PDF Operation And Maintenance Manual CAT 8200 Walking Dragline - 2 MB
The CAT 8200 Walking Dragline is a colossal piece of mining machinery that demands precise care and skilled operation.
This official Operation and Maintenance Manual is the authoritative guide for your equipment.
It covers all necessary procedures for safe operation, troubleshooting, and scheduled maintenance to ensure maximum uptime and safety.
Following the manufacturer's recommendations is critical for protecting your investment and ensuring the longevity of this massive machine.
This manual is an essential resource for operators and maintenance crews working with the CAT 8200.
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BI616884
Bucyrus International, Inc.
8200 Walking Dragline
10237_T.pmd
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BI616884
Bucyrus International, Inc.
8200 Walking Dragline
MACHINE OVERVIEW
NOMENCLATURE
Manual No. 10237 1-8 Dec. 2004
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Bucyrus International, Inc.
8200 Walking Dragline
TRI-STRUCTURE
Manual No. 10237 1 - 18 Dec. 2004
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Bucyrus International, Inc.
8200 Walking Dragline
Section 2
Operation
Table of Contents
GENERAL INFORMATION ............................................................................................................ 3
8200 Nomenclature ..................................................................................................................... 3
Deck Plan ................................................................................................................................... 4
OPERATOR’S CAB AND ANTEROOM ......................................................................................... 5
Operator’s Cab - Anteroom .......................................................................................................... 5
OPERATOR’S CONTROLS ................................................................................................... 6
PRIMARY CONTROLLERS .......................................................................................................... 7
Operator’s Seat ........................................................................................................................... 7
PLUGGING THE MOTION ....................................................................................................... 9
SECONDARY CONTROLS .................................................................................................. 10
Operators Controls ..................................................................................................................... 10
Left-hand Operator’s Controls ..................................................................................................... 11
Right-hand Operator’s Controls ................................................................................................... 13
WINDSHIELD WIPER ........................................................................................................... 15
Windshield Wiper Assembly Operator’s Cab .............................................................................. 15
OPERATOR’S DISPLAY ............................................................................................................. 16
OPERATOR’S DISPLAY IN THE CAB................................................................................... 16
Operator’s Display ...................................................................................................................... 16
DISPLAY AREA & INDICATORS ...................................................................................... 17
CAB DISPLAY SCREENS ..................................................................................................... 17
Operator’s Cab Title Screen ....................................................................................................... 17
Operator’s Main Menu Screen .....................................................................................................18
Display Information Screen ........................................................................................................18
Active Alarms Screen ................................................................................................................ 19
Alarm History Screen .................................................................................................................19
Walking Shoe Positions and Error Screen ................................................................................. 20
Hoist/Drag Limit Calibration Screen ........................................................................................... 20
Walking Shoe Encoder Calibration Screen ................................................................................21
Fault Counters and Operating Hours Screen .............................................................................. 21
Tightline Parameters & Operating Data Screen ..........................................................................22
Operator’s Screen ...................................................................................................................... 22
Maintenance Menu Screen ......................................................................................................... 23
Master Switch Calibration Screen ...............................................................................................23
POWER CONTROL ROOM (PCR) DISPLAY SCREENS.................................................... 24
Power Control Room Screen ...................................................................................................... 24
Power Control Main Menu Screen ...............................................................................................24
Set Panel Date/Time Screen ...................................................................................................... 25
Communications and I/O Screen ...............................................................................................25
Electrical Menu Screen ..............................................................................................................26
Dec. 2004 2-1 Manual No. 10237
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8200 Walking Dragline
Left-hand Operator’s Controls
Dec. 2004 2 - 11 Manual No. 10237
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8200 Walking Dragline
Walking Shoe Encoder Calibration Screen
Fault Counters and Operating Hours Screen
Dec. 2004 2 - 21 Manual No. 10237
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Bucyrus International, Inc.
