CAT Bucyrus 182-M SHOVEL MAINTENANCE AND OPERATION Manual BI005718

BI005718

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI005718

MANUAL 1048

182-M

SHOVEL MAINTENANCE AND OPERATION

MA ION POWER SHOVEL COMPANY, INC. • MARION, OHIO, U. S. A.

Printed in USA

BI005718

BI005718

.-------------------------------

Dl E TO THE DANGERS INHERENT IN THE OPERATION OF ANY HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SA E GROUNDING SYSTEM SHOULD BE USED. SUCH A SY~TEM SHOULD INCLUDE GROUND CONDUCTORS IN T" E CABLE, A NEUTRAL GROUNDING RESISTOR AND RE~TED RELAYS AND SWITCHGEAR. A GROUND CON· Til UITY CHECK SYSTEM IS ALSO RECOMMENDED. W SUGGEST YOU CONTACT YOUR ELECTRICAL SUP· PL ER IN REGARD TO THE ABOVE EQUIPMENT; MARION WI~L BE GLAD TO ASSiSt YOU IF YOU SO DESIRE.

------.

BI005718

TABLE OF CONTENTS Introduction --Basic Machine Front End Equipment Operating Instructions Lubrication .-_._ .__ ... ..

Air Controls -_ ._._ . . .__________ Electric Controls

Section 1 Section 2 Section 3 Section 4 ... _... .

Section 5 ._._.

Section 6 __ .... __ .. _. . Section 7

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182-M

This m nual is to serve as a guide to the operators and maintenance me . To all who service and operate this machine, we recommend a careful reading of this manual. All information, measurements and specifications in this manual have been approved by the Marion P er Shovel Engineering Department and should be followed carefully.

INTRODUCTIOt

This m nual is not to be used when ordering parts. You have been furni hed a repair parts catalogue which lists all parts by group nu bers with item and part numbers for your particular machine.

1.

2 3.

4

The foil wing information is required when ordering parts: Type Serial Number Group or Repair List Number Item r Part Numbers

To spee correspondence please refer tu your particular machine by its serial number, fOund on the nameplate in the operator's cab.

On the pper frame, right hand and left hand correspond to the operator's ight and left hands when he is facing forward. On the lower fram , standing at the rear and facing the crawler drive end, right and I ft correspond to your right and left.

RIGHT AND LEFT HAt PAR

The rep Ir parts catalogue for this machine gives complete information n ordering parts. Order carefully so the right perts in the right uantities can be furnished. Wrong parts, ordered by mistake returned to the company, are subject to a rehandling charge

ORDERING PAR'

No char es for service or labor are accepted unless the work has been p eVlously authorized by the Company in writing.

CHARGES FOR SERVIC LABOR, ETI

MARIO POWER SHOVEL COMPANY, I NC, guarantees the parts man factured by It to be free from defects in material and workmansh p under normal use and service, its obligation under this warran y being limited to making good at its factory any part or parts the eof manufactured by it which shall, within six (6) months after dellv ry of said machine to the original purchaser, be returned to it with transportation charges prepaid, and which its examination shal disclose to its satisfaction to have been thus defective;

STANDARD WARRANt

Section 1

Page 1

.-----BI005718

this warranty being expressly in lieu of all other 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, INC., harmless therefrom.

MARION POWER SHOVEL COMPANY, INC., makes no guarantee or warranty, express or implied, as to adequacy, fitness, quality, or performance of any machine, 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,

NERAL INFORMATION

Preventive Maintenance , ._ .

To insure thet the machine IS ready for operation at all times it must be Inspected systematically so problems may be corrected before they result in serious damage or failure.

We recommend the entire machine be inspected daily. If a condition is noted dUring inspection which would cause damage to the equipment, corrections should be made before operation is continued.

The following check list for daily visual inspection will serve as a guide for operating personnel: 1.

Inspect both tread belts and crawler frames for wear, cracks, etc. Check drive tumblers and tread belt tension, 2.

Visually inspect dipper for excessive wear, cracks, loose or worn teeth and tooth pins, 3 i"'~pec+ (jipper handles for cracks and sufficient lubrication.

