CAT Dragline Marion 8750 Walking Dragline Operation & Maintenance Manual – PDF DOWNLOAD

Description

CAT Dragline Marion 8750 Walking Dragline Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION

S/N 23204

CAT Dragline Marion 8750 Walking Dragline Operation & Maintenance Manual – PDF DOWNLOAD

GENERAL INFORMATION

• This manual is designed to assist the owner in the operation and preventive maintenance of this machine.
• Following easy to understand step-by-step procedures, maintenance personnel can perform these tasks in a safe manner.
• When a systematic and thorough maintenance/service procedure (a responsibility of the maintenance superintendent) is used for this machine, minimum unplanned downtime and reliable operation will result.
• THIS MANUALS IS NOT THE PARTS BOOK, and cannot be used to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by group and/or product code numbers with item/part numbers for THIS SPECIFIC MACHINE. Order parts in exact quantity. Parts ordered by mistake and returned, are subject to a reachandling charge.
• RIGHT and LEFT HAND PARTS on the upper frame correspond to the operator’s hands at the controls; as seated when operating the machine. Please state the correct machine SERIAL NUMBER (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 when given this number, your machine’s specific design and original equipment is accessed quickly by the Dresser parts representative.

TABLE OF CONTENTS:

CAT Dragline Marion 8750 Walking Dragline Operation & Maintenance Manual – PDF DOWNLOAD

