FURTHER INFORMATION CHARGE FOR SERVICE LABOR, ETC.
STANDARD WARRANTY
If further information is required which is not found in this Manual or in the Parts Books, communicate with the Marion Power Shovel Company at Marion, Ohio.
No charge for service or labor are accepted unless the work has been previously authorized by the Company in writing.
MARION POWER SHOVEL COMPANY guarantees the manufactured by it to be free from defects in materjal and workmanship under normal use and service, its obligation under this warranty being limited to making good at its factory any part or parts thereof manufactured by it which shall, within six (6) months after delivery to BUYER, be returned to it, with transportation charges prepaid, and which its examination shall disclose to its satisfaction to have been thus defective, this warranty being "expressly in lieu of all other warranties, express or implied, and of all other obligations or liabilities on MARION POWER SHOVEL COMPANY'S part.
MARION POWER SHOVEL COMPANY 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 COMPANY harmless therefrom.
MARION POWER SHOVEL COMPANY makes no guaranty or warranty, express or implied, as to adequacy, fitness, quality, or performance of any machinery, equipment, apparatus or accessories not manufactured at its own factory, which are subject only to such guaranty as may be made by the respective manufacturers thereof.
MARION 5900 1968
Page 2 Section 1 BI005610
SAFETY PRECAUTIONS
The usefulness of this machine depends entirely on the man at the controls. The operator is it's brains. HE MUST THINK SAFETY AND WORK SAFELY.
Neatness and safety go hand in hand. Good housekeeping habits should be developed.
1. Keep the floor clean and free from oil and grease.
2. Keep the walkways clean, clear, and free from obstructions.
3. Prevent the accumulation of grease and oil around bearings and gears. Grease and oil collect and hold grit and dirt which work into finely machined parts.
4. A clean machine is easier to operateeasier to inspect - easier to service.
5. Keep hands and clothing away from moving parts.
6. Replace guards, inspection plates, access covers, etc., promptly after reason for removal is accomplished.
Strip mining equipment is subject to tremendous stresses and shock loads. These stresses are throughly studied and considered in the design and building of Marion equipment.
This machine is built with an ample reserve pf power and strength and is well fitted to meet the demands of its tasks.
However, the Marion engineers cannot foresee the conditions imposed by abuse, mismanagement and neglect. These factors are more damaging to any piece of equipment than years of continuous operation and normal wear.
Care, sound judgement and reason are an economic necessity in the operation of power equipment.
MARION 5900 1968
Page 3 Section 1 BI005610
PREVENTIVE MAINTENANCE
Open pit mlnlng machinery is required to operate in the most adverse conditions of any industrial. machines.
Conditions are rarely ideal. It is always too hot, too cold, too dry or too wet. The air is always saturated with fine abrasive dust. High production schedules tax both men and machines.
Down time and delays are intolerable. Down time can not be eliminated, but it can be kept to a minimum by a progressive and conscientious program of preventive maintenance.
Aside from regular lubrication, proper and accurate adjustments, the personnel should be aware of any deviation from the normal, which could be evidence of impending break down or component failure.
The maintenance people should inspect, during their rounds, structural members for evidence of cracked, broken or loose parts. Evidence of a member stretching, bending, or buckling can often be determined by the conditions of the surface paint. Highly stressed parts will show striae ripples or waves in the paint or check marks.
Grease or oil on the surface or a collection of dust along a line indicate a crack in the metal. Pay particular attention to those areas around openings where corners or angles are cut out, at the ends of gussets or at brace connections and at transitional points where heavy and thin parts join.
MARION 5900 1968 -
Page 4 Section 1 BI005610
Stresses in a monolithic structure may travel some distance from the damaged area and manifest itself at a remote· point in some seemingly unrelated place.
The maintenance people should check all bolts, nuts, cap screws and rod bolts. Lock washers and other locking devices must be in place.
Be sure that bolted and assembled parts are tight. Evidence of movement may be detected by signs of scuffed paint, worn or bright spots adjacent to the part. Often a slight movement of parts that can't be seen with the eye can be felt with the finger tip when the machine is working.