4 '/I~l;a:!y tr,spect lower frame for cracks and the main rotating .:jeer onc! r)lr1lc..ns for proper lubrication, 5, Cicek b::Jcm G'Id .::mwd machinery for lubrication and mainte~.

7.

(tc"t • ..,~. ')',~\'':'''': G:~ci :t1oke certain all are operating properly, with sL:H;::ient :Jm:xmt of air output, ,n"peet all revo!Vlng parts on machinery deck, All tools and I::>o~e 't'?ms sh)IJH fie stored In proper place and all guards in

~!ac~~

8

Cnec,,- gear cases for eVidence of lubrication leakage,

Cene;.~,

"';CJusekee;'::lng cf rotating or movable parts IS important.

The proper lubricCJn~ should be used in all cases, bearings, gears, etc, This is according to ASTM specifications, See the follow'~g check list and lubr ication section, Check the auto~at;c !ubrrcotlon svstems Keep the flo<Y frc~ f'om oil and grease I"ICer wolkwo'/s c!ean -:Iear and free of obstructions.

Drevf'r"t the accl!mulation of grease and oil around bearings and geGr,;. Grease and oil collect grit and dirt, which can work into machined parts Keen h:mds and clothing away from moving machinery, :_'~:')fl(~(]tl;m

3 4

5.

Section 1

Page 2

BI005718

182-M

6.

7.

8

Care and sound Judgment are the most Important work rules Chec all bolts, nuts, lock nuts and cotter pins.

Keep all loose objects such as tools and grease guns stored in aloe er or cabinet when not in use.

9. Repo t anything wrong and all signs of trouble to the operator.

He is responsible for the machine 10. Chec , clean and maintain proper oil level in air compressor dally Check V-belt tension, air cleaner, and the anti-freeze in sys em In the winter.

11. Keep II oil and grease ports and covers closed to prevent entry of di and grit.

Safety Pr cautions......... . __ ._ 1. Keep the machine as level as pOSSible. "Rocking action" of the m chine creates unnecessary stresses on the entire machine.

2. Keep the machine close to the toe of the bank to eliminate worki g at the end of the dipper handle.

3 Consi er the safety of the people around machine. Be certain every ne is clear of the machine before moving. Don't swing the di per over personnel or truck cabs.

4. Keep records and check lists for scheduled maintenance, and report necessary repairs to supervisor. Make certain the oiler is aw re of his duties and perfoms them.

5. Keep he pit floor clean with normal digging action.

6. Don't wing the machine while the dipper is still in the bank.

7. Don't ndercut the bank or wait for a loose portion or boulder to fall. This endangers personnel and machinery.

8. Don't teer the machine 180 without stopping. The machine should be propelled forward or backward enough to clean the cr wier belts of rocks. Prevent digging ditches with the crawle s.

9. Strive 0 operate the machine smoothly with peak performance.

Unnec ssary damage to the machine is a reflection on the ope rat r.

10 Don't ttempt to push stalled trucks with the dipper as this could result in damage to the dipper, handles and crowd mecha ism.

0

Section 1

Page 3

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..

SECTION 2 BASIC r.1ACHINE

rawler Tread Belt rawler Tread Rollers

Page 3 ,

"

Page 3

rawler Tread Belt Adjustment

Page 4

teering Clutch

Page 5

ower Frame

Page 7

p~opel 3rake

Page 8

~Ydraulic Ram Cylinder

. Page 10

I

~~Ydraulic System

Page 12

Rpller Circle

Page 15

C~nter Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Page 17

Flrst Intermediate Propel Shaft Assembly

Page 20

I

C~lIector Rings

Page 22

C~lIector Rings (Propel Brake & Steering)

Page 23

M~in Rotating Gear Case

!\Mlin Rotating Brakes In~ermediate Hoist Gear Case

"

Page 24

. . . . . . . . . . . . . . . . . . . .. Page 28 . . . . . . . . . . . . . . . . . .. Page 31

H+ist Drum Shaft Assembly

Page 33

Htist Check Srake .....•.......•...••...•.••.•.......

Page 35

!

Section 2

Page 1

IV

\Q III

o

\J

IV

:J

.... o·

n

III

3

4

(

-

.

