CAT BUCYRUS MARION 201-M ELECTRIC SHOVEL MAINTENANCE AND OPERATION MANUAL 2002A

Technical Manual

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TABLE OF CONTENTS

available.

Additional information that IS required will be furnished as soon as such information is

chinemay not be covered.

advanced engtneennCJ design, optional equipment or the particular requirements of this ma-

This manual has been prepared for the standarrl prorluction machine. Any deviation due to

READ AND OBSERVE ALL warning siCJns, they're placed for your health and safety.

Marion Power Shovel Co., Inc.

closed maintenance and operational rrocedures as they refer to your machine; please contact

In the event you dOLjbt, for any REASON, your ability to safely perform any of the en-

ITY CHECK SYSTEM IS ALSO RECOMMENDED.

RESISTOR AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINU-

CLUDE GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING

AGE

ELEGTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM SHOULD IN-

DUE TO THE DANGERS INHERENT IN THE OPERATION OF ANY HIGH VOLT

WARNING

INTRODUCTION

The information contained in this manual provides guidance to all persons who care about the operation and maintenance of this machine. Needed data for operation, lubrication, adjustments and other tasks suppl ied in the various sections permits accurate operation and service. All enclosed specifications agree with the Marion Power Shovel Engineering Department. This information allows for quality maintenance when followed exactly.

This Manual is NOT a Parts Book. Do not use it to order parts. You have been supplied with a separate, detailed Parts Book. Please read carefully the instructions in the front of it. All parts are listed by group number with items and part numbers for this SPECI FIC machine. Please order the correct parts in exact quantity. Parts ordered by mistake and returned are subject to a Company rehandling charge. RIGHT and LEFT HAND PARTS on the upper frame correspond to the operator's hands at the controls as he faces the dipper. Please state the correct machine SERIAL NUMBER in any conversation or correspondence. Records of each machine are filed by serial number. Given this number, the specific design and original equipment check is accurate and quick.

ADDED INFORMATION, when required, not found in this Manual or the Parts Book may be obtained from Marion Power Shovel Company, Inc. at Marion, Ohio 43302.

SERVICE and LABOR CHARGES are NOT accepted unless previously authomed by the Company in writing.

STANDARD WARRANTY

Marion Power Shovel Company, Inc. guarantees the equipment manufactured by it to be tree of defects in material and workmanship under normal use and service, its obligation under this warranty being limited to making good at its factory any part of 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 warranties, express or implied, and of all other obligations or liabilities on Marion Power Shovel Company's part.

Marion Power Shovel Company, Inc. 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, I nc harmless therefrom.

Marion Power Shovel Company, Inc. makes no guaranty or warranty, express or implied as to adequancy, 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 resflective manufilcturers thereof.

The Company reserves the nght to improve or change the design at its products and specifications thereof and the Company shall incur no liability thereby or any obligations to install such improvements on products previously sold.

SAFETY SUGGESTIOIIS

The operator controls the machine and its usefulness. The crew alone thinks for it. Safety, constantly in mind, prevents accidents. Develop good habits. Everyone has bad habits, but try to erase them quickly. Cleanliness and safety go together. A clean machine is easier to operate, inspect, and maintain.

READ and OBSE RVE ALL warning signs, they're placed for your health and safety.

KNOW the location of fire extinguisher.

DO NOT START machine without a FULL tank of air pressure.

DO NOT LEAVE the controls without pushing the button marked "EXCITATION" and turning ALL brake switches to "SET"

DO NOT APPL Y swing brakes while machine is rotating e)(cept in emergency.

DO NOT HOLD the bucket'dipuPr load IOr1l1er than needed in clumping cycle.

DO NOT SERVICE or lube moving parts.

DO NOT BOAR 0 an operatinq madline.

PLEASE READ carefully th is Manudi and Parts Book.

PLEASE LUBE regularly.

PLEASE CREATE A SYSTErli1ATIC procedure and follow it.

PLEASE WATCH clearance when swinrJinrJ.

PLEASE OPERATE machine on as near level ']round as nossible

PLEASE KEEP safe operating procedures In mind at ALL limes.

CAUTION IS THE BYWORD. Develop a feel for the machine. Trv to sense failure before it arrives. Take that extra second to look aqain at somethinq that seems out of place. A pant chip or bubble may be an early warninq A slight hiss may indicate a qrowing air leak. it's much easier to tlC]hten a packinfJ nut than shutdown fOi< packing repair.