8200 Walking Dragline
MACHINERY HOUSE REAR DOORS
The rear doors of the machinery house consists of a set of 3 doors on each half of the rear wall.
Each set of doors includes 1 top door, and a left and right side door. The doors are opened and
closed by hydraulic cylinders, actuated by manual hydraulic valves, one for each door, located at
the center of the rear machinery house wall. Refer to the figure on the following page.
Either set of doors or both can be opened, however each set must be opened in sequence and
closed in the opposite sequence.
CAUTION: DO NOT ATTEMPT TO OPERATE THE REAR DOORS UNTIL THE
GREEN LIGHT IN ILLUMINATED, INDICATING THE DOOR LATCHES
HAVE BEEN RELEASED.
CAUTION: DO NOT OPEN OR CLOSE THE REAR DOORS OUT OF THE
SEQUENCE SHOWN. FAILURE TO FOLLOW THE SEQUENCE WILL
RESULT IN DAMAGE TO THE DOORS.
CAUTION: DO NOT OPERATE THE MACHINE (DIG OR PROPEL) WITH THE REAR
DOORS OPEN.
CAUTION: DO NOT LEAVE THE REAR DOORS OPEN DURING INCLEMENT
WEATHER. FAILURE TO FOLLOW THIS CAUTION MAY RESULT IN
DAMAGE TO THE DOORS OR TO THE EQUIPMENT INSIDE THE
MACHINE.
Dec. 2004 2 - 31 Manual No. 10237
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Bucyrus International, Inc.
8200 Walking Dragline
GROUND PREPARATION
Ground preparation is very important. The walking dragline requires a properly prepared ground
base for operation. The tub and walking shoes must have full contact with the ground when the
machine is digging or propelling. With the machine weight distributed over the entire tub bottom or
the partial tub bottom and the two walking shoes area, moderate ground bearing pressure is obtained
and the machine components are less stressed.
The ground supporting a walking dragline must be as near level as possible, firm, and dry. Sand,
clay, and topsoil can be leveled easily with a dozer or grader. Sharp rocks and boulders cause point
loading which will damage the tub and shoes structures and should be removed if possible. Where
this is impractical, cover the working area with fill dirt to a sufficient depth that will eliminate the
effects of the rocks.
This walking dragline can be propelled up or down a grade or ramp. Ramping the machine, moving
it from one level to another, requires exercising great care because this situation subjects the tub
and rotating frame to stresses much greater than experienced while digging. For a new machine,
ramping should be restricted to no greater than a 5% grade (See Note). Later, this can be increased
up to a 10% grade maximum. It is possible to traverse (cross) a 5% grade with this machine;
however, AVOID CROSSING ANY GRADE IF POSSIBLE.
NOTE: When beginning to propel the machine, the transition from one grade to the next should
gradual, no more than 2% over the length of the walking shoes (for this machine is
approx. 70 feet). For example, starting from level ground, the machine should travel at
least 3 shoe lengths before reaching a 5% grade.
The 8200 dragline design incorporates a calculated balance between boom length, boom angle,
allowable bucket load, machine weight, and ballast used. During normal digging cycles, the center
of gravity shifts from the front to the rear within a specific area called the “kern”. The machine
maintains stability and relatively even ground bearing pressure over the entire tub area. If, for any
reason, the digging radius or load increases to cause the center of gravity to extend out of the kern
to the tub perimeter, an undesirable rocking motion will occur due to the cone shape that will
develop in the ground under the tub. This results in an unstable machine and concentrated ground
bearing pressure at the center of the tub. This condition is very detrimental to the machine and
must be eliminated. Contact Bucyrus for consultation on this problem immediately.
