt tension, replace if needed. Fill the anti-freezer. Check auto-lube system for loose or broken fittings or injectors. Use a hand grease gun at each injector. Fill ALL grease lines and purge EACH bearing with MPG. Remember to replace ALL phJgs, covers and inspection plates.

center journal thrust washer and bearing. Secure ALL guards and safety features in place. DISCONNECT POWER SOURCE with machine shut down so electrical crew may adequately clean and inspect motor generators and electrical cabinets. NOTE any discolored electrical parts, it's a sign of overheating. In humid areas, look for fungus and mildew. Dry compressed air at LOW pressure works well for dust removal. Clean corrosion from 1-6

parts, joints and connections. Retighten, where needed, any loose connections and terminals. Use of proper tools eliminates broken terminals and terminal blocks. Replace missing or damaged tags and labels. Bundle loose wiring. Fasten ALL components and wiring in cabinets. Assure cable armor is tight in the fixture. Look closely where wires and/or cables pass thru openings and grommets. Insulation damage generally occurs here. Replace grommets if needed. Arcing of motors and generators causes discolored commutators. Look at brushes and brush holder condition. Correct the brush tension where needed. Collector rings need cleaning and checking also.

This may seem like a lot of running around, checking, looking, inspecting, cleaning and then greasing; but this is the machine that makes the payroll possible. Keeping it running is very important.

Passing equipment condition reports along the line is important also. Wear patterns show up at varying degrees in time. Recording and checking these reports at a future date allows comparison and planned shutdowns. Planned repairs, part orders and crews for a scheduled shutdown eliminates idle downtime.

OPERATION AND MAINTENANCE TRAINING is the best way to reduce downtime and keep your machin.e in good running condition. Marion's maintenance and operation training experts have produced many different tape/slide workbook presentations to be used as your training guidelines. These comprehensive courses will familiarize mechanics, oilers, operators and other interested personnel in the proper maintenance and operation of your Marion machine.

The overall objectives of Marion's training programs are to increase machine availability thru properly trained and knowledgeable personnel. These objectives are attained using field proven training concepts where the student sees, hears and participates in the program. The programs are elementary and covers maintenance instructions for a specific machine, electrical maintenance and general instructions for routine repairs/adjustment of Marion machines.

Further information about these cost-saving programs can be obtained by calling or writing Marion's Maintenance and Operation Training Section.

CAUTION IS THE 1-7

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.