23204 Maint Man.pdf...............................................................  0
	INTRODUCTION..................................................................  5
		GENERAL INFORMATION.......................................................  5
		SAFETY PERCAUTIONS
.......................................................  6
		TRAINING
.................................................................  9
		PREVENTIVE MAINTENANCE
................................................... 10
		WARRANTY
................................................................. 12
	MACHINE SPECIFICATIONS........................................................ 13
		NOMENCLATURE.............................................................. 14
		DECK PLAN................................................................. 15
		MACHINE SPECIFICATIONS.................................................... 16
		PRINCIPAL WEIGHTS......................................................... 17
	OPERATION..................................................................... 20
		GENERAL................................................................... 20
			NOMENCLATURE.......................................................... 21
			DECK PLAN............................................................. 22
		CAB AND ANTEROOM.......................................................... 23
		PRIMARY CONTROLLERS....................................................... 25
			PLUGGING THE MOTION................................................... 27
			SECONDARY CONTROLS.................................................... 27
			ANNUNCIATOR PANEL..................................................... 31
		OPERATOR CONTROLS IN THE MACHINERY HOUSE.................................. 36
			STARTING AND METERING PANEL........................................... 36
		PRE-START INSPECTION...................................................... 38
		TYPICAL START-UP.......................................................... 39
		TYPICAL DIGGING CYCLE..................................................... 42
		GROUND PREPARATION........................................................ 44
		WALKING/PROPEL OPERATION.................................................. 45
			WALKING MACHINERY..................................................... 45
			WALKING MACHINERY CONTROL............................................. 46
			WALKING............................................................... 47
		SHUTDOWN.................................................................. 49
			PARTIAL SHUTDOWN...................................................... 49
			COMPLETE SHUTDOWN..................................................... 49
	LUBRICATION................................................................... 52
		GENERAL................................................................... 52
			LUBRICATION FITTINGS.................................................. 52
			ANTI-FRICTION BEARINGS................................................ 52
			ENCLOSED GEAR CASES
.................................................. 52
			WIRE ROPE PENDANT LUBRICATION......................................... 53
			CHECK LIST
........................................................... 53
		AUTOMATIC LUBRICATION SYSTEM.............................................. 54
			ALARM RESET
.......................................................... 54
			LUBE INJECTOR - FARVAL................................................ 55
		AUTO LUBE FOR ROTATING FRAME (MPG)
....................................... 56
			CONTROL PANEL PIPING
................................................. 57
			ELECTRICAL CONTROL PANEL
............................................. 59
		AUTO LUBE FOR OPEN GEARS (OGL
)........................................... 63
			CONTROL PANEL PIPING.................................................. 64
		AUTO LUBE FRONT END (MPG)
................................................ 66
			CONTROL PANEL PIPING
................................................. 69
			ELECTRICAL CONTROL PANEL
............................................. 71
		LUBE INJECTOR............................................................. 73
			ADJUSTING A LINCOLN INJECTOR
......................................... 73
		PROPEL BEARINGS LUBE SYSTEM (WCL)......................................... 76
			CONTROL PANEL PIPING
................................................. 77
			ELECTRICAL CONTROL PANEL
............................................. 79
			FARVAL LUBE INJECTOR
................................................. 81
		MANUALLY OPERATED ROPE SPRAY SYSTEM
...................................... 82
			LUBE CONTROL PANEL PIPING
............................................ 83
		GEARCASE LUBRICATION SYSTEM
.............................................. 84
			LUBE SYSTEM - ROTATING GEARCASE
...................................... 85
			LUBE SYSTEM - PROPEL GEARCASE
........................................ 86
			LUBE SYSTEM - HOIST & DRAG GEARCASE
.................................. 87
		STANDARD LUBRICATION INSTALLATION......................................... 88
			PIPE / HOSE MOUNTING
................................................. 88
			MINIMUM HOSE BEND RADIUS
............................................. 89
			ASSEMBLY OF HOSE FITTINGS
............................................ 89
		LUBRICATION SPECIFICATIONS
............................................... 90
			GREASES
.............................................................. 90
			OILS
................................................................. 90
			GL - GEAR LUBRICANTS (OIL TYPE)
...................................... 91
			DESCRIPTION OF OIL GREASE CLASSIFICATIONS............................. 92
			SPECIAL PRODUCTS
..................................................... 95
			APPROVED PRODUCTS
.................................................... 95
			PROPER LUBRICANT
 .................................................... 96
		LUBRICATION POINTS
....................................................... 97
			PROPEL MACHINERY
..................................................... 97
			CENTER JOURNAL
....................................................... 99
			ROTATING MACHINERY.................................................... 99
			ROLLER RAIL AND ROLLER CIRCLE
........................................100
			HOIST MACHINERY
......................................................100
			DRAG MACHINERY
.......................................................101
			HOIST, DRAG AND PROPEL BRAKES
........................................102
			GANTRY AND FAIRLEAD
..................................................102
			MAST
.................................................................103
			BOOM
.................................................................103