Front Roller

-

-"

=-=--

4

(.

Fig. 1 eRAWLER ASSEMBLY

. _._=~=,,=~b==~==-==_·-

I

~=z£;;~~ngB1~k ./i<~ ::d

Roller

-

-n-'<:C""-

2

Drive Sprocket

6_~

2 -

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CRAWLER TREAD BELT

Each craf'ller tread belt has 49 shoes connected with hardened steel pins ~ hese shoe pins are held in place by T-head pins secured by cotter pi s Any JOint of the belt car: be taken apart by removing the T-heod )Ins and driving out shoe pins with a long punch The belt s properly adlusted when about two inches of sag eXist In top of bE It between the front roller and front slide bar and the -; same amour t between drive sprocket and rear slide bar while bottom L)f belt is tight When belt IS too tight, unnecessary wear and loss of power Will r suit. If belt is too loose, tread Will climb drive sprocket, and serious damage may result.

The front roller shaft is mounted in two adjusting blocks fitted Into rectan~ ular openings on each side of crawler side frames.

Shoulder pir s go through both the roller shaft and adjusting blocks anrl extend Jehlnd the blocks. ThiS allows adjustment of the roller shaft. When roller shaft IS properly adjusted, shims are inserted In bock of adJ' sting blocks to hold blocks In place Rrmnining shims orc 'lullr I I front of the blocks.

LUBRICATJON OF CRAWLERS Locotion

No.

Nome of Part

Type

Drr e Sprocket & Gear Shift

2

-

3

---------

-

Lub Locotion of Fittings Aut0matic

Lube System

#1

MPG

4·8

AlJt0matic

Lube System

#1

MPG

4·8

----~-----

----

Fr0 t RolJer

Bushing

Aut0matic

Lube System

#1

Bnt 0m Tread Roller

Bushing

AutC'mntic

Lube System

#1

TC'1l Slide Rails Dri\

SIlr0cket Spur Gear

SIre rng Clutch

Lub Periocl in Hours

Bushing

4·8

MPG -

5

Sf"'

Bushing

- - -----

5th Intermediate Propel Shaft

No. of Fittings

--~~--

4·8

MPG

No Lc,hricati0n Required Fill thl0ugh opening in tap of case.

Level with plug in side of case.

GL

Apply to Spline

Me'

Check Daily f------

Srven tre d rollers, mounted on the bottom of each crawler side frr:nlC distil ute the weight of the machine over the bottom crawler tread belt. he rollers turn independently on fixed shofts bolted to the side fame. Each roller is equipped with a bushing and two br0n7e thrus washers. The spring-loaded thrust washers are forced 0<J 0ln . t the nner boss preventing entry of dirt Into bearings.

Three slic-le ralls, on top of each side frame, support the top crawler treae belt and do not require lubrication Tr: remov a crawler tread roller, move the crawler over a hole deep enough to allow the roller to clear the underside of the side frame Slack off on crawler belt and force crawler belt il1to the hole for ("laugh 0 disconnect the belt.

Remove tre roller shaft lock bolt and block the roller, Drive shaft toward the 0 ltslde of the frame. (The shaft has a stepr:'ed diameter and can be emoved to the outside only) T0 replac a roller, clomp the thrust washers tight cL]alnst the roller with s~ rings and dowels in place Insert the roller assembly be· tween the baring bosses and align holes in roller With those In the Side frar e Insert shaft from the outside, small end first, and lock In place Reconnect and adjust the crawler tread belt.

Keep Coated

CRAWLER TREAD ROLLERS

Section 2

Page 3

.------BI005718

CRAWLER TREAD 8ELT ADJUSTMENT

The two hydraulic jocks furnished with this machine are to be used in making this adjustment.

1. Place one jock on each side of crawler side frame in space behind roller shaft slide and against shoulder pin.

IMPORTANT: Both ends of roller shaft must be moyed at

same time and same amount to keep roller shaft square with crawler side frome.

2.

3.

Section 2

Page 4

Remove cover plate from adjusting block. Take out shims in front of block. Release shims behind block by putting pressure on jocks. Remove rear shims. The roller is now free to be adjusted.

