Cat Bucyrus MARION 151-M Dragline Operation & Maintenance Instruction Manual BI006018 – PDF DOWNLOAD

Technical Manual

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OPERATION AND MAINTENANCE

INSTRUCTION MANUAL

No. 1002

MARION 151-M(Amplidyne ContrOl)

47;7irdL -

Manufactured by

MARION POWER SHOVEL CO.

MARION, OHIO, U.S.A.

ERECTING INSTRUCTIONS FOR MARION 151-M

(The following materials and instl"uctions are based upon a Jnachine completely dismantled. as for export shiprnent. In many domestic shipments, therefore. SOIne of the following does not apply since the machine is shipped in component units as rnuch as possible).

The following list of tools and Inaterials are recommended to erect a 151-M shovel and are to be furnished by the purchaser. This is in addition to tools furnished with machine for tnaintenance.

180 to 200 railroad ties

40 to 45 small blocks. can be cut from railroad ties

60 pieces 2 inch blocks 2 ft. long 8 to 10 inches wide

90 pieces 1 inch blocks 1 ft. long 8 to 10 inches wide

2 bundles of shingles

Mechanical Erecting Tools

1 12 inch monkey wrench

12 inch socket wrench

2 5/8 construction wrenches

2 3/4 construction wrenches

2 7/8 construction wrenches

2 3/8 construction wrenches

4 1/2 construction wrenches

21 inch construction wrenches

1 1-1/2 single end wrench

1 3/4 socket wrench

1 7/8 socket wrench

11 inch socket wrench

2 1-1/2 socket wrenches

1 1/2 inch socket wrench

2 18 pound sledge harnrners

12 pound hand hammer

2 flat files

1 1/2 round file

2 gouges

2 cold chisels

4 pinch bars

2 1- 3/4 chain 15 ft. long. hooks each end

6 7/16 barrel drift pins

6 9/16 barrel drift pins

1 1-1/2 barrel drift pin

42 inch barrel drift pins

2 25 ton standard ratchet jacks

12 rnan cross cut saw

1 l/Z to 5 ton chain hoist

2 crowbars

2 25 ton track jacks

1 lifting crane capable of handling 20 tons at a 20 ft. radius and having a 50 ft. boom.

I

Electrical Erecting Tools

I

IiI 4 inch screw driver

21 8 inch screw drivers

11 pair 8 inch pliers, side cutting

.I

1 pair 6 inch long nosed pliers

1 pair 10 inch gas pliers

1 12 inch mill file

1 12 inch double cut file

2 12 inch hall round file

I8 inch round file

I 1/4 to 3/4 pipe bender

I 10 inch Stilson wrench

1 10 iJlCh crescent single end wrench

16 inch' crescent sinsle end wrench

2 II inch pipe wrenches

1 cold chisel

I gouge

I 1-1/2 pound hammer

11 quart blow torch

7 feet of steel fish tape

1 250,000 ohm magneto

I set of 3/16 steel lett-ers

1 set of 3/16 steel figures

I hack saw

£> hack saw blades

BI006018

Note: T 0 lists of tools are recommended insomuch as more than one crew my be working at a time.

GENERAL

achine is shipped from the factory, it is match marked throughout. , when assembling, much care should be taken to follow these match he erection drawings accompanying each machine show how the. its are assembled.

All polish d bearing surfaces are protected against corrosioJl and these aurfaces should be horoughly cleaned before assembling. When assembling the rnachine. all bearin surfaces should be lubricated.

Select an recting sit e of approximately 50 feet by 150 feet, level off, and if necessary use stone to rnake a solid foundation.

ERECTING PROCEDURE

L Assemble and place one crawler side frame. All machined surfaces between lower frame and crawler frame and between lower frame and ring gear should be thoroughly cleaned before assembling. The lower frame is then placed on the crawler frame and temporarilysecured.

Assemble and install the other crawler side frame. Securely bolt the entire lower frame assembly and crawler side frames.

Install rotating gear and securely bolt to lower frame.

