Cat Bucyrus Marion 8200 Dragline Programmable System Manual SN 23139 - PDF DOWNLOAD

Technical Manual

• 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.

MARION PROGRAMMABLE SYSTEM

* THESE PAGE NUMBERS REFER TO THE PRODUCT DATA SHE S IN SECTION 10 OF THIS MANUAL.

** INPUT MODULE MAY BE CONFIGURED FOR LOW-TRUE RATHE THAN HIGHTRUE LOGIC; REFER TO ELEC. SCHEMATIC IN SECTION 6.

TROUBLESHOOTING REFERENCES

Introduction

GENERAL INFORMATION

This manual is designed to assist the owner in the operation nd preventive maintenance of this machine. Following easy to understand step-by-s ep procedures, maintenance personnel can perform these tasks in a safe manner. Wh n a systematic and thorough maintenance/service procedure (a responsibility of t e maintenance superintendent) is used for this machine, minimum unplanned downtime and reliable operation will result.

THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used to order parts. A separate, detailed parts book has been supplied. Please carefully read he instructions in it. All parts are listed by group and/or product code numbers with ite /part numbers for THIS SPECIFIC MACHINE. Order parts in exact quantity. Parts ord red by mistake and returned, are subject to a rehandling charge. RIGHT and LEFT H ND PARTS on the upper frame correspond to the operator's hands at the controls; s seated when operating the machine. Please state the correct machine SERIAL NUM ER (located on a plate in the operator's cab) when corresponding or contacting factory service or parts departments. Records on each machine are filed by serial number and hen given this number, your machine's specific design and original equipment is acc ssed quickly by the Marion parts representative.

Periodic additions or revisions may be made to this manual. These will e mailed direct to you from the factory. Should you require additional information or factory service assistance contact your regional service representative or

Service Department

Marion Division of INDRESCO Inc.

617 West Center Street

P.O.Box 505 Marion, OH 43302

or Telephone 614/ Telex 24-5307

Telecopier 614/

It is Marion's policy to improve its products whenever possible and pr ctical to do so. The company reServes the right to make changes or add improveme ts at any time without incurring any obligation to install such changes on machines old previously.

Due to this continuous program of product research and deve opment some procedures, specifications and parts may be altered in a constant ef ort to improve machines.

SAFETY ALERT SYMBOLS

AThis safety alert symbol is used here and throughout thi your attention to instructions concerning your personal s read and follow these instructions and observe all SA and CAUTION graphics mounted on various areas of th

manual to call fety. Carefully TY, DANGER, machine.

Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definition. In the event you question your ability to safely perf rm any of the enclosed maintenance and operational procedures contact your regiona Marion service representative or the factory.

The following defines distinctions between safety instructions. In all t ese definitions the safety alert signal is used.

ADANGER: ACAUTION:

Denotes extreme intrinsic hazard which exists an could result in high probability of death or irreparable injury if pro er precautions are ignored.

Denotes a reminder of safety practices or dire ts attention to unsafe practices which could result in personal injury if proper precautions are ignored.

An example of a safety alert symbol and special instructions is show below.

ADANGER: Inherent danger exists in the operation of an high voltage electrical equipment. A safe grounding system i eludes ground conductors in the power cable, a neutral groundi g resistor. and related relays and switch-gear. A ground continuit check system is required by law in many parts of the world.

Operating, maintaining or servIcing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he i alert, has the n-ecessary skill, knowledge, proper tools and equipment, and that all th methods used are safe and correct. Factory service representatives and specialists re available to provide additional information or technical assistance.

The operator must be alert, physically fit, and free from the influence of alcohol, drugs, or medications that might effect his eyesight, hearing or reactions.

Safety must always be the most important concern. Consult your s pervisor when safety is in doubt.

SAFETY PRECAUTIONS

The owner and/or operator must replace any and all safety and arning product graphics if they are defaced or removed from the machine.

Before doing any work on the machine, a qualified electrician must 10 k out or remove the electric power supply from the machine and tag it so personne are aware that someone is working on the machine.