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8200 Walking Dragline
ASTM Standard Viscosity / Temperature Chart ......................................................................... 66
OGL - OPEN GEAR LUBRICANT ......................................................................................... 67
MINIMUM PERFORMANCE REQUIREMENTS ............................................................... 68
ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT ................................................ 70
MPO - MULTIPURPOSE OIL ................................................................................................. 71
RWRL - RUNNING WIRE ROPE LUBRICANT ..................................................................... 72
STANDARD LUBRICATION INSTALLATION ......................................................................... 73
TYPICAL PIPE MOUNTING ...................................................................................................... 73
TYPICAL HOSE MOUNTING .....................................................................................................73
MINIMUM HOSE BEND RADIUS ...............................................................................................73
LUBE POINTS ............................................................................................................................. 75
PROPEL MACHINERY .......................................................................................................... 76
CENTER JOURNAL .............................................................................................................. 77
SWING MACHINERY ............................................................................................................. 78
ROLLER RAIL & ROLLER CIRCLE ...................................................................................... 78
HOIST MACHINERY .............................................................................................................. 79
DRAG MACHINERY .............................................................................................................. 80
FAIRLEAD ............................................................................................................................. 81
TRI-STRUCTURE ................................................................................................................. 82
BOOM ................................................................................................................................... 83
MISCELLANEOUS POINTS .................................................................................................. 84
Dec. 2004 3-3 Manual No. 10237
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8200 Walking Dragline
7. MANUAL PROPEL - A yellow pushbutton that changes the 3 auto lube systems from DRAG
to PROPEL. Press this button and any of the 3 manual buttons when testing the system’s
propel operation.
8. PROPEL MODE - Amber light which indicates the machine is operating in PROPEL.
9. ROTATING FRAME-MANUAL - Pushbutton to manually cycle the Rotating Frame lube
system.
10. ROTATING FRAME-FAULT - Red light indicates a fault in the Rotating Frame lube system.
11. OPEN GEAR-MANUAL - Pushbutton to manually cycle the Open Gear lube system.
12. OPEN GEAR-FAULT - Red light indicates a fault in the Open Gear lube system.
13. LINE A - An amber light that indicates that Line A is activated for the Rotating Frame system.
14. LINE B - An amber light that indicates that Line B is activated for the Lube Reel.
15. LINE A - An amber light that indicates that Line A is activated for the Hoist/Drag Open Gear
system.
16. LINE B - An amber light that indicates that Line B is activated for the Propel Open Gear
system.
17. PROPEL-MANUAL - Pushbutton to manually cycle the Propel lube system.
18. PROPEL-FAULT - Red light indicates a fault in the Propel lube system.
19. FRONT END-MANUAL - Pushbutton to manually cycle the Boom lube system.
20. FRONT END-FAULT - Red light indicates a fault in the Boom lube system.
21. LINE 1 - An amber light that indicates that Line 1 is activated for the Propel system.
22. LINE 2 - An amber light that indicates that Line 2 is activated for the Propel system.
23. LINE 1 - An amber light that indicates that Line 1 is activated for the Boom system.
24. LINE 2 - An amber light that indicates that Line 2 is activated for the Boom system.
OPERATION
A. If LE has been de-energized less than 60 minutes, the timers will restart when LE is energized
and continue the lube intervals prior to the shutdown.
B. If LE has been de-energized more than 60 minutes, the system will cycle immediately when
LE is energized. Each of the 3 systems (OGL, Rotating Frame, Lower Frame) cycles in
sequence and continue cycling per their programmed intervals.
C. If LE is de-energized less than 15 minutes when in propel mode, the timer will restart and
continue the lube intervals prior to the shutdown, or when LE is re-energized.
D. If LE is de-energized more than 15 minutes in propel mode, the system will cycle immediately
when LE is energized and continue cycling per the programmed intervals.
A typical lube cycle operation for any of the circuits occurs in the following manner:
Dec. 2004 3 - 13 Manual No. 10237
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Bucyrus International, Inc.
8200 Walking Dragline
AUTO LUBE ~ MPG
ROTATING FRAME
The Auto lube for the Rotating Frame supplies the center journal, the main rotating shaft bottom
bearings, the intermediate hoist and drag shafts, the hoist and drag drum shafts, Tri-Structure and
Fairlead. The air pressure regulator is set at 55 PSI (379 kPa). The end-of-line pressure switches
are set at 2500 PSI (17238 kPa).
