Cat Bucyrus 7500 Dragline Maintenance & Operation Manual BI379367 - PDF DOWNLOAD

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TABLE OF CONTENTS

Introduction. Section 1

Operation {Gold}. Section 2

Lubrication {Green} Section 3

Mechanical Adjustments {Orange}. Section 4

Electrical Maintenance {Lt. Blue} .. ..................... .. Section 5

Compressed Air Systems {Yellow}. ...................... .. Section 6

Engineering Data {Red} " Section 7

Inspection Reports {Dark Blue} Section 8

....,"""""',...... 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 GROUNDING RESISTOR AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.

In the event you doubt, for any REASON, 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.

All goods are sold and delivered subject to standard manufacturing and other variations and practices customary in the trade. Seller warrants goods manufactured by Seller to be free from defects in material and workmanship under 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 or alterations thereon have been carried out without Seller's consent in writing. Liability of Seller for goods found to be defective or not in accordance 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 ARE SUBJECT TO NO OTHER WARRANTIES, EXPRESS OR IMPLIED. SELLER DISCLAIMS AND BUYER WAIVES ANY IMPLIED WARRANTY OF MERCHANTABILITYOR FITNESS OTHER THAN THE EXPRESSED SIX MONTHS WARRANTY SET FORTH ABOVE.

Marion Power Shovel Division shall not be held responsible or liable in any event for special or conse'quential damages, arising from any cause whatsoever, and Buyer agrees to indemnify and save Marion Power Shovel 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_.. ,0.. a

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 owner, 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 IS NOT A PARTS BOOK, nor is it to be used to order parts. You have been supplied with a separate, detailed 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 rehandling 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 SE RIAL NUMBE R (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, ADDED INFORMATION not published in this Manual or the Parts Book, may be obtained from your local service representative or send correspondence to:

Technical Services Department

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 safety 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, clean habits and erase the bad ones quickly.

Observe and acknowledge ALL warning signs. Ignoring one of these signs could not only be dangerous 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 loose clothing.

Wear required safety equipment.

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

OPERATOR TIPS

The operator, controlling 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 operating procedures in mind at all times.

Know location of fire extinguishers.

Operate mach ine on 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.

Check limit switches to assure proper "within reason" functioning.

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

Never leave the controls until the "Excitation" button is pushed and flippinglturning all brake 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. How about a bubble or discolored crack in the paint? It is an early warning for metal stress or breakage. 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.

Lube regularly.

Never lubricate parts in motion, that is gears, etc.

Look for and secure 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 inspection/repai r.

USE EXTREME CAUTION around ANY electrical lines and equipment. This pertains to low as well as high voltage.

Never attempt electrical repairs, unless qualified.

Assure power source is properly grounded.

Check limit switches for proper operation.

Check overloads and thermal breakers. 1-4

SUGGESTIONS FOR INSPECTING

PREVENTIVE MAINTENANCE MEANS PEAK PRODUCTION AND LONGEVITY.

Open pit 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 years of continuous operation and normal wear. Care, sound judgment and reason govern the economic need in the operation of power equipment.

Downtime exists, but an ongoing program of inspection and evaluation minimizes it. Awareness of unusual conditions generally warns personnel before breakdown 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 SERIOUS when weld repaired while SMALL. Cold weather causes faster expansion and brittleness than warm weather. Early detection and quick repair prevents failure. A stretch, bend or defect often: shows up in condition of surface paint. A collection of dust along a line may indicate a crack 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 bolts 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 MAl N reasons for breakdown. If any part shows wear or distortion beyond expected normal wear, order replacement and quickly install. The cost of parts is nothing when compared to: breakdown cost and loss of man hours and production.

Production machines operating 24 hours, 7 days every week deserve an 8 hour inspection and cleaning every 10 days. Cleaning before inspection eliminates dirt and dust falling into machinery parts when inspection plates and covers are removed.

On the upper frame, a solvent makes removal of the accumulation of grease around bearings, gears, motors and the like easier. 1-5

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

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