CAT BUCYRUS 191-M ELECTRIC SHOVEL MAINTENANCE AND OPERATION MANUAL BI005621

Technical Manual

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-WARNING-

DUE TO THE DANGERS INHERENT IN THE OPERATION OF ANY HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM SHOULD INCLUDE GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR. AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED

In the event you doubt, for any REASON, your ability to safely perform any of the en· closed maintenance and operational procedures as they refer to your machine; please contact your Local Service Representative or Service Department at Marion, Ohio 43302.

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

This manual has been prepared for the standard production machine. Any deviation due to advanced engineering design, optional equipment or the particular requirements of this machine may not be covered.

Additional information that is required will be furnished as soon as such information is available.

*STANDARD WARRANTY

Marion Power Shovel Division, Dresser Industries, Inc. ("Marion") warrants that its products, when shipped, for a period of six (6) months from the date of delivery, F.O.B. point of shipment, will meet applicable, 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 maintained. 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, express, 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 which have been returned to it for examination, transportation prepaid, or otherwise examined by Marion, and which examin'ation discloses the nonconformity to Marion's satisfaction; or 2) refund an equitable portion of the purchase price.

The foregoing is Marion's only obligation and Buyer's exclusive remedy for breach of warranty and, except for gross negligence or willful misconduct, the foregoing is Buyer's exdusive remedy against Marion for all claims arising with respect to Marion products or relating thereto, whether such claims are based on breach of contract, tort (induding negligence and strict liability) or other theories. Buyer's failure to submit a claim as provided above shall specifically waive all claims for damages or other relief, including, but not limited to, claims based on latent defects.

In no event (including, but not limited to, avoidance of the above limited warranties and remedies) shall Buyer be entitled to any indirect, special, incidential or consequential damages, whether arising from late performance or a failure to perform, 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 liability) or other theories. Any action by Buyer arising with respect to Marion products 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.

SECTION 1 INTRODUCTION

This manual is designed to be informative and helpful during the operation and preventive maintenance of this equipment. Great care has been taken to provide you, the owner, with the most comprehensive, up-to-date material available from our engineering, service and training departments. Following the easy to understand step-by-step procedures, the maintenance crew will be able to perform their duties without sacrificing safety or production. When a systematic and thorough maintenance/service procedure (a responsibility of the maintenance superintendent) is instituted for the Equipment, quality maintenance and operation will resu It.

THIS MANUAL IS NOT A PARTS BOOK, nor is it to be used to order parts. You have been supplied with a separate, detailed Parts Book. Please carefully read the instructions in the front of it. All parts are listed by group numbers with item/part numbers for THIS SPECIFIC MACHINE. Order parts in exact quantity. Parts ordered by mistake and returned, are subject to a rehandling charge. RIGHT and LEFT HAND PARTS on the upper frame correspond to the operator's hands at the controls; that is, facing forward and looking out the cab front window. Please state the correct machine SERIAL NUMBER (located on a plate in the operator's cab) when corresponding or conversing with us. Our records on each machine are filed by serial number and when given this number, your specific design and original equipment is both accurate and quick.

When required, ADDED INFORMATION not published in this Manual or the Parts Book, may be obtained from your local service representative or send correspondence to:

Services Department

Marion Power Shovel Division

Dresser I ndustries, Inc.

617 West Center Street

P.O. Box 505 Marion, Ohio 43302

or:

Telephone 614/383-5211

Telex 24-5307

TWX 810/487-2772

Telecopier 614/383-5211

Ext. 2275

Service and labor charges not accepted unless previously authorized, in writing, by Marion Power Shovel Division.

SAFETY TIPS

Safety, the main factor and CONSTANTLY in mind, prevents accidents and near mishaps. Cleanliness and safety go hand in hand, thus making the machine easier to operate, inspect and maintain. A safety conscious crew will carefully read this manual and-:

Create a systematic maintenance schedule and STICK to it.

Develop good, clean habits and erase the bad ones quickly.

Observe and acknowledge ALL warning signs. Ignoring one of these signs could not only be dangerous but fatal.

Keep safe operating procedures in mind at ALL times.

Never take a "short cut" that could jeopardize a life or limb.

Know the location of fire extinguishers.

Never board an operating machine.

Keep away from moving parts.

Never wear loose clothing.

Wear required safety equipment. Keep floors/walkways/ladders clear and free of oil or grease.

OPERATOR TIPS

The operator, controlling the machine for maximumefficiency and production, can "feel" when something is or is not functioning properly. An efficient operator will:

Have required air pressure before starting machine.

Keep safe operating procedures in mind at all times.

Know location of fire extinguishers.

Operate machine on level ground.

Watch air system performance.

Watch clearance in the swing mode.

Never set swing brakes while machine is in swing mode, except in an emergency situation.

Never hold load longer than needed in the dump cycle.

Check limit switches to assure proper "within reason" functioning.

Inform the maintenance crew on any malfunction or "odd feeling".

Never leave the controls until the "Excitation Off" button is pushed and flipping/turning all brake switches to "Set".

MAINTENANCE TIPS

Just as the operator acquires a "feel" for the machine, the entire crew should try to sense failure before it strikes. Take that extra step to examine anything that appears out of place. How about a bubble or discolored crack in the paint? It is an early warning for metal stress or breakage. Could that slight hiss indicate a growing air leak? After all, it i.s easier tq tighten a packing nut than shut down for packing repairs. An alert crew will:

Check operating air pressure.

