Cat Bucyrus 8750 Dragline 87503 Maintenance & Operation Manual BI005716 – 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 INCLUD GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESIS OR AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY Cf ECK SYSTEM IS ALSO RECOMMENDED.

In the e\ent you doubt, for any REASON, your ability to safely perform any of the enclosed m intenance and operational procedures as they refer to your machine; please contact Marion P )wer Shovel Co., Inc.

READ 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 mall not be covered.

Addition I intormation that IS required will be furnished as soon as such information is available.

TABLE OF CONTENTS

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

This Man al is NOT a Parts Book. Do not use it to order parts. You have been supplied with a separat , 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 SPEC I FIC machine. Please or er the correct parts in exact quantity. Parts ordered by mistake and returned are subject ta Company rehandling charge. RIGHT and LEFT HAND PARTS on the upper frame co respond to the operator's hands at the controls as he faces the bucket. Please state the carre t machine SERIAL NUMBER in any conversation or correspondence. Records of each mac ine are filed by serial number. Given this number, the specific design and original equipme t check is accurate and l1uick.

NFORMATION not found in this Manual or the Parts Book may be obtained from wer Shovel Co., Inc., 617 West Center Street, P.O. Box 505, Marion, Oh io 43302.

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

STAND RD WARRANTY Marlon Power Shovel Company, Inc. quarantees the equipment ma ufactured by it to be free of defects in material and workmanship under normal use and 5 rvice, its obligation under this warranty being limited to making good at its factory any part of parts thereof manufactured by it which shall, within six (6) months after delivery to B yer, be returned to it, with transportation charges prepaid, and which its examination shal disclose to its satisfaction to have been thus defective, this warranty being expressly in lie of all wqrrantles, express or implied, and of all other obligations or liabilities on Marion ower Shovel Company's part.

Marion ower Shovel Company. Inc shall not be held responsible or liable in any event for SrWCidl 0 consequential damages, arlsinq from any cause whatsoever, ami Buyer af]rees to indemnif and save Marion Power Shovel Company, Inc. harmless therefrom.

" ,owcr Shovel Company, Inc makes no guaranty or warranty, express or implied as tu ;WHiC'I fitness. quality, or performance of any machinery, equipment, allparatus or .s not manufactured at its own factory which are subject only to such quaranty as mav br, ?de hy the respective manufacturers thereof.

The Co pany reserves the r1(jht to Im[1rove or change the desiCJn of its products and specifications t rreof and the Company shall incur no liability thereby or any obligations to install such irr'i rovements on products preViously sold. Page 1

SAFETY SUGGESTIO.S

The operator cOlltrols 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 OBSE 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 HOLD the bucket/dipper load longer than needed in dumping cycle.

DO NOT SERVICE or lube moving parts.

DO NOT BOAR D an operating machine.

PLEASE READ carefully this Manual and Parts Book.

PLEASE LUBE regularly.

PLEASE CR EATE A SYSTEMATI C procedure and follow it.

PLEASE WATCH clearance when swinging.

PLEASE OPERATE machine on as near level ground as possible.

PLEASE KEEP safe operating 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 pa:nt 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. Page 2

CHECK oom suspension, hoist and drag ropes for early signs of wear or failure. Kinks cause per anent damage.

CHECK IMIT switches for proper operation.

CHECK VERLOAD and thermal breakers.

MAl NT IN correct supply of lubricant.

MAINT

LOOK FR loose bolts and locking devices.

KEEP F OORS CLEAN and free of oil and grease.

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

KEEP h nds, feet and clothing away from moving parts.

PROMP LY REPLACE all guards, inspection doors, access covers and other safety features after ins ection or repair.

NEVER attempt electrical repair, unless qualified.

HIGH OLTAGE power lines require using EXTREME CAUTION.

Openpi mining equipment undergoes tremendous shock and stress. Marion's design considers thes loads. This machine, built with an apple reserve of power and strength, will meet the de ands of its task. Marion's engineers cannot foresee the conditions imposed by abuse, neglect nd mismanagement. These factors damage any piece of equipment more than years of cont nuous operation and normal wear. Care, sound judgement and reason govern the economic need in the operation of power equipment.

Downtl e exists, but an on(jolng program of Inspection and evaluation minimizes it. Awareness of unusual conditions generally warns rersonnel before breakdown occurs. Normal wear of mac inery parts escapes exact definition. Parts cia not suddenly expire. Wear takes place at Jaryillg deqrees over time. Constant checking Indicates a wear pattern. An alert mainte1>"(-'; ; rew checks AL L structural members for evidence of stressed, broken or loose items. Minor racks occur in steel structures_ It's true of ALL machines. This is NOT SERIOUS when eld repaired while SMALL. Cold weather causes faster expansion and brittleness than warm eather. Early detection and quick repair prevents failure. A stretch, bend or defect often sows 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 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 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, grooves and 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

Lower ucket/dipper to ground and shut down machine. I nspect bucket/dipper for cracks and bre ks. Do not permit tooth base exposure. Teeth may be reversed. Remove bucket/ dipper f om service and rebuild in shop before breakdown. Check main rotating gear hold down b Its. Use impact wrench if needed. Test ALL hold down bolts on rotating frame. Especial y swing gear case, motor mounting, machinery pedestal and base bolts. Check also motor g nerator and air compressor mount and base bolts. Tighten rod bolts on bearing housing.

Examin and readjust, if needed, hoist and drag brakes and drag clutch. Look at the condition of rake and clutch lining. Remove inspection plate from swing gear case. Look at conditio of gears. Use pry bar to detect any side motion of shaft indicating worn bearings. Examin condition of rotating brakes and their adjustment. Adjust, if needed. I nspect air compres or "V" belt tension, replace if needed. Fill the anti-freezer but don't drink that stuff. heck auto-lube system for loose or broken fittings or injectors.

Check c nter journal thrust washer and bearing. Secure ALL guards and safety features in place. ISCONNECT POWER SOURCE with machine shut down so electrical crew may adequat Iy clean and inspect motor generators and electrical cabinets. NOTE any discolored electrica parts, it's a sign of overheating. In humid areas, look for fungus and mildew. Dry compres ed air at LOW pressure works well for dust removal. Clean corrosion from parts, joints ad connections. Retighten, where needed, any loose connections and terminals. Use of prop r tool here eliminates broken terminals and terminal blocks. Replace missingor damage tags and labels. Bundle loose wiring. Fasten ALL components and wiring in cabinets. C eck the cabie armor tiqht in the fixture. Look closely where wires and cables pass thru op nings and grommets. Insulation damage generally occurs here. Replace grommets if neede Arcing of motors and generators causes discolored commutators. Look at brushes and bru h holder condition. Correct brush spring tension where needed. Collector rings need cle ning and checking also. Use a hand grease gun at each injector. Fill ALL grease lines an purge EACH bearing with MPG. Remember to replace ALL plugs, covers and inspection plates.

This rna seem like a lot of running around checking, looking, inspecting, cleaning and then greasing but this is the machine that makes the payroll possible. Keeping it running is very importa t.

Passinq quipment condition reports along the line is important also. Wear patterns show up at varyi 9 degrees in time. Recording and checking these reports at a future date allows comp2 r i;:1n , nd planned shutdowns. Planned repairs, part orders and crews for a scheduled shuteliminates idle downtime.

• 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.