Do not start an engine indoors unless adequate exhaust ventilators ar provided. Once an engine is running, move the machine outdoors as soon as possibl

Keep hands, feet, and clothing away from rotating parts.

Do not move or operate the machine without knowing the location a d purpose of all personnel, plus test or support equipment, in or near the machine.

Think before you act. Carelessness is one luxury the service man ca not afford.

Do not wear rings, wrist watches or loose fitting clothing when worki g on machinery. They could catch on moving parts causing serious injury. Never adju t and/or service a machine in bare feet, sandals or sneakers.

Always wear safety glasses when using a hammer, chisel or othe tools that may cause chips to fly.

Excessive or repeated skin contact with sealants or solvents may cau e skin irritation. In case of skin contact, remove sealant or solvent promptly by washi g with soap and water.

Never utilize the machine air or hydraulic systems for support when working on the machine. Deactivate and isolate the system prior to performing main enance.

Equipment should be parked on level ground at all times during machi e servicing and periods of idleness.

Cranes and hoists must be of sufficient capacity to lift the heavier c mponents (gear cases, dipper/bucket, boom, etc.) and have an ample safety margin.

Be sure heavy items are properly supported from cranes or hoists efore removing supporting members from machine.

Have sufficient service personnel available when removing or instal ing large heavy items to maintain control at all times.

Always use safety stands in conjunction with hydraulic jacks or hoist Do not rely on the jack or hoist to carry the load, they could fail.

Use safety catch on all hoist hooks. Do not take a chance, the load co Id slip off of the hook.

If a heavy item begins to fall, let it fall, don't try to catch it.

When disassembling machine, be sure to use safety stands and ade uate cribbing to prevent tipping or rollover of components.

Keep work area organized and clean. Wipe up oil or spills of any kind Keep tools and parts off of the ground. Eliminate the possibility of a fall which could result in serious injury.

Floors, walkways and stairways must be clean and dry. After draini g operations be sure all spillage is cleaned up. Electrical cords and wet metal floors m ke a dangerous combination.

Check all wire ropes for telltale signs of early wear or failure. Look fo and secure any loose bolts or locking devices.

Use extreme caution while working near any electrical lines or equip ent whether it be high or low voltage. Never attempt electrical repairs unless quali ied. Check limit switches for proper operation.

When using an acetylene torch, always wear welding goggles and gloves. Keep a "charged" fire extinguisher within reach. Be sure the acetylene and ygen tanks are separated by a metal shield and are chained to the cart. Do not weld 0 heat areas near transformers or electrical cabinets and utilize proper shielding around ubrication lines.

Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. hen applicable. Use hammers, punches and chisels only when absolutely necessary. hen, be sure to wear safety glasses.

Be careful when using compressed air to dry parts. Use approved air bl w guns, do not exceed 30 psi (207 kPa), wear safety glasses or goggles and use pr per shielding to protect everyone in the work area.

Be sure to promptly reinstall safety devices, guards or shields after djusting andlor servicing the machine.

After servicing, be sure all tools, parts or servicing equipment are re oved from the machine, or secured in an appropriate storage area.

Protective eye goggles should be worn at all times when wor ing on the air conditioning system. Work on the air conditioning 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 constantly aware of swing learance. Never hold a load longer than needed in the dump cycle. Use swing br kes only when machine is stopped.

FIRE PREVENTION

Always have a "charged" fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate.

DO NOT smoke while handling flammables or when near batteries.

Inspect all lines, tubes, and hoses carefully. Tighten all co nections to the recommended torque. See the Visual Inspection Schedule for he walk around inspection procedure.

Loose or damaged lines, tubes, and hoses, which leak, can cause a fire.

Make certain. that all clamps, guards, and shields are replaced c rrectly so as to prevent vibration and the rubbing of one part against another whi h might result in heat build-up during operation.

DO NOT carry flammable fluids such as gasoline or solvents on boa d the machine.

