.8200WA,LKIN GDRAG:l.IN ..E
WARD LEONARD -.STATIC CONTROL - INDEPEND.ENTPROPEL
SPECIFICATION 8200-52A
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.Boom. .Length (Center·li.ne) .. _ •.•. _ ......... '...... e" .- • ,- e" '_. " ..O" Angle (Approx.) .•.•••....•.•...•.•...... ,.; ••..••. .•..• ; •.. 35-1/4° .B -: Dump Radius _. ' I-I " " e "•• " " I" ,' ••• '31.2'·0" C - Dump'HeJght I, It .••• ,'.-."" I,' I,' .•.• '165'·0" :.0 -.Depth- ............... _ .. _, .• :................. I_I I' D"" 1_' E - Tub Nominal Outside Diameter •.•.•....•.. '; .•..••• ' ••......•••....•. '-68'·0" 'Rail. Cjrcie 'M.ean O"iameter " .. ",. _ ...................' .............. t- · ·• ,-, - •••.•..,It ',50-1.;0" 'MainSwing Gear Pitch Diameter .•......•.•..•..•.. : •..•...•..•.. , ..• F - Width of 'Shoe •..•..•.•.....••• I •• • 't .•••. - '13' 0" G - Len'gth of Shoe .• _ ,I 'I t· ••.•.••.•- ••.• ".' • I • -"1 I 70" .(J'" H ·Wi·dth ever·Soth··Shoes I! •. '. '1-, ,':., •. •.• .• t .' - ·:96!;.;.OIl Gf 'Step, (A.pprox.) ,., •..• ,•••.• -to •••• ••••• - ••• :" ••• t:;' .-' 1If·-.· ·It '. '.,1' e 7l .;.O" ,J..- 'Flear -E'nd ·Width ". e t· •••.• , •...•.. .•.. : ,I ••...•.•.• 1'-' : K ...... Length :of .R..otatin.g .-Frame iI' e ,- .' -." e· ••...•• 1-":' .• '·e. t .,' •. e· •.•••..• t· . L - :R-ear -E'nd :Cleararice RadIus ........•. I •••• t. I ••••.•• - •• .•••• 7.1 M,- Clearance Under 'Rotating Frame ..........•••.....•..•••............• 8'-0" N - Center Rotation to Boom Foot •..•.........••••..•.....•. ; ............ 21 '-6" P - Grou·nd. to 'B-oom 'F'oot •• 1,·1t- •••• • Working· Weight, Lbs........•..................... It •.•••• 8,764,8'00 .L,bs. -••.••• It •• It·•. .•. •.••..••• •..•••• ".,2'50,000 Maximum Allowable Load, Lbs 38Q·tO·OO BI116027
This manual is djvided into sections coveringvariou$ servi.ceable com.p0f:lents and ivstemsof. the Model 82QO dragline.These 'sections are organized by thumb j'ndex tabs shown below and right-black inktab marks.
SE,CT.ION '1 -INTRODUCTION
:SECTJON 2 - OPERATION
SECTION 3-LUBRICATION
SECTION 4- MECHANICAL ,ADJUSTMENTS
SECTION 5- :ElECTR ICAl 'MAINTENAN.CE
seCTIONB -COMPRESSED AIR SYSTEMS
:SECTION 7 -ENGINEERING DATA
SECTIONS -INSPEcnONSCHEDU'LE
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\. INTRODUCTION INDEX Page Generaf -lnfornlation", ,,_ _ ....• 1'_. I - - ••• ,-, .' ••• ". -••• •• - ••• ••••• '''-'1 .Safety Precau-tion-s •. _.'." •.• ".. ' > - "Preventive MaIntenance Traini-n,g ......... , ._. "I' •• ••• II " •.•. .- II""'"' ,,-.---.' I' '"-"-"- ••••.••••• .t" '., ._'. 1-9' - ", \ .1 " ',': BI116027
.SE:CTtON '1
'JNTRODU'CTION
GENERAL INFORMATION
This manual is designed to assist the owner in the operation .and prev.entive maintenance of this machine. Following easy to understand step by-step procedures,maintenance personnel can perform these tasks in a safe manner. When asystematic and thorough maintenance/ service procedure (a responsibility of the maintenance superintendent) is used for this machine, minimum unplanned downtime andreTiableoperation will result.