4. Install circle roller assembly and collector rings.

5. Place rotating frame on the circle rollers and install center journal, securing with lock plate. Adjust center journal lock nut allowing 1/8 inch clearance above flanged bushing.

). Install vertical propel shaft and lower and upper bevel gears.

7. Tighten the nut in the lower end of vertical propel shaft as tightly as possible and make sure brass dowels are in place under locking screws. Tighten nut at top of propel shaft leaving. 010 to 015 clearance between bevel gear and lock nut. Secure with set screws. Do not omit brass dowels.

8. Assemble third intermediate propel shaft in lower frame. Tighten bearing bolts as tightly as possible. checking to see that the shaft turns freely.

Install fourth intermediate propel shaft on rear end of lower frame.

o. Install ballast boxes and side wings.

1. Install conduit. boom electric wiring, and collector rings.

Z. Install gantry complete.

3. Install baliast. Care should be taken that the ballast is evenly distributed. also that conduit is not damaged while installing ballast. Ballast is to be furnished by purchaser. and shall weigh not less than 250 lbs. per cu. ft. (Standard ballast is 50.000 lbs. Check with Marion Power Shovel Co. engineers for any variation from standard. )

4. Install rotating gear cases, oil pump and air compressor. then start at center journal and locate 1st into propel shaft and bearing. Locate and assemble drum shaft including bearings. Locate and assemble

motor extension shaft and bearings. Locate and assemble hoist otor and coupling. Assemble <;:heck band and support. Lubricate all g ar teeth and put two pints of proper grade oil in couplings.

electrical cabinet, motor generator set, and bolt them in position. house, and install equipment in operator's cab and levers.

air and hydraulic pipe work and all wiring.

Afsemble bOOIn and install boom support cables in cable at point.

all guards, gear cases, hand rails, ladders and platforms.

In.jspect and tighten all anchor bolts.

lubricate all bearings and movable parts and put proper arpount and grade of oil in all gear cases. (See lubrication instructions in! Section III. )

trail c. able. After electrical settings have all beel) made, run al motors and Inachinery to Inake certain that the machine is properly a sembled.

A1 brake bands, and friction bands must be adjusted..

(s e L. P. 165) To raise boom, using the hoist cable. reeve a double li e from druIn, over top of double sheave in center of gantry and over bo m point sheaves. Then place loop of cable over half sheave welded on the under side of boom at foot. Hoist boom into place with hoist m tor. Secure and adjust support cables and remove hoist cable.

A seInble dipper and dipper handle. When assembling dipper handle, m ke absolutely certain that the teeth on the shipper shaft pinions are in line with each other. Reeve hoist cable for hoisting dipper, and di per trip cable.

Af er the machine is completely erected. it should then be run under nOtload for a sufficient length of time to make certain that no bearings ar heating and no gears cutting. After this. the machine Inay be placed in peration.

REEVING DIAGRAM FOR RAISING SHOVE L BOOM

Gantry

Boom Point Sheavas

Anchor Sheave On Boom Foot

Both Ends Of Coble Dead Ended On Hoist Drum.

Boom Point Sheaves

REEVING DIAGRAM FOR SHOVEL OPERATION

Equalizer Sheave

Both Ends Of Coble Dead Ended On Hoist Drum--l

The Marion 151-M has been designed for easy adjustment and maintenance. All parts are accessible and ample room is provided to facilitate servicing and adjustment. The entire machine should be checked periodically and all bolts tightened and cotter pins replaced if lost or showing evidence of shearing. The nature of the work performed by the machine is at times quite severe and bolts will come loose in time. This is particularly true of a new machine and if allowed to remain loose, bolts and pins will wear stretch until eventual failure might occur. Safety demands that the machine be given regular attel!tionc

Above all, keep the machine clean. Grease and dirt accumulate rapidly and should be removed regularly. A clean machine is easy to maintain and service and all parts are more readily visible for checking against wear or possible failure. Accumulations of grease will collect dirt and grit which might work itself into bearings or gears and prontote wear.