The roller shaft is moved forward by applying pressure to the jacks and moved backwards by releasing pressure on jacks and allowing weight of belt to move the shaft to the rear. If roller shaft does not move when,jacks are withdrawn, propel machine back and forth until adjusting blocks are released.

4.

5.

Move shaft forward or backward until top of belt has proper sag.

After crawler tread belt has bee", r>r~perly adjusted, insert shims in back of adJusting block until back opening is filled. Use the same number and kind of shims on each Side of crawler frame.

6.

Remove Jacks and Insert remaining shims in front of adjusting block. Apply light oil or grease to all parts. Replace cover plate.

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J82-M

Each steerln clutch is a splined collar. Movement of the collar JOins or separa es the fourth and fifth intermediate propel shafts.

The collars moved by shifter levers operated by hydraulic ram cylinders.

To drive m chine left, the left collar is shifted left, and the teeth of the c liar lock on matching lugs on the left crawler side frame locking hat side. This disengages the left fifth intermediate propel shaft fr m the fourth intermediate propel shaft. When the left fifth inter ediate propel shaft is locked, the right fifth inteimediate propel haft will drive the machine to the left.

The machin, when steered to the right, reacts in a similar manner. The ri ht fifth intermediate propel shaft disengages from the fourth inte mediate propel shaft and locks on the lugs of the crawler side fr me. The left fifth intermediate propel shaft will then drive the achine to the right.

A bar, conn cting the two shifter levers, Clilows only one collar to disengage at a time.

No adJustm nt is required on the steering clutches. However, the hydraulic r m cylinders should be checked at regu 10 r interva Is for oil leaks.

After the ma hine has been turned to a new line of travel, forward or reve rse cann t be accomplished until the splines on the fourth and fifth interm diate propel shafts are in alignment and the clutch collar engaged. herefore, it is necessary to move the controller slowIy at fi rst to per it the steering clutch to fully engoge.

STEERING

CLUTCH

Second Intermediate Pr?pel Shaft

ropel Brake

First Intermediate 12

14

12

Third Intermediate Propel Shaft 11

Fourth Intermediate Propel Shaft

15

Sliding Clutch

Fifth Intermediate

7

13

Fifth Intermediate Propel Shaft

Propel Shaft

7 16

16

Drive Tumbler -T~

6

Sprocket Shaft

Fig. 2 PROPEL GEAR TRAI N

Section 2

Page 5

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ClI

"

C

01 C

;:

ClI ClI

Vi

~

0

~ 01

C

;; 0

0

L

O!

~

c

U

0

01

::l

~

!ction 2

.§ ClI ClI

'Vi

1M

~

«GIl: Yo

GIl:

1M

~.

...0 M

Page 6

'".2' Yo

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'82- M

LUBRICATION QF LOWER FRAME Type

No. of Fittings

Bushing

location

No. II

Ne me of Port Third In ermediate Propel Shaft

Locotion of Fittings

lub Sym

lub Period in Hours

-

Automatic Lube System #1

MPG

4-8

-

Automatic Lube System #1

MPG

48

-

Automatic Lube System #1

---~--

12

PrC'[1el Bake Shaft

13

Fourth Ir termediate Propel Shaft

Bushing - -

Bushing -~---

14

15

Gear Co I' at Center of Lower Frome (2nd & 3rd Shafts)

-

-------+-----_. --

Gear Co \> at Rear of Lower Frome (3rd & 4th Shafts) -

16

1-- -..

Steering

-

----

-

- - . - - - - - - 1 - - - - --- - -

lutch Shifter Fork

Plain

MPG -._.

---

Fill at plug in side of case (reach from under lower frame) Fill through opening in top of Qear case, capacity - 7 gallons -------

---~-----

Automatic Lube System #1

.

-

----

GL

Seasonal Change

GL

Seasonal Change

1-----

--

MPG

4-8

Section 2

Page 7

.-------------BI005718

PROPEL BRAKE

The propel broke is used as a "chocking" brake to hold machine while parked and against shovel crowd reaction. The brake is spring set and released by a hydraulic cylinder.

