Cat 8200 PDF
Cat 8200 PDF
Cat 8200 PDF
Dragline
Contents
AC Electrics..........................................................4
Operator’s Cab .....................................................6
Mechanical Systems ..........................................8
Major Structures ...............................................10
Cat® MineStar™ System and
Technology Solutions .......................................12
Dragline Model Selection ................................14
Aftermarket Solutions ......................................15
Safety ..................................................................16
Serviceability .....................................................17
Customer Support .............................................18
Operator Training ..............................................20
Sustainability .....................................................21
Specifications ....................................................22
2
Delivering extremely high levels of overburden removal productivity at a low cost per tonne (ton), the Cat 8200 model
dragline offers all of the innovative technology of our flagship model – the Cat 8750 – but on a mid-range size scale.
Along with a lower initial capital outlay compared to larger draglines, the 8200’s unique combination of technology, size,
and long operating life ensures the low total cost of ownership you need for a strong return on your investment.
3
AC Electrics
More reliable and efficient electrics
Tried and True AC IGBT Electric Benefits over DC Machines • Less maintenance
Drive System, Now on Mining Include: – No regular maintenance is required
Equipment’s Largest Platform • Superior availability on IGBT power control modules.
You will experience greater machine – Routinely demonstrated electrical Motor maintenance is reduced to
uptime, lower operating costs, and faster availabilities of greater than 95%. greasing and replacing bearings
cycle times with our AC dragline designs – Extended mean time between failures, around 30,000 hours.
that leverage institutional knowledge built and reduced mean time to repair. – Reduced maintenance resulting from
on 30 years of experience commissioning lack of motor and generator brushes
• Better reliability
more than 200 AC equipped machines requiring change-out. This translates
– Less vulnerable to input voltage to increased machine electrical
worldwide.
variation. availability and reduced maintenance
– No filters, robust design, independent labor costs.
of mine network.
• Reduced inventory
– Full power available with voltage ±10%.
– IGBT modules are interchangeable
– Continues to operate with reduced
between Active Front Ends (AFEs),
power with voltage –10% to –30%.
inverters, motions and machines.
• Greater efficiency – All AC motors for drag, hoist, swing
– Provide 10% energy savings over and propel motions.
the life of the dragline. – No brush inventory to maintain.
– AC drives have an overall efficiency
of 92% vs. DC machines of 88%.
4
AC Technology
Optimizing your AC system performance and reliability, we’ve incorporated the latest
in AC technology and utilized the most durable components available.
Harmonics
• Staggered Active Front Ends (AFEs) naturally cancel harmonics without filters,
which makes the dragline very robust and independent of mine network configuration.
• Provides better Total Harmonic Distortion (THD) than required by IEEE 519.
5
Operator’s Cab
Maximize your performance with enhanced safety and comfort features
6
Comfort infused, State-of-the-art Operator’s Cab and Station
Providing more comfort, added safety, and greater reliability, our newly designed
state-of-the-art operator’s cab will help you produce more. The product of a
multi-year collaboration with mining companies from across the globe, our
Design Engineers, armed with insights into the aspects most desired by you,
have designed what we believe to be the most comfortable and productivity-
enhancing operator’s cab in the industry.
• Improved operator performance
– Reduced cognitive fatigue and enhanced productivity via the intuitive
and visually aesthetic display screens.
– Effortless operation and improved control response resulting from new
Hall Effect joysticks (patent pending), with custom-designed ergonomic
handles and “finger touch control” spring tension.
• Enhanced safety
– Rear ingress/egress door with no step floor prevents trip hazard, particularly
in cases of emergency where rapid exit from the cab is necessary.
– Superior visibility with full operator-to-boom point line of sight.
– Maximum operator situational awareness via external camera system
with direct feed to overhead monitors in cab.
– Enhanced safety during operator training with additional emergency
stop button within reach of trainer seat.
7
Mechanical Systems
Maximizing your uptime with durable and dependable mechanical systems
8
Keeping you Up and Running with Meticulous Engineered
and Globally Proven Mechanical Systems
Reliability you’ve come to depend on, our dragline mechanical systems
have proven field history in mine sites across the globe, from the
extreme heat of Australia to the frigid temperatures of Canada.
