CAT Dragline 8200 Walking Dragline Maintenance And Operation Manual – PDF DOWNLOAD
DESCRIPTION
S/N 23326
CAT Dragline 8200 Walking Dragline Maintenance And Operation 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 MANUAL 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 TH IS SPECIFIC MACHiNE. Ord.er parts in exact quantity. Parts ordered by mistake and returned, are subject to a rehandling 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. Periodic additions or revisions may be made to this manual. These will be mailed direct to you from the factory. Should you require additional information or factory service assistance contact your regional service representative or
TABLE OF CONTENTS:
CAT Dragline 8200 Walking Dragline Maintenance And Operation Manual – PDF DOWNLOAD
23326 Maint Man.pdf........................................... 0 INTRODUCTION.............................................. 0 GENERAL INFORMATION................................... 7 SAFETY PRECAUTIONS.................................... 8 PREVENTIVE MAINTENANCE................................ 12 WARRANTY.............................................. 14 TRAINING.............................................. 15 OPERATION................................................. 0 CAB AND ANTEROOM...................................... 17 OPERATOR'S SEAT ADJUSTMENT............................ 23 PRIMARY CONTROLLERS (JOYSTICKS)....................... 24 PLUGGING THE MOTION............................... 26 SECONDARY CONTROLS.................................... 27 MID-SECTION PANEL................................. 27 OPERATOR INTERFACE TERMINAL (OIT)................. 31 OTHER COMPONENTS ON THE OPERATOR CONSOLE.......... 32 DIGMATE AND BOOMSENTRY................................ 34 OPERATOR CONTROLS IN MACHINERY HOUSE ................. 36 START-UP PANEL ................................... 38 PRE-START INSPECTION.................................. 40 TYPICAL START-UP ..................................... 41 TYPICAL DIGGING CYCLE ................................ 44 WALKING/PROPEL OPERATION ............................. 47 WALKING MACHINERY ............................... 47 WALKING MACHINERY CONTROLED ...................... 48 WALKING .......................................... 48 GROUND PREPARATION ............................... 52 PARTIAL SHUTDOWN ..................................... 53 COMPLETE SHUTDOWN .................................... 53 LUBRICATION............................................... 0 LUBRICATION FITTINGS ................................. 56 ANTI-FRICTION BEARINGS................................ 56 ENCLOSED GEAR CASES .................................. 56 WIRE ROPE PENDANT LUBRICATION......................... 57 CHECK LIST ........................................... 57 LUBRICATION SPECIFICATIONS ........................... 58 GREASES .......................................... 58 OILS ............................................. 58 GL - GEAR LUBRICANTS (OIL TYPE) .................. 59 DESCRIPTION OF OIL AND GREASE CLASSIFICATIONS .... 60 SPECIAL PRODUCTS ................................. 63 APPROVED PRODUCTS ................................ 63 LUBRICATION POINTS ................................... 64 PROPEL MACHINERY (1 OF 2) ........................ 64 CENTER JOURNAL ................................... 66 ROTATING MACHINERY (1 OF 5) ...................... 66 ROLLER RAIL AND CIRCLE ........................... 67 HOIST MACHINERY .................................. 67 DRAG MACHINERY ................................... 68 FAIRLEAD ......................................... 69 TRI-STRUCTURE .................................... 69 BOOM ............................................. 70 MISCELLANEOUS POINTS ............................. 71 DRAGLINE BUCKET................................... 72 AUTOMATIC LUBRICATION SYSTEM.......................... 73 ALARM CLEAR ...................................... 73 AUTO LUBE FOR PROPEL MACHINERY, OGL .................. 75 AUTO LUBE FOR ROTATING FRAME, OGL .................... 77 AUTO LUBE FOR ROTATING FRAME, MPG ................... 78 AUTO LUBE FOR TRI-STUCTURE, MPG (SCHEMATIC ONLY) ..... 79 AUTO LUBE FOR FAIRLEAD, MPG (SCHEMATIC ONLY) ......... 80 AUTO LUBE FOR BOOM, MPG (SCHEMATIC ONLY) ............. 