THIS MANUAL IS NOT THE PARTS BOOl<;, and cannot .be used to order parts. Aseparate, detailed parts book has been suppHed. Please carefully readthe,instructions in it. All pamara listed by group and/or product code numt>erswith item/part.numbersfor THIS SPECIFIC MACHINE. Order parts inexact quantity. Parts ordered by mistake andraturned, are 'subject to a rehandling charge. 'RIGHTandLEFTHAND PA.RTS ontheupper frame correspond hands at the contrQls;as seated when operating the machine. Please state the correct machine SERIAL NUMBER (located on a plate In .theoperator's cab) when corresponding or contacting factory service or parts departments. Records on each machine are filed bY.serialnumber and ,when given this number, your machine'sspecificdesignand original equipment isaccessedquickly.bythe Marion parts representative.
PeriodicadditioAs or revisi.onsmaybe madam this mar:lust ThesewiUbemaileddiFect to' you from the factory; Should you require additional information or 'factory,service assistance contact your regionalssrvlce representative or '. .;
Service Department .
Marion Power Shovel Division
'Dresserlndustties, 'Inc. ,617
<P;O.Sox505
'Marion,OH' ,43302 .;, ", ,,'
"(elephone614/383;5211 ..
'$vlex.24-'S30V
It is Marion Power Shovel Division policy to improve its products whenever possible and practical to do so. Marion reserves the. right to make changes or add improvements at any time without incurring any obligation to install such changes on machines sold previously.
Due to thiscontinu.ous 'pf,Qg!am of,pro¢lUCtresearch ;(lAd develepm.emt'SGmeprooladures, specifications and parts maytle altered ina constanteffortto:i'mprove .machiftas.
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This safety alert symbol is used here and throughout this manual to call your attention to instructions conoerning your personal safety. Carefu..IIy read and follow these instructions and .observesll safety and danger, and caution graphics mounted on various areas of the machine.
8e certain anyone servicing this machine is aware of these SAFETY PRECAUTIONS. In the event you question your abiHtyto safely perform any ·Of theeAclosed maintenance srtdoperational procedures contact your regional Marion service representative or the factory.
TheioUowing defines distinctions betwe.en safety ·instructi.ons.tnall these definitions the 'safety.alertsignal is used •
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:OAN.G. ER:.. Denotes extrema intrinsic hazard which exists and could result in .highprobabiJitVof death or irreparable . are ignored.
'CAUTION: Denotes a reminder ' of::;afetvpractices" Of directs attention to unsafe practices Which could result in personal injury if .properprecautions -arefgnored. -
An example of a safety alert symboland:special safety instructions is showribelow .
DANGER: . Inherent danger exists in the operation .ofany high voltage tHeatrical A safe grou:nding .system includes grGUndeonducmnin 'tbepower cable,s neu:tralgroundingr:esis'torandrelatedrela,'YS end switchgear.. Aground continuity check system is' required ,by law in ," Qftheworld.
maintaining Of servicing thisri,aehinecan be dangerous unless periormedprO,per. ly.Each person must satisfy himself ,and his empcloyer that he is alert and has the necessary skill and informatioo,proper tools and equipment, and aU methodssre safe and correct. 'Factory service aod .sp-8cialists aTe -availabJe.ro .prov.ime:additi:ornaliRfGrtma· tion ortechni'cal assistance.
'A:FETY.·PRECAUTIONS
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SAFETY PRECAUTIONS continued
, The operator must be alert, physically fit, and free from the influence of alcohol, drugs; Ot medications that might effect his eyesight, hearing or reactions .
Sa,fisty must al.ways be the operator's most important concern. He must refuse to operate .when he knows it i:s unsafe ,and cOHSU It his supervisor when safety is iridoubt.
The owner and/or operator must replace any and all.safety and warning productgraphics if they are defaced or removed from the machine.
Before doing any work on the machine, lock out or remove electric power supply from the machine and tag it50 persGnnel are aware that someone is wotkin'gon the mach ine.
K.eep hands, fe.et, clothing away from rotating parts.
Beforewa;lkingmachine, place trail cable in,a safe position.
Think before you act. Carelessness is one luxury the serviceman cannot afford.
00 not wear rings, wrist watches or loose fitting clothing. They cou Idcatch on movi ng parts causing serious injury. Never adjust and/or service a machine in bare feet, sandals or 'srH:la-kers. Never workonrotatingbr moving machinery .
Always wear safety glasses when using a hammer, chisel or other tools that may cause chips to fly.
Excessive or skin contact or "solvents may cause skin irritation. In case of skin contact. remove sealant or solvent pr'omptlyby washing with soap and water.
