CAT BUCYRUS MARION 301-M MINING SHOVEL MAINTENANCE & OPERATION MANUAL 2212

Technical Manual

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The FEEDER CABLE must contain a provision for a ground connection, where 2300 volts and above are used. The power line end must attach (see the paragraph on ground circuits) to a suitable permanent ground. The machine end must .$8CUrely attach through a bolted connection to ground the machine frame. This provides a constant ground for the machine and electrical equipment. Failure to provide this adequate ground endangers employees and equipment.

POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CA-'OT BE OVER-EMPHASIZED. Without a good grounding system, high voltage exists between the machine and the ground. The portable cable and power lines su;plying the machine must have a ground wire, ample in capacity, running parallet'tO tlJe main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult the local electric supplier for. details.

Marion 30 1-M Mining Shovel MAINTENANCE AND OPERATION

- Table of Contents -

This manual is divided into major sections covering the various serviceable components and systems of the 301-M Mining Shovel. These sections and their contents are organized as shown below.

INTRODUCTION

Section 1 -- MACHINE SPECIFICATIONS

Section 2 -- OPERATION

Section 3 -- LUBRICATION

Section 4 MECHANICAL ADJUSTMENTS

Section 5 COMPRESSED AIR SYSTEMS

Section 6 ELECTRICAL MAINTENANCE

Section 7 -- ENGINEERING DATA

Section 8 PREVENTIVE MAINTENANCE

Section 9 -- AIR CONDITIONER

Section 10 -- APPENDIX

IMPORTANT NOTE

The informetion end documentetion enclosed were developed end essembled by the Merion Division of INDRESCO Inc. for the limited purpose of releting necessery technologicel meteriel to our customers. The contents herein were developed end produced et substentiel expense end ere velued by Merion Division et e proprietery level. Therefore, this informetion end documentetion is being furnished solely for use with the subject mechine end is not to be used, reproduced or disclosed in eny wey, in whole or in pert, without the prior express wrinen permission of Merion Division of INDRESCO Inc.

Introduction

GENERAL INFORMATION

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.

THIS 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 THIS SPECIFIC MACHINE. Order parts in exact quantity. Parts ordered by mistake and returned, are subject to a rehandling charge. RIGHT HAND and LEFT HAND 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 SER/AL 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 given 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

Service Department

Marion Division of INDRESCO Inc.

617 West Center Street

P.O.Box 505 Marion, OH 43302

or Telephone 614/383-5211

Telex 24-5307

Telecopier 614/383-5211

It is Marion's policy to improve its products whenever possible and practical to do so. The company 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.

SAFETY ALERT SYMBOLS

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, DANGER, and CAUTION graphics mounted on various areas of the machine.

Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definition. 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: ACAUTION:

Denotes extreme intrinsic hazard which exists and could result in high probability of death or irreparable injury if proper precautions are ignored.

Denotes a reminder of safety practices or directs attention to unsafe practices which could result in personal injury if proper precautions are ignored.

An example of a safety alert symbol and special instructions is shown below.

ADANGER: Inherent danger exists in the operation of any high voltage electrical equipment. A safe grounding system includes ground conductors in the power cable, a neutral grounding resistor, and related relays and switch-gear. A ground continuity check system is required by law in many parts of the world.

Operating, maintaining or servIcIng this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skill, knowledge, proper tools and equipment, and that all the methods used 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 effect his eyesight, hearing or reactions.

Safety must always be the most important concern. Consult your supervisor when safety is in doubt.

SAFETY PRECAUTIONS

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, a qualified electrician must lock out or remove the 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, and clothing away from rotating parts.

Do not move or operate the machine without knowing the location and purpose of all personnel, plus test or support equipment, in or near the machine.

Think before you act. Carelessness is one luxury the service man 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.

Never utilize the machine air or hydraulic systems for support when working on the machine. Deactivate and isolatethe system prior to performing maintenance.

Equipment should be parked on level 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 machine, 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 serious injury.

Floors, walkways and stairways must be clean and dry. After draining operations be siJre 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 welding 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 30 psi (207 kPa), 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, or secured in an appropriate storage area.