ROTATING FRAME CONTROL PANEL, Line-A
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8200 Walking Dragline
INJECTOR ADVANTAGES
.
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8200 Walking Dragline
If the piston is jammed, proceed with disassembly. Dismantle distributor by first removing tie-rods.
With individual sections on the bench, remove the hex head plugs from both ends of each section.
Now taking one section at a time, remove the piston. If it appears to be stuck, try removing it from
the other direction. If it is badly jammed, it may be necessary to use a brass rod to tap it out. Now
flush the section and piston in a clean suitable solvent until all the lubricant has been cleaned away.
Blow out all ports thoroughly and use a small piece of wire to make sure that all passages are clean
and open. Next inspect the cylinder bore carefully for scratches, score marks, or other damage.
Inspect the piston in the same manner. If either of these parts is damaged, a new section should be
installed. If the distributor section and piston both appear in good condition, reassembly as before
making certain that the piston slides smoothly but snugly in the cylinder bore. Repeat the operation
on each section. Take care, however, not to replace piston in any section except the one from
which it was removed. (Early models of the new M and MX Distributors with Check Valves, employed
a nylon ball in the circular check valve, located at top center of each Intermediate Section. Under
heat or special pressure conditions, these nylon balls, now replaced by steel, would sometimes
become deformed causing blockage. Replace if necessary.)
After all sections have been cleaned, blown out, inspected and found to be in good condition,
reassemble the distributor assembly by following your sketch. IMPORTANT - use the torque settings
listed below. Test the operation of the assembly on the bench by pumping lubricant (preferably oil)
into the inlet of the distributor with a hand grease gun. If it now functions properly, replace it in the
system and again test for proper operation. REMEMBER Ă„ DIRT AND FOREIGN MATERIAL
ARE THE WORST ENEMIES OF ANY LUBRICATING SYSTEM. All servicing should be carried
out under the cleanest possible conditions.
Lube Distributor Torque Data
(Ft.Lbs.)
MJ M-MV MX
Tie Rod Nuts 12 20 25
Alternate Outlets 10 10 24
Check Valves 10 15 19
End Plugs 15 15 45
NOTES:
1. Re-stack distributor according to your sketch.
2. Check proper assembly, including gaskets, etc.
3. Draw up assembly to proper torque settings.
4. Test distributor with light oil.
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8200 Walking Dragline
9. Pack the ball bearing with multi-
purpose grease, NLGI #2. Place on
the shaft and push or gently drive into
place in the bracket.
10. Press the lip seal, with the lip facing
the end of the shaft, into the outer
end cap and insert the end cap in
the bracket. Turn the end cap in the
bracket until it is tight against the
bearing.
11. Put the lockwasher and locknut on
the shaft. Insert a length of hardwood
or brass through the port opening
between the rotor teeth to keep the
shaft from turning.
Tighten the locknut and bend one tang of the lockwasher into the slot of the locknut.
12. Adjust the pump end clearance. Refer to “Thrust Bearing Adjustment”.
13. Lubricate all grease fittings with multi-purpose grease, NLGI #2.
DANGER: BEFORE STARTING THE PUMP, BE SURE ALL DRIVE EQUIPMENT
GUARDS ARE IN PLACE. Failure to properly mount guards may result
in SERIOUS INJURY or DEATH.
INSTALLATION OF CARBON GRAPHITE BUSHINGS
When installing carbon graphite bushings, extreme care must be taken to prevent breaking. Carbon
graphite is a brittle material and is easily cracked. If cracked, the bushing will quickly disintegrate.
Using a lubricant and adding a chamfer on the bushing and the mating part will help in installation.
The additional precautions listed below must be followed for proper installation:
• A press must be used for installation.
