CAT BUCYRUS MARION 201-M ELECTRIC SHOVEL MAINTENANCE AND OPERATION MANUAL – PDF DOWNLOAD

Technical Manual

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TABLE OF CONTENTS

WARNING

DUE TO THE DANGERS INHERENT IN THE OPERATION OF ANY HIGH VOLTAGE EQUIPMENT, A SAFE GROUNDING SYSTEM 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 d04bt, for any REASON, your ability to safely perform any of the enclosed maintenance and operational procedures as they refer to your mach ine; please contact Marion power Shovel Co., Inc.

REft.-D 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 mamay not be covered.

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

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 supplied 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 SPECIFIC 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 authorized 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 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 Shovei Company, I nco 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 Mijlrion Power Shovel Company, I nco 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 respective manufacturers thereof.

The Company reserves the right to improve or change the design of its products and specifications thereof and the Company shall incur no liability thereby or any obligations to install such improvements on products previously sold. Page 1 201-M

SAFETY SUGGESTIO.S

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 OBSERVE 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.

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

DO NOT APPLY swing brakes while machine is rotating, except in emergency.

DO NOT HOLD the bucket/dipper load longer than needed in dumping cycle.

DO NOT SE RVICE or lube moving parts.

DO NOT BOARD an operating machine.

PLEASE READ carefully this Manual and Parts Book.

PLEASE LUBE regularly.

PLEASE CREATE A SYSTEMATIC procedure and follow it.

PLEASE WATCH clearance when swinging.

PLEASE OPERATE machine on as near level ground as possible.

PLEASE KEEP safe operating procedures in mind at ALL times.

CAUTION IS THE BY·WORD. Develop a feel for the machine. Try to sense failure before it arrives. Take that extra second to look again at something that seems out of place. A paint chip or bubble may be an early warning. A slight hiss may indicate a growing air leak. It's much easier to tighten a packing nut than shutdown for packing repair.

PROPERLY 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.

MAINTAIN CLEAR walkways.

LOOK FOR loose bolts and locking devices.

KEEP FLOORS CLEAN and free of oil and grease.

WI PE AWAY excess grease and oil around bearings 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 repair.

NEVER attempt electrical repair, unless qualified.

HIGH VOLTAGE power lines require using EXTREME CAUTION.

Open pit mining equipment undergoes 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. Awareness of unusual conditions generally warns personnel before breakdown occurs. Normal wear of machinery parts escapes exact definition. Parts do not suddenly expire. Wear takes place at varying degrees over time. Constant checking indicates a wear pattern. An alert maintenance 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 often 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 MAl N 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 operating 24 hours, 7 days every week deserve an 8 hour inspection and cleaning every 10 days. Cleaning before inspection eliminates dirt and dust falling into machinery parts when inspection plates and covers are removed.

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

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 paces of hoist-lowering: Broken teeth are asy to spot, but splayed or an 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 indicates backlash. Comparing them gives an indication of misalignment. If excessive backlash is suspected, measure with a dial indicator. There just isn't enough room between the gear guard and the pinion to use a feeler gauge.

Slowly rotate the upper works 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 rotating pinion.

While hoist operates, check condition of point sheaves groove and bearings. 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 ALL points, it's important.

201-M Page 4

(Sect. 1 - Eng. Data cont.) Page

(Sect. 1- Eng. Data cont.)

(Sect. 1- Eng. Data cont.)

Material Information: Rail Steel

Austenitic Manganese Steel

Friction Housings

Welding Instructions

Material Symbols and Major Component Parts

Descriptions and Brinells

and Postheats

Welding Cross Reference Table

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 a minimum of four dowels to restrict bushing rotation. Dowel material is softer than bushing.

BUSHING LI FE is figured on the table so that when running clearance exceeds three times the figures shown, REPLACE the bushing.

BUSHING 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 1.0. with white lead. Then PULL the bushing in place.

RUNNING CLEARANCE FOR BRONZE BUSHINGS

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