MATERIAL AND EQUIPMENT
(The following materials and instructions are based upon a machine completely dismantled, as for export shipment. In many domestic shipments. therefore. some of the following does not apply since the machine is shipped in component units as much as possible.)
The following list of tools and materials are recommended to erect a 191-M shovel and are to be furnished by the purchaser. This is in addition to tools furnished with machine for maintenance.
200 to 225 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 hammers
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 man cross cut saw
1 1/2 to 5 ton chain hoist
2 crowbars
2 25 ton track jacks
2 50 ton track jacks
1 lifting crane capable of handling 40 tons at a 20 ft. radius and having a 50 ft. boom. (The main upper frame. as shipped domestically. weighs approximately 60 tons and must be skidded onto lower frame. )
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BI005995
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Electrical Erecting Tools
14 inch screw driver
28 inch screw drivers
1 pair 8 inch pliers, side cutting
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 half round files
18 inch round file
1 1/4 to 3/4 pipe bender
1 10 inch Stilson wrench
1 10 inch crescent single end wrench
1 6 inch crescent single end wrench
2 18 inch pipe wrenches
1 cold chisel
1 gouge
1 1-1/2 pound hammer
11 quart blow torch
75 feet of steel fish tape
1 250,000 ohm magneto
1 set of 3/16 steel letters
1 set of 3/16 steel figures
1 hack saw
6 hack saw blades
Note: Two lists of tools are recommended as more than one crew may be working at a time.
GENERAL
When the machine is shipped from the factory, it is match marked throughout. Therefore, when assembling, much care should be taken to follow these match marks. The erection drawings accompanying each machine show how the various units are assembled.
All polished bearing surfaces are protected against corrosion and these surfaces should be thoroughly cleaned before assembling. When assembling the machine, all bearing surfaces should be lubricated.
Select an erecting site of approximately 50 feet by 150 feet, level off, and if necessary, use stone to make a solid foundation.
All electrical equipment and finished parts should be protected froITl the weather until the house is asseITlbled.
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ERECTING PROCEDURE
The following is a recommended procedure to follow for erecting the machine when completely disassembled for shipment. (Domestic shipments have only major units to assemble. )
1. 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 temporarily secured.
2. Assemble and install the other crawler side frame. Securely bolt the entire lower frame assembly and crawler side frames.
3. Install rotating gear and securely bolt to lower frame.
4. Install the circle roller assembly and the top half of the collector ring dri ve tube. This part of the drive tube must be installed before the upper frame is in place. Refer to the Electrical Instructions for details.
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.
6. 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 vertical propel shaft leaving. 010 to .015 inches clearance between bevel gear and lock nut. The vertical propel shaft should be jacked up from the bottom as far as possible to obtain this clearance. 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.
9. Install fourth intermediate propel shaft on rear end of lower frame.
10. Install rear section of upper frame, including ballast boxes and M. G. Set and side wings.
11. Install conduit, boom electric wiring, and collector rings.
12. Install gantry complete.
13. Install ballast. 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 we;.gh 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.)
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14. Install rotating gear cases, oil pump and air compressor, then start at center journal and locate 1st into propel shaft and bearing. Locate and as semble intermediate hoist shaft including bearings. Locate and assemble hoist drum shaft and bearings. Locate and assemble hoist motor extension shaft and bearings. Locate and assemble hoist motor and coupling. Assemble check band and support. Lubricate all gear teeth and put two pints of proper grade oil in couplings.
15. Place electrical cabinet, and bolt it in position.
16. Assemble house, and install levers and equipment in operator's cab.
17. Complete air and hydraulic pipe work and all wiring.
IS. Assemble boom and install boom support cables on cable connections at boom point and gantry. (The boom assembly can be a simultaneous operation with other phases of erection. )
19. Install all guards, gear cases, hand rails, ladders and platforms.
20. Inspect and tighten all anchor bolts.
21. Thoroughly lubricate all bearings and movable parts and put proper amount and grade of oil in all gear cases. (See lubrication instructions in Section IV. )
22. Attach trail cable. After electrical setting s have all been made, run all motors and machinery to make certain that the machine is properlyassembled.
23. All brake bands, and friction bands must be adjusted.
24. (See L. P. 165). To raise boom, using the hoist cable, reeve a double line from drum, over top of double sheave in center of gantry and over boom 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 motor. Secure and adjust support cables and remove hoist cable.
25. Assemble dipper and dipper handle. When assembling dipper handle, make absolutely certain that the teeth on the shipper shaft pinions are in line with each other. Reeve hoist cable for hoisting dipper, and dipper trip cable.
26. After the machine is completely erected, it should then be run under no load for a sufficient length of time to make certain that no bearings are heating and no gears cutting. After this, the machine may be placed in operation.
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REEVING DIAGRAM FOR RAISING SHOVE L BOOM
Gantry Sheove-7
Both Ends Of Cable Dead Ended On Hoist Drum.