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 parts in motion.

Operate machine on level ground and be constantly aware of swing clearance. Never hold a load longer than needed in the dump cycle. Use swing brakes only when machine is stopped.

FIRE PREVENTION

Always have a "charged" fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate.

DO NOT smoke while handling flammables or when near batteries.

Inspect all lines, tubes, and hoses carefully. Tighten all connections to the recommended. torque. See the Visual Inspection Schedule for the walk around inspection procedure.

Loose or damaged lines, tubes, and hoses, which leak, can cause a fire.

Make certain that all clamps, guards, and shields are replaced correctly so as to prevent vibration and the rubbing of one part against another which might result in heat build-up during operation.

DO NOT carry flammable fluids such as gasoline or solvents on board the machine.

DO NOT over-bend or strike pressurized hose lines. DO NOT install bent or damaged lines, tubes, or hoses. Replace them with new immediately.

DO NOT start the machine or move any of the controls if a warning tag is attached to the controls or the start panel.

Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.

Keep all structural frame compartments, walkways, and work areas clean and free of lubricant residue.

NEVER weld, burn, or perform service on the machine alone.

If a motor or other component is running hot, shutdown the machine until it has cooled and/or the cause eliminated.

TRAINING

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 training materials are to provide the means for developing and maintaining on-site service repair capability.

For further information about Marion service training capabilities and programs contact:

Customer Service Department

Marion Division of INDRESCO Inc.

61 7 West Center St.

P.D.Box 505 Marion, DH 43302

REPAIR/SPARE PARTS WARRANTY

Marion Division of INDRESCO Inc. 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 examination 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 EXCLUSIVELY REMEDY FOR BREACH OF WARRANTIES AND, EXCEPT FOR GROSS NEGLIGENCE, WILLFUL MISCONDUCT, OR REMEDIES PERMITTED UNDER THE PERFORMANCE, INSPECTION, AND ACCEPTANCE CLAUSE OF MARION'S TERMS AND CONDITIONS, THE FOREGOING IS BUYER'S EXCLUSIVE 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 (INCLUDING 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, INCIDENTAL 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.

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Section 1

Machine Specifications 7

Boom Bumper

Dipper Trip Rope

301-M NOMENCLATURE

Gantry

Front of Machine

Auto Lube Panel (Each Crawler)

301-M LOWER FRAME and CRAWLERS ASSEMBLY

301-M MACHINERY HOUSE NOMENCLATURE

No.2 (6th CabiMla L.--

Hoist Drum Shaft Lba. ""

Rope Reeving Winch 1375 Lba. (625 Kg.)

G4tarcue SlrUcture with Intermediate Holst Shaft 25,580Lba. (11,600 Kg.)

,

Rod, 3 InchTension per Instruc:ti0n8 on page 4.6.4 (4 places)

NOTE: Apply Loctite 271 (or equal) to the threads on this end only.",,-

'"Front of Machine Motor Blower

I Left Holst

"",I Drum Pecleatal 8470 Lbs. (3840 ISg.)

Motor Baae Shims

CapecntW, 1.76 Inch Gr.6 Tighten per Instructions on page 4.6.3.

'screw, 2.0 Inch Gr.8 -Tighten to 7500 Ft.Lba. (10,169 Nm) -4 places.

301-M HOIST MACHINERY ASSEMBLY

Isometric View

Orient Brake Air gOO clockwise from Junction box as .hown.

Orient Motor Junction Box opposite 011 Inlet as 8hown"

Blower Motor

Inlet with Level Indicator _-+ Lifting Eye, 30M (3 places)

Coupling Acce Cover

Planetary Gearca.e

ew.-y310.wpg 301-M SWING MACHINERY

Gear Inspection Door

Boom Point Sheaves

Boom Support Rope Attach Points

Boom

301-M BOOM ASSEMBLY

Yoke Block Assembly

Crowd Gearcase (2 places)

Crowd Motor Coupling and Guard (2 places)

Electric Motor and Blower Assembly (2 places)

301-M ROPE SYSTEM

rope301 1.wpg

COMPONENT WEIGHTS - 301-M SHOVEL

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