The brake consists of two brake shoes, four friction blocks, the brake housing, and a toggle linkage.

The brake housing is mounted on a shaft that extends horizontally from the third intermediate propel shaft through the front wall of the lower frame. A pinion on the propel brake shaft meshes with a gear on the third intermediate propel shaft.

PROPEL BRAKE ADJUSTMENT

The propel brake is set by pulling the two links to a near-straight line or toggle.

As the friction blocks wear, these points approach a straight line.

To compensate for wear, loosen jam nuts and adjust turnbuckle between the two clevises. When brake is set, point "A" should be about one inch from the line formed by points "B" and "C". (See Illustration) Adjust stop screw until clearances between the brake shoes and the brake housing are equal when brake is in released position. The propel brake shoes are equipped with oilite bushings.

No lubrication is required.

FRICTION BLOCK REPLACEMENT

IMPORTANT: Block machine or park on level ground before proceeding.

1. Loosen set screw at side of hydraulic cylinder.

2. Back off sleeve of cylinder to relieve initial compression of spring.

3. Remove shoulder bolt, and pivot lever weldment up.

4. Remove pin from clevis and pins from brake shoes.

5. Remove old rivets and blocks from shoes and install new ones.

6. Return brake shoes to housing.

7. Insert pins in clevis and brake shoes.

8. Turn lever weldment down and bolt to lower shoe.

9. Screw cylinder sleeve in to original position and lock sleeve with set screw.

10. Adjust toggle Iinkage on propel brake.

LUBRICATION OF PROPEL BRAKE l"r.,ti,," ~".

Name of Part Links and pins

18 -

19

Section 2

Type

N". of Fitting.

-

-

Oilite

-

'.

Brake Shoe Pivot Pins

Page 8

... -

location of FItting. e..-.

luh $ym

Luh Perioel In HOUri

--

MO

Keep Coated

---

-

No Lubrication Necessary

0.{)

(1)

"U 0 CO

IV

::J

0"

....

n

(1)

Vl

I

A

C

//

/

1"

/

B

Linkage

~.

\ ,,!

\

\

~

Fig. 4 PROPEL BRAKE

Shoulder Bolt

I' \

II

I\ < \\ '~

\

\\' ' ~\ \

\-..

/

\\

(18i

"

,I

\1..

1

1//)

1/ ,~

Sleeve

VI~r

Brake Shoe Pins (19)

Friction Block

~--- Stop Screw

-----

Broke Shoe

Set Screw

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·-------------BI005718

If hydraulic ram cylinders in lower frame fail to work properly, check for hydraulic oil leaks. Leakage will indicate loose or worn packing in ram cylinder. . To tighten or replace packing: 1. Loosen set screw at side of cylinder. A block of soft metal under set screw protects sleeve threads.

HYDRAULIC RAM CYLINDER

tion 2

\

Pocking

~

Set Screw

L

Spring Retainer Sleeve

Pocking Cup

Cop Screw

Fig. 5 RAM CYLINDER

2.

Back off sleeve from cylinder to relieve initial compression of spring.

3. Remove cylinder head.

4. Remove cap screw and lift off packing cup.

5. Remove necessary shims and reassemble 6. Tighten cap screw.

7.

Replace cylinder head.

8. Screw sleeve in full length of threads 9. Lock sleeve with set screw.

If removal of shims does not tighten packing enough, install new packing, cup, and chevron packing.

Page 10

---f-----------.

NOTES BI005718

,

. l

Section 2

Page 11

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HYDRAULIC SYSTEM FOR PROPEL BRAKE AND STEERING CLUTCHES

Hydraulic ram cylinders release the propel brake and operate the steering clutches. These cylinders are powered by a hydraulic system on the rear of the lower frame. Electric control for the system is in the upper frame. This system consists of a motor-driven hydraulic pump, three hydraulic ram cylinders, the required pipe, fittings, and a supply reservoir.