PROPERL Y GROUND the power source.

WATCH AI R system performance

CHECK boom suspension and hoist ropes for early signs of wear of failure. Kinks cause permanent damage.

CHECK LIMIT switches for proper operation.

CHECK OVERLOAD and thermal breakers.

MAl NTAI N correct supply of lubricant.

MAl NT AI N CLEAR walkways.

LOOK FOR loose bolts and locking devices.

KEEP FLOORS CLEAN and free of oil and grease.

WIPE AWAY excess grease and oil around beanngs and gears.

KEEP hands, feet and clothing away from moving parts.

PROMPTL Y REPLACE all guards, inspection doors, access covers and other safety features after inspection or rerair.

NEVER attempt electrical repair, unless qualified.

HIGH VOLTAGE power lines require using EXTREME CAUTION.

Open pit mining equipment undergoes tremendous shock and stress. Marion's design considers these loads. This machine, built with an apple 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 judgement and reason govern the economic need in the operation of power equipment.

Downtime exists, but an ongoing program of Inspection and evaluation minimizes it. Awarenpss of unusual conditions generally warns rersonnel before breakdown occurs. Normal wear of machinery parts escares exact definition. Parts do not suddenly expire. Wear takes place at 'Jarylng degrees over time. Constant checking indicates a wear pattern. An alert mainten1r'ce crew checks ALL structural members for evidence of stressed, broken or loose items. 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 indicate movement and becomes second nature to most personnel. Retighten ALL bolts shortly after initial start up. Grease and oil stains otten indicate problems. Perhaps just 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 operatinq 24 hours, 7 every week deserve an 8 hour inspection and cleaning every 10 days. Cleaning before inspectlOr' e i iminates dirt and dust falling into machinery parts when inspection plates and covers are remDveej

On the upper works, a solvent makes removal of the accumulation of grease around bearings, gears, motors and the like easier.

Start up the machine and die; enoullr1 to warn: up machinerv, open the inspection cover over qears and pinions. Look al DP;jr t"eth as machinery' slowly qO!?I: thru its paces of hOist·lower ing: Broken teeth are asy to sDot, but splayed or an unUSUdl vvear pattern takes a closer look.

For a quick check, run a piece of soft wire thru the qear mesh at each side of the pinion. Measure thickness of the two adlacent loops 'with micrometer. The sum of the two loops indicates backlash. Comparing them (Jives an indication of misaili]!!rnent If excessive backlash is suspected, measure with a dial IIldicator There just isn't enouqh room hetween the gear guard and the pinion to use a feeler qauge.

Slowly rotate the upper works several times In each d,rec'ion L.ook dt condition of railer circle, rail, gear and swing pinion Sound her·c may indicd1E; a flat or chioped railer or even suggest burrs or damaged teeth on the rotatinri pinion

While hoist operates, check condition of point sheaves groove and Test hold down bolts on boom point end plate. Test ALL hold down bolts with impact wrench. Check rope guides for wear. Look at hoist and drag ropes for broken wires. While on boom point and gantry, may as well check auto-lube system for loose, broken or damaged fittings or lines. Note condition of injector Properly lube A.LL points, it's important.

Lower bucket/dipper to ground and shut down machine. Inspect bucket/dipper for cracks and breaks. Do not permit tooth base exposure. Teeth may be reversed. Remove bucket/ dipper from service and rebuild in shop before breakdown. Check main rotating gear hold down bolts. Use impact wrench if needed. Test ALL hold down bolts on rotating frame. Especially swing gear case, motor mounting, machinery pedestal and base bolts. Check also motor generator and air compressor mount and base bolts. Tighten rod bolts on bearing housing.

Examine and readjust, if needed, hoist brakes. Look at the condition of brake lining. Remove inspection plate from swing gear case. Look at condition of gears. Use pry bar to detect any side motion of shaft indicating worn bearings. Examine condition of rotating brakes and their adjustment. Adjust, if needed. Inspect air compressor "V" belt tension, replace if needed. Fill the anti-freezer but don't drink that stuff. Check auto-lube system for loose or broken fittings or injectors.

