Cat Bucyrus 8750 Dragline 87505-6 Maintenance & Operation Manual BI005717 - PDF DOWNLOAD

Technical Manual

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WARN.NG

DUE TO THE DANGERS INHERENT IN THE OPERATION OF ANY HIGH VOlTAGE EQUIPMENT, A SAFE GROUNDING SYSTEM SHOULD INClUDE GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY HECK 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 Marion Power Shovel Co., Inc.

READ AND OBSERVE ALL warning signs, they're placed for your health and safety.

This has been prepared for the standard production machine. Any deviation due to advanc d engineering design, optional equipment or the particular requirements of this machine not be covered.

Additic nal information that is required will be furnished as soon as such information is availab e.

TABLE OF CONTENTS

The inf rmation contained in this manual provides guidance to all persons who care about the ope ation and maintenance of this machine. Needed data for operation, lubrication, adjustmen s and other tasks supplied in the various sections permits accurate operation and service. All enclosed specifications agree with the Marion Power Shovel Engineering Department. his information allows for quality maintenance when followed exactly.

This Ma ual is NOT a Parts Book. Do not use it to order parts. You have been supplied with a separa e, detailed Parts Book. Please read carefully the instructions in the front of it. All parts ar 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 a a Company rehandling charge. RIGHT and LEFT HAND PARTS on the upper frame c rrespond to the operator's hands at the controls as he faces the bucket. Please state the cor ect machine SERIAL NUMBER in any conversation or correspondence. Records of each m chine are filed by serial number. Given this number, the specific design and original equipm nt check is accurate and quick.

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

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

STAN ARO WARRANTY

Marion Power Shovel Comrany, Inc. guarantees the equipment anufactured by it to be tree of defects in material and workmanship under normal use and service, its obligation under this warranty being limited to making at its factory any ra t of parts thereof manufactured by it which shall, within six (6) months after delivery to uyer, be returned to it, with transrortation charges prepaid, and which its examination sh II disclose to its satisfaction to have been thus defective, this warranty being express 1'1 in Ii u 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 s[)ecial or consequential damages, arising from any cause whatsoever, and Buyer agrees to indemnify and save Marion Power Shovel Company, Inc. harmless therefrom.

r1dl ':.'\ Power Shovel Company, I nc makes no guaranty or warranty, ex[)ress or im[)lied as to uanc'!. fitness. quality, or performance of any machinery, equi[)ment, a[)paratus or acCf;SSO IPS not manufactured at its own factory which are subject only to such quaranty as mayor made by the resrective manufacturers thereof.

The Cmpany reserves the r1qht to imrrove or change the desiqn ot its products and specifications thp,reof ann the Company shall incur no liability thereby or any obligations to install such i provemen1s on products previously sold. Page 1

SAFETY SUGGESTIO.S

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 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 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 KEEP 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 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 pe manent damage.

CHECK IMIT switches for proper operation.

CH ECK VE R LOAD and thermal breakers.

MAl NT IN correct supply of lubricant.

MAl NT IN CLEAR walkways.

LOOK FOR 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,

L TAGE power lines require usinq EXTREME CAlfTION.

Open pi 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 dem nds 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 conti uous operation and normal wear. Care, sound judgement and reason govern th e econom c need in the operation of power equipment.

Downti e exists, but an ongoing program of Inspection and evaluation minimizes It. Awareness of nusual conditions generally warns personnel before breakdown occurs. Normal wear of machinery parts escapes exact definition. Parts do not suddenly expire. Wear takes place at Jaryil g degrees over time. Constant checkincj indicates a wear pattern, An alert mainteI'nrC!:: (; ew checks ALL structural members for evidence of stressed, broken or loose items. Minor c acks occur in steel structures. It's true of ALL machines. This is NOT SERIOUS when w Id repaired while SMALL. Cold weather causes faster expansion and brittleness than warm VI! ather. 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 n 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 conditi9n of injector. Properly lube ALL points, it's important. Page 4

Lower bucket/dipper to ground and shut down machine. I nspect bucket/dipper for cracks and br aks. Do not permit tooth base exposure. Teeth may be reversed. Remove bucket/ dipper rom service and rebuild in shop before breakdown. Check main rotating gear hold down olts. Use impact wrench if needed. Test ALL hold down bolts on rotating frame. Especi lIy swing gear case, motor mounting, machinery pedestal and base bolts. Check also motor enerator and air compressor mount and base bolts. Tighten rod bolts on bearing housin

Exami e and readjust, if needed, hoist and drag brakes and drag clutch. Look at the condition of brake and clutch lining. Remove inspection plate from swing gear case. Look at conditi n of gears. Use pry bar to detect any side motion of shaft indicating worn bearings. Exami e condition of rotating brakes and their adjustment. Adjust, if needed. Inspect air compr ssor "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 enter journal thrust washer and bearing. Secure ALL guards and safety features in place. DISCONNECT POWER SOURCE with machine shut down so electrical crew may adequa ely clean and inspect motor generators and electrical cabinets. NOTE any discolored electric I parts, it's a sign of overheating. I n humid areas, look for fungus and mildew. Dry compr ssed air at LOW pressure vvorks well for dust removal. Clean corrosion from parts, joints nd connections. where needed, any loose connections and terminals. Use of pro er tool here eliminates broken terminals and terminal blocks. Replace missing or damag d tags and labels. Bundle loose wiring. Fasten ALL components and wiring in cabinets. heck the cabie armor in the fixture. Look closely where wires and cables pass thru a enings and grommets. Insulation damaqe generally occurs here. Replace grommets if need d. Arcing of motors and generators causes discolored commutators. Look at brushes and br sh holder condition. Correct brush spring tension where needed. Collector rings need cl aning and checking also. Use a hand grease gun at each injector. Fill ALL grease lines ad purge EACH bearing with MPG. Remember to replace ALL plugs, covers and inspectio plates.

y seem like a lot of running around checking, looking, inspecting, cleaning and then ; but this is the machine that makes the payroll possible. Keeping it running is very nt.

Pil'SSinll equipment condition reports along the line is important also. Wear patterns show up at varyi g degrees in time. Recording and checking these reports at a future date allows comp,,.-isCln 2nd planned shutdowns. Planned repairs, part orders and crews for a scheduled shutCOV\T) e iminates 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.