R BUCYRUS 141428mc.cdrPg. 1 8750 8750 WALKINGDRAGLINE WALKINGDRAGLINE SN:141428 ManualNo. BucyrusInternational,Inc. 1100MilwaukeeAve.•P.O.Box500•SouthMilwaukee,Wisconsin53172-0500USA OPERATOR’SMANUAL OPERATOR’SMANUAL 10863 10863 BI010575 BI010575
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Bucyrus International, Inc.
March 2011 BI010575 BI010575
8750 Walking Dragline Manual No. 10863
DANGER:
THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.
DANGER:
DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY.
The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.
THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between the machine and the ground. The portable trail cable and power lines supplying electric energy to the machine must have a ground wire, ample in capacity, running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult your local electrical supplier for details.
DANGER:
DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.
Bucyrus International, Inc.
March 2011 Manual No. 10863
8750 Walking Dragline
BI010575 BI010575
Bucyrus International, Inc.
March 2011 BI010575 BI010575
8750 Walking Dragline Manual No. 10863
8750 Walking Dragline Bucyrus International, Inc. March 2011 1 Manual No. 10863
Operator’s Manual Manual No. 10863 sn: 141428 Lot 36
NOTE
document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability. © 2011 Bucyrus International, Inc. All Rights Reserved. Table of Contents INTRODUCTION ...........................................................................................................................5 SAFETY ..................................................................................................................................6 GENERAL SAFETY PRECAUTIONS ......................................................................................7 MAINTENANCE SAFETY PRECAUTIONS ..............................................................................9 OPERATING SAFETY PRECAUTIONS ................................................................................11 FIRE PROTECTION SYSTEMS.................................................................................................12 MATERIAL STORAGE CABINETS ..............................................................................................13 Hazardous Material Storage Cabinet Locations ..........................................................................13 MACHINE OVERVIEW ................................................................................................................14 Nomenclature .............................................................................................................................14 BASE FRAME .......................................................................................................................15 Base Frame (Tub)......................................................................................................................15 BASE BAY NUMBERING .......................................................................................................16 Base Bay Numbering ....16 SAFETY RAILS FOR BASE FRAME ACCESS.....................................................................17 Safety Rail .............17 ROTATING GEAR AND RAILS ..............................................................................................18 Rotating Gear and Rails (Section View) ......................................................................................18 ROLLER CIRCLE.................................................................................................................19 Roller Circle (Section Views) ......................................................................................................19 ROTATING FRAME BAY NUMBERING ..................................................................................20 Rotating Frame Bay Numbering .................................................................................................20 MACHINERY HOUSE ............................................................................................................21 Machinery House ........................................................................................................................21 OPERATOR’S CAB..............................................................................................................22 Operator’s Cab ...........................................................................................................................22 OPERATOR’S SEAT.............................................................................................................23 Operator’s Seat and Controls .....................................................................................................23 PROPEL MACHINERY ..........................................................................................................24 Propel Machinery ........................................................................................................................24 HOIST AND DRAG MACHINERY ..........................................................................................25 Hoist and Drag Machinery ..........................................................................................................25 SWING MACHINERY .............................................................................................................26 FAIRLEAD .............................................................................................................................27 Fairlead Assembly .......27 BI010575 BI010575
8750 Walking Dragline
IMPORTANT
This
8750 Walking Dragline Bucyrus International, Inc. 2 March 2011 Manual No. 10863 TRI-STRUCTURE.................................................................................................................28 Tri-Structure 28 TRI-STRUCTURE SAFETY ROPES....................................................................................29 Tri-Structure Safety Ropes ....29 BOOM ASSEMBLY AND BOOM SUPPORT.........................................................................30 Boom Assembly and Boom Support ..........................................................................................30 BOOM SUPPORT ROPES..................................................................................................31 Boom Support Ropes .................................................................................................................31 BOOM CLUSTER IDENTIFICATION.....................................................................................31 OPERATOR CAB AND ANTEROOM..........................................................................................32 Operator’s Cab and Anteroom ....................................................................................................32 OPERATOR’S CAB - ANTEROOM.......................................................................................33 OPERATOR CONTROLS ..........................................................................................................34 Operating Controls .....................................................................................................................34 PRIMARY CONTROLS .........................................................................................................35 Primary controllers .....................................................................................................................35 PLUGGING THE MOTION ...............................................................................................37 OPERATOR'S SEAT ADJUSTMENTS............................................................................38 SECONDARY CONTROLS..................................................................................................39 Top View....................................................................................................................................39 LEFT HAND CONSOLE