The hydraulic system is controlled from the operator's station and is connected to the fi rst intermediate propel clutch on the upper frame. When the first intermediate propel clutch is engaged, the hydraulic pump motor is activated and the right hand solenoid valve is closed, shutting the line from the propel brake cylinder to the supply reservoir. As oil pressure rises to 250 psi, the propel brake ram cylinder piston moves out and releases the propel brake. When the first intermediate propel clutch is disengaged or power failure occurs, the hydraulic pump motor stops. A spring then opens a solenoid valve, allowing oil to return to supply reservoir from the brake ram cylinder. A spring built into the ram cylinder then sets the brake.

The hydraulic pump motor must be in operation to steer the machine and release the propel brake. Movement of the selector switch in the operator's station will cause a solenoid valve to open the pressure line to the proper steering ram cylinder.

Oil pressure in the hydraulic system will cause the steering ram cylinder to move a shifter lever. The shifter lever will disengage the clutch and lock the fifth intermediate propel shaft to the side frame. When the selector switch is turned off the solenoid valve will open. The spring in the cylinder will force oil out and pull the piston in. This will engage the steering clutch to the fourth and fifth intermediate propel shaft. The machine is now ready to move forward or backward.

HYDRAULIC SYSTEM CARE

1.

2.

3.

4.

5.

6.

7.

8.

Section 2

Page 12

Use hydraulic oil specification "HO". See Oil Specification in Lubrication Section in this manual.

Keep all joints tight. Check carefully for leaks.

If relief valve becomes noisy or pressure does not remain constant, remove valve for inspection. Replace worn parts or entire valve.

Should pump fail to develop proper pressure, make sure valves are closed and look for worn or leaky parts.

If solenoid valve fails to operate, valve should be taken apart and cleaned. Worn and damaged parts should be replaced.

Clean oil filter once a month unless unusually dirty conditions warrant a more frequent cleaning.

Ojl in system should be changed every six months or sooner, if operating conditions are extremely dusty or dirty.

Capacity of HYQraullc System is 5 gallons. Care should be exercised when filling system to bleed the air from all lines and cyl inders.

----+------.

BI005718

Propel 'Jrake Cylinder Solenoid Valves .I }-

I

Steering Cylinder

~

Steering Cylinder

I

Pump

Reservoir

~ ;[1-_--i.J _ _-", PROPEL BRAKE RELEASE

R. H. STEERING

Ii

r-' J.,, Jh..d1r]~::__ ---~_-_ _... i

I

,

L. H. STEERING

Fig. 6 HYDRAULIC CONTROL DIAGRAM Section 2

Page J 3

Vl til

~

til

(Q

o

-u

N

::s

o

....

n

\

alves

.

I

(-'-I

Propel Brake Cylinder

-

I

-

. .

~

Mo,o,

~

Oil Filter

Fig. 7 HYDRAULIC PIPING

.r'['

Relief Valve

-'---

~

I

!,

~

/ 'it ---,

/1

LI

r--

Shifter Lever

Steering Cylinder

. ---"jJg11

~, -~lf-:~~

--- Ii

~-~----- ~

Pump

~ ~~_ Hydraulic

-c

~

/ /'/ . - '

..."c',

~ ~l)-~::_~~.

.

.

1 1 =__.~f _B--:~-C'C'CJ:-C=~J.,. .~~ ... _.c~ c"~ cfi~"'-

"if.

u~

if'

Supply Reservoir--"

Cylinder Solenoid V

?~t::mg

Steering Cylinder

1-

'€

u ):u

~

~i,:'

BI005718

-------.

BI005718

I l The weight Oft the upper frame and front end attachments is carried on 42 fla ged rollers. The rollers revolve between a bar, a channel, and two rails. The lower frame roil forms a full circle and is welded to the . ain rotating gear. The upper frame rail consists of a front and b ck section. Each section has two rail segments welded to a plate hich is bolted to the upper frame weldment.

The circular brand channel have three sections each, and these sections are joined by splice bars. Each roller turns independently and is lubri ated by the automatic lubrication system A flat or splayed roller must be replaced. Keep roller roils clean and lightly coated with dilut d open gear lubricant (OGU. At the beginning of each work shi t, rotate upper frame one full turn to change position of the rol ers.

ROLLER CIRCLE

Upper Rail Roller Channel ~----.

