STANDARD WARRANTY
All goods are sold and delivered subject to standard manufacturing and other variations and practices customary in the trade. Seller warrants goods manufactured by Seller to be free from defects in material and workmanship under normal use and service for a period of six (6) months from the date of delivery, provided that the goods have, since the date of delivery, been properly used, maintained and stored, and no repairs or alterations thereon have been carried out without Seller's consent in writing. Liability of Seller for goods found to be defective or not in accordance with agreed specifications or for other breach of contract, negligence, strict liability or otherwise shall be limited to replacement of goods F .O.B. Seller's plant or return of goods and refund of the purchase price therefor as the Seller shall elect. Goods which have not been manufactured by Seller shall be subject only to such warranty as may be made by the manufacturer thereof. THE GOODS ARE SUBJECTTO NO OTHER WARRANTIES, EXPRESS OR IMPLIED. SELLER DISCLAIMS AND BUYER WAIVES ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS OTHER THAN THE EXPRESSED SIX MONTHS WARRANTY SET FORTH ABOVE.
Marion Power Shovel Division shall not be held responsible or liable in any event for special or consequential damages, arising from any cause whatsoever, and Buyer agrees to indemnify and save Marion Power Shovel Division harmless therefrom.
Marion Power Shovel Division reserves the right to improve or change the design of its products and specifications thereof and the Marion Power Shovel Division shall incur no liability thereby or any obligations to install such improvements on products previously sold. 1- -
BI006290
SECTION 1 INTRODUCTION
This manual is designed to be informative and helpful during the operation and preventive maintenance of this equipment. Great care has been taken to provide you, the owner, with the most comprehensive, up-to-date material available from our engineering, service and training departments. Following the easy to understand step-by-step procedures, the maintenance crew will be able to perform their duties without sacrificing safety or production. When a systematic and thorough maintenance/service procedure (a responsibility of the maintenance superintendent) is instituted for the Equipment, quality maintenance and operation will result.
THIS MANUAL IS NOT A PARTS BOOK, nor is it to be used to order parts. You have been supplied with a separate, detailed Parts Book. Please carefully read the instructions in the front of it. All parts are listed by group numbers with item/part numbers for TH IS SPECIFIC MACHINE. Order 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; that is, facing forward and looking out the cab front window. Please state the correct machine SERIAL NUMBER (located on a plate in the operator's cab) when corresponding or conversing with us. Our records on each machine are filed by serial number and when given this number, your specific design and original equipment is both accurate and quick.
When required, ADDED INFORMATION not published in this Manual or the Parts Book, may be obtained from your local service representative or send correspondence to:
Technical Services Department
Marion Power Shovel Division
Dresser Industries, Inc.
617 West Center Street
P.O. Box 505 Marion, Ohio 43302
or:
Telephone 614/383-5211
Ext. 2454 or 2359
Telex 24-5307
TWX 810/487-2772
Telecopier 614/383-5211
Ext. 2275
Service and labor charges not accepted unless previously authorized, in writing, by Marion Power Shovel Division.
Left Hand Right Hand ------ -11.--
1-1 BI006290
SAFETY TIPS
Safety, the main factor and CONSTANTLY in mind, prevents accidents and near mishaps. Cleanliness and safety go hand in hand, thus making the machine easier to operate, inspect and maintain. A safety conscious crew will carefully read this manual and -:
Create a systematic maintenance schedule and STICK to it.
Develop good, clean habits and erase the bad ones quickly.
Observe and acknowledge ALL warning signs. Ignoring one of these signs could not only be dangerous but fatal.
Keep safe operating procedures in mind at ALL times.
Never take a "short cut" that could jeopardize a life or limb.
Know the location of fire extinguishers.
Never board an operating machine.
Keep away from moving parts.
Never wear loose clothing.
Wear required safety equipment. Keep floors/walkways/ladders clear and free of oil or grease.
THINK
1-2
BI006290
SAFETY
OPERATOR TIPS
The operator, controlling the machine for maximum efficiency and production, can "feel" when something is or is not functioning properly. An efficient operator will:
Have a full tank of air pressure before starting machine.
Keep safe operating procedures in mind at all times.
Know location of fire extinguishers.
Operate mach ine on level ground.
Watch air system performance.
Watch clearance in the swing mode.
Never set swing brakes while machine is in swing mode, except in an emergency situation.
Never hold load longer than needed in the dump cycle.
Check limit switches to assure proper "within reason" functioning.
Inform the maintenance crew on any malfunction or "odd feeling".
Never leave the controls until the "Excitation" button is pushed and flipping/turning all brake switches to "Set".
PAYS 1-3 BI006290
REMEMBER
MAINTENANCE TIPS
Just as the operator acquires a "feel" for the machine, the entire crew should try to sense failure before it strikes. Take that extra step to examine anything that appears out of place. How about a bubble or discolored crack in the paint? It is an early warning for metal stress or breakage. Could that slight hiss indicate a growing air leak? After all, it is easier to tighten a packing nut than shut down for packing repairs. An alert crew will:
Check operating air pressure.
Wipe away excess lube around bearings and gears.
Maintain correct supply lubricants.
Lube regularly.
Never lubricate parts in motion, that is gears, etc.
Look for and secure any loose bolts or locking devices.
