Cat Bucyrus 8750 Dragline Maintenance & Operation Manual 87508 & 87509 – PDF DOWNLOAD

Technical Manual

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STANDARD WARRANTY

All goods are sold and delivered subject to standard manufacturing and other variations and practices customary in the trade. Seller warrants goods manufactured by Seller to be free from defects in material and workmanship under normal use and service for a period of six (6) months from the date of delivery, provided that the goods have, since the date of delivery, been properly used, maintained and stored, and no repairs or alterations thereon have been carried out without Seller's consent in writing. Liability of Seller for goods found to be defective or not in accordance with agreed specifications or for other breach of contract, negligence, strict liability or otherwise shall be limited to replacement of goods F.O.B. Seller's plant or return of goods and refund of the purchase price therefor as the Seller shall elect. Goods which have not been manufactured by Seller shall be subject only to such warranty as may be made by the manufacturer thereof. THE GOODS ARE SUBJECT TO NO OTHER WARRANTIES, EXPRESS OR IMPLIED. SELLER DISCLAIMS AND BUYER WAIVES ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS OTHER THAN THE EXPRESSED SIX MONTHS WARRANTY SET FORTH ABOVE.

Marion Power Shovel Division 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 Division harmless therefrom.

Marion Power Shovel Division reserves the right to improve or change the design of its products and specifications thereof and the Marion Power Shovel Division shall incur no liability thereby or any obligations to install such improvements on products previously sold. IM 'oHi!.'mn'

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 procedures as they refer to your mach ine; please contact your Local Service Representative.

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 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

From SPEC I FICATION 8750-25A

IIiTRODUCTIOIl

The information contained in this manual provides guidance to all persons who care about the operation 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. All enclosed specifications aqree with the Marion Power Shovel Engineering Depart· ment. This information ililows for quality maintenance when followed exactly.

This Manual is NOT a Parts Book. Do not use it to order parts. You have been supplied with a separate, 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 SPECI FIC machine. Please order the correct parts In exact quantity. Parts ordered by mistake and returned are subject to a Company rehandlinq charqe. RIGHT and LEFT HAND PARTS on the upper frame correspond to the operator's h21nds at the controls as he faces the bucket. Please state the correct machine SERIAL NUMBER in any conversation or correspondence. Records of each machine are filed by serial number. Given thiS numher, the specific design and original equipment check is accurate and qUick

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

SERVICE and LABOR CHARGES an: NOT accepted unless rreviously authOrIZed by the Company In writing

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 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 rotatinq, except in emergency.

DO NOT HOLD the bucket/dirper load longer than needed in dumring cycle.

DO NOT SERVICE or lube moving parts.

DO NOT BOARD an operating machine.

PLEASE READ carefully th is 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 nant chip or bubble may be an early warning. A slight hiss may indicate a growing air leak. I t's much easier to tighten a racking nut than shutdown for packing repair.

PROPERL Y GROUND the power source.

WATCH AI R system performance

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

CHECK LIMIT switches for proper operation.

CHECK OVERLOAD and thermal breakers.

MAINTAIN correct supply of lubricant.

MAINTAIN CLEAR walkways.

LOOK FOR loose holts and locking deVices.

KEEP FLOORS CLEAN and free of oil and grease.

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

KEEP hands, feet and clothlnq away from movlnq flarts

PROMPTL Y REPLACE all quards, Insrection doors, access covers anci other safety features after inspection or repair.

NE VE R attempt electrical repair, unless qualified.

HIGH VOLTAGE power lines require usinq 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 ol1eration and normal wear. Care, sound judgement and reason govern th e economic need in the operation of flower equlflment.

Downtime eXists, but an on'iOlnq prOLjram of inspection and evaluation ITllnlmizes It. Awareness of unusual conditIOns qenerally warns flersonnECI before hreakdown occurs. Normal wear of parts escapes eXJct definition. Parts cia not suddenly expire. Wear takes place ,; rierjrees over time. Corlstant cl1ecklnq Indicates a wear pattern. An alert mainte:,' "t· dew checks ALL structlJrdl members for evidence of stressed, broken or loose items. fI.1,flC)f crJcks occur In steel structuff!S. It's true of ALL machines. ThiS is NOT SERIOUS when weld repaired while SMALL. Cold weather CdUses faster expansion and brittleness than warm weather. Early detection and quick repair prevents failure. A stretch, hend or defect olten shows UfJ in condition of surface palOt. A collection of alonq a IlOe may indicate d ( If' the lTletal. Look closely at areas around openlnqs where ancJles 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 AL.L 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 [1lates 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, CJear and swing pinion. Sound here may indicate a flat or chipped roller or even suggest burrs or damaged teeth on the rotating pinion.

hoist o[1erates, 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 bucket/dipper to ground and shut down machine. I nspect bucket/dipper for cracks and breaks. Do not permit tooth base exposure. Teeth may be reversed. Remove bucket/ dipper from service and rebuild in shop before breakdown. Check main rotating gear hold down bolts. Use impact wrench if needed. Test ALL hold down bolts on rotating frame. Especially swing gear case, motor mounting, machinery pedestal and base bolts. Check also motor generator and air compressor mount and base bolts. Tighten rod bolts on bearing housing.

Examine 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 condition of gears. Use Dry bar to detect any side motion of shaft indicating worn bearings. Examine condition of rotatin<l brakes and their adjustment. Adjust, if needed. Inspect air compressor "V" belt tension, replace if needed. Fill the anti-freezer but don't drink that stuff. Check auto-lube system for loose or broken fittings or injectors.

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 cahinets. NOTE any discolored electrical parts, it's a siqn of overheatlnq. In humid areas, look for funqus and mildew. Dry compressed air at LOW pressure works well for dust removal. Clean corrosion from parts, joints and connections. Retighten, where needed, any loose connections and terminals. Use of proper tool here elimin;Hes broken trrminals and terminal blocks. Replace missing or damaged tags and labels. Bundle loose wiring. Fasten ALL components and Wiring in cabinets. Check the cahle armor tlqht in the fixture. Look closely where wires and cables pass thru openinqs ann qrommets. Insulation damaqe qenerally occurs here. Replace grommets if needed. Arcing of motors and generators causes discolored commutators. Look at brushes and brush holder condition. Correct brush sprinq tension where needed. Collector rings need cleaninq and checkinq also. Use a hand wease qun at each injector. Fill ALL grease lines and purge EACH bearinq with MPG. Remember to replace ALL plugs, covers and insDection plates.

This may seem like;:; lot of runnlnq around checklnq, lookinq, inspectinq, cleaning and then qreasinq; but this is the machine that makes the payroll [lossible. Keepinq it running is very Irnnorti]nt

rhSirq pr)IJirment r:onriitlon rCl)orts Cllon r ] tlw line IS Imrwrtant also. Wear ratterns show up ill varYInC] rleqrees in Record1nq :lnrl checkmq these rerorts at a future date allows comr"-;c:ln ?nrl Dlanned shutdowns Planned rep;JIrS, part orders and crews for a scheduled shutcJc)\<\''l eliminates Idle downtlTne

Section

Shrink

Preliminary

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