Swing Machinery
• Highly reliable swing planetary transmission and output pinion.
• Interchangeable parts across all swing drives.
• Potential for machine to operate with removal of one swing unit
(typical maintenance).
• Cooler/filtration unit plumbed to each planetary gearcase.
Controlled and monitored via dragline PLC.
Hoist/Drag Machinery
• Parallel shaft gearcases, with eccentric bearing cartridges
for optimal gear alignment.
• Gearing, bearings, drums, etc. are interchangeable between hoist
and drag motions.
• Splash lubricated gearcases with optional filtration available.
• Leak proof inspection hatches for inspection of all gear mesh.
• Drums mounted on self aligning, anti-friction bearings.
• Motors coupled to input pinions with grid couplings to reduce
impact loads.
Propel Machinery
• Heavy duty eccentric cam, driven by bull gear and parallel shaft gearbox.
• Eccentric bushing continuously monitored via RTD’s. PLC will alarm and shut down
machine if permissible temperatures are exceeded.
• Each side independently driven, but electrically synchronized, monitored and
adjustable via dragline PLC.
• Shoe incorporates ball swivel mounting to accommodate variable ground conditions.
• Ability to propel machine up and down 10% grade and transverse across 5% grade.
9
Major Structures
Bolstering your life-of-mine investment with robust
and durable dragline structures
Rugged Structures Designed and Fabricated to Withstand Your Extreme Mining Conditions
To extend service life and ultimately reduce your maintenance cost, all major dragline structures are designed for durability and
dependability. Extended performance in the harsh mining conditions you face daily is accomplished through selection of high-strength
steels, and rugged castings, joined and thermally stress-relieved to create a reliable shell capable of the most productive surface
extraction machine in the industry.
10
Revolving Frame Assembly Boom Assembly
• Deep, rectangular frame structure, • Rectangular, deep cross section
running full length of assembly. geometry, constructed of high strength
• Integrated thick rail pad circumferential wide flange beams.
diaphragm sub-weldment, UT tested, • Pre-stretched galvanized main support
and ground. ropes with equalizers. Kevlar intermediate
• Thick integrated plates for support boom support ropes.
of main machinery. • Drop down stabilizer rope to mitigate
• Penetrations reinforced with through dynamics in main support ropes.
thickness plates as determined per FEA. • Pressurized apex lacings, monitored
through PLC.
Fairlead Assembly • Boom point sheave assembly with rope
• Over-under fairlead provides constant protecting swivel motion.
rope contact with sheaves.
• Sheaves interchangeable with boom Bucket Assembly
and tri-structure. • Bucket capacity and style application
• Shimless fairlead adjustment system dependent.
for lower swivel. • Final capacity takes into account ground
• Rubber composite “donut” between mass per cubic meter, soil characteristics,
swivels to dampen dynamics. abrasion, and digging style.
• Bucket capabilities range from 76-129 m3
Tri-Structure Assembly (100-169 yd3).
• Tri-structure design reduces front end • Rigging configuration will be twin dump.
weight and enables optimization with • Custom wear packages designed to suit
boom configurations, increasing a variety of soil conditions.
allowable load and reach.
• Three different bucket styles available,
• Simplified wide flange beam construction, HPS, Conventional, and Fabricated.
with high impact strength steel.
• Less maintenance points compared Dynavane Assembly
to A-frame/Mast assembly. • Modular Dynavane assemblies decrease
• Crack detection system for back legs roof weight, easier to maintain and install.
and tri-structure head assembly.
11
Cat MineStar System and
Technology Solutions
Evolving your mine for greater safety and productivity
12
The Cat 8200 Dragline is currently able to utilize two of the
Cat MineStar System capability sets:
• Fleet
– Fleet provides real-time machine tracking, assignment and
productivity management, providing a comprehensive overview
of all your asset operations from anywhere in the world.
• Terrain
– Terrain enables high-precision management of drilling, dragline,
grading and loading operations through the use of guidance
technology. It increases machine productivity and provides
you real-time feedback for improved efficiency.
• AccessDirect
– Enables factory experts to join the local maintenance team.
– Prepares maintenance personnel to arrive on site ready
to fix rather than analyze the problem.
– Reduces MTTR and daily maintenance efforts.
– Enhances local and remote diagnostic capabilities.