Check all wire ropes for early signs of wear or failure.
Promptly replace all guards, inspection plates, access covers or other safety devices after inspectiotl/repair.
USE EXTREME CAUTION around ANY electrical lines and equipment. This pertains to low as well as high voltage.
Never attempt electrical repairs, unless qualified.
Assure power source is properly grounded.
Check limit switches for proper operation.
Check overloads and thermal breakers.
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SUGGESTIONS FOR INSPECTING
PREVENTIVE MAl NTENANCE MEANS PEAK PRODUCTION AND LONGEVITY.
Open pit mining equipment undergoes tremendous shock and stress. Marion's design con· siders these loads. This machine, built with an ample reserve of power and strength, will meet the demands of its task. Marion's engineers cannot foresee the conditions imposed by abuse, neglect and mismanagement. These factors damage any piece of equipment more than years of continuous operation and normal wear. Care, sound judgment and reason govern the economic need in the operation of power equipment.
Downtime exists, but an ongoing program of inspection and evaluation minimizes it. Awareness of unusual conditions generally warns personnel before breakdown occurs. Normal wear of machinery parts escapes exact definition. Parts do not suddenly expire. Wear takes place at varying degrees over time. Constant checking indicates a wear pattern. An alert maintenancecrew checks ALL structural members for evidence of stressed, broken or loose parts.
Minor cracks occur in steel structures. It's true of ALL machines. This is NOT SERIOUS when weld repaired while SMALL. Cold weather causes faster expansion and brittleness than warm weather. Early detection and quick repair prevents failure. A stretch, bend or defect often shows up in condition of surface paint. A collection of dust along a line may indicate a crack in the metal. Look closely at areas around openings where angles are cut out. Also check gusset connections and points where thin and heavy metals join. The good crew watches for loose bolts, nuts, cap screws, lock washers and other locking devices. Rod bolts are important too. Signs of scuffed paint, worn or bright spots next to any part indicates movement and becomes second nature to most personnel. Retighten ALL bolts shortly after initial start-up. Grease and oil stains often indicate problems. Perhaps poor housekeeping, but at least something is wrong.
Replacement and maintenance schedules may conform to planned shutdowns. Lack of proper lube, poor adjustments and abuse cause and speed up wear. These facts show up as the MAIN reasons for breakdown. If any part shows wear or distortion beyond expected normal wear, order replacement and quickly install. The cost of parts is nothing when compared to breakdown cost and loss of man hours and production.
Production machines operating 24 hours, 7 days every week deserve an 8 hour inspection and cleaning every 10 days. Cleaning before inspection eliminates dirt and dust falling into machinery parts when inspection plates and covers are removed.
On the upper frame, a solvent makes removal of the accumulation of grease around bearings, gears, motors and the I ike easier.
1-5 BI006290
Start up the machine and dig enough to warm up machinery, open the inspection cover over gears and pinions. Look at gear teeth as machinery slowly goes thru its paces. Broken teeth are easy to spot, but splayed or unusual wear pattern takes a closer look.
For a quick check, run a piece of soft wire thru the gear mesh at each side of the pinion. Measure thickness of the two adjacent loops with micrometer. The sum of the two loops indicates backlash and gives an indication of misalignment. If excessive backlash is suspected, measure with a dial indicator. There just isn't enough room between the gear guard and the pinion to use a feeler gauge.
Slowly rotate the upper frame several times in each direction. Look at condition of roller circle, rail, gear and swing pinion. Sound here may indicate a flat or chipped roller or even suggest burrs or damaged teeth on the swing pinion.
During dig cycles, check condition of sheave grooves and bearings. Test all hold down bolts with impact wrench. Check rope guides and bails for wear. Inspect all rope for broken wires or a lose in diameter. When inspecting the boom point or gantry, check the auto-lube system for loose or damaged fittings. Note injector condition. Properly lube all points; IT'S IMPORTANT.
Lower bucket/dipper to the ground and shut off machine. Inspect bucket/dipper for cracks. Do not permit tooth base exposure. Teeth may be reversed with minimal effort. Remove bucket/dipper and rebuild.
Check main swing gear hold down bolts. Use impact wrench if needed. Test all hold down bolts on upper frame, especially on swing gear case, motor mounting, machinery pedestal and base bolts. Also, check motor generator, air compressor mount and base bolts. Tighten rod bolts on bearing housing.
Examine and readjust, if needed, all brakes, Look at the condition of brake lining. Remove inpsection plate from swing gear case. Look at condition of gears. Use pry bar to detect any side motion of shaft indicating worn bearings.
Inspect air compressor "v" belt tension, replace if needed. Fill the anti-freezer. Check auto-lube system for loose or broken fittings or injectors. Use a hand grease gun at each injector. Fill ALL grease lines and purge EACH bearing with MPG. Remember to replace ALL plugs, covers and inspection plates.
Check center journal thrust washer and bearing. Secure ALL guards and safety features in place. DISCONNECT POWER SOURCE with machine shut down so electrical crew may adequately clean and inspect motor generators and electrical cabinets. NOTE any discolored electrical parts, it's a sign of overheating. In humid areas, look for fungus and mildew. Dry compressed air at LOW pressure works well for dust removal. Clean corrosion from 1-6
BI006290
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