			DRAGLINE BUCKET
......................................................103
			MISCELLANEOUS POINTS
.................................................104
	MECHANICAL ADJUSTMENTS - 
MECHANICL MAINTENANCE ..............................109
		TUB.......................................................................109
		CENTER JOURNAL
...........................................................110
		ROTATING GEAR AND RAIL SEGMENTS
..........................................111
			GEAR SEGMENT TENSIONING SEQUENCE......................................113
			UPPER RAIL SEGMENTS
..................................................114
			ROLLER CIRCLE
........................................................116
			ROLLER RAILS
.........................................................117
		HOOK SHOES
...............................................................119
		DECK PLAN
................................................................120
		PROPEL MACHINERY
.........................................................121
			PROPEL GEAR CASES
....................................................122
			PROPEL GEAR CASE DISASSEMBLY
.........................................124
			PROPEL GEAR CASE ASSEMBLY
............................................125
			PROPEL MOTOR EXTENSION SHAFT ASSEMBLY
................................126
				SEAL INSTALLATION
................................................127
			FIRST INTERMEDIATE PROPEL SHAFT ASSEMBLY
.............................128
			SECOND INTERMEDIATE PROPEL SHAFT ASSEMBLY ............................129
			MAIN PROPEL SHAFT.....................................................130
			PROPEL LIMIT SWITCH
..................................................131
			PROPEL LINKAGE
.......................................................132
			ASSEMBLY OF WALKING SHOE AND KNUCKLE..................................133
		WALKING SHOE..............................................................134
			WALKING SHOE ROLLERS 
................................................134
			WALKING SHOE RETURN MECHANISM
........................................135
			ROPE INSTALLATION AND ADJUSTMENT
.....................................135
		ROTATING (SWING) MACHINERY
...............................................136
			ROTATING (SWING) MACHINERY DIAGRAM
 ..................................137
			MOTOR EXTENSION SHAFT ASSEMBLY
.......................................141
			INTERMEDIATE SHAFT ASSEMBLY
..........................................143
			MAIN DRIVE GEAR ASSEMBLY
.............................................144
			MAIN GEAR ASSEMBLY OIL SEAL
..........................................145
			MAIN ROTATING SHAFT REMOVAL
..........................................148
			MAIN ROTATING SHAFT REINSTALLATION....................................148
			MAIN ROTATING SHAFT SEAL INSTALLATION
................................149
			MAIN ROTATING SHAFT SHAFT PINION LIMIT................................150
			SWING RECORDER (SEE APPENDIX A
)......................................151
		HOIST AND DRAG MACHINERY
.................................................152
			HOIST AND DRAG DRUM SHAFT ASSEMBLIES
.................................153
			HOIST AND DRAG DRUM SHAFT BEARING REPLACEMENT
........................155
			HOIST AND DRAG DRUM SHAFT GEAR & DRUM END REMOVAL
....................156
			DRUM LAGGING
.........................................................159
			HOIST AND DRAG DRUM LIMIT SWITCHES
...................................160
			ENCODER INSTALLATION PROCEDURE
.......................................161
			HOIST & DRAG ROPE FOULED ROPE LIMIT SWITCHES
.........................162
			HOIST & DRAG GEARCASE DISASSEMBLY.....................................165
			HOIST INTERMEDIATE SHAFT ASSEMBLY.....................................167
			DRAG INTERMEDIATE SHAFT ASSEMBLY......................................169
			HOIST & DRAG MOTOR EXTENSION SHAFT....................................170
			MOTOR EXTENSION SHAFT SEAL REPLACEMENT
...............................171
			REASSEMBLY OF HOIST & DRAG GEARCASES
.................................172
			HOIST ROPE DEFLECTING SHEAVES (HOUSE )................................173
			PROPEL MOTOR EXTENSION SHAFT O-RING INSTALLATION
.....................174
			INTERMEDIATE PROPEL SHAFT O-RING INSTALLATION
........................175
			INTERMEDIATE SWING GEAR CASE SHAFT O-RING INSTALLATION
...............176
			HOIST & DRAG MOTOR EXTENSION SHAFT O-RING INSTALLATION
 ..............177
			INTERMEDIATE HOIST & DRAG SHAFT O-RING INSATLLATION
..................178
		HOIST & DRAG ROPES
.......................................................179
			HOIST & DRAG ROPE REEVING.............................................179
			HOIST ROPE REPLACEMENT................................................182
			DRAG ROPE REPLACEMENT.................................................185
		BOOM ASSEMBLY
............................................................186
			BOOM POINT SHEAVE ASSEMBLY
...........................................187
			REMOVAL OF BOOM POINT SHEAVE ASSEMBLY
................................188
			ALTERNATE REMOVAL PROCEDURE...........................................189
			INSTALLATION OF BOOM POINT SHEAVE ASSEMBLY
...........................189
			DISASSEMBLY OF BOOM POINT SHEAVES ....................................190
			REASSEMBLY OF BOOM POINT SHEAVES .....................................192
			BOOM POINT SHEAVE TORSION BAR REPLACEMENT
 ...........................195
			HOIST ROPE DEFLECTING SHEAVES ON BOOM
................................197
			DISASSEMBLE THESE SHEAVES
............................................197
			BOOM SUPPORT PENDANTS
................................................199
			VIBRATION DAMPERS - BOOM PENDANTS
....................................201
			INTERMEDIATE BOOM SUPPORT
............................................202
			ACCUMULATOR CHARGE....................................................205
			ACCUMULATOR RECHARGE..................................................207
			HYDRAULIC SYSTEM MAINTENANCE - INTERMEDIATE BOOM SUPPORT
.............209
			FILTERS
..............................................................209
			RESERVOIR
............................................................211
			PUMP
.................................................................213
			CYLINDER ASSEMBLY
....................................................215
			REMOVAL & INSTALLATION OF I.B.S. PENDANTS & CYLINDERS.................216
			METHOD OF LOWERING THE BOOM...........................................220
			RAISING THE BOOM
.....................................................225
		MAST ASSEMBLY
............................................................226
			MAST SUPPORT LINKS
