Cat Bucyrus 8200 Dragline Maintenance & Operation Manual BI116023 - PDF DOWNLOAD

Technical Manual

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8200 WALKING DRAGLINE

WARD LEONARD - STATIC CONTROL- INDEPENDENT PROPE'L

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 GROUND.lNG 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 part,icular requirements of this machine may not be covered.

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

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, cOhtrolling the machine fQr maximum efficiency and production, can "feel" when something is or is not functioning properly. An efficient operator will:

Have required air pressure before starting machine.

Keep safe operating procedures in mind at all times.

Know location of fire· extinguishers.

Operate machine 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.

I nform the maintenance crew on any malfunction or "odd feeling".

Never leave the controls until the "Excitation Off' button is pushed and flipping/turning 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 lubricants.

Lube regularly.

Never lubricate parts in motion, gears, shafts, clutches, 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/repair.

USE EXTREME CAUTION around ANY el.ectrical 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.

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 mismanggement. 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 parts.

Minor cracks occur in steel structures. It's true of ALL machines. This is NOT SER 10US 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 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 is minimal 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.

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. 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 and gives an indication of misalignment.

Slowly rotate the upper frame 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 swing pinion.

During dig cycles, check condition of sheave grooves and bearings. Check lock plate and shaft cap bolts at each end of boom point shaft and note condition of dust boots and capscrews in sheave bearing retainers. Test all hold down bolts with proper torque wrench. Check rope guides and bails for wear. Inspect all rope for broken wires or a loss 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 IMPORTANT

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

Check main swing gear hold down bolts. Use proper torque wrench. Test all hold down bolts on upper frame, especially on swing gear case, motor mounting, machinery pedestal and base bolts. Also, check motor generator, air compressor mount and base bolts. Tighten rod bolts on bearing housing.

Examine and readjust, if needed, all 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.

Inspect air compressor JJV" belt tension, replace if needed. F ill the anti-freezer. Check auto-lube system for loose or broken fittings or injectors. This can be accomplished by manually cycling lube systems and visually inspecting components. Also inspect bearing areas for visual signs of lack of lubrication. 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 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 lahels. 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 th is is the machine tl1at 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 machine 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 k'nowledgeable 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 cover 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.

SECTION 2 OPERATION INDEX

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