MARION 5900 1968
Page 5 Section 1 BI005610
SECTION 2
LUBRIC A" T ION
INDEX
Selection of Lubricants
Extreme Temperature
Automatic Lubrication
Key to Lubrication
Lubrication Specifications
Lubrication of Crawler
Lubrication of Axle & Steering
Hydraulic Leveling System
Lubrication of Roller Circle
Lubrication of Center Journal
Lubrication of Hoist Motor
Extension Shaft
Lubrication of Hoist Drum
Lubrication of Hoist Check
Brake Levers
Lubrication of Lubrication of Lubrication of Lubrication of Lubrication of Lubrication of Gantry
Page 3
Page 3
Page 4
Page 5
Page 6
Page 7
Page 8
Page 8
Page 8
Page 9
Page 9
Page 9
Page 9
Rotating Gear Case Page 10
Swing Lock Brake P2ge 10
Crowd Drum AssemblyPage 10
Crowd Brake Page 11
Crowd Limit Switch Page 11
Crowd Sheaves &
Lubrication of Knuckle Joint
Lubrication of Boom Point
Lubrication of Dipper Trip
Lubrication of Dipper
Lubrication of Cable Reel
Lubrication of Crane on Gantry
Auxiliary Hoist Motor & Miscellaneous Parts
Sheave Block for Jib Crane
Lubrication of Auxiliary Winch
Winch Machinery
Crane Travel Machinery
Boom Hoist Components
Page 12
Page 12
Page 13
Page 13
Page 14
Page 14
Page 14
Page 15
Page 15
Page 15
Page 16
Page 16
Page 16
BI005610
SELECTION OF LUBRICANTS LUBRICATION OF ANTI-FRICTION BEARINGS
SECTION 2 LUBRICATION
No part of the care of your Marion machine is more important than proper lubrication. WITH OUT PROPER LUBRICATION, the air compressor, anti-friction bearings, finished shafts, gears and other important parts of this precisionbuilt piece of machinery can be quickly ruined.
All roller and ball bearings on the machine should be kept about 1/3 to 1/2 full of the lubricant recommended in the Lubrication Instructions. Add only enough lubricant to maintain this level. These are oil-tight bearings and the lubricant level will usually remain constant over a long period of time. Therefore, only very small quantities need be added. Unless otherwise specified, we recommend a small amount of lubricant every 500 hours which will usually maintain the desired level in the bearing of about 1/3 to 1/2 full at all times.
If these bearings should ever become completely filled, the addition of more lubricant would result in pressure being built up inside the bearing and heating would result. If a bearing should run excessively warm, it is advisable to remove the pressure fittings and allow some of the excess lubricant to escape.
It is important to make sure every rotating or movable part is properly lubricated. The pinions and gears on hoist and crowd machinery, and on all other gears and pinions which are not enclosed should also be kept coated with a good grade of gear lubricant as recommended in Lubrication Instructions.
Oil should be kept at the proper level in all enclosed gear cases.
EXTREME TEMPERATURE OPERATION
The lubrication specifications in this manual covers the lubrication requirements of the machine when operating within an ambient temperature range from -20 degrees to 110 degrees F.
If this machine is to be operated at temperatures below -20 degrees or above 110 degrees F., contact the Marion Power Shovel Company, Inc., Marion, Ohio or local supplier for special lubrication recommendations. Give full particulars concerning your conditions of operations.
MARION 5900 1968
Page 3 Section 2 BI005610
INTRODUCTION TO AUTOMATIC LUBRICATION
The automatic lubrication system as furnished on this machine is arranged to lubricate the bronze bushings, plain bearings and wire ropes.
Three separate systems are provided. One system, which includes pumps, automatic control panel, etc., is located in the lower frame and furnishes lubricant to all crawler truck blies, steering and leveling systems. Also, provides lubricant for the roller circle. The second system is located on the upper frame and supplies lubricant to the center journal, deck machinery, gantry and front end equipment. The third system provides spray-on lubricant for wire ropes (Crowd & Hoist).
The wire rope lubrication spray-on system is actuated manually by a push button as required.