...................................................227
		GANTRY-FAIRLEAD ASSEMBLY
.................................................228
			FAIRLEAD SWIVEL SNUBBERS..............................................230
			SNUBBER ADJUSTMENT
...................................................232
			SNUBBER REPLACEMENT
..................................................233
			SWIVAL FRAME THRUST ADJUSTMENT
.......................................233
			LOWER FAIRLEAD SHEAVES................................................236
			TO DISASSEMBLE A LOWER FAIRLEAD SHEAVE
...............................237
			TO INSTALL A LOWER FAIRLEAD SHEAVE
...................................238
			TO REMOVE A FAIRLEAD SWIVAL FRAME
....................................240
			TO INSTALL  A FAIRLEAD SWIVAL FRAME ..................................242
			UPPER FAILEAD SHEAVES
................................................243
			TO DISASSEMBLE AN UPPER FAILEAD SHEAVE ...............................244
			TO INSTALL AN UPPER FAILEAD SHEAVE....................................245
			HOIST ROPE DEFLECTING SHEAVES
........................................247
			TO DISASSEMBLE A HOIST ROPE DEFLECTING SHEAVE ........................248
			TO INSTALL A HOIST ROPE DEFLECTING SHEAVE ............................249
			BEARING SET-UP PROCEDURE - HOIST ROPE DEFLECTING SHEAVE IN GANTRY
....250
			SAFETY ROPES - GANTRY BACKLEGS .......................................252
		DRAGLINE BUCKET
..........................................................253
			DRAG CHAIN ATTACHMENT.................................................253
			HOIST CHAIN ATTACHMENT................................................254
			WEAR PLATES...........................................................254
			DRAGLINE BUCKET CHAINS
...............................................255
			WEIGHT OF MARION BUCKET AND COMPONENTS
...............................256
	COMPRESSED AIR SYSTEMS........................................................258
		AIR COMPRESSORS
..........................................................258
		ANTI-FREEZER
.............................................................258
		MAGNET VALVES
............................................................259
		PRESSURE REGULATORS
......................................................259
		AIR FILTERS
..............................................................259
		AIR VALVES................................................................260
		LUBRICATORS...............................................................260
		FLOW RATE CONTROL VALVES
.................................................260
		AIR PRESSURE SWITCHES
....................................................261
		PIPING, COMPRESSED AIR SYSTEM.............................................262
			CONNECTION TO AIR COMPRESSORS & BRAKES
...............................263
		AIR FILTER SYSTEM
........................................................264
		PRESSURIZED WELDMENTS
....................................................265
			CHARGING PROCEDURE....................................................266
			PROCEDURE WHEN LOSS OF AIR PRESSURE OCCURS ...........................266
	ELECTRICAL MAINTENANCE........................................................269
		GENERAL...................................................................269
			CARE OF D.C. MOTORS AND GENERATORS
...................................269
			BRUSHES
..............................................................270
			BRUSH INSTALLATION....................................................270
			COMMUTATORS
..........................................................271
			PROPER LUBRICATION....................................................272
			BEARING LUBRICATION DATA..............................................273
			FEEDER CABLE..........................................................274
			POWER LINE GROUNDING CIRCUIT
.........................................274
		COLLECTOR RINGS...........................................................275
			MAIN COLLECTOR RING ASSEMBLY..........................................275
			AUXILIARY COLLECTOR RINGS.............................................276
		POWER CONTROL ROOM (PCR)..................................................277
		ELECTRICAL TROUBLESHOOTING................................................278
			PREPARATION
..........................................................278
			INVESTIGATION.........................................................279
			PERFORMANCE...........................................................281
			TYPES OF FAILURE......................................................281
			FAULTS................................................................282
			SHORT CIRCUITS
.......................................................282
		REFERENCE PUBLICATION
....................................................286
	ENGINEERING DATA
.............................................................290
		BUSHINGS
.................................................................290
		SEALS.....................................................................296
			SEAL INSTALLATION.....................................................296
		GEAR ALIGNMENT ECCENTRICS
................................................298
		GEAR BACKLASH
............................................................299
		ECCENTRIC CARTRIDGES
.....................................................303
			OBJECTIVE.............................................................304
			THEORY................................................................306
			ORIENTATION...........................................................308
			OUT OF PLANE ADJUSTMENT...............................................308
			OUT OF PARALLEL ADJUSTMENT............................................308
			COMMENT...............................................................308
			TYPICAL ECCENTRIC CARTRIDGES..........................................310
		CONTACT PATTERNS - ECCENTRIC CARTRIDGES...................................312
		SPLINES
..................................................................331
			INVOLUTE SPLINE ASSEMBLY..............................................331
		SHRINK FIT COMPONENTS
....................................................332
			INSTALLATION
.........................................................332
			REMOVAL
..............................................................334
		CAPSCREWS.................................................................335
			CAPSCREW GRADE........................................................335
			TURN-OF-NUT METHOD
...................................................335
			TORQUE METHOD
........................................................336