• Be certain the bushing is started straight.
• Do not stop the pressing operation until the bushing is in the proper position. Starting and
stopping will result in a cracked bushing.
• Check the bushing for cracks after installation.
Carbon graphite bushings with extra interference fits are frequently furnished for high temperature
operation. These bushings must be installed by a shrink fit:
1. Heat the bracket or idler to 750°F.
2. Install the cooled bushings with a press.
3. If facilities are not available to reach a temperature of 750°F., it is possible to install at 450°F.:
however, the lower the temperature, the greater the possibility of cracking the bushing.
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8200 Walking Dragline
Viscosity And Viscosity Index:
For the maximum gear life the heaviest viscosity gear oil should be used, limited by the gearcase
ambient temperature and duty cycle. The gear oil used must have a viscosity index equal to or
greater than the required minimum of this specification.
The AGMA (American Gear Manufacturer’s Association) grade is SUS (Saybolt Universal Seconds)
as specified in this standard for gear oil viscosity. This tends to overcome the confusion of selecting
a grade of oil based on SAE numbers (motor oil & gear oil, viscosity at what temperature, etc.).
NOTES:
1. Ambient Temperature: The ambient temperature is defined as the air temperature in the
immediate vicinity of the gearcase. Refer to the following in determining the ambient
temperature:
• Use atmospheric temperature for gearcases in an extreme exposed location.
• Use machinery house temperature for gearcases inside of the house. Some machines
are equipped with house heaters.
• Use oil temperature for gearcases having either strip heaters or immersion heaters.
• Gearcases exposed to the direct rays of the sun will run hotter and must therefore be
given special attention.
2. Requirements For Selecting Gear Lubricant:
• Lubrication of the gears and anti-friction bearings with the same gearcase oil.
• Lubrication for the gears only whenever the bearings are sealed and lubricated separately.
• Duty Cycle:
- Semi-continuous operations such as: dragline hoist, drag and swing; shovel hoist,
swing and crowd; drill rotary drive.
- Intermittent operation such as propelling.
3. Guidelines For Selecting Temperature Range For Any Gear Oil:
• Minimum Ambient Temperature:
- Use oil pour point temperature when gears only are to be lubricated.
- Use a temperature 10°F above pour point when gears and bearings are to be lubricated.
• Maximum Ambient Temperature when oil viscosity is 2000 SUS
• At many locations, a winter and summer grade of Regular Gear Oil will be used.
• Use ASTM standard viscosity / temperature chart (later in this section) to plot temperature
range.
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8200 Walking Dragline
STANDARD LUBRICATION INSTALLATION
TYPICAL PIPE MOUNTING
For more than one hose, clip one and secre
the others to the 1st with tiewraps.
TYPICAL HOSE MOUNTING
MINIMUM HOSE BEND RADIUS
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8200 Walking Dragline
BOOM
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8200 Walking Dragline
LUBRICANT CLEANLINESS
Even the best lubricant is a useless wear preventative if it has become contaminated by careless
handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep it
clean. It is the responsibility of the person performing the machine lubrication to be sure that no dirt
gets into the lubricant.
Follow these points of good lubrication practice:
• Keep all oil and other lubricants in tightly covered containers.
• Wipe off covers before opening containers.
• Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off with a
clean lint-free cloth before using.
• Wipe off each fitting before attaching the lubricant gun.
• Wipe off oil filler caps or covers and the surrounding area before removing them.
Refer to the topic “Lubricant Benchmarks” in Section 3 of this manual for an explanation of each
type of lubricant required for servicing this machine. Make sure the lubricant was not dirty or of
improper viscosity. When the machine is operated for more than one shift each day, all crews must
cooperate on checking lubrication. This is to ensure that no lubrication point will be missed or over-
lubricated. It is usually best to do this at the beginning of each shift. Reproducible service schedules
are provided for recording service information.
NOTE: Lubrication instructions provided by any vendor for a vendor supplied item have priority
over Bucyrus lubrication intervals and procedures.
