Cat Bucyrus 8050 Walking Dragline Operation & Maintenance Manual BI116005 – PDF DOWNLOAD

Technical Manual

• 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.

Marion Power Shovel Division Dresser Industries, Inc.

TABLE OF CONTENTS

Introduction .......................................... Section 1

Operation (Gold) Section 2

Lubrication (Green) , Section 3

Mechanical Adjustments (Orange) , Section 4

Electrical Maintenance (Light Blue) Section 5

Compressed Air System (Yellow) .......................... Section 6

Engineering Data{Red) Section 7

I nspection Reports (Dark Blue) .............. , ............. Section 8

Cross I ndex (White) - Back of Manual

WARNIf'J6:

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 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.

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.

STAN,'OAR;O WARRANTY

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 fo'r other breach of contract, 'negligence, strict liability or otherwise shall be limited to re" placement of goodsF .O.B. Seller's plant or return of goods and refund of the purchase price therefor as the Seller shall elect. Goods which tJave not been manufactured by Sel!er shall' be subject only to such warranty as may be made by the ma/nufacturer thereof. TH E GOODS ARE SUBJECT TO NO OTHER WARRANTIES, EXPRESS OR IMPLlED.SELLER DISCLAIMS AND BUYER WAIVES ANY IMPLIED WARRANTY OF MERCHANTABILITY OR 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 consequential damage,s, 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. IMA ..,oN

INTRODUCTION

The information contained in this manual provides guidance to persons who care about the and maintenance of this machine. Needed data for operation, lubrication, adjustment and other tasks supplied in the various sections permits accurate operation and service. This information allows for quality maintenance when followed exactly.

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. SERVICE and LABOR CHARGES are NOT accepted unless previously authorized in writing by Marion.

All enclosed specifications agree with the Marion Power Shovel Division Engineering Department.

This Manual is NOT a Parts Book. Do not use it to order parts. You have been supplied 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 SPECIFIC machine. Please order the correct parts in exact quantity. Parts ordered by mistake and returned are subject to a 'MPSD rehandling charge. RIGHT and LEFT HAND parts or direction referred to in this manual or parts book correspond to the operator's hands at the controls as he faces the bucket. Please state the correct machine SERIAL NUMBER in any conversation or correspondence. This number is located on a plate located in operator's cab. Records, at MPSD, of each machine are filed by serial number. Given this number, the specific design and original equipment is accurate and quick.

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

SAFETY SUGGESTIONS

The operator controls the machine and its usefulness. The crew alone thinks for it. Safety, constantly in mind, prevents accidents. Develop good habits. Everyone has 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 OBSERVE ALL warning signs, they're placed for your health and safety.

KNOW the location of fire extinguisher.

PROMPTL YREPLACE all guards, inspection doors, access covers and other.safetyfeatures after inspection or repair.

PROPERLY GROUND the power source.

HIGH VOLTAGE power lines require using EXTREME CAUTION.

<NEVER attempt repairs, unless qualified.

PLEASE READ carefully thisManual and Parts Book.

PLEASE CREATE ASYSTEMATIC 'MAINTENANCE procedure and follow it.

PLEASE KEEP safe operating procedures in mind at ALL times.

CAUTION IS THE Develop a feel forthemachine. Try to sense failure before it arrives. Take that extra second to look at something that seems out of place. Apaint chip or bubble may be an early warning. A slight hiss may indicate a growing air leak. It's much easier to tighten a packing nuUhan shutdown for packing repair.

LOOK FOR loose bolts and locking devices.

KEEP FLOORS CLEAN and free of oil and grease.

WIPE AWAY excess grease and oil around bearings andgears.

KEEP hands, feet and clothing away from moving parts.

MAINTAIN CLEAR walkways.

PLEASE LUBE regularly. 1-:2

MAl NT AI N correct supply of lubricant.

DO NOT SERVICE or lube moving parts.

WATCH AI Rsystem performance.

PLEASE OPERATE machine on as near level ground as possible.

DO NOT START machine without FULLtankof air pressure.

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

PLEASE WA TCHclearance when swinging.

DO NOT HO LD the bucket load longer than needed in dumping cycle.

DO NOT BOARD anoperating machine.

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 and thermal breakers.

DO NOT LEAVE the controls withou't pushing the button marked "EXCITATION" and turning ALL brake switches to "SET".

SUGGESTIONS 'FOR INSPECTION'

Open pit mining equipment undergoes tremendous shock and stress. Marion's design consid· ers these loads. This machine, builtwith 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 judgement 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 notsuddenlyexpire. Wear takes place at varying degrees over time. Constant checking indicates a wear pattern. An alert mainte· nance crew checks ALL structural members for evidence ofstressed,broken or loose items. 'Minor cracks occur in steel structures. It's true of ALL machines. This is NOT SERIOUS 1-3

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 connec,tions 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 conformto 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 anB 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 works, a solvent makes removal of the accu'mulation of grease around bearings, gears, motors and the like easier. The dirt shield under the drag drum and the trough under the open gears may requi re a number 3 coal shovel to get the job done

. Start up the machine and dig enough to warm.up machinery, open the inspection cover over gears and pinions. Look at gear teeth as machinery slowly goes thru its paces of hoist/lowering Broken teeth are easy to ,spot, but splayed or an unusual wear patterri 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. 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.

Slowly rotate the upper works several times in each direction. Look at condition of roller circle, rail l gear and swing pinion. Sound here may indicate a flat or chipped roller or even suggest ,burrs or damaged teeth on the rotating pinion.

While hoist operates, check condition of point sheaves groove and bearings. Test hold down bolts on boom point end plate. While operating drag, checkfairlead sheaves, grooves and bearings. Look at fairleadswivel. Test ALL hold down bolts with impact wrench. Check '1-4

rope guides for wear. Look at hoist and drag ropes for broken wires. While on boom point and gantry I may as well check auto-lube system for loose, broken or damaged fittings or lines. Note condition of injector. Properly lube ALL points, it's important.

Lower bucket to ground and shut down machine. Inspect bucket for cracks and breaks. Do not permit tooth base exposure. Teeth may be reversed. Remove bucket 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 compressor mount.and base bolts. Tighten rod bolts on bearing housing.

Examine and readjust; if needed, hoist and drag brakes. Look at the condition of brake lining. Remove inspection plate from swing gear case. Look at condition of gears. Use pry bar -to detect any side motion of shaft indicating worn bearings. Examine condition of rotating brakes and their adjustment. Adjust, if needed. Inspect air compressor "V" belt tension, replace if needed. Fill the anti-freezer but don't drink that stuff. 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 plugs, covers and inspection plates.

Check 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 parts, joints and connections. Retighten, where needed, any loose connections and terminals. Use of proper tool here eliminates broken terminals and terminal blocks. Replace missing or damaged tags and labels. Bundle loose wiring. Fast,en- ALL components and wiring in cabi: nets. Check the cable armor tight in the fixture Look closely where wires and 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 brush spring tension where needed. Collector rings need cleaning and checking also .

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

Passing equipment condition reports along the line is important also. Wear patterns show up at varying degrees intime. Recording and checking these reports at a future date allows comparison and planned shutdowns. Planned repairs, part orders and crews for. a scheduled shutdown el iminates idle downtime. 1-5

OPERATION ,·J.\:ND 'MAINTENANCE TRAINING is the best way to reduce downtime and keep your machine in good running condition. Marion's .Service Department experts have produced three different tape/slide/workbook presentations to be used as your training guidelines. These·comprehensivecourses, at a minimalcha'rge to you, 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 fieldproven 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 the Training Section of ' Marion's Service Department. 1-6

• 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.