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 parts, joints and connections. Retighten, where needed, any loose connections and terminals. Use of proper tool here eliminates broken terminals and terminal blocks. Replace missing or damaged tags and labels. Bundle loose wiring. Fasten ALL components and wiring in cabinets. Check the cable armor tight in the fixture. Look closely where wires and cables pass thru openings and grommets. I nsulation damage generally occurs here. Replace grommets if needed. Arcing of motors and generators discolored commutators. Look at brushes and brush holder condition. Correct brush spring tension where needed. Collector rings need cleaning and checking also. Use a hand grease gun ilt each injector. Fill ALL grease lines and purge EACH bearing with MPG. Remember to replace ALL plugs, covers and inspection plates.

This may seem like a lot of running around checking, lookinq, inspecting, cleaning and then greasing; but this is the machine that makes the payroll possible. Keeping it running is very important.

Passing equipment condition reports along the line is important also. Wear patterns show up at varying degrees in time. Recording and checking these reports at a future date allows comparison and plannedshutdowns. Planned repairs, part orders and crews for a scheduled shutdown eliminates idle downtime.

Lower bucket/dipper to ground and shut down machine. I nspect bucket/dipper for cracks and breaks. Do not permit tooth base exposure. Teeth may be reversed. Remove bucket/ dipper from service and rebuild in shop before breakdown. Check main rotating gear hold down bolts. Use impact wrench if needed. Test ALL hold down bolts on rotating frame. Especially swing gear case, motor mounting, machinery pedestal and base bolts. Check also motor generator and air compressor mount and base bolts. Tighten rod bolts on bearing housing.

Examine and readjust, if needed, hoist brakes. Look at the condition of brake lining. Remove inspection plate from swing gear case. Look at condition of gears. Use pry bar to detect any side motion of shaft indicating worn bearings. Examine condition of rotating brakes and their adjustment. Adjust, if needed. I nspect air compressor "v" belt tension, replace if needed. Fill the anti-freezer but don't drink that stuff. Check auto-lube system for loose or broken fittings or injectors.

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 parts, joints and connections. Retighten, where needed, any loose connections and terminals. Use of proper tool here eliminates broken terminals and terminal blocks. Replace missing or damaged tags and labels. Bundle loose wiring. Fasten ALL components and wiring in cabinets. Check the cable armor tight in the fixture. Look closely where wires and cables pass thru openings and grommets. Insulation damage generally occurs here. Replace grommets if needed. Arcing of motors and generators discolored commutators. Look at brushes and brush holder condition. Correct brush spring tension where needed. Collector rings need cleaning and checking also. Use a hand grease gun pt each injector. Fill ALL grease lines and purge EACH bearing with MPG. Remember to replace ALL plugs, covers and inspection plates.

This may seem like a lot of running around checking, lookinq, inspecting, cleaning and then greasing; but this is the machine that makes the payroll possible. Keeping it running is very important.

Passing equipment condition reports along the line is important also. Wear patterns show up at varying degrees in time. Recording and checking these reports at a future date allows comparison and planned shutdowns. Planned repairs, part orders and crews for a scheduled shutdown eliminates idle downtime.

(Sect. 1- Eng. Data cant.)

(Sect. 1- Eng. Data cont.)

SECTION 1

ENGINEERING DATA

The Marion machine design and construction follows rigid specifications in accordance to acceptable industry standards. This section provides information for proper machine maintenance. NOTE: Consider the information in this seciton general in nature. It includes established procedures recommended by Marion Engineers which mayor may not wholly apply to your machine, but remains applicable by reference.

STRAIGHT BRONZE SLEEVE BUSHINGS assemble in bearing boss with a light press fit.

Each FLANGE BUSHING secures thru flange with rninimurn of four dowels to restrict bushing rotation. Dowel materia! is softer than bushing.

- BUSHI NG LI FE is figured on the table so that vvhen ,,,,.,,r,,r',n clearance exceeds three tirnes the figures shown, REPLACE the bushing.

BUSHI NG REPLACEMENT first reqUires dismantling machinery and shaft assemblies. An air chisel, cautiously used, slits bushing for easy removal. Be careful not to CUT or SCORE the bearing boss. CLEAN the boss completely. Remove ALL burrs. Check that outer leading edge of bushing for insertion is de-burred and a chamfer exists. This is important.

The de-burred clean bushing installs easily in a clean bore if bushing is cooled (using dry ice and alcohol} to point where it drops freely into place.

An alternate method installs the bushing using a long threaded rod, steel plates and a hollow center jack. Assemble these items as shown in sketch. Lightly coat bushing 0.0 and boss I.D. with white lead. Then PULL the bushing in place.

Boss

Wlme l.ead Steel Pla:e

Holl()VJ

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