81 AUTO LUBE FOR WIRE ROPE, WRL ......................... 82 LUBRICATION OF ROTATING GEARCASE TELL-TALE FILTER .... 83 TYPICAL LUBE ROOM CONTROL PANEL....................... 84 TYPICAL LUBE PANEL FUNCTION ......................... 84 TYPICAL LUBE ROOM TANK LAYOUT ........................ 85 TYPICAL ROLLER CIRCLE LUBE OPERATION ................. 86 TYPICAL AUTO LUBE HEAT SYSTEM PANEL .................. 86 TYPICAL GEAR CASE DRAIN SYSTEM ....................... 87 TYPICAL GREASE REMOVAL SYSTEM ....................... 88 STANDARD LUBRICATION INSTALLATION .................... 89 ADJUSTING AND MOUNTING OF LINCOLN INJECTOR ........... 90 MINIMUM HOSE BEND RADIUS.............................. 90 ASSEMBLY OF HOSE FITTINGS ............................ 91 MECHANICAL ADJUSTMENTS.................................... 0 TUB .................................................. 97 CENTER JOURNAL ....................................... 98 ROLLER CIRCLE.........................................105 ROLLER RAILS .....................................106 HOOK SHOES ...........................................106 PROPEL MACHINERY .....................................107 PROPEL GEAR CASES ................................108 PROPEL MOTOR EXTENSION SHAFT ASSEMBLY.............109 FIRST INTERMEDIATE PROPEL SHAFT ASSEMBLY..........111 SECOND INTERMEDIATE PROPEL SHAFT ASSEMBLY ........113 SEAL INSTALLATION ON EXTENSION SHAFT .............115 PROPEL GEAR CASE DISASSEMBLY......................116 PROPEL GEAR CASE ASSEMBLY ........................117 MAIN PROPEL DRIVE PINION SHAFT....................118 MAIN PROPEL SHAFT.................................119 WALKING SHOE..........................................120 WALKING SHOE ROLLERS .............................121 WALKING SHOE RETURN MECHANISM ....................122 ROTATING (SWING) MACHINERY ...........................123 MACHINE ROTATION .................................123 MOTOR EXTENSION SHAFT ............................123 INTERMEDIATE SHAFT ASSEMBLY ......................123 MAIN ROTATING SHAFT ..............................123 MAIN ROTATING SHAFT REINSTALLATION ...............125 MAIN DRIVE GEAR ASSEMBLY..............................131 MAIN GEAR BEARINGS ...............................131 MAIN GEAR ASSEMBLY OIL SEAL ......................132 HOIST AND DRAG MACHINERY..............................134 DRUM ASSEMBLY.....................................134 INTERMEDIATE SHAFT ASSEMBLY.......................137 SEAL INSTALLATION.................................138 HOIST AND DRAG GEARCASE DISASSEMBLY...............141 HOIST AND DRAG MACHINERY DRUM REMOVAL.............142 DRUM ROD BOLT TIGHTENING .........................142 DRUM SHAFT ASSEMBLY ..............................142 HOIST, DRAG, SWING AND PROPEL BRAKES .................143 HOIST AND DRAG ROPES .................................153 CHANGING HOIST ROPE(S) ...........................154 CHANGING DRAG ROPE(S) ............................154 ROPE WINCHES .....................................155 METHOD OF LOWERING BOOM...............................156 METHOD OF RAISING BOOM ...............................158 BOOM POINT SHEAVE ASSEMBLY ...........................162 DISASSEMBLY OF BOOM POINT SHEAVE ................162 BEARING ASSEMBLY PROCEDURE, BOOM POINT SHEAVE ....163 REASSEMBLY OF BOOM POINT SHEAVES .................163 BOOM SUPPORT BRIDGE STRANDS ..........................164 VIBRATION DAMPER .................................165 INTERMEDIATE BOOM SUPPORT ROPES ADJUSTMENT .......166 TRI-STRUCTURE ASSEMBLY ...............................170 HOIST DEFLECTING SHEAVES .........................171 DEFLECTING SHEAVE BEARING ADJUSTMENT .............172 SAFETY ROPES .....................................173 FAIRLEAD ASSEMBLY ....................................174 FAIRLEAD SNUBBERS ................................174 WEDGE ADJUSTMENT .................................176 DRAG ROPE LOWER SHEAVES ..........................177 LOWER SWIVEL SHEAVE BEARING ADJUSTMENT ...........178 DRAG ROPE LOWER SHEAVES ..........................179 UPPER FAIRLEAD SHEAVE BEARING ADJUSTMENT .........180 DRAGLINE BUCKET.......................................181 WEAR PLATES ......................................182 DRAGLINE BUCKET CHAINS ...........................183 ELECTRICAL MAINTENANCE.................................... 