Cat Bucyrus 8200 Dragline Maintenance & Operation Manual 82008 & 82009 - PD

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 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 nrocedures as they refer to your machine; please contact Marion Power Shovel Division of Dresser Industries, Inc.

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 eqUI[1ment 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.

TABLE OF CONTENTS

Introduction

Engineering Data (Red)

1

Lubrication (Green) Section 2

Compressed A ir System and Components (Yellow)

Mechanical Adjustments (Orange)

Electrical Maintenance (B lue)

3

4

5

Operation (Gold) Section 6

SAFETY SUGGESTIOIIS

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.

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 HOLD the bucket/dipper load longer than needed 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 KE EP safe operating procedures in mind at All times.

CAUTION IS THE BY-WORD. 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 paint 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 nut than shutdown for packing repair.

PROPERLY GROUND the power source.

WATCH AI R system performance.

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

CHECK LIMIT switchesfor proper operation.

CH ECK aVE R LOAD and thermal breakers.

MAl NTAI N correct supply of lubricant.

MAINTAIN CLEAR walkways.

LOOK FOR loose bolts and locking devices.

KE EP FLOORS CLEAN and free of oil and grease.

WI PE AWAY excess grease and oil around bearings and gears.

KEEP hands, feet and clothing away from moving parts.

PROMPTL Y REPLACE all guards, inspection doors, access covers and other safety features after inspection or repair.

NEVE R attempt electrical repair, unless qual ified.

HIGH VOLTAGE power lines require using EXTREME CAUTION.

Open pit mining equipment undergoes tremendous shock and stress. Marion's design considers these loads. This machine, built with an apple 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 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 items. 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 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 someth ing 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 works, a solvent makes removal of the accumulation 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 require 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 and drag-in pay-out. Broken teeth are easy to spot, but splayed or an 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. 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, 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, check fairlead sheaves, groovesand bearings. Look at fairlead swivel, Test ALL hold down bolts with impact wrench. Check rope guides for wear. Look at hoist and drag ropes for broken wires. While on boom point and gantry, 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. Page 4

• 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

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