Cat Bucyrus 8050 Dragline 80511 Maintenance & Operation Manual BI005605 - PDF DOWNLOAD

Technical Manual

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WARNING

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

If' the event you douLJt, for any REASON, your ahility to safely perform any of the en closed maintenance amJ operational procedures as they refer to your machine; please contact Marion Power Shovel Co., Inc.

READ AND OBSERVE ALL warninq siqns, they're placed for your health and safety.

ThiS manual has been preparcel for the standard production machine. Any deViation due to advanced enqineennq deslqn, o[Jtlona! eflulnment or the particular requirements of this machine may not he covered.

Additional that IS reqUired will t)8 furnished as soon as such Information is available

TABLE OF CONTENTS

The information contained in this manual provides guidance to all persons who care about the operation and maintenance of this machine. Needed data for operation, lubrication, adjustments and other tasks supplied in the various sections permits accurate operation and service. All enclosed specifications agree with the Marion Power Shovel Engineering Department. This information allows for quality maintenance when followed exactly.

This Manual is NOT a Parts Book. Do not use it to order rarts. You have been suprlied with a separate, detailed Parts Book. Please read carefully the instructions in the front of it. All parts are listed by group number with Items and part numbers for this SPECI FIC machine. Please order the correct parts In exact quantity. Parts ordered by mistake and returned are subject to a Company rehandling charge. RIGHT and LEFT HAND PARTS on the upper frame correspond to the operator's h21nds at the controls as he faces the bucket. Please state the correct machine SERIAL NUMBER In any conversation or correspondence. Records of each machine are filed by serial number. Given this number, the srecific design and original equirment check is accurate and quic:k

ADDED INFORMATION not found in this Manual or the Parts Book may be obtained from Marion Power Shovel Co., Inc., 617 West Center Street, P.O. Box 505, Marion, Ohio 43302.

SERVICE and LABOR CHARGES arr NOT accerted unless rreviously iwthorlzed by the Comrany In wrltlnq

STANDARD WARRANTY

Marlon Power Shovel Comrany, Inc. quarantees the equir ment manufactured by It to t)(· trrr of defects in material and workmanshiP under normal use and serVice, Its obligation under thiS warranty beinq Imilted to maklnq qoor! at Its factory any rart of parts thereof manufacturrd by It which shall, vVlthin six (6) months after deliv ery to Buyer, be returned to it, With transportation charqes prepaid, and which its examina tlon shall disclose to its satisfaction to have been thus defective, this warranty bring express Iy In IIPu of all warranties, express or Implied, and of all other obligations or liabilities on Marion Power Shovel Comrany's part

Marion Prm,r'l Shovi'l CompiJnY Inc Shilll not hi' hpld responsihlp or liahle in any event for s:wr1dl CJt (()[lsr'qll\'fltlill (L:Jm,lqf's, ilrlSlnq trom ;lnV (;lIISP whatsoPvi'r, and Buyer ilflreeS to rCld"ITln:fy ilflll SilVf' M,H:()n POi/vel Shovel CI)rnp,Ifl'y'. Inc: hiHmless therefrom

f';,_jl P()\/\/flr Shovel' inc rl)dkCS no CllJZlrantv or \/\fC!rrantv, eXrrp.ss or Imn1ird as 'II' !e,ill!ry l:tness. qllClI!lV, or Iwrform,lnce of any rnachlnrry, elluipment, apPClratus or Ilnt nlAtllrfacturerJ ,11 Its ovvn tilCtory whic:h ;irc sublpct onlY' to such qUClrCltl!y as rT'la'/ :V' thr rr;c1prct\\,lp rll11ntl f:lctlJr()rS

Thf> Compcltl\( tllf' nr;ht 10 Improve or chanqe the deslqn ot Its rroducts and sreclfi Cclt!CH1S thf'li'of imd thi' Companv shall Incur no Ilahility th('(rhy or Clny ohllqCltions to install suel, Itl'i)IOVemclits on products preViously sold,

SAFETY SUG5ESTIO.S

The operator controls the machine and its usefulness. The crew alone thinks for it. Safety, constantly in mind, prevents accidents. Develop good habits. Everyone hss bad habits, but try to erase them quickly. Cleanliness and safety go together. A clean machine is easier to operate, inspect, and maintain.

READ and OSSE RVE All warning signs, they're placed for your health and safety.

KNOW the location of fire extinguisher.