			WIRE LOCKING CAPSCREWS
...............................................336
		WIRE ROPE CARE
...........................................................338
			PROPERLY SEIZING......................................................341
			BOOM STRAND PENDANTS
.................................................342
		REPAIR WELDING PROCEDURE..................................................369
			EXAMPLES OF CORRECT WELD REPAIRS......................................355
			SHEAR BLOCK INSTALLATION..............................................358
		O-RING GUIDE..............................................................359
		COUPLINGS.................................................................367
			STEELFLEX.............................................................367
			GEAR .................................................................373
			MOTOR/GENERATOR KEYLESS...............................................376
		HOIST, DRAG, SWING AND PROPEL BRAKES......................................379
			SWING MOTOR BRAKE.....................................................379
				ADJUSTING.........................................................381
			HOIST AND DRAG BRAKE..................................................381
				CENTERING.........................................................381
				ADJUSTING.........................................................382
			PROPEL BRAKE..........................................................383
				CENTERING.........................................................383
				ADJUSTING
........................................................384
	DRAGLINE MAINTENANCE INSPECTION SCHEDULE......................................387
		DAILY - EVERY 24 HOURS....................................................388
		WEEKLY - EVERY 150 HOURS
.................................................396
		PERPETUAL WEEKLY ROUTINE
.................................................400
		MONTHLY - EVERY 600 HOURS
................................................401
		QUARTERLY - EVERY 1800 HOURS
.............................................402
		SEMI-ANNUAL - EVERY 3600 HOURS
...........................................404
		ANNUAL - EVERY 7200 HOURS
................................................406
		BIENNIAL - EVERY 15,000 HOURS
............................................408
		SCHEDULED COMPONENT REPLACEMENT...........................................410
	DRESSER/SIGMA AIR CONDITIONER
................................................413
		GENERAL DESCRIPTION
......................................................413
			OPERATION
............................................................413
			REFRIGERANT...........................................................413
			CAB MOUNTED AIR CONDITIONER/HEATER
...................................414
			CONDENSING UNIT
......................................................414
			COOLING (EVAPORATOR) UNIT
............................................414
			FRESH AIR, PRESSURIZATION PACK
.......................................414
			PCR MOUNTED AIR CONDITIONER/HEATER
...................................415
		START-UP INSTRUCTIONS ....................................................416
			OILS TO BE USED.......................................................417
		ELECTRICS AND CONTROLS
...................................................418
			OPERATION.............................................................418
			PRESSURE SWITCHES
....................................................418
			ELECTRICAL MAINTENANCE SCHEDULE
......................................418
			ELECTRICAL MAINTENANCE................................................419
			COMPRESSOR PRESSURE SWITCH - ADJUSTMENT ..............................419
		MECHANICAL MAINTENANCE....................................................420
			MECHANICAL MAINTENANCE SCHEDULE.......................................420
			LEAK TESTING - GENERAL INSTRUCTIONS ..................................421
			NITROGEN LEAK TEST
...................................................421
			VACUUM DRYING
........................................................422
			FIELD CHARGING PROCEDURE..............................................422
			REPLENISHING REFRIGERANT
.............................................423
			ADDING OIL............................................................424
			COMPONENT MAINTENANCE
................................................425
				COMPRESSOR - GENERAL..............................................425
				COMPRESSOR - REMOVAL FROM SYSTEM
.................................426
				COMPRESSOR - REPLACEMENT
.........................................426
				AIR COOLED CONDENSER
.............................................426
		OPERATING DATA (REFRIGERANT R12)..........................................427
		SPECIFICATIONS............................................................428
			CAB MOUNTED AIR CONDITIONER/HEATER
...................................428
				POWER SUPPLY
.....................................................431
			PCR MOUNTED AIR CONDITIONER/HEATER
...................................432
		TROUBLE ANALYSIS
.........................................................435
			COMPRESSOR FAILS TO START
............................................435
			COMPRESSOR "SHORT CYCLES".............................................436
			COMPRESSOR RUNS CONTINUOUSLY
.........................................436
			COMPRESSOR LOSES OIL
.................................................437
			COMPRESSOR IS NOISY
..................................................437
			SYSTEM SHORT OF CAPACITY..............................................438
			HEAD PRESSURE TOO HIGH
...............................................439
			HEAD PRESSURE TOO LOW
................................................439
			SUCTION PRESSURE TOO HIGH
............................................440
			SUCTION PRESSURE TOO LOW
.............................................440
			TROUBLE ANALYSIS CHART NOTES
.........................................441
	SWING RECORDER................................................................443
		GENERAL INSTRUCTIONS......................................................444
			SPECIAL RECORDING INSTRUMENT
.........................................444
			CHART DRIVE SYSTEM....................................................445
			OPERATION
............................................................446
			MAINTENANCE
..........................................................448
			SUPPLIES AND ATTACHMENTS
.............................................459

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CAT DRAGLINE MARION 8750 WALKING DRAGLINE OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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