DO NOT over-bend or strike pressurized hose lines. DO NOT install bent or damaged lines, tubes, or hoses. Replace them with new immediately.

DO NOT start the machine or move any of the controls if a warning ag is attached to the controls or the start panel.

Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.

Keep all structural frame compartments, walkways, and work areas clean and free of lubricant residue.

NEVER weld, burn, or perform service on the machine alone.

If a motor or other component is running hot, shutdown the machine ntil it has cooled and/or the cause eliminated.

TRAINING

Qualified maintenance personnel using a scheduled maintenance prog am are the best way to minimize machine downtime and maximize productivity of e uipment.

Marion offers factory and mine site maintenance seminars and speci I familiarization programs for mechanics, oilers, electricians and operators on a fee b sis.

These programs are presented by qualified factory specialists and se ice technicians. Special customized training programs can also be developed to me t specific mine requirements.

Objectives of training and training materials are to provide the mean for developing and maintaining on-site service repair capability.

For further information about Marion service training capabilities and pr grams contact:

Customer Service Department

Marion Division of INDRESCO Inc.

617 West Center St.

P.O.Box 505

Marion, OH 43302

Marion Division of INDRESCO Inc. warrants that its products, when shipped, for a period of six (6) months from the date of delivery, F.O.B. point of shipment, will meet applicable, agreed specifications, if any with respect thereto, and will be free fron defects in material and workmanship, provided that the Marion products sold are stored, assembled, used and maintained. Products not manufactured by Marion shall be ubject only to such warranty as may be made by the manufacturer thereof. All claims Jnder this warranty must be made in writing immediately upon discovery. THE FOREGOING IS EXPRESSLY IN LIEU OFALL OTHER WARRANTIES WHATSOEVER, EXPRESS, IMPLlEO AND STATUTORY, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF AND FITNESS.

Should any failure of the Marion products to conform to this appear within the limited time period set forth above, Marion shall, upon Buyer's subm ssion of a claim as provided above, either 1) repair or replace, F.O.B. point of shipment, any nonconforming part or parts of Marion's products which have been returned to it for examination, transportation prepaid, or otherwise examined by Marion, and which e><amination discloses the nonconformity to Marion's satisfaction; or 2) refund an portion of the purchase price.

THE FOREGOING IS MARION'S ONL Y OBLIGATION AND BUYER'S EXCLUSIVELY REMEDY FOR BREACH OF WARRANTIES AND, EXCEPT FOR GROSS NEG IGENCE, WILLFUL MISCONDUCT, OR REMEDIES PERMITTED UNDER THE PERFORMANCE INSPECTION. AND ACCEPTANCE CLAUSE OF MARION'S TERMS AND CONDITION:;. THE FOREGOING IS BUYER'S EXCLUSIVE REMEDY AGAINST MARION FOR ALL CLAIMS ARISING 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 FAILURE TO SUBMIT A C( AIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR DAMAGES OR OTHER RELIEF. INCLUDING, BUT NOT LIMITED TO, CLAIMS BASED ON LATENT DEFECTS.

IN NO EVENT (INCLUDING, BUT NOT LIMITED TO. AVOIDANCE OF T ABOVE LIMITED WARRANTIES AND REMEDIES) SHALL BUYER BE ENTITLED TO ANY I SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER ING FROM LATE PERFORMANCE OR A FAILURE TO PERFORM. DEFICIENCIES OR N GLIGENCE IN THE DESIGN, MANUFACTURE, SALE DELIVERY OR ASSEMBLY OF MARIPN PRODUCTS OR FAILURE OF MARION PRODUCTS OR FROM ANY CAUSE WHATSOE\ ER AND WHETHER BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES. ANY ACTION BY BUYER ARISING WITH RESPECT TO MARION PRODUCTS OR RELATING THERETO MUST BE COMMEN(,ED WITH ONE (1) YEAR AFTER THE CAUSE OF ACTION ACCRUES OR IT SHALL BE B .

• 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.