Boom Point Sheaves
REEVING DIAGRAM FOR SHOVEL OPERATION
Equalizer Sheave
Both Ends Of Cable Dead Ended On Hoist Drum---I
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L.R 165 BI005995
SECTION II
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MARION 191-M General Hydraulic Steering and Propel Brake System Lower Frame Upper Frame Front End -910 10 14 14 22 BI005995
ADJUSTMENTS
GENERAL
The Marion 19l-M has been designed for easy adjustInent 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 corne loose in time. This is particularly true of a new machine and, if allowed to remain loose, bolts and pins will wear and stretch until eventual failure might occur. Safety demands that the machine be given regular attention.
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 di rt and grit which might work itself into bearings or gears and promote wear.
Tt.f' lnachine is given a coat of primer and several coats of good machinery enClmel before shipment. With use, however, this paint will wear and become chipped. Bare spots should be repainted at regular intervals of twelve to ighteen months. A regular m.aintenance schedule should be followed at all times.
HYDRAULIC STEERING AND PROPEL BRAKE SYSTEM
The 191-1\/I uses hydraulic rams on the lower fram.e, which are electrically ccntrolled, to operate the propel brakes and steering clutches. By means of collector rings between the upper and lower frames, the electrical control is brought to switches at the operator's station, thereby making it a sirnple matte!:" to release or set the propel brakes and engage or disengage the proper set of cra"wlers to steer the machine in any directiop.
The type of oil raITI as used with the hydraulic systern is shown in L. P. 246. Disregarding rninor details. the raIn as indicated, applies to all raInS used' on the rnachine. Should the rarn leak oil and refuse to operate properly, t.he most likely cause is loose packing. To tighten the packing, some of the shims (1) must be ren'1oved and packing retai.ner (2) tightened down. If the packing rernains loose after all have beeT\. the packing should be renewed. When tightening the internal ram spring (3), the locking nut (4) must first be loosened and the set screw (5) b&tckec out, thus releasing the adjusting nut (6). The adjusting nut Hlay then be turned deeper into the ram hOl;;.sing which i11.Cl'eases the spring pres sure. i\.fter the spring has been tightened to the point required, the locking nut and set screw must be carefully retightened.
L. P. 24'1 (following Page 17) shows a diagram of the hydraulic system as used, and its functions are described as follows:
The propel brakes are spring set and the steering clutches are spring engaged with the driving mechanism so oil pressure is required only when propelling. The oil pump motor runs only when propelling. In case of electrical power failure, the oil pump motor will stop and the brakes will set.
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HYDRAULIC RAM -L.R 246 BI005995
When the operator wishes to move ahead, the hoist clutch selector switch must be turned to "Release". This will release the hoist clutch, set the hoist brake and engage the propel clutch. (All of these are on upper frame.) When the propel clutch is engaged, the propel clutch limit switch contact will close, and the operator can release the propel brakes by turning the propel brake selector switch to "Release". This will start the oil pump motor and close valve II A". As the oil pressure rises, the ram cylinder pistons for the propel brakes will move out to the brakes. To set the brakes, the motor is stopped and the oil in the rams is forced out into the tank through valve" A".
To turn the rnachine, or propel around curves, the steering clutches can be engaged to steer right or left as desired. This operation is controlled by means of a steering clutch selector switch, located at the operator's station. For example, if it is desired to turn right, the switch energizes the solenoid valve "B". When valve "B" opens, it permits the oil to flow into the right hand steering ram, which forces the ram piston out to disengage the right hand steering clutch. When either steering clutch is shifted so the crawler is disengaged from the propel driving shaft, it also locks the crawler to the side frame, thereby assuring a positive turning point for turning the machine. The clutches are mechanically interlocked so only one at a time can be disengaged. When valves "B" or "C" are closed, the ram piston is brought back to the normally engaged position by means of a spring in the ram and the oil is exhausted through the three -way solenoid valve to the tank. Springs also keep the steering clutches engaged while propelling straight ahead.
If the steering clutches fail to shift when the valves "B" or "C" are energized, the machine should be moved slightly forward or backward to relieve strain on the clutch teeth.
To properly maintain the propel hydraulic system, the following recommendations are made:
1. Use a good grade of oil.
2. Keep all joints tight to avoid oil leaks, and clean strainer once each week.
3. If relief valve becomes noisy or if pressure does not remain constant, remo've valve for inspection; if parts are found worn, replace with new or replace the entire valve.
4. Should the system 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.
S. Keep the solenoid valves working freely. Sticky valves may 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.
- 12 - (Cont'd. on page 14) BI005995
CRAWLER BELT L.P.248 BI005995
LOWER FRAME ADJUST MENTS
CRAWLER BELT ADJUSTMENT (L. P. 248)
Each crawler belt should have 2 11 to 3" total up and down m.ovem.ent in the top portion when the bottom. is straight and tight. If a belt is too tight, it will result in a binding action and heavy strain, with a resultant loss of power. If belt is too loose, the shoes will clim.b up on the driving sprocket and serious breakage of shoes or side fram.es m.ay result. Tightening a crawler belt is accom.plished by the u",e of two jacks placed against end plates (1). First rem.ove shims (2) ahead of blocks (3) and force the blocks out with the jacks. Shim.s are then inserted behind the blocks. Lock bars (4) are then m.oved forward against end plates (1) and cap screws (5) replaced and tightened. Rem.ove jacks and check the belt adjustm.ent. Loosening the belt is accom.plished by first removing cap screws (5) and lock bars (4). Place jacks in position and force sleeves and end plates (1) out. Next rem.ove the rear shim.s (6), then rem.ove jacks and allow roller and bearing blocks to slide back. In case they do not corne back, propel the m.achine slightly until the roller and blocks do release. (Note: Adjustm.ent of belts must be done sim.ultaneously on both sides of each crawler, using two jacks).