Description
– Electrical interface system that facilitates remote access
to machine’s on board computer via internet.
– Permits monitoring, adjustment, resetting, and modification
of electrical parameters.
– Arrives with software for PLC, software for drives resident,
and one server per fleet.
– Features high-speed data transfer.
13
Dragline Model Selection
Maximizing your return on investment and
optimizing your dragline performance
• Specialize in analyzing mine environments and applying - Calculate cycle time and production estimates
for each portion of the dig plan
findings to recommendations for new draglines configured ESTIMATE - If production does not align with customer expectations,
PRODUCTION need to return to evalutation phase
specifically to meet your productivity targets.
• Analyze existing dragline performance and apply findings - If estimated production aligns with desired
production, recommend dragline
to recommendations for upgrade solutions. SELECT - If the dragline is not the optimum model
go back to the evaluation process
14
Aftermarket Solutions
Improving your productivity and reliability over the life of your machine
Mechanical Upgrades
• Provide full mechanical component
upgrades for existing draglines.
• In-house and third party Finite Element
Analysis expertise employed to ensure
that replacement parts outperform the
original components
• Solutions include: Electrical Upgrades Dragline Relocation and
– Major dragline structure repair/ • Owners of legacy draglines can reap Field Assembly
replacement for improved reliability the benefits of the latest technology, • Fundamental elements of the
and productivity enhancement. reducing operating cost, and improving Cat dragline portfolio.
– Boom modifications to optimize machine productivity and reliability. • Offer turn-key solution of OEM dragline
Rated Suspended Load (RSL), • Tailored solutions that address your parts, dragline service expertise, and
operating radius, digging depth, specific needs, whether you own local resources.
and dumping height. an AC or DC powered dragline. • Unmatched institutional knowledge
– Re-engineered components • Allows electrical system to work in of current and legacy dragline
for improved performance. harmony with on-board mechanical models ensures informed upgrade
systems. recommendations, leading to more
• Solutions include: productive and reliable operations
– Drive system upgrades for enhanced following relocation.
performance (AC and DC machines).
Component Rebuilds
– Programmable Logic Controller (PLC)
• Highest quality OE component rebuild
and Human Machine Interface (HMI)
services for both legacy draglines
upgrades for enhanced safety and
and current models in use today.
availability.
– Production Monitoring System for
optimized productivity.
– On-board troubleshooting and remote
diagnostics for improved reliability.
15
Safety
Designed with your safety as our top priority
Sharing your commitment to safety, and • Observer’s seat, positioned behind • Arc Flash evaluation available.
driven by our commitment to Zero Harm, operator, provides maintenance • Single point of motion disable for
we work tirelessly to design the safest personnel with the operator’s view mechanical maintenance of machine.
machines possible to protect your most while allowing him or her to monitor • Key interlocking prevents access to
important asset; your employees. operator actions. incoming High Voltage connection areas.
Some examples of the safety-enhancing • Separate operator and trainer • Stored energy warning signs installed at
features of Cat draglines include the emergency stop buttons. appropriate locations reduce injuries.
following:
Structures/Surfaces Emergency Lighting
• Sturdy handrail mounting clamps • Improves personnel safety by lighting
Operator’s Cab prevent vibration induced weld cracks. the machine during power outages.
• Industry leading visibility. • Non-skid material on roof and shoe
• Additional visibility provided by walkway surfaces prevent falls. Operator Training
five optimally mounted cameras and • Provides a safe and controlled learning
• Serrated bar grating stairs, platforms
operator cab mounted overhead displays. environment to help produce a greater
and walkways facilitate safe movement
• Dual egress doors; rear door and level around the machine. skilled and safer operator.
floor provide unimpeded stretcher
to operator access. Electrical Equipment
• Unique three seat design • Emergency stop system is hardwired
accommodates operator, trainer, dual string with safety relay.
and maintenance person. • All operator interface controls are
24 volt.
16
Serviceability
Designed to get you back to work fast
Lowering your operating costs
through reduced incidents of unplanned
maintenance, longer intervals between
scheduled service, and easier serviceability
are of supreme importance to us.
Base Access
• Easy accessibility to base via manholes
inside and outside of roller circle path.