0 CARE OF D.C. MOTORS AND GENERATORS ...................186 BRUSH INSTALLATION ...................................186 COMMUTATORS ..........................................187 NEVER USE EMERY CLOTH OR EMERY PAPER .................187 PROPER LUBRICATION ...................................188 FEEDER CABLE .........................................190 POWER LINE GROUNDING CIRCUIT .........................190 ELECTRICAL TROUBLESHOOTING ...........................191 PREPERATION ......................................191 INVESTIGATION ....................................192 PERFORMANCE.......................................194 TYPES OF FAILURE .................................194 SHORT CIRCUITS ...................................195 MAIN COLLECTOR RINGS .................................199 AUXILIARY COLLECTOR RINGS ............................200 HOIST/DRAG LIMIT SWITCHES ............................200 PROPEL LIMIT SWITCHES.................................201 POWER CONTROL ROOM (PCR) .............................202 COMPRESSED AIR SYSTEMS AND COMPONENTS..................... 0 AIR COMPRESSORS ......................................204 ANTI-FREEZER..........................................204 MAGNET VALVES ........................................205 PRESSURE REGULATORS ..................................205 AIR CYLINDER VALVES ..................................205 AIR FILTERS...........................................206 AIR VALVES ...........................................206 LUBRICATORS ..........................................206 SYSTEM PIPING (ILLUSTRATION ONLY) ....................207 SYSTEM COMPONENT CONNECTIONS (ILLUSTRATION ONLY) .....208 AIR FILTER SYSTEM ....................................209 PRESSURIZED WELDMENTS ................................210 CHARGING PROCEDURE - PRESSURIZED WELDMENTS .......212 PROCEDURE WHEN LOSS OF AIR PRESSURE OCCURES ......212 ENGINEERING DATA.......................................... 0 BUSHINGS..............................................215 SEALS.................................................222 GEAR ALIGNMENT ECCENTRICS (DRAGLINES ONLY)............223 GEAR BACKLASH ........................................224 SPLIT GEAR INSTALLATION...............................228 ECCENTRIC CARTRIDGES (DRAGLINES ONLY )................233 OBJECTIVE.........................................234 THEORY ...........................................236 ORIENTATION.......................................238 TYPICAL ECCENTRIC CARTRIDGES .....................240 CONTACT PATTERN ..................................242 CAUTION...........................................242 SPLINES...............................................261 ANTI-FRICTION BEARINGS ...............................261 SHRINK FIT COMPONENTS ................................262 CAP SCREWS ...........................................265 WIRE LOCKING CAP SCREWS ..............................266 WIRE ROPE CARE .......................................268 BOOM STRAND PENDANTS .................................272 REPAIR WELDING PROCEDURES ............................275 O-RING GUIDE .........................................289 GRID COUPLINGS .......................................297 FALK STEELFLEX COUPLINGS .............................302 GEAR COUPLINGS .......................................307 MOTOR-GENERATOR KEYLESS COUPLINGS (DRAGLINES ONLY)....310 OIL TIGHT SEALING OF BOLTED JOINTS PROCEDURES ........314 MAINTENANCE INSPECTION SCHEDULE........................... 0 DRAGLINE MAINTENANCE INSPECTION SCHEDULE..............318 DAILY - EVERY 24 HOURS............................320 WEEKLY - EVERY 150 HOURS .........................328 PERPETUAL WEEKLY ROUTINE .........................332 MONTHLY - EVERY 600 HOURS ........................333 QUARTERLY - EVERY 1800 HOURS .....................334 SEMI-ANNUAL - EVERY 3600 HOURS ...................336 ANNUAL - EVERY 7200 HOURS ........................338 BIENNIAL - EVERY 15,000 HOURS ....................340 SCHEDULED COMPONENT REPLACEMENT...................342
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- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
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