DO NOT START machine without a FULL tank of air pressure.

DO NOT LEAVE the controls without pushing the button marked "EXCITATION" and turning All brake switches to "SET".

DO NOT APPLY swing brakes while machine is rotating, except in emergency.

DO NOT H')LD the bucket/difJper load longer than neederl in dumping cycle.

DO NOT SERVICE or lube moving parts.

DO NOT BOARD an operating machine.

PLEASE READ carefully this Manual and Parts Book.

PLEASE LUBE regularly.

PLEASE CREATE A SYSTEMATIC procedure and follow it.

PLEASE WATCH clearance when swinging.

PLEASE OPERATE machine on as near level ground as possible.

PLEASE KEEP safe ofJerating procedures in mind at ALL times.

CAUTION IS THE BYWORD. Develop a feel for the machine. Try to sense failure before it arrives. Take that extra second to look again at something that seems out of place. A ,'ant ChiP or bubble may be an early warning. A slight hiss may indicate a growing air leak. It's much easier to tighten a fJaCking nut than shutdown for packing repair.

PROPERLY GROUND the power source.

WATCH AI R system performance

CHECK boom suspension, hoist and drag ropes for early signs of wear or failure. Kinks cause permanent damage.

CHECK LIMIT switches for proper operation.

CHECK OVERLOAD ancJ thermal breakers.

MAINTAIN correct supply of lubricant.

MAl NT AI N CLEA R walkways.

LOOK FOR loose holts and locklnq devices.

KEEP FLOORS CLEAN ancJ free of oil anrl qrease

WI PE AWAY excess qrPilse and Ol! around beannqs and qears

KEEP hands, feet dnd cloThlnq avvay from movlnq parts

PROMPTLY REPLACE eli I qu,mis Insr)ccTion doors, access covers and other safety features after inspection or rep,JJr

NEVER attempt electrical frpilit, unless qualified

HIGH VOLT AGE pO\.'Ver Iwps require USlnlj EXTREME CAUTION

Open Pit mJnlnq equipmenT underqoes \remendOllS shock dnd stress. Marlon's deslqn consid· ers these loads. ThiS machine. bUilt with an apple reserve of power and strenqth, will meet the demands of ItS task. Marion's enrJlneers cannot foresee the conditions imposed by abuse, neqlect and mismanaqement. These factors damage any piece of equipment more than years of continuous operation and normal wear. Care, sound Judgement and reason qovern the economic In the operation of power equipment.

OO\",nTII'lf: f;)(lstS, tJut "n on'ilJlnq IHOijldili 01 :nspcct!Orl dnd evaludtlon rn!rllm!ZeS It. Aware npss f unusual condiTions C]enerally warns personrwi before hreakdown occurs. Normal wear (I' parts escapes i:X:Jct <!CtJlilllon IJarts no not suddenlY' expire WPiJr takes place y /,\',,; rJf"I:[f'('S UVPr ti<n,:. ConsLJnt c!leck:nq Incllcates a wear pdtlprn An alert mainte "I ,.rpw c'l"cks AL.L strUC\IJfdl rnerl1!jf,rs for pVlcJence of stressed. tlloken or loose itpms.

iI,' liCH cracks occur In stecl StilictUrl'S it s true of ALL machines. ThiS IS NOT SERIOUS

\'\IH'll:v,'lrl rr>pdlrpc! wi'.lil: S(,lALL Col,I,\'f,Jtlil'l CdLJSeS fdS!l:r expansion and brittleness than \\Jrm weather Eally detection and qUick repdlr prevents failure. A stretch, bend or defect oltel1 shows UiJ In COncl!tlOn of surface pdlnt. A collection at ti,lSt alonq d Illle may Inrlicate

a, 'dl", il": the mel,d. Look CiOSl'iy dl dli'd', ;,rCiUn!! ooenlnqs ','o'herl' dnqles dre 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 locking devices. Rod bolts are important too. Signs of scuffed paint, worn or bright spots next to any part indicate movement and becomes second nature to most personnel. Retighten ALL bolts shortly after initial start up. Grease and oil stains often indicate problems. Perhaps just 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 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 IJlates and covers are removed.

On the uprwr works, a solvent makes removal of the accumulation of grease around bearings, gears, motes and the like easier. The dirt shield under the drag drum and the trough under the open gears may require a number 3 coal shovel to get the job done.