Wipe away excess lube around bearings and gears.

Maintain correct supply lubricants.

Lube regularly.

Never lubricate parts in motion, that is gears, etc.

Look for and secure any loose bolts or locking devices.

Check all wire ropes for early signs of wear or failure.

Promptly replace all guards, inspection plates, access covers or other safety devices after inspection/repair.

USE EXTREME CAUTION around ANY electrical lines and equipment. This pertains to low as well as high voltage.

Never attempt electrical repairs, unless qualified.

Assure power source is properly grounded.

Check limit switches for proper operation.

Check overloads and thermal breakers.

SUGGESTIONS FOR INSPECTING

PREVENTIVE MAINTENANCE MEANS PEAK PRODUCTION AND LONGEVITY.

Open pit mining equipment undergoes tremendous shock and stress. Marion's design considers these loads. This machine, built with an ample 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. Awareness of unusual conditions generally warns personnel before breakdown occurs. Normal wear takes place over a period of time. Constant checking indicates a wear pattern. An alert maintenance crew checks ALL parts for evidence of stressed, broken or loose parts.

Check for minor cracks in all structures. Early detection and repair will prevent major weld repairs. During cold weather, steel becomes brittle. Make good maintenance procedures essential. A bent or stretched plate often shows in condition of the 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 metal 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 indicates movement and becomes second nature to most personnel. Retighten ALL bolts shortly after initial start-up. Grease and oil stains often indicate problems. Perhaps 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 minimal when compared to breakdown cost and loss of man hours and production.

Production machines operating 24 hours, 7 days every week, should be scheduled for maintenance an 8 hour period every 7 days.

Start up the machine and dig enough to warm up machinery, open the inspection cover over gears and pinions. Look at gear teeth as machinery slowly goes thru its motion. Broken teeth are easy to spot, but splayed or unusual wear pattern takes a closer look.

For a quick check, run a piece of soft wire thru the gear mesh at each side of the pinion. Measure thickness of the two adjacent loops with micrometer. The sum of the two loops 1-5

indicates backlash and gives an indication of misalignment. If excessive backlash is suspected, measure with a dial indicator. There just isn't enough room between gear guard and the pinion to use a feeler gauge.

Slowly rotate the upper frame several times in each direction. Look at condition of roller circle, rail, gear and swing pinion. Sound here may indicate a flat or chipped roller or even suggest burrs or damaged teeth on the swing pinion.

Check condition of sheave grooves and bearings. Test all hold down bolts with impact wrench. Check rope guides and bails for wear. Inspect all rope for broken wire or a loss in diameter. When inspecting the boom point or gantry, check the auto-lube system for loose or damaged fittings. Note injector condition. Properly lube all points; IT'S IMPORTANT.

Inspect bucket/dipper for cracks. Teeth may be reversed with minimal effort to equalize wear... Remove dipper and rebuild in shop for major repairs.

Check main swing gear hold down bolts and torque to specification if required. Test all hold down bolts on upper frame, especially on swing gear case, motor mounting, machinery pedestal and base bolts. Also, check motor generator, air compressor mount and base bolts. Tighten rod bolts on bearing housing.

Examine all brakes, also clutches. 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.

Inspect air compressor "V" belt tension, replace if needed. Fill the anti-freezer and lubricator. Drain water from the air reservoir daily. Check auto-lube system for loose or broken fittings or injectors. Use a hand grease gun at each injector. Fill ALL grease lines and purge EACH bearing with MPG. Remember to replace ALL plugs, covers and inspection plates.

Check center journal thrust washer and bearing. Secure ALL guards andsafety features in place. DISCONNECT POWER SOURCE with machine shut down so electrical crew may adequately clean and inspect 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 tools eliminates broken terminals and terminal blocks. Replace missing or damaged tags and labels. Bundle loose wiring. Fasten ALL components and wiring in cabinets. Assure cable armor is tight in the fixture. Look closely where wires and/or cables pass thru openings and grommets. Insulation damage generally occurs here. Replace grommets if needed. Arcing of motors causes discolored commutators. Look at brushesand brush holder condition. Correct the brush tension where needed. Collector rings also need cleaning and checking. 1-6

This may seem like a lot of running around, checking, looking, inspection, 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 also important. 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.

OPERATION AND MAINTENANCE TRAINING is the best way to reduce downtime and keep your machine in good running condition. Marion's maintenance and operation training experts have produced many different tape/slide workbook presentations to be used as your training guidelines. These comprehensive courses will familiarize mechanics, oilers, operators and other interested personnel in the proper maintenance and operation of your Marion machine.

The overall objectives of Marion's training programs are to increase machine availability thru properly trained and knowledgeable personnel. These objectives are attained using field prov.en training concepts where the student sees, hears and participates in the program. The programs are elementary and covers maintenance instructions for a specific machine, electrical maintenance and general instructions for routine repairs/adjustment of Marion machines.

Further information about these cost-saving programs canbe obtained by calling or writing Marion's Maintenance and Operation Training Section.

CAUTION IS THE BY-WORD

1. Hoist/Swing Joystick

2. Dipper Trip Latch

3. Crowd Lever

4. Wiper Switch

5. Horn Button

6. Transfer Switch

7. PCM XFMRS Stop

8. Excitation Stop Button

9. Excitation Start Button

10. Warning Alarm

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• 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.