The machine is given a coat of primer and several coats of good machinery enamel before shipntent. With use, however, this paint will wear and become chipped. Bare spots should be repainted at regular intervals of twelve to eighteen months. A regular maintenance schedule should be followed Cl:t all times.

HYDRAULIC STEERING AND PROPEL BRAKE SYSTEM

The 151-M uses hydraulic rams on the lower frame, which are electrically controlled, to operate the propel brakes and steering clutches. By means of slip rings between the upper and lower frame, the electrical control is brought to switches at the operator's station, thereby ntaking it a simple matter to release Or set the propel brakes and engage or disengage the proper set of crawlers to steer machine in any direction.

The type of oil ram as used with the hydraulic system is shown in L. P •. 153. Disregarding minor details, the ram as indicated, applies to all rams used on the machine. Should the ram leak oil and refuse to operate properly, the most likely cause is loose packing. To tighten packing, some of the shims (1) must be removed and packing retainer (Z) tightened down. In case the packing remains loose after all shims have been removed, the packing be renewed. Some rams use the internal spring (3), others use the external spring. When tightening the internal ram spring, the set screw (4) must be backed out and the locking nut (5) loosened. By inserting a pin into the sInall holes "A" of the locking nut, the nut may be screwed deeper into the ram housing, thus increasing the spring pressure. After the spring has been tightened to the point required, the locking nut and set screw must be carefully retightened.

L. P. 154 (following Page 17) shows a diagram of the hydraulic system as used, and its functions are described as follows:

rhe propel brake is spring set and the steering clutches are spring engaged, bus oil pressure is required only when rnoving. Consequently, the oil purnp (lotor runs only while propelling or steering. If the electric power falls, he propel brake automatically sets. When it is desired to release the brake o rnove ahead, the propel clutch selector switch rnust be closed, thus starting he oil purnp motor and at the same tirne closing valve "A". As the oil presmre rises to 250 pounds 'per square inch, the propel brake rarn moves out releases the brake. To set the brake, the rnotor is stopped and the oil n rarn is forced to discharge to the oil tank through valve "A".

ro turn the tnachine, or propel around curves, the steering clutches can be . to steer right or left as desired. This operation is controlled by neans of a steering clutch selector switch, located at the operator's station. exarnple, if it is desired to turn right, the switch energbes the solenoid ralve "B". When valve "B" opens, it perrnits the oil to flow into the right land steering rarn, which forces the rarn piston out to disengage the right land steering clutch. When either steering clutch is shifted so the crawler .s disengaged [rom the propel driving shaft, it also locks the crawler to the dde frarne, thereby assuring a positive turning point for turning the tna:hine. The clutches are mechanically interlocked so only one at a tirne can )e disengaged. When valves "B" or "C" are closed, the raIn piston is t>rought back to the" norInally engaged position by rneans of a spring in theraIn and the oil is exhausted through the three -way solenoid valve to the tank. rhe springs also keep the steering clutches engaged while propelling straight Olhead.

[[ the steering clutches fail to shift when the valves "B" or >'G" are energized, the Inachine should be moved slightly forward or backward to relieve strain on the clutch teeth.

To properly Inaintain the propel hydraulic system, the following recomrnend'l-tions are rn';l-de:

1. Use a good of oil.

2. Keep all joints tight to a void oil leaks, and clean strainer once each week.

3. If relief valve becomes noisy or if pressure does not rernain constant, remove valve for inspection; if parts are found worn, replace with new or replace the entire valve.

4. Should the pump fail to develop pressure, first make certain the relief valve is working properly, suction line is clear and valve "A" closed tightly. If nothing is found wrong with the above. look for worn parts in the pump as a leaky or worn pump will prevent the pressure building-up.

5. Keep the valves working freely. Sticky valves !Jlay cause the solenoid to burn out.

6. If valve" A" sticks shut after power is turned off, the propel brake will not set. To open valve, simply pull solenoid plunger out by hand. Should valve "A" stick frequently, increase the tension on spring at bottom of solenoid enclosing case.

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.