Start up trw machine and dig enough to warm up machinery, open the inspection cover over gears and p'nlOns. Look at Clear teeth as machinery slowly goes thru its paces of hoistlower· inC] and drag in payout. Broken teeth are easy to spot, but splayed or an unusual wear pat· tern 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. Comparing them gives an indication of misalignment. I f 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.

SlowlV rotate the uprJPr works several times In each cil rectlon. Look at condition of roller Circle, raii gear and SV\.ilnq rinlon. Sound here mav indicate a flat or chipped roller or even suqgest burrs or darnaqed teeth on the rotating pinion

W'lie hOist oflPrates check conditIOn of POint sheaves groove and bearings. Test hold down hoi t5 on boom point enc! plate While operating drag, check fairlead sheaves, grooves and hearlnrJS. Look at fiJlrlracJ svvlvel, Test ALL hold down bolts with Imoact wrench. Check rope guides for wear. Look at hOist and drag ropes for broken wires. While on boom point and 'lantry, may as wei! check alJto·lube system for loose, broken or damaged fittings or imes. Note condition of Injector. Properly lube ALL points, it's important.

Lower bucket/dipper to ground and shut down machine. Inspect bucket/dipper for cracks and breaks. Do not permit tooth base exposure. Teeth may be reversed. Remove bucket/ dipper from service and rebuild in shop before breakdown. Check main rotating gear hold down bolts. Use impact wrench if needed. Test ALL hold down bolts on rotating frame. Especially swing gear case, motor mounting, machinery pedestal and base bolts. Check also motor generator and air comrressor mount and base bolts. Tighten rod bolts on bearing housing.

Examine and readjust, if needed, hoist and drag brakes and drag clutch. Look at the condition of brake and clutch lininq. Remove Insrectlon plate from swing gear case. Look at condition of gears. Use orv bar to detect anv side motion of shaft indicating worn bearings. Examine condition of rotating brakes and their arJjustment. Adjust, if needed. I nspect air compressor "V" belt tension, rerlace if neederJ. Fill the anti-freezer but don't drink that stuff. Check auto-lube system for loose or broken fittings or injectors.

Check center journal thrust washer and hearing. Secure ALL qLJards and safety features in place. DISCONNECT POWER SOURCE with machine shut down so electrical crew may adequately clean and inspect motor qrnerators dnd r>lectrical cabinets NOTE any discolored electrical parts, II's a Sign of oVP'iwatlnq In hunl1li areas, look for funqLJs and mildew. Dry comrressed air at LOW prrssure wOlks well for dust rfcmoval Clean corrosion from parts, jOints and connections. RetiGhten, wllPre ner,drd. ,mv loose connections and terminals. Use of proper tool herr; el irnlrldtes broken 1r:rmlnills and terminal blocks. missinq or d;imaged taCJs and labels. Bundle loose wlrinq. Fasten ALL components and wiring in cabiIwtS. Check thi? r"hii' ClrrT,nr : qt11 in the fixlurt'. Look closely whrre wirf's and cables Dass thru openinqs and (rfOi'lrTiP1s insui'ltlCJn fLnnaqf: [JPf 1 rralJy occurs herr. Rpnlacp qrommets If necded. Arcinf] of ITHltorS ,Hlfl (]f:W'fil1ors rr,j';es dlsco!ored commutators Look at brushes and brush holdcr conrJltion. Correc1 brush sprinq tension where neerJed. Collector rings npecJ c!eaninq anc! checklr1l] cliso USI' a hand qrcase qun at pach Irljector. Fill ALL grease li'18S and purqe EACH bCClrinq With MPG. Rrrnernher to replace ALL plugs, covers andinspection plates.

ThiS may secm llkr (j fGt Of nil'f'lnrl around chrckrnf1. looklnr:, insoectinq, c!eaninq and then weasing, hut this IS the macl'! til t rndf<CS till' lJ(lvloll posslhle. KePllrnn it runnlnCJ is very

1;:1 [")crt n 1

1'1 'J "(lUlnnlf'n t cn ii: "" 'I ,ii: ",p lin" is (liso \\!ear patterns show UD

a' VilrV1rw deqrc0s in Ilm't PI'c,lrr!'ilCimr! ch(;ckrnq tl1('se r"[lorts at a fulLlre date allows com :lldr,,,,,! ';hl:tdrw'flS Pleln'll !" 1(:;.: ,1ft nrdprs ,lnr! crrws for a scheduled shut-

Section 1 - Engineering Data (Continued)

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