PDF Maintenance and Operation Manual CAT Marion 8750 Walking Dragline - 1 MB
This manual provides critical maintenance and operation information for the massive CAT Marion 8750 walking dragline.
It details the complex procedures required for safe operation and routine servicing of this mining equipment.
The guide covers all major systems, from the hoist and drag functions to the walking mechanism.
An indispensable document for the highly skilled crews who operate and maintain these giant machines.
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BI005602
© Bucyrus
All Rights Reserved
BUCYRUS R
Technical Manual
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e"
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Section 1 - Engineering Data (Continued) Page -
Shrink Fit Mounting Data " . 13
Cap Screw (Bolt) Class " . 14
Turn-of-Nut Method . 14
Torque Method . 14
Engineering Standard 1101-2 . 16
Dragline Boom Inspection . 16
Preliminary I nstructions for Gear Installation . 18
Clean . 18
Find the Match Marks . 18
Before Mounting the Coupling Hub . 18
The Mounting Surface . 19
Split Ring Gear Installation Instructions:
Mount One Gear Half. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19
Bolt Assembly Clearance Check ' . . . .. 19
Mounting Second Gear Half . . . . . . . . . . . . . . . . . . . . . . . .. 19
Alignment Bolt Installation:
An Alignment Bolt Assembly. . . . . . . . . . . . . . . . . . . . . . .. 19
Coat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19
Insert Tapered Alignment Bolt. . . . . . . . . . . . . . . . . . . . . .. 20
Check Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20
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8750
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til""& _
BI005602
Shaft Running Shaft Running
Nom. Clear- Nom. Clear-
Oiam. 0.0. ance Oiam. 0.0. ance
34-1/2 34.500 .046 38-1/2 38.500 .051
34.494 .068 38.494 .073
34-3/4 34.750 .046 38-3/4 38.750 .051
34.744 .068 38.744 .073
35 35.000 .046 39 39.000 .051
34.994 .068 38.994 .073
35-1/4 35.250 .046 39-1/4 39.250 .051
35.244 .068 39.244 .073
35-1/2 35.500 .046 39-1/2 39.500 .051
35.494 .068 39.494 .073
35-3/4 35.750 .048 39-3/4 39.750 .052
35.744 .070 39.744 .074
36 36.000 .048 40 40.000 .052
35.994 .070
1
! 39.994 .074
36-1/4 36.250 .048 40-1/4 40.250 .052
35.244 .070 40.244 .074
36-1/2 36.500 .048 40-1/2 40.500 .052
36.494 .070 40.494 .074
36-3/4 36.750 .049 40-3/4 40.750 .054
36.744 .071 40.744 .076
41 41.000 .054
. 40.994 .076
41-1/4 41.250 .054
41.244 .076
41-1/2 41.500 .054
41.494 .076
41-3/4 41.750 .055
41.744 .077
42 42.000 .055
41.994 .077
42-1/4 42.250 .055
42.244 .077
42-1/2 42.500 .055
42.494 .077
42-3/4 42.750 .056
42.744 .079
8750 Page 6 Section 1
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BI005602
ENGINEERING STANDARD 1101-2 for wire lock cap screws. This standard establishes
recommended method for these fasteners. Use here is for designs where maximum locking
assurance is required and periodic visual inspection is not possible. Check classification 121 F
for special fasteners with 1/8" holes for locking with 14 gauge soft annealed wire. RECOM-
MENDED WIRING METHOD: The following procedures will exert a tightening force on
cap screws as the wire is twisted tight.
Wired in Pairs: Establish left and right hand fasteners as viewed from center of bolt circle.
Insert left end of wire thru left hand fastener from inside to outside of bolt circle. Insert
right end of wire thru right hand fastener from outside to inside of bolt circle.
DRAGLINE BOOM INSPECTION on a systematic and regular basis must be established.