The upper frame and the lower frame systems are automatic, and are controlled by a timer device in conjunction with the operating circuits which determine the cycle interval.
The quanitity of lubricant delivered to each point is determined by the setting of the injector.
The lower frame system control and pump is connected to the propel so the crawler truck assemblies will be lubricated only when the machine is propelling.
Like-wise, the upper frame system will only operate during the digging cycle.
The roller circle is lubricated from the lower frame system by means of a hook-on arrangement and only when the machine is stopped. A hose with a quick connect fitting is manually connected to the roller circle piping at one of four convenient locations. The system is then cycled by a push button as required. The entire roller circle, spacers and thrust washers are lubricated at one application.
MARION 5900 1968
Page 4 Section 2 BI005610
NOTE: Unusually dusty and dirty atmosphere, high humidity and/or extreme temperatures can alter the effective life of a lubricant. Therefore, it shall be the responsibility of the operator and/or owner to determine the most lubrication interval in accordance wlth eXlstlng environmental conditions for all components, bearing (plain and anti-friction), gears, gear cases, etc.
THIS KEY TO LUBRICATION CODE IS APPLIED TO CHARTS COVERING THE ENTIRE MACHINEFAMILIARIZE YOURSELF WITH THE FOLLOWING TABLES:
(MPG) MULTIPURPOSE GREASE (Replaces WB & CG) This is a high quality, water resistant grease which has good mechanical and oxidation stability and good pumpability at operating temperatures. The grease may have a lithium or mixed bose, must contain no graphite ar other fillers and have the properties shown in the toble.
USES-Anti-friction Bearings both packed and gun lubricated, Chassis and Plain Bearings and central lubricating systems.
(RGL) REGULAR GEAR LUBRICANT These semifluid greases, summer and winter, have just enough body to retain them in a semi·enclosed case. The grease may have a sodium or mixed bose, have good adhesive, load carrying and non-channeling properties ond meet the specifications in the table.
USES-Semi-enclosed Gear Cases.
(OGL) OPEN GEAR LUMICANTS REPLACE SYMBOL (GC) must not drip or sling off while parts are idle or in motian, must be water and rust resistant and have extreme pressure characteristics.
Type (B) is applied withaut heat or a dil· uent by brush, gun or paddle
Type (H) is an asphaltic type lubricant used in the same applications as (Type B) and requires heat or a diluent to apply.
USES-Open Gears.
.. NOTE: All oils are non-detergent except (EO) and (PO).
MO Motor Oil-SAE 20 for winter, SAE 30 for summer
(EO) ENGINE CRANKCASE See Instructions by manufacturer of Engine
(MO) AIR COMPRESSOR CRANKCASE This is a highly refined low carbon residue oil having rust, foam and oxidation resisting properties. See Specifications in table.
(HL) HAND LUBRICATION Use Oil (MO) above or a general machine oil (S·SAE 30, W-SAE 20 W)
(Gl) ENCLOSED GEAR CASE This is on extreme pressure corrosion and shock resistant type oil. See specifications in toble.
USES- Sliding Surfaces.
(PO) PNEUMATIC OIL This is a special oil available thru the Marion Power Shovel Company used in the air piping systems. It is a high detergent oil with good lubricity containing anti-wear, clinging and anti-freeze properties. It will not cause swelling nor deterioration in rubber or leather.
(EMO) ELECTRICAL MOTOR OIL Use special lubricant supplied by the manufacturer of the elecfrical equipment.
(HO) HYDRAULIC OIL This is a stable, high viscosity index oil with axidation, corrosion, foam, sludge, gum and rust resistant properties with a low pour point and a low carbon residue. This oil shall not couse swelling nor deterioration in rubber or leather. Used in Hydroulic Systems for leveling and power transmission. See specifications in table.
MARION 5900 1968
Page 5 Section 2 BI005610
LUBRICATION SPECIFICATIONS
Pour Summer Winter
"Flash Summer Winter
"Viscosity @ 100 [)
"Viscosity @ 210 0 Summer Winter
'Viscosity Index
Carbon Residue
Rust-48 hr. Syn.