PROPEL BRAKE (L. P. 249)
The proper adjustm.ent of the propel brakes consists of, the adjustm.ent bolts (1) and the bottom. brake shoe links (2) being 1/2 inch less than full toggle when the brakes are set; the bottom. brake shoe stop screws (3) limiting the travel of the bottom brake shoes (4) so the top brake shoes (5) have clearance equal to that of the bottom brake shoes; and the adjushnent sleeves for the ram. cylinders set in as far as possible so the springs within the ram cylinders will furnish enough power to set both propel brakes completely and equally. The propel brake should be in the released position, when changing the length of the adjustment bolts (1). The propel brake should be released when adjusting the bottom. brake shoe stop screws (3) and set when adjusting the ram. cylinder spring adjustment sleeves. Occasional adjustment to compensate for wear of the lining lTIUst be made. Caution: To prevent damage to the packing, when releasing the propel brakes, the rarn cylinder adjustment sleeves must be screwed into the cylinder as tight as possible.
After adjusting the propel brake, the propel brake limit switches must be adjusted as outlined in the electrical adjustment instructions.
UPPER FRAME ADJUSTMENTS
PROPEL CLUTCH RAM (L. P. 155)
The propel clutch is engaged by the movement of the piston (1) toward the right side of the machine. when air is admitted to the cylinder (2). It is disengaged by spring (3) moving the piston toward the left side of the machine, when the air is released from the cylinder. A special nipple (4) with a 1/8 inch hole (5) prevents the cylind.er acting too quickly and with such force as to damage the cylinder or the clutch. Hole (5) should be kept clear at all times.
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PROPEL BRAKE2 I II II II 'I BI005995
If the ram fails to operate, first make sure that the air pressure is not less than 95 pounds per square inch; that the air lines are not clogged; and that the solenoid valve works properly. With the foregoing conditions correct, and if the ram still fails to operate, replace the packing cup (6). Only the cylinder piston rod nut (7) and washer (8) need to be removed. Care should be exercised in removing the cylinder parts, since the spring is about 40% cOITlpressed. When reassembling, lubricate the packing cup with Elco
If 158 -LO grease. (Note: Leather packing cup should be stored submerged in a leather preserving oil).
After adjusting the propel clutch, the propel clutch limit switch should be adjusted as outlined in the Electrical Adjustment Instructions.
CROWD AND SWING BRAKES AND RAMS (L. P. 160)
The crowd and swing brakes are spring set and air released. With the brake set, pressure is applied to both shoes (1) by spring (2). With the brake released, the shoes are forced away from the brake wheel (3) by the action of the piston (4). To increase the pressure on the brake shoes, loosen lock screw (5) and screw sleeve (6) into cylinder (7) until pressure is enough to set shoes properly, then tighten lock screw. Adjusting screw (8) is used to regulate the clearance between the brake shoes and the brake wheel. Screw (8) will usually be used to adjust for lining wear. The shoes should be adjusted very close to the brake wheel, but t.hey must not drag. Adjustment can be made only when the brake is blocked in the position. With the brake in the released position, the arms (9) against stan (10), the limiting screws (11) should be adjusted so that one of the shoes just bears on the screw at lug (12) and the other shoe has 1/16 inch clearance with its screw at lug (12). (Moisture should be blown from cylinder heads daily).
If the ram should fail to operate, first check the air pressure to see that it is at least 95 pounds per square inch; that there are no leaks; that the lines are not clogged; and that the solenoid valve is working properly.
With the foregoing conditions correct, and if the ram still fails to operate; screw out sleeve (6) until all compression is reITloved from spring (2); remove cylinder head (13) and piston (4). By removing some of the shims (14), the packing (15) will be tightened in the cylinder (7). Care should be taken to avoid damaging the piston or cylinder. If removing all the shiITlS does not tighten the packing enough, new packing ITlust be installed. With new packing, shims will be needed to keep the piston from being too tight.
The piston should fit the cylinder snugly, but should be free enough to be moved by hand when reassembling, the packing should be lubricated with a good mediuITl grade oil.
HOIST CHECK BRAKE (L. P. 250)
The hoist brake is spring set, air released and is operated by a switch mounted to the right of the operator. To adjust the hoist brake band, tighten or loosen, as the case may be, the band adjusting bolt (1). The band should be adjusted so that the air cylinder lever (2) is 1/4 to 1/2 inch less than full toggle when the
- 16 - (Cont 'd. on page BI005995
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2 L.P. 155 BI005995
PROPEL CLUTCH RAM
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