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This manual is divided into sections covering various serviceable components and systems of the Model 191-M electric mining shovel. These sections are organized by thumb index tabs shown below and right-black ink tab marks.
SECTION 1- MACHINE SPECIFICATIONS
SECTION 2- OPERATION
SECTION 3- LUBRICATION
SECTION 4- MECHANICAL MAINTENANCE
SECTION 5- ELECTRICAL MAINTENANCE
SECTION 6- COMPRESSED AIR SYSTEMS
SECTION 7- ENGINEERING DATA
SECTION 8- INSPECTION REPORTS
This manual is designed to assist the owner in the operation and preventive maintenance of this machine. Following easy to understand step-by-step procedures, maintenance personnel can perform these tasks in a safe manner. When a systematic and thorough maintenance/ service procedure (a responsibility of the maintenance superintendent) is used for this machine, minimum unplanned downtime and reliable operation will result.
TH IS MANUAL IS NOT THE PARTS BOOK, and cannot be used to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by group and/or product code 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 HAN D PARTS on the upper frame correspond to the operator's hands at the controls; as seated when operating the machine. Please state the correct machine SERIAL NUMBER (located on a plate in the operator's cab) when corresponding or contacting factory service or parts departments. Records on each machine are filed by serial number and when giv\3n this number, your machine's specific design and original equipment is accessed quickly by the Marion parts representative.
Periodic additions or revisions may be made to this manual. These will be mailed direct to you from the factory. Should you require additional information or factory service assistance contact your regional service representative or
Serv ice Depa rtment
Marion Power Shovel Division Dresser Industries, Inc.
617 West Center Street
P.O. Box 505
Marion, OH 43302
or:
Telephone 614/383-5211
Telex 24-5307
TWX 810/487-2772
Telecopier 614/383-5211
It is Marion Power Shovel Division policy to improve its products whenever possible and practical to do so. Marion reserves the right to make changes or add improvements at any time without incurring any obligation to install such changes on machines sold previously.
Due to this continuous program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve machines.
AThis safety alert symbol is used here and throughout this manual to call your attention to instructions concerning your personal safety. Carefully read and follow these instructions and observe all safety and danger, and caution graphics mounted on various areas of the machine.
Be certain anyone servicing this machine is aware of these SAFETY PRECAUTIONS. In the event you question your ability to safely perform any of the enclosed maintenance and operational procedures contact your regional Marion service representative or the factory.
The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.
ADANGER: Denotes extreme intrinsic hazard which exists and could result in high probability of death or irreparable injury if proper precautions are ignored.
ACAUTION: Denotes a reminder of safety practices or directs attention to unsafe practices which could in personal injury if proper precautions are ignored.
An example of a safety alert symbol and special safety instructions is shown below.
ADANGER: Inherent danger exists in the operation of any high voltage electrical equ ipment. A safe grounding system includes ground conductors in the power cable, a neutral grou nding resistor and related relays and switchgear. A ground continuity check system is required by law in many parts of the world.
Operating, maintaining or servicing this machine can be dangerous unless performed proper Iy. Each person must satisfy himself and his employer that he is alert and has the necessary skill and information, proper tools and equipment, and all methods are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance.
The operator must be alert, physically fit, and free from the influence of alcohol, drugs, or medications that might affect his eyesight, hearing or reactions.
Safety must always be the operator's most important concern. He must consult his supervisor when safety is in doubt.
The owner and/or operator must replace any and all safety and warning product graphics if they are defaced or removed from the machine.
Before doing any work on the machine, lock out or remove electric power supply from the machine and tag it so personnel are aware that someone is working on the machine.
Do not start an engine indoors unless adequate exhaust ventilators are provided. Once an engine is running, move the machine outdoors as soon as possible.
Keep hands, feet, clothing away from rotating parts.
As a machine is being moved, the operator must face the direction of travel.
Think before you act. Carelessness is one luxury the serviceman cannot afford.
Do not wear rings, wrist watches or loose fitting clothing when working on machinery. They could catch on moving parts causing serious Injury. Never adjust and/or service a machine in bare feet, sandals or sneakers.
Always wear safety glasses when using a hammer, chisel or other tools that may cause chips to fly.
Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact, remove sealant or solvent promptly by washing with soap and water.
Always use a safety bar to block air or hydraulic operated cylinders. Never rely on the machine air or hydraulic systems to hold when working on machines. An air or hydraulic line or cylinder could fail or someone could accidently strike the control levers causing the equipment to fall.
Equipment must be level on ground at all times during machine servicing and periods of idleness.
Cranes and hoists must be of sufficient capacity to lift the heavier components (gear cases, dipper/bucket, boom, etc.) and have an ample safety margin.