Alwaysu"saa "safety bar to block air or hydraulic operated cylinders. 'Never rely on the madhlne air .or hyelrsu!.icsystems to hold when working on machines. An air Or hydraulic . lif1te Of'oylinderoould fa;N or someone could accidently strike the c.ontro\ leverSCBU$ing the equipment to fall.
iqui,pment must be level on ground at all times during machine servicing and periods of idleness.
Cranes and horsts must be of sufficient capaCity to lift the heavier components (gear cases, dipper/bucket, boom, etc.) and have an ample safety margin.
'Be sure heavy ,items are prope.rly supported from cranes or hoists before removi-ngsupport· in:g members from machine.
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SAFETY PRECAUTIONS - continued
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 cou Id fail.
Use ,safety catch on all hoist hooks. Do not take a chance, the load could slip off of the hook.
If a ,heavy item begins to fall, let it fall, don't try to catch it.
When disassembling machines, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.
Keep work area organized and clean. Wipe up Oll or spills of any kind. Keep tools and parts off of the ground. Eliminate the possibility ofa fall whichcouJd result in a serious injury.
Floors, walkways and stairways must be clean and dry. After draining operations be sure all spiUageiscJesf1led up. Electrical cords and wet metal flo.orsmake a dangerous combination.
Check all wire ropes for telltale signs of early wear or failure. Look for .andsecureany loose bolts or locking devices.
Use extreme caution while working near any electricaJ lines or equipment whether it be high .or low voltage. Never .attempt electrical repairs unless .qualified. Check limftswitchesfor praperoperatlon.
When using an acetylene torch, always wear welding goggles and gloves. Keep a "charged" fire extinguisher within ,.each. Be sure the acetylene and oxygen tanks ,are separated by metal shield and are chained to the cart. Do not weldor heat areas near transformers or electrical cabinets and uti lize proper .shielding around lubrication lines.
Use pullers to remove bearings, bushings, gear.s,cyJinder 'sleeves, ·etc. when .appli.cable. Use hammers, punches and chisels only when absolutely necessary. Then, be sure to wear safety glasses.
Be careful when using compressed air to dry parts. Use approved air blow guns, do not exceed 207 kPa (30 psi), wear safety glasses or goggles and use proper shielding to protect everyone in the work area.
Sesur,e to promptly reinstall safety devlces,guardsorsnialds ,after adjusting andlor servicing the· machine.
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SAFETY PRECAUTIONS -continued
After servicing, be sure all tools,parts or sarvicin<g equipment are removed from the machine.
Protective eye goggles should. be worn at all times when working on the air conditioning system. Work on the air eonditioning system only in a well ventilated area.
Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.
Operate machine on level ground and be continuously aware·of swing clearance. Never hold a load longer than needed in dump cycle. Use swing brakes only when machine is stopped.
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PfilEVENTIVEMAINTEN ANCE
Machine downtime is costly to owners in lost production. Preventive maintenance is the task of identifying, replacing or repairing machine components before they fail so that downtime is minimized.
A'CAUTION:tlo not perl""" iR''''''''i"" activities ,""ile mach",. is in <'Jl81'8tion.
Due to variations in operational wear rates of machine components and machine application conditions, component life cycles are different. A scheduled program of machine insp.ection with accurate record keeping can identify machine component and their rates of wear.
A continuous careful inspection routine can spot unusual conditions or fatiguing components before a failure occurs. Maintenance, repair and component replacement schedules 'should conform to scheduled machine shutdowns. If during daily, weekly or monthly inspection routines any part shows wear or distortion beyond expected normal patterns replace them with genuine Marion parts at the next scheduled maintenance interval. The cost of parts is small when compared to unscheduled breakdowns with their resulting lost manhours and· machine production.
Machines which operate .24 hours, 7 days per week should have a scheduled 8-hour preventive maintenance period each 7-day period. See Section 8 for recommended inspection schedules.
ACAUTION: Maintenance and operating personnel should be aware of mechanical and electrical hazards inherent in servicing this machine.
INSPECTION CHECKLIST
Cheokcondition ef rope sheave groQves 'and bearings
Test all hold down bolts with impact wrenches
Check rope guides and bails for wear
Inspect all rope for broken wire or loss in diameter
Check auto-lube system for loose or damaged fittings and injector condition
Inspect dipper/bucket for cracks
DANG ER: Remove electrical power from machine whenever inspection of center journal, collector rings, rails or rollet circle is performed. Use extreme ,c.ar-e in removing guards and protective devices. 1--6
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PREVENTIVE MAINTENANCE - continued
INSPECTION.CHECKLIST
Check condition of roller circle, rails, and gearing
Check main swing gear hold down bolts and re-torque to specifications
Test all hold down bolts on upper frame components such as swing gear case, electric motor mounts, machinery pedestals and air compr-essors
.Examineall brakes, clutches and their linings for excessive wear
Check center all guards and protection devices removed
.ADANGER: REMOVE ELECTRICAL POWER FROM MACHINE BEFORE P'ER'FORMING ANY OF THE FOLLOWING INSPECTIONS:
Inspect electrical cabinets; any discC?lored wires or components indicate overheating conditions h.ave
Look for 'moisture, fungus or mildew in electrical cabinets. If found clean with approv.edsolvents only, .or air.