Sea Water
SAE Summer Winter
Pressure Min.
Copper Corrosion
Oxidation @ 1500 hr.
• Aniline Point
"Minimum Values
MARION 5900 1968
SPECIFICA nONS-GREASES CODE OR SYMBOL ASTM or Test MPG GREASES RGl OGl Type B Type HPenetration Worked 60 Str. 77° Summer NlGI # Winter NLGI # 0-217 2 1 Semi- 1 fluid 0 10% 325 200 10% 325 140 Min. 200 10% 20% 350° 70 Min. 10 PSI 0-217 0-942 0-1264 Dropping Point Min.-Oeg. Base Oil Vis: @ 210° Oxidation Stability Max. P. S. I. Drop in 100 hrs. Penetration
Str. Max. Change Water Resistant-Max. loss @ 100° Texture Very Adhesive Very Tacky
worked 5000
Pressure-Min. in Ibs. CODE OR SYMBOL NO.
Page 6 Section 2 BI005610
LUBRICATION OF CRAWLER SIDE FRAME
(Typical 8 Locations)
1968
MARION 5900
NO. NAME OF PART TYPE NO. OF POINTS LOCATION LUB METHOD & SYM FREQUENCY (HRS.) 1. Drip on Support Rollers 6 Above Front & Rear Support MPG Cycled By Auto. Rollers Lubrication 2. Front Roller Bushi ng In End Of Shaft MPG Cycled By Auto. Lubrication 3. Support Roller Bushi ng 4 In End of Shaft MPG Cycled By Auto. Lubrication 4. Equalizer Roller Bushi ng 4 Piped to Frame MPG Cycled By Auto. Lubrication 5• Equalizer Pivot Pin Bushing 4 In End of Shaft MPG Cycled By Auto. Lubrication 6. Intermediate Support Roller Bushing 2 In End of Shaft MPG Cycled By Auto. Lubrication 7. Crawler Axle Bushing 4 Two From Each Side of Crawler Frame MPG Cycled By Auto. Lubrication 10. 1st Reduction Bearings See Mnfrg's Rec. Fill Plug in Side of Case GL 8. 9. Propel Motor Bearing Gear Case (1st Reduction) Ant iFriction 2 2 In Gear Case GL 2-1/2 Gal. Capacity Seasonal - Chk. Level Weekly Splash From Gear CaseI1 12 Propel Shaft Couplings Gear Case (2nd Reduction) 2 In Hub of Coupl i ng Fill Plug in Cover Plate GL See Mnfgr's Rec. 5-1/2 Gal. Capacity Seasonal - Chk. Level Weekly 13. 2nd Reduction Bearings AntiFriction 2 In Gear Case GL Splash From Gear Case 15. Gear Case (3rd Reduction) Fill Plug in Side of Case GL 9 Gal. Capacity Seasonal - Chk. Level Weekly 16. 3rd Reduction Bearings Ant iFriction 2 In Gear Case GL Splash From Gear Case GL 17. 18. 1 g. Gear Case (4th Reduction) 4th Intermediate Propel Shaft Bearings 5th Intermediate Propel Shaft Bearings Bushing Bushing 4 4 Fill Plug in Side of Frame 2 From Each Side of Crawler Frame 2 From Each Side of Crawler Frame 69 Gal. Capacity Seasonal - Chk. Level Weekly MPG Cycled By Auto. Lubrication MPG Cycled By Auto. Lubrication 20. Gear Case (5th Reduction) Fill Plug in Cover Plate GL 15 Gal. Capacity Seasonal - Chk. Level Weekly MPG Cycled By Auto. Lubrication GL 2 From Each Side of Crawler Frame Fill Plug in Cover Plate 63 Gal. Capacity Seasonal - Chk. Level Weekly 2 From Each Side of Frame MPG Cycled By Auto. Lubrication 4 4 Bushing Bushing Sprocket Shaft Bearings 6th Intermediate Propel Shaft Bearings Gear Case (6th & Sprocket) 22. 21. 23. 24. Tread Link Pins Apply to Pin DI OGL Page 7 Section 2 BI005610
• 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.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