Be sure heavy items are properly supported from cranes or hoists before removing supporting members from machine.
Have sufficient service personnel available when removing or installing large heavy items to maintain control at all times.
Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load, they could fail.
Use safety catch on all hoist hooks. Do not take a chance, the load could slip off of the hook.
If a heavy item begins to fall, let it fall, don't try to catch it.
When disassembling machines, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.
Keep work area organized and clean. Wipe up oil or spills of any kind. Keep tools and parts off of the ground. Eliminate the possibility of a fall which could result in a serious injury.
Floors, walkways and stairways must be clean and dry. After draining operations be sure all spillage is cleaned up. Electrical cords and wet metal floors make a dangerous combination.
Check all wire ropes for telltale signs of early wear or failure. Look for and secure any loose bolts or locking devices.
Use extreme caution while working near any electrical lines or equipment whether it be high or low voltage. Never attempt electrical repairs unless qualified. Check limit switches for proper operation.
When using an acetylene torch, always wear livelding goggles and gloves. Keep a "charged" fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart. Do not weld or heat areas near transformers or electrical cabinets and utilize proper shielding around lubrication lines.
Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Then, be sure to wear safety glasses.
Be careful when using compressed air to dry parts. Use approved air blow guns, do not exceed 207 kPa (30 psi), wear safety glasses or goggles and use proper shielding to protect everyone in the work area.
Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing the machine.
After servicing, be sure all tools, parts or servicing equipment are removed from the machine.
Protective eye goggles should be worn at all times when working on the air conditioning system. Work on the air conditioning system only in a well ventilated area.
Wipe away excess lubricants around bearings and gears. Never lubricate pl:lrts in motion.
Operate machine on level ground and be continuously aWfire of swing clearance. Never hold a load longer than needed in dump cycle. Use swing brakes only when machine is stopped.
Machine downtime is costly to owners in lost production. Preventive maintenance is the task of identifying, replacing or repairing machine components before they fail so that downtime is minimized.
ACAUTION: 00 not perform inspection activities while machine is in operation.
Due to variations in operational wear rates of machine components and machine application conditions, component life cycles are different. A scheduled program of machine inspection with accurate record keeping can identify machine component and their rates of wear.
A continuous careful inspection routine can spot unusual conditions or fatiguing components before a failure occurs. Maintenance, repair and component replacement schedules should conform to scheduled machine shutdowns. If during daily, weekly or monthly inspection routines any part shows wear or distortion beyond expected normal patterns replace them with genuine Marion parts at the next scheduled maintenance interval. The cost of parts is small when compared to unscheduled breakdowns with their resulting lost manhours and machine production.
Machines which operate 24 hours, 7 days per week should have a scheduled 8-hour preventive maintenance period each 7-day period. See Section 8 for recommended inspection schedu les.
Preventive maintenance inspection procedures listed below are suggested as an example of specific typical inspection activities. Each owner should establish his own preventive maintenance inspection schedule based on machine application conditions and production cycle.
ACAUTION: Maintenance and operatin,.. personnel should be aware of mechanical and electrical inherent in servicing this machine.
Check condition of rope sheave grooves and bearings
Test all hold down bolts with impact wrenches
Check rope guides and bails for wear
Inspect all rope for broken wire or loss in diameter
Check auto-lube system for loose or damaged fittings and injector condition
Inspect dipper/bucket for cracks
ADANGER: Remove electrical power from machine whenever inspection of center journal, collector rings, rails or roller circle is performed. Use extreme care in removing guards and protective devices.
PREVENTIVE MAINTENANCE - continued
INSPECTION CHECKLIST
Check condition of roller circle, rails, and gearing
Check main swing gear hold dovvn bolts and re-torque to specifications
Test all hold down bolts on upper frame components such as swing gear case, electric motor mounts, machinery pedestals and air Gompressors
Examine all brakes, clutches and their linings for excessive wear
Check center journal---secure all guards and protection devices removed
DANGER: REMOVE ELECTRICAL POWER FROM MACHINE BEFORE PERFORMING ANY OF THE FOLLOWING INSPECTIONS:
Inspect electrical cabinets; any disoolored wires or components indicate overheating conditions have occured.
ALook for moisture, fl!ngus or mildew in electrical If found clean with approved solvents only, or compressed air.
Check all electrical cabinets for messy or torn fasteners, cable armor or grommets, loose insulation
Inspect electrical motors for discolored commutators orworn brushes.
These inspection points are representative of typical preventive maintenance routines. Use Section 8 as a detailed guide for all areas of machine inspection and suggested scheduled periods.