Service personnel should quickly develop the habit of looking over ALL boom parts in their
regular, daily routines. Early detection and quick repair prevents failure. A stretch, bend or
defect often shows up in surface paint condition. Wrinkles or waves in surface paint show a
problem. A collection of dust along a line may indicate a crack in metal or weld. Bright or
shiny spots indicate movement. A complete and competent visual inspection, ONCE A
WEEK, is necessary to emphasize the following points.
1. Boom foot castings and gussets: Look closely at welds on gusset plate ends.
2. Are boom chords straight? is ANY area of chord and web BENT OR DEFORMED, as if
struck by the bucket? It happens.
3. Is boom lacing straight? Look for break in weld or parent metal. Check closely where
lacing pipe attaches to boom chord and where these lacing pipes join. The CRITICAL
AREA IS the WELD and the PIPE METAL just NEXT TO WELD. Sight along the boom.
Bent pipes show up easily this way. Check ALL horizontal, vertical and diagonal pipes.
4. Inspect the boom foot apex. This is the MOST CRITICAL AREA. Carefully look and
check the gusset plates, weld and pipe connections.
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8750 Page 16 Section 1
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BI005602
Contact Backlash
The EXAMPLE (right) shows the Position of Gear Relative to Mesh left Right left Right
contact and backlash measurements CL CR BL BR
of a gear set of 1 diametral pitch.
Start Position .000 .002 .048 .047
From table 3, the recommended
D
90 from Start Position .000 .001 .047 .045
backlash is .030 minimum and .060
maximum. 180 D from Start Position .002 .000 .042 .045
270 0 from Start Position .003 .000 .037 .040
ALTERNATE METHOD OF CHECKING TOOTH CONTACT AND BACKLASH: When
impossible to use a feeler gauge due to space limitations, obtain proper contact pattern by
the trace method. Satisfactory patterns are shown in sketch.
~~l
THIS
"'-.-/
"",
After a correct pattern is established, CHECK the backlash with an indicator as shown in
sketch. DETERMINE praoer backlash from table 3. USE CARE in adjusting pedestals to
establish correct backlash. Use indicators at EACH pedestal for EQUAL in - out movement
so not to affect a change in contact settinlJ. After proper backlash is obtained, RECHECK
contact.
FINAL CHECK FOR UNIFORM CONTACT PATTERN: After establishing pinion align-
ment (with pedestals firmly secured); make a f:mal check for tooth contact to assure accurate
gear alignment. Apply a very thin coat of Prussian blue pigment, lamp black, or red lead to
five or six pinion teeth, previously cleaned (see above), COVE R ENTI RE profiles of the
8750 Page 26 Section 1
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tttt wee
BI005602
on a new rope due to minimum surface contact of each wire. As these wires wear, they pre-
sent a flattened su rface and the rate of normal wear decreases.
Determine the cause of outer wire breaks by examining the break.
Tension breaks show a cup and cone effect at the break. This is caused by
overload, shock load, jerking a load or catching a falling load.
Car:eless operational load handling.
Fatigue break showing a square end break with granular metal appearance.
Repeated bending over sheave causes fatigue or the sway and vibration at
dead end anchor and static sheave.
A shear break indicated by a smooth, twisted break generally comes from
external damage (nicks or kinks) in the rope.
Several outer wire breaks at isolated areas along rope length cause little concern. Concen-
trated breaks at a single location indicate severe rope damage. Retire this rope.
External corrosion indicated by rust, scales or pitting on rope surface remains out in the
open. Internal corrosion may appear as pitting in strand valley or rust and scale working out
from under strands. Outside wire or strands appear slack or seem to stand out from inner
portion with severe corrosion. Under a load this rope shows a loss in diameter.
Internal wear or core fatigue indications emulate those of severe corrosion. Wire or strands
appear slack and noticeable loss in diameter occurs under load. Internal wear often results
from faulty equipment (tight sheave groove, etc.) in a local area.
Rope retirement from service requires a decision based upon a combination of factors.
Inspection determines the abrasive wear effect on outer wires. Percentage of rope area in-
tact indicates rope strength percentage remaining.
The number of broken wires contained within one lay (one full strand wrap) evaluates re-
maining rope strength to some degree.