CONTROLS............................................................................40 Left Hand Console Controls ..40 RIGHT HAND CONSOLE CONTROLS..........................................................................42 Right Hand Console Controls .....................................................................................................42 WINDSHIELD WIPER...........................................................................................................45 Windshield Wiper Assembly Operator’s Cab..............................................................................45 CLOSED CIRCUIT VIDEO MONITOR..................................................................................46 OPERATOR’S DISPLAY.......................................................................................................46 Operator’s Display ......................................................................................................................46 DISPLAY AREA & INDICATORS......................................................................................47 CAB DISPLAY SCREENS...............................................................................................48 Operator’s Cab Title Screen ...48 Operator’s Main Menu Screen .....................................................................................................49 Display Information Screen ...50 Alarm History ...........52 Rope calibrations and set points................................................................................................53 Shoe position .............................................................................................................................54 Operating Hours .........................................................................................................................55 Tightline .....................................................................................................................................56 Boom Raise-Lower .....................................................................................................................57 Lube Setup ...........58 Lube Status ...........59 Encoder calibration ....................................................................................................................60 HOIST/DRAG LIMIT CALIBRATION .......................................................................................61 HOIST LIMIT ....................................................................................................................61 DRAG LIMIT .....................................................................................................................63 HOIST AND DRAG ENCODER CALIBRATION...............................................................64 BI010575 BI010575
8750 Walking Dragline Bucyrus International, Inc. March 2011 3 Manual No. 10863 EMCP3 SERIES CONTROL PANEL.............................................................................. (INSERT) PNEUMATIC SUSPENSION OPERATING INSTRUCTIONS .........................................(INSERT) POWER CONTROL ROOM.......................................................................................................66 Power Control Room ..................................................................................................................66 MACHINERY HOUSE REAR DOORS........................................................................................67 Machinery House Rear Doors .....................................................................................................67 REAR DOOR OPERATION..................................................................................................68 Door Operating Sequence ..........................................................................................................69 REAR DOOR CONTROL PANEL.........................................................................................70 Control Panel for the House Rear Doors .....................................................................................70 BOARDING STAIRS ....................................................................................................................72 Right Side Boarding Stairs ....72 RUNNING THE MACHINE ...........................................................................................................74 PRE-START INSPECTION...................................................................................................74 TYPICAL STARTUP...............................................................................................................75 PREPARING TO DIG............................................................................................................80 TYPICAL DIGGING CYCLE ...................................................................................................81 GROUND PREPARATION....................................................................................................82 CHANGING TO PROPEL MODE................................................................................................83 PROPEL OPERATION..........................................................................................................84 Walking Phases ........................................................................................................................85 WALKING MACHINERY CONTROL ................................................................................86 AUTO PARK..............................................................................................................86 WALKING ..............................................................................................................................87 Operator’s Seat and Controls .....................................................................................................88 TURNING THE MACHINE ......................................................................................................89 RETURNING TO DRAG (DIGGING) MODE................................................................................90 NORMAL SHUTDOWN PROCEDURE......................................................................................90 PARK AND SHUTDOWN PROCEDURE...................................................................................91 EMERGENCY SHUTDOWN PROCEDURE........................................................................91 TIGHTLINE PARAMETERS ...................................................................................................92 JOYSTICK CALIBRATION .....................................................................................................95 REMOTE ROPE REEVING..................................................................................................96 AIR SYSTEM .........................................................................................................................97 STANDBY GENERATOR......................................................................................................98 MAIN HOUSE CRANE ...........................................................................................................99 MAIN HOUSE CRANE BRIDGE LOCKDOWN...................................................................100 CRANE TRANSFER BEAM................................................................................................101 TYPICAL MACHINE SPECIFICATIONS ...............................................................................102 WORKING RANGES.....................................................................................................103 BI010575 BI010575
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8750 Walking Dragline
Operator’s Manual
INTRODUCTION
This manual is designed to assist the owner in the operation of this machine. By following easy to understand step-by-step procedures the operators and maintenance personnel can perform all tasks in a safe manner. When a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.