CAUTION: When not possible to work on the machine with a safety harness, use
a “cherry picker” or “man basket” when inspecting or servicing
elevated areas. A slip or fall can result in severe personal injury or
death.
Dec. 2004 4-9 Manual No. 10237
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Bucyrus International, Inc.
8200 Walking Dragline
Maintenance Inspection
WEEKLY CHECK POINTS
(CONTD.)
Description Action
WEEK 21 through 22
~ Fairlead
WEEK 23 through 24
~ House Roof, Arches, Supports, Propel
Linkage and Exciter Set
WEEK 25 through 26
~ Propel Linkage and M-G Sets
Dec. 2004 4 - 19 Manual No. 10237
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Bucyrus International, Inc.
8200 Walking Dragline
MAJOR COMPONENT LOCATIONS
MACHINE NOMENCLATURE
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8200 Walking Dragline
FAIRLEAD ASSEMBLY
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8200 Walking Dragline
CENTER JOURNAL
The CENTER JOURNAL pin holds the Rotating Frame and the Base Frame (Tub) in concentric
alignment at the center of rotation.
DANGER: REMOVE POWER FROM MACHINE PRIOR TO REMOVING HOUSING
FROM COLLECTOR RINGS OR GAINING ACCESS TO THE RING
AREA.
CENTER JOURNAL
The CENTER JOURNAL PIN is fitted into tub structure with an interference fit as follows:
CENTER JOURNAL INTERFERENCE FIT
Top: {.005} over {.009} Inch ~Bottom:{.004} over {.008} Inch
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Bucyrus International, Inc.
8200 Walking Dragline
5. Remove the roller rail and carefully clean the mounting surface of the rail and pad on the
rotating frame.
6. Lift the new rail (approx. 2300 Lbs.) into place and secure with 2 inner and 2 outer bolts at
each end of the segment. DO NOT use the holes for the body-fit bolts.
7. Check the new and the existing rail height. The offset between adjacent rail ends should be
.005 inch maximum.
8. Ream the 2 body-fit holes to 1.251/1.253 diameter when the rail(s) is properly aligned.
9. Remove the rail, clean all parts and re-install the rail. Install the body-fit bolts first.
TENSIONING SEQUENCE for the UPPER ROLLER CIRCLE RAILS
10. If additional rails are to be replaced, rotate the machine to place the roller circle opening over
the rail to be replaced and repeat steps 4 through 13.
11. Replace the rollers and cage bars. Tighten the tie rods to 265 Ft.Lbs.
12. After 200 hours of operation, retighten the bolts. Check the bolt tension every 90 days.
ROLLER CIRCLE
The ROLLER CIRCLE contains 143 tapered steel rollers. The rollers are held in place by retainers,
splice bars and a thrust rail.
NOTE: To prevent damage to rails or other rollers, immediately remove a roller from the roller
circle if it becomes chipped, broken or damaged in any way.
Remove the roller by rotating the machine until the damaged roller is directly below one of the roller
removal holes in the rotating frame. Remove the 2 rods which secure the roller in the cage. Use
suitable tongs or a sling to lift the roller from the roller circle.
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8200 Walking Dragline
REAR DOOR OPENING AND CLOSING
REAR DOOR OPERATION
NOTE: Either set of doors or both can be opened, however each set must be opened in
sequence and closed in the opposite sequence.
CAUTION: DO NOT ATTEMPT TO OPERATE THE REAR DOORS UNTIL THE
GREEN LIGHT IS ILLUMINATED, INDICATING THE DOOR LATCHES
HAVE BEEN RELEASED.
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8200 Walking Dragline
MAIN PROPEL SHAFT / WALKING ARM ASSEMBLIES
The MAIN PROPEL SHAFT assembly consists of the main drive gear, the propel shaft and the
walking eccentric.
Dec. 2004 5 - 37 Manual No. 10237