Cat Bucyrus 8400 Walking Dragline Operator's Manual BI005609 - PDF DOWNLOAD

Technical Manual

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INTRODUCTION

SECTION I

GENERAL INFORMATION

This manual is provided for the guidance of all persons who operate, lubricate, adjust or maintain the Marion 8400 Walking Dragl ne The information was prepared with the purpos in mind of furnishing accurately and concisely all the data necessary to the operation and servicing of this machine.

All information, measurements, and specifications herein are in accord with the Marion Power Shovel Engineering Department and should be strictly adhered to in all work on this machine.

PARTS BOOK

THIS MANUAL IS NOT A PARTS BOOK AND SHOULD NOT BE USED IN ORDERING PARTS,

You have been furnished detailed Parts Books which list all parts by group numbers with items and parts numbers for your specific machine.

Read carefully the instructions in the front of the Parts Book for ordering parts.

SERIAL NUMBER OF MACHINE RIGHT AND LEFT HAND PARTS

ORDERING PARTS

Be sure that the serial number of the machine is given in any letters, telegrams, orders or other communications. Records for each individual machine are filled by serial number and if this number is available, the design and original equipment can be quickly and accurately checked.

On the upper frame, right hand (R.H.) and left hand (L.H.) cor'respond to the operator's rill. and left hands when he is facing the bucket while at the operator's controls.

The Parts Book covering this machine qive cn plete information on ow to order parts. a der carefully so that e right parts n the ri quantities an be nished. Wrong part ordered by mistake, which are returned to company are subject to a rehandling charge.

FURTHER INFORMATION CHARGE FOR SERVICE, LABOR, ETC.

STANDARD WARRANTY

If further information is required which is not found in the Manual or in the Parts Books, communicate with the Marion Power Shovel Company, Inc., at Marion, Ohio.

No charges for service or labor are accepted unless the work has been previously authorized by the company in writing.

Marion Power Shovel Company, Inc. guarantees the equipment manufactured by it to be free from defects in and workmanship under normal use and service, its obligation under this warranty being limited to making good at its factory any part or parts thereof manufactured by it which shall, within six (6) months after delivery to Buyer, be returned to it, with transportation charges prepaid, and which its examination shall disclose to its satisfaction to have been thus defected, this warranty being expressly in lieu of all warranties, express or implied, and of all other obligations or liabilities on Marion Power Shovel Company's part.

Marion Power Shovel Company, Inc. shall not be held responsible or liable in any event for special or consequential damages, arising from any cause whatsoever, and Buyer agrees to indemnify and save Marion Power Shovel Company, Inc. harmless therefrom.

Marion Power Shovel Company, Inc. makes no guaranty or warranty, express or implied, as to adequacy, fitness, quality, or performance of any machinery, equipment, apparatus or accessories not manufactured at its own factory, which are subject only to such guaranty as may be made by the respective manufacturers thereof.

The company reserves the right to improve or change the design of its products and specifications thereof and the company shall incur no liability thereby or any obligations to install such improvements on products previously sold.

SAFETY PRECAUTIONS

The usefulness of this machine depends entirely on the man at the controls. The operator is its brains. He must think safety and work safely.

Neatness and safety go hand in hand. Good housekeeping habits should be developed.

1. Keep the floor clean and free from oil and grease.

2. Keep the walkways clean, clear, and free from obstructions.

3. Prevent the accumulation of grease and oil around bearings and gears. Grease and oil collect and hold grit and dirt which work into finely machined parts.

4. A clean machine is easier to operateeasier to inspect - easier to service.

5. Keep hands and clothing away from moving parts.

6. Replace guards, inspection plates, access covers, etc., promptly after reason for removal is accomplished.

Strip mining equipment is subject to tremendous stresses and shock loads. These stresses are thoroughly studied and considered in the design and building of Marion equipment.

This machine is built with an ample reserve of powerand strength and is well fitted to meet the demands of its tasks.

However, the Marion engineers cannot foresee the conditions imposed by abuse, mismanagement and neglect. These factors are more damaging to any piece of equipment than years of continuous operation and normal wear.

Care, sound judgement and reason are an economic necessity in the operation of power equipment.

PREVENTIVE MAINTENANCE

DO

1. Carefully read this Manual and Parts Books.

2. Lubricate regularly. Establish a systematic procedure and stick to it.

3. When lubricating, check all bolts, nuts, lock nuts and cotter pins.

4. Keep loose objects in tool box or in suitable enclosure or cabinet.

5. Always replace guards.

6. Always watch your clearance when swinging.

DONIT

1. Service or lubricate parts that are moving.

2. Leave the load suspended in air.

DONIT APPLY SWING BRAKES WHILE MACHINE IS ROTATING, EXCEPT IN EMERGENCY.