No reliable means of determining corrosive effect and internal wear exists. Good operating
conditions and effective lubrication keeps these factors to a minimum.
Study the entire rope to determine the section suffering the most severe deterioration. One
or more of the following indicates this deteriorating:
Drastic loss in rope diameter and lay lengthening.
Outer wire abrasion.
8750 Page 32 Section 1
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iIl-- i i ... tt - me
BI005602
':. 1 : '<: ;:~"-i"
~:::;~ ;, ::'; '-\~
correctly and brace, clamp, or tack weld to maintain
-
alignment. Use the specified welding preheats for ALL
arcing or burning.
PREHEAT area adjacent to weld area to specified tem-
peratures. (See Welding Specifications).
f +
Crack not completely removed
reappears in repair weld
INCREASE preheat. temperature 50 degrees F. (10 de-
grees C.) for material (at weld) 1-1/2 to 2-1/2 inches
thick and up to 100 degrees F. (38 degrees C.) for mate-
rial OVER 2-1/2 inches thick.
f Whenever possible make center
pass last as shown
MAINTAIN preheat until weld is completed. This is important. Templi-Stiks (from Tempil
Corp., N.Y., N.Y.) are helpful for temperature determination.
POSTHEAT area adjacent to weld 100 degrees F. (38 degrees C.), higher than preheat speci-
fied. (See Welding Specifications). MAINTPdN postheat for one hour PLUS 1/2 hour for
each inch of thickness. CONTROL cooling rate so temper?ture is about 50 degrees F. (10
degrees C.) per hour until temperature reaches 150 degrees F. (65.5 degrees C.). This is im-
portant.
THE ORDER OF WELDING reduces warpage and provides a favorable locked up or residual
stress pattern. The use of block welding (short, full size welds) helps reduce warpage. In
many cases, V-ing out small areas and rewelding each of these areas; continuing until com-
pleting repair eliminates warpage. A favorable locked up or residual stress condition is ob-
tained by making FULL DEPTH welds at the area farthest from the neutral axis first; then
making welds closest to this neutral axis last.
To eliminate fusion cracks that persist
when welding castings; first deposit a thin
layer of weld metal on surfaces for weld,
then complete the weld. In box section
members this means; first, weld the two
diagonal corners; second, the remaining
corners; third, the top and bottom; and
last, the sides. (See sketch). This proce-
dure creates residual compression at the Preferred sequence for blocking
in butt joint in box section
extreme fibers where it is most beneficial.
PEENING often reduces locked up stresses and maintains original dimensions and alignment,
as well as, help prevent weld metal cracking in rigid sections. Use a blunt nosed tool. DO
NOT peen the first (root or base) pass or cover passes. Avoid EXCESSIVE peening in other
passes.
8750 Page 42 Section 1
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BI005602
DO NOT USE pointed, sharp-€dged or hardened steel tools (screwdrivers, church keys or
knives) for removal or installation of backup rings or seals. Soft-metal !bois of brasi or Ilu-
minum, plastic, wood or phenolic rod when formed into desired shape save the critical sur-
faces.
Tool surfaces need to be well rounded, polished and no burrs on working end. This obvious-
ly prevents scratches.
Removal from cylinders and pistons means every effort is needed to avoid contact with ma-
chined surfaces.
=
TY?lCA~ S:"GL[ O-OI"G INTEo"AL
TYPTCAl DuAL o.RING lNHRN.A.l ['(iRA':TION =RA~T,:" UTrLIz".G [OG[
AND SI~UL TANEOUS FH.MOVJJ. TYP£ £),T~.A,':TIN~ TOOL :-..0
MOO« Re",OVAl. Tee..