Marion Power Shovel Division, Dresser Industries, Inc. ("Marion") warrants that its products, when ship-
ped, for a period of six (6) months from the date of delivery, F.O.B. point of shipment, will meet ap-
plicable, agreed specifications, if any with respect thereto, and will be free from defects in material and
workmanship, provided that the Marion products sold are properly stored, assembled, used and maintain-
ed. Products not manufactured by Marion shall be subject only to such warranty as may be made by the
manufacturer thereof. All claims under this warranty must be made in writing immediately upon
discovery. THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER, EX-
PRESS, IMPLIED AND STATUTORY, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS.
Should any failure of the Marion products to conform to this warranty appear within the limited time
period set forth above, Marion shall, upon Buyer's submission of a claim as provided above, either 1)
repair or replace, F.O.B. point of shipment, any nonconforming part or parts of Marion's products wt;lich
have been returned to it for examination, transportation prepaid, or otherwise examined by Marion,
which examination discloses the nonconformity to Marion's satisfaction; or 2) refund an equitable portion
of the purchase price.
.t. THE FOREGOING IS MARION'S ONLY OBLIGATION AND BUYER'S EXCLUSIVE REMEDY FOR BREACH .t• •%. OF WARRANTY AND, EXCEPT FOR GROSS NEGLIGENCE OR WILLFUL MISCONDUCT, THE FOREGOING
•t. IS BUYER'S EXCLUSIVE REMEDY AGAINST MARION FOR ALL CLAIMS ARISING WITH RESPECT TO .t•
•t. MARION PRODUCTS OR RELATING THERETO, WHETHER SUCH CLAIMS ARE BASED ON BREACH OF .t•
•t. CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES. BUYER'S .t•
•t. FAILURE TO SUBMIT A CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR .t•
•t. DAMAGES OR OTHER RELIEF, INCLUDING, BUT NOT LIMITED TO, CLAIMS BASED ON LATENT .t• •t. DEFECTS. .t.
.t. IN NO EVENT (INCLUDING, BUT NOT LIMITED TO, AVOIDANCE OF THE ABOVE LIMITED WARRANTIES .t• •t. AND REMEDIES) SHALL BUYER BE ENTITLED TO ANY INDIRECT, SPECIAL, INCIDENTIAL OR CONSE- .t• •t. QUENTIAL DAMAGES, WHETHER ARISING FROM LATE PERFORMANCE OR A FAILURE TO PERFORM, .t• •t. DEFICIENCIES OR NEGLIGENCE IN THE DESIGN, MANUFACTURE, SALE DELIVERY OR ASSEMBLY OF
MARION PRODUCTS OR FAILURE OF MARION PRODUCTS OR FROM ANY CAUSE WHATSOEVER AND
WHETHER BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT L1ABILI-
TY) OR OTHER THEORIES. ANY ACTION BY BUYER ARISING WITH RESPECT TO MARION PRODUCTS +-t•
OR RELATING THERETO MUST BE COMMENCED WITH ONE (1) YEAR AFTER THE CAUSE OF ACTION +.+
ACCRUES OR IT SHALL BE BARRED.
.;. Marion reserves the right to improve or change the design of its products and specifications thereof and
Marion shall incur no liability thereby or any obligations to install such improvements on products
previously sold.
*The above warranty relates to spare/repair parts for the Marion equipment referenced in this document.
For specifics on the machine warranty, reference should be made to the purchase contract or Marion
Power Shovel Division, Dresser Industries, Inc. may be contacted directly. Please identify machine serial
number.
Qualified maintenance personnel using a scheduled maintenance program are the best way to minimize machine downtime and maximize productivity of equipment.
Marion offers factory and mine site maintenance seminars and special familiarization programs for mechanics, oilers, electricians and operators on a fee basis.
These programs are presented by qualified factory specialists and service technicians. Special customized training programs can also be developed to meet specific mine requirements.
Objectives of training and train ing materials are to provide the means for developing and maintaining on-site service repair capability. The Marion training programs use field proven concepts where your employees see, hear and participate in "hands on" practice of service repair operations.
For further information about Marion service training capabilities and programs contact:
Training Supervisor
Marion Power Shovel Division
P.O. Box 505 Marion, Ohio 43302
Specification 191 M-HR-1 6
Deck Plan
Approximate Component Weights (Table) 1 -1
ILLUSTRATIONS
·
Lower Frame
R.H. Crawler Frame
Crawler Shoes .
Rotating Frame Naked
Rotating Frame Assembly
Ballast Box (Naked)
Naked Boom .
Boom Assembly Complete
Dipper Handle
15 Yd. Dipper w/Bail
... ....
·.
Item 1 1-2
Item 2 1-2
Item 3 1-2
Item 6 1-3
Item 7 1-3
Item 8 1-3
Item 11 1-3
Item 12 1-3
Item 15 1-3
Item 16 1-3
• 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.