Safe operation of the machine minimizes production delays and costly damage to equipment. Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to prevent accidents from occurring and are provided in the interest of all mine personnel. Overall safety depends upon the use of good judgement and the alertness of the entire mining crew.
Throughout this manual, the use of the terms “LEFT, RIGHT, FRONT, and REAR” refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.
THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied for this purpose.
Periodic additions or revisions may be made to this manual. Should you require additional information or factory service assistance contact your regional service representative or:
Bucyrus International, Inc.
1100 Milwaukee Avenue
P.O. Box 500
South Milwaukee, Wisconsin, USA 53172-0500
Telephone (414)-768-4000
It is the policy of Bucyrus International, Inc. to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations to install such changes on machines sold previously. Due to this ongoing program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve our machines.
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The safety alert symbols displayed here and throughout this manual, are used to call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted in various areas of the machine.
Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions. If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional Bucyrus service representative or the factory.
The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.
NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken.
CAUTION:This signal word serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to.
DANGER:This signal word denotes an imminently dangerous hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.
DANGER:This signal word denotes an imminently dangerous electrical hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.
Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit and free from the influence of alcohol, drugs, or any medications that might impair his eyesight, hearing or reactions.
CAUTION:STORED ENERGY! Components on machine are heavy and removal of pins without proper preparation and precaution can cause serious bodily injury and/or damage to the front-end of the machine.
Safety must always be paramount!
Consult your supervisor when safety is in doubt.
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SAFETY
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GENERAL SAFETY PRECAUTIONS
•A scheduled maintenance program performed by qualified maintenance personnel is the best way to minimize machine downtime and maximize productivity of equipment.
•Keep hands, feet, and clothing away from rotating parts.
•Wear a hard hat, safety shoes and protective lenses at all times.
•Replace any and all safety and warning placards if they are defaced or removed from the machine.
•Think before you act. Carelessness is one luxury service personnel cannot afford.
•Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested method of cleanup.
•Inspect safety catches (keepers) on all hoist hooks. Do not take a chance; the load could slip off the hook if they are not functioning properly.
•If a heavy item begins to fall, let it fall, don’t try to catch it.
•Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.
•Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure all spillage is cleaned up.
•Electrical cords and wet metal floors make a dangerous combination.
•Regularly inspect for any loose bolts or locking devices and properly secure them.
•Use extreme caution while working near any electrical lines or equipment whether it is high or low voltage. Never attempt electrical repairs unless you are qualified.
•Check all sensors and limit switches for proper operation.
•After servicing, be sure all tools, parts or servicing equipment are removed from the machine and secured in an appropriate storage area.
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•Mechanical Brakes are designed for use as static holding brakes only. Use them as a motion (dynamic) brake in emergency situations only.
•Use proper interior and exterior lighting.
•Install and maintain proper grounding and ground fault protection systems.
•Perform functional tests of all safety circuits.
•Electrical inspection and maintenance should only be performed by a qualified electrician.
•National, state and site safety systems must be read in conjunction with this manual.
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MAINTENANCE SAFETY PRECAUTIONS
•Do not wear rings, wristwatches or loose fitting clothing when working on machinery. They could get caught on moving parts causing serious injury.
•Always wear a safety belt or harness when the danger of falling exists.
•If a lifeline is used when working in confined spaces, always have a second person monitoring it.
•Do not start an engine indoors unless adequate exhaust ventilators are provided and in operation.
•Never utilize the machine air or hydraulic systems for support when working on the machine. Deactivate or isolate the entire system prior to performing maintenance.
•Equipment should be parked on level ground at all times during machine servicing and periods of idleness.
•Cranes and hoists must be of sufficient capacity to lift the heavier components (gearcases, etc.) Always work within the limitations of the equipment being utilized.
•Be sure heavy items are properly rigged and supported from cranes or hoists before removing supporting members from the machine.
•Utilize guide lines or ropes to minimize the swing of heavy suspended components.
•Have sufficient service personnel available when removing or installing large, heavy items to maintain control at all times.
•Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load; they could fail.
•When disassembling a machine, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.
•When using an oxygen/acetylene torch, always wear welding goggles and gloves. Keep a charged fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart.
•Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Always be sure to wear safety glasses.
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• 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.
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