c =
().I=fING RfJ..10YAl TOOL (HOOK}
~=====
O-Il"'G ooRACTO;; ro:x (W!OGO
O-~ING
R['-'O:>l
SPOON
o-g .,:; [Xi~.&...:T·"'l':'
Te-=-.. (,V::X::)
TYPIc:.:.. S!~C ... :. o-Q'NG ~E"'C·J.1~ ~- 1""~
TYPlCAl OO[RNAl O-RING RE"'OVAl VTllIZ'NG WEX~ TV;:::: t..xTqA.(TiNG rc..:;. .l'.: :;..~~
C>lllNG REMOVAL SPOON TYPE R['.',~'AJ. TOG'-
CAlfTlON: 00 NOT P(R""T UNN[CESSARV J«)TE; AFIER OR:\G IS OIS:..CX.€J ;-Z,,)·,
~"C; OF' TOOLS Y."TH BEARtNG AND CROC\,,~. ~C ...O S?OC."l TCC... '5.T:"7'':·~.lQv
CYl!t~O(R WAll SUIH"ACES "velD OROFo1NC SHr.4<J~i':','::Ju5t...'!' RQTA7( A,r-.J '..... ,r..,;.PA.'1
T~ INTO cYUNQ[RS, ~STc..-.. n;~~ ~;NG
8750 Page 52 Section 1
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BI005602
FALK COUPLING
T Y PEG AND GV
G TYPE INSTALLATION
1~IORIZON1AL Typf'S G'O and ~O veRTICAL Types GV10 and 20
~20
f~21
~22
-----.23
~20
20~ GV Fl •• Hub 21 ~ Center Ph!.
1 ~ Seal Ring 4. Ga,k~' (Sp.cif)' 80r. 22~ Thru.I Butf<m
:I~ flanged Sleeve and Keyway)
S. Lub. Plug 23~ Thru,t Plote
3. G Flex ~:(Ju 6. Bolt. ~Iut, l0ckwasher P:1rt~ I, :.:. "". 5 o;~ci 6 ~~.:twn of the 1~lt
(~p(l'<:ify Bore and Keywcyj (o'Tlpi~'''' '''to b·.l'C'-'Cf' 0 1 ~r~ cO',J!=-,',n(j
1. Clean all parts. Heat hubs in an oil bath or oven to a maximum of 275 degrees F.
(135 degrees C.). DO NOT rest gear teeth on container bottom or apply a flame direct-
Iy to gear teeth.
Pack sleeve teeth with grease and lightly coat seals with grease BEFORE assembly. DO
NOT use cup grease. DO NOT DAMAGE SEALS.
Use a dial indicator to align dynamically balance couplings and assembly parts with
mating match marks aligned. Mount indicator on one hub and take readings for OFF-
SET check on O.D. of other hub. The difference between minimum and maximum
readings DIVIDED by two should not exceed the values in Table. For ANGULAR
check, take readings on either face of other hub. The difference between the minimum
and maximum readings should not exceed the values in Table.
2. MOUNT FLANGED SLEEVES, SEAL AND HUBS-
Place flanged sleeves WITH seal rings on shafts before
mounting hubs. CAUTION: DO NOT DAMAGE
SEALS. Mount hubs on respective shafts, as shown
so each hub face is flush with its shaft end. Position
equipment in approximate alignment with approxi-
2 MOUNT flANGED SLEEVES,
mate gap specified in Table. SEALS AND HUBS
8750
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Page 62 Section 1
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BI005602
(O:\\'EH:'IO:-: T\BLE
Fr(lNiollal IlIl'/' t() D,',-ill'''/ Tnl'/, Ill/( I .11 i/linlt'tf'r8
------
co:\n:nslo:\ TABLE
Milliml'll'rs to [ 1Ic/1C1
--------------
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FrA'liun.. 1 l)"rim.1 frlt('tiunClI 1.~\irn.1 Millimrtlon Jnd\! .... ~ljllimt"lrr' Ind''Il''s Millim..li'u Jnchr-I
JIll-h Inrh ~1iil;m('tN" Inrh In,h ~1jlliJOctt'"r. ----_..
------------------------------- 1 0.r,,91 36 1.1173 71 2.7%3
I/q 0.01 :.r.~~ (' ..1%9 3L't~1 0:': !If,:! S 1.1,(\:'~9 2 O.U,S. 37 1.1':'1;7 7Z 2.,315
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Si64 O.OtG~75
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