Check all electrical cabi nets for messy or torn fasteners, cable armor or grommets, loose insulation
Inspect electrical motors 'for discolored commutators or worn brushes.
inspection points are representative of typical preventive maintenance routines. Use Section 8 as a detailed guide for' all areas of machine inspection and suggested schedwled periods.
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+:+ Marion Power Shovel Division, Dresser Industries, Inc. ("Marion") warrants that its- products, when ship-
pad, for a period of six (6) months from the date of delivery, F.O.B. point of shipment, will meet ap-
pI/cable, agreed specifications, if any with respect thereto, and will be free from defects in material and
workmanship, provided that the Marion products sold are properly stored, assembled, used and maintain··.· ed.Productsnot manufactured by Mari"on shall be "subject only to such warrant yes may be made by the
manufacturer thereof. All claims under this warranty must be made in writing immediately upon
discovery. THE FOREGOING IS EXPRESSLY IN LJEU OF ALL OTHER WARRANTIES WHATSOEVER, EX.·:·
PRESS. IMPLIED AND STATUTORY, INCLUDING, WITHOUT LIMITATION, THEIMFlUED WARRANTIES
Should any failure of the Marion products to conform to this warranty appear within the limited time period set forth above, Marion shall, upon Buyer's submission of a claim as provided above, either 1 I
repair or replace, F.O.B. point of shipment, any nonconforming.part or parts of Marion's products which
have been returned to it tor examination, transportation prepaid, or otherwise examined by Marion, and
which examination discloses the nonconformity to Marion's. satisfaction; or 21 refund an equitable portion the purchase
THE FOREGOING IS MARION'S ONLY OBLIGATION AND BUYER'S :EXCLUSIVE REMEDY FOR BREACH
OF WARRANTY AND, EXCEPT'FOR GROSS NE'GLIGENCEOR WILLFULMISCONDUCT, THE FOREGOING.:"
REMEDY AGAINST MARION FOR ALL· CLAIMS ·ARtS1NG WITH RESPECT to·
MARION PRODUCTS OR RELATING THERETO, WHETHER SUCH CLAIMS ARE BASED ON BREACH OF .%.
CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES, BUYER'S SUlaMITA CLAIM AS PROVIDED ABOVE ,SHALL "SPEiCIFfCAUY WAIVE ALL CLAIMS FOR
.DAMAGESOR OTHER RELIEF, INCLUDING, BUT NOT LIMITED TO, CLAIMS BASED ON LATENT
,DEFECTS.
INNOEVENi (INCLUDtNG,BUT NOT LIMITED TO. AVOIDANCE OF THE ABOVE LIMITED WARRANTIES
BE ENTITLED TO ANY INDIRECT, SPECIAL. INCIDENTIAL OR CONSE·
aUENTIALDAMAGES, WHETHER ARISING FROM LATE PERFORMANCE OR A FAILURE TO PERFORM,.f:. DEFiCIENCIES OR NEGLIGENCE IN THE DESIGN, SALE DELIVERY OR ASSEMBL YOF
MARION PRODUCTS OR FAILURE OF MARION PRODUCTS OR FROM ANY CAUSE WHATSOEVER AND
WHETHER BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILI·
OTHER THEORIES. ANY ACTION BY BUYER ARISING WITH RESPECT TO MARION PRODUCTS
RELATING THERETO MUST BE COMMENCED WITH ONE (1') YEAR AFTER THE CAUSE OF ACTION
ACCRUES OR IT .SHALL Be BARRED.
Marion reserves the right t. a improve or change the design of its products and specifications thereof and
Marion shall incur no liability there:byor ,any ,obligations to ,install such improvements on products previously sold.
*The above warranty relates to spare/repair parts for the Marion equipment referenced in this document.
For specifics on the machine warranty, reference should be made to the purchase contract or Marion
Power Shovel Division, Dresser Industries, Inc. may be contacted directly. Please identify machine serial
number.
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