17
Customer Support
Stay up and running with service and support
from our unmatched global network
Providing You a Unified Team Unlike Any Other in the Mining Industry
While the Caterpillar acquisition of Bucyrus is complete, we are still in the process of integrating the two companies.
However, you can rest assured that both your Cat and Bucyrus products will continue to be supported and that there
will be no disruption in the service you have come to expect from both organizations.
We are committed to business as usual – with sales, parts fulfillment, technical support, and all other customer services
continuing uninterrupted. For the time being, Caterpillar Global Mining will operate from two distinct distribution channels:
• Legacy Bucyrus products, including our draglines, will continue factory direct with support from former Bucyrus employees
that are now part of Caterpillar’s Global Mining Division.
• Traditional Cat products will continue through Cat dealers with support from Caterpillar’s Global Mining Division.
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We Will Transition Products to the
Cat Dealer Network
With the goal of providing you with one face and
the distribution approach that positions you best
for success, we will leverage the strength of the
Cat dealer network. All products will eventually
be sold and serviced by Cat dealers; however,
the transition will occur in phases until complete.
19
Operator Training
Maximize your investment
Aimed at advancing a novice operator to expert levels in a rapid timeframe, our combination of on-site and computer-based training
provides all the tools your staff will need.
To help maximize your investment in a Cat dragline, we provide on-site operator training assessments, on-site electrical
and mechanical maintenance training, and a variety of computer-based training options.
Customized Training
• On-site and/or classroom training for dragline operators and mine operation supervisors.
• Aimed at developing internal training competency for your operation.
• Designed in module form to target key production issues specific to your operation.
• Trainers have years of experience with hands-on and classroom training, offering the necessary skills to implement changes
on all aspects of operation, machine management, and maintenance.
• Utilizes cutting-edge technologies to improve knowledge retention, increase training efficiency, and create a safer learning
environment via machine simulation.
20
Sustainability
Higher standards for a better tomorrow
Meeting the needs of today without compromising the needs of tomorrow is the goal for all Cat machinery. The commitment
to helping you operate safely and sustainably is affirmed in the production of the 8200 Dragline.
21
8200 Dragline Specifications
Electrical
IGBT-AFE Inverter Cabinets 2 Water-Cooled*
Hoist Motors 3 or 4 × 3 or 4 ×
1230 kW 1,650 hp
Drag Motors 3 or 4 × 3 or 4 ×
1230 kW 1,650 hp
Swing Motors 3 or 4 × 3 or 4 ×
932 kW 1,250 hp
Walking Motors 2 × 932 kW 2 × 1,250 hp
* Motor combinations and IGBT-AFE Inverter Cabinets vary with
boom length, angle, and rated suspension load.
22
Dimensions
All dimensions are approximate.
1
6
7
4 5
3 8
2
6 DRAG HOIST
2 7 8
Rated Boom
Boom Boom Operating Suspension Point Dumping Digging Drum Rope Drum Rope
Length Angle Radius Load Height Height Depth Diameter Number Diameter Diameter Number Diameter
m ft m ft kg lb m ft m ft m ft cm in cm in cm in cm in
100 328 39 85.6 281.0 181 437 400,000 69.1 226.8 48.2 158 39.6 130 254 100 2 9.53 3.75 254 100 2 9.53 3.75
100 328 35 90.1 295.5 181 437 400,000 62.6 205.4 41.8 137 46.3 152 254 100 2 9.53 3.75 254 100 2 9.53 3.75
100 328 32 92.7 304.0 172 365 380,000 58.7 192.7 38.1 125 49.7 163 254 100 2 9.53 3.75 254 100 2 9.53 3.75
100 328 39 85.6 281.0 136 078 300,000 69.1 226.8 48.2 158 39.6 130 254 100 2 8.25 3.25 254 100 2 8.25 3.25
100 328 35 90.1 295.2 136 078 300,000 62.6 205.4 41.8 137 46.3 152 254 100 2 8.25 3.25 254 100 2 8.25 3.25
100 328 32 92.7 304.0 136 078 300,000 58.7 192.7 38.1 125 49.7 163 254 100 2 8.25 3.25 254 100 2 8.25 3.25
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For more complete information on Cat products, dealer services, AEHQ6963 (02-2013)
and industry solutions, visit us on the web at www.cat.com