Open pit mlnlng machinery is required to operate in the most adverse conditions of any industrial machines.

Conditions are rarely ideal. It is always too hot, too cold, too dry or too wet. The air is always saturated with fine abrasive dust. High production schedules tax both men and machines.

Down time and delays are intolerable. Down time can not be eliminated, but it can be kept to a minimum by a progressive and conscientious program of preventive maintenance.

Aside from regular lubrication, proper and accurate adjustments, the personnel should be aware of any deviation from the normal, which could be evidence of impending break down or components failure.

The maintenance people should inspect, during their rounds, all structural members for evidence of stressed, broken or loose parts. Evidence of a member stretching, bending, or deflecting can often be determined by the conditions of the surface paint. Stressed parts will show wrinkles or waves in the paint or check marks.

Breaks· or chips in the surface or a collection of dust along a line may indicate a crack in the metal. Pay particular attention to those'areas around openings where corners or angles are cut out, at the ends of gussets or at brace connections and at transittional points where heavy and thin parts join.

Stress in a monolithic structure may travel some distance from the damaged area and manifest itself at a remote point in some seemingly unrelated place.

The maintenance people should check all bolts, nuts, cap screws and rod bolts. Lock washers and other locking devices must be in place.

Be sure that bolted and assembled parts are tight. Evidence of movement may be detected by signs of scuffed paint, worn or bright spots adjacent to the part. Often a slight movement of parts that can't be seen with the eye can be felt with the finger tip when the machine is working.

Grease or oil stains that are unaccountable, or out of place are often evidence of a fault.

AIR SYSTEM AND COMPONENTS

The hoist, drag, propel and swing brakes of the 8400 walking dragline are released by compressed air. Compressed air is also used to actuate the automatic lubrication system.

The Marion air control system is simple in operation and, with reasonable care and maintenance, will have a long trouble free life.

The system can best be explained by a brief description ot its components and their functions in the system. Fig. 1 shows a schematic view of the complete system used on the machine.

The operator must be constantly aware of the air pressure gauge reading. If at any time the pressure drops below the operating differential, the operator should shut down the machine and investigate the cause.

Do not operate the machine without full tank pressure.

The air compressor that supplies the system is located on the rotating frame at the right of the center journal.

The compressor is a complete unit that includes a storage tank, electric motor and a two stage air compressor with a pressure switch. Read the manual that is attached to the unit.

Check the oil level in the compressor crank case daily. Keep the oil level to the full mark on the dip stick. Drain and flush the crank case every 500 hours of operation. Refill with oil specified on the chart "Oil Specifications" in the lubrication section.

The air cleaner located at the air compressor intake is an oil bath type cleaner. The cleaner should be disassembled and cleaned once a week under normal conditions. In dusty and dirty conditions clean daily. Fill with oil to the mark on the side of the cup with the same grade of oil as used in the crank case.

QUICK RELEASE VALVE

A quick release valve is located in the air line adjacent to each hoiit and drag brake release cylinder. The air to the cylinder must pass through the quick release valve. Air depresses the diaphragm to close the exhaust port and open the port from the tank to the cylinder.

Full tank pressure will pass through the valve. When the supply pressure is shut off, the diaphragm spring will return the diaphragm to normal position and the exhaust port will open. This will permit the pressure inside the cylinder to escape into the atmosphere and not be required to return through the control valve.

No adjustment of this valve is required. If the valve fails to function properly, disassemble the valve, clean and inspect for damaged parts. A repair kit is available which contains parts for replacement.

QUICK RELEASE VALVE

In Diaphragm

MAGNET VALVES

The magnet valves are electrically controlled valves. The valves are non-compensating or on and off valves.

The magnet valves are normally de-engergized and closed.

A spring loaded plunger shuts off the air from the supply to the cylinder and the exhaust port from the cylinder to the atmosphere is open.

When the coil is energized the plunger moves down, closing the exhaust port and opening the port from supply to the brake release cylinder.

Magnet valves are rugged and require little or no attention.

MAGNET VALVES (CONT'D.)

If the valve fails to shut off or to admit the proper volume of air, the valve should be cleaned as dirt and scale can cause the valve to leak.

Open and close the valve several times by means of the hand lever on top of the valve. The valve can usually be cleaned this way without disassembling the valve,

If not, dismantle the valve and clean or replace the worn or damaged parts.

The anti-freezer is a pressurized unit that is installed in the system to prevent icing and freeze-up when operating at temperatures below or near freezing.

The unit is installed in the delivery line from the compressor far enough away so that the heat will not effect the unit. The anti-freezer introduces an alcohol vapor into the air stream that mixes with the water vapor in the air.

Chamber

Lower Chamber

ANTIFREEZER

ANTI-FREEZER

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