Ma,., Rotating Gear

--------~ Splice Bar

---.~--

-- lower Roil

17

Fig. 8 ROLLER CIRCLE

Section 2

Page 15

.-----BI005718

\ " ' ' ' ' 8m

~,

Roller

\

/~

Roller Shoft

BOlts

Bar

Chonnel

20 -

Fig. 9 ROLLER CIRCLE

LUBRICATION OF ROLLERS Ho. of Fittings

l,,~~tio"

Home of Part

Ho. 17

20

Section 2

-~---

Rollers

Page 16

-

-

Roller Poth -_.-

Type

--~._.~.

"-"-----"- f-----

Ploin

_.- f-

Location of Fittings Apply to Part

---- - r - - - . - - - - - - - - - - "

-

Automatic Lube System :it 1

lub Sym

Lub Period in Houri

Diluted OGL

Keep Cooted ._---" 4-8

MPG

BI005718

182 -M

CENTER JOURNAL

The upper and lower frames are connected by the center journal.

The Journal kee~~ the two frames in concentric alignment and absorbs the stresse, of digging reaction The lower end of the journal IS flanged and I held against a shoulder by a two-piece retainer bolted to the lower frame. The journal is keyed to the lower frame to keep the JOUrn I from rotating. The top of the journal is threaded.

A nut holds the l pper frame on the journal. With the weight of the rotating frame e\ enly distributed on the roller circle, tighten nut by wedging a block bf wood between the lug on the nut and the hoist machinery fram€ and slowly rotate the upper frame about the center Journol ur til the running clearance is Ys inch between the lock plate and sloulder bushing. Check with feeler gage The nut IS locked by boltirg it to a lock plate lugged to the center Journal.

Rotate machine ( full circle to make sure there is no binding.

The second int rmediate propel shaft fits inside the center journal and IS mounted i bushings. The top of this shaft is threaded, and o nut IS provided 0 hold shaft in place. Adjust the nut until running clearance under tle nut exceeds the clearance of the center journal nut Tipping load will then be taken by the center Journal nut and not the propel sh Jft nut. The propel shaft nut is locked with a set screw A soft m tal plug under the set screw protects the shaft threaas The nut IS reversible if greater take-up is required.

Two-piece shlr s are placed between the gear and the thrust washer to obtain proper mesh or to remove backlash of the bevel gear and bevel p nion. To Insert or remove shims, the brass studs must be removed The first Interlnediate propel shaft assembly is located on the upper frame to t e right of the center of rotation The assembly c,nSlsts of the pr pel shaft, intermediate propel gear, a hevel gear and sliding clutd. The first intermediate propel shaft is supported at the left end by an anti-friction tapered roller bearing and on the right end bv an anti-friction bearing. Procedure for assembling beorlngs with spa er: 1 Press In cps.

2 Assemble ones, clomp uSing J-131514 until bearings bind sllghtl\ (Jllvailable from Marion Power Shovel Co) 3 Measure C Imenslon between cones using Inside micrometer at 3 POint 120 apart, and calculate average. ,1.

Grind spac r to above dimension plus 0.003 to plus 0.004 inch. ') Complete pssembly

LUBRICATION OF CENTER JOURNAL lub

lub Period

location of Fittings

Sym

in Hours

Bushing

Automatic Lube System # 1

MPG

4-8

Automatic Lubr System

l(')('f'tt;on

No

Nom

of Part

23

Center JOl rnal In Lower Fame

Type

24

Crntrr Jm rnal in Upper Fame

Bushing

?5

Bevrl Gear Thrust Washer

Bushing

14

Geer Case pt center of Lower Frome ( nd & 3rd Shafts)

No. of Fittings

#1

-~_._----+._---

26

---~---~- i--------.-+----l---~-

Bevel Gear Teeth (Top)

Section 2

Page 17

.-----BI005718

Propel Shaft Nut J~"

26

Bevel Gear

Center Journal Nut

Shims

Lock Plate

Running Clearance

' 8"

,

~~=----==------:J) -

Shoulder Bushmg

------"

24

24

/

Upper Frame

Center Journal

25 '

_

I1~H:---------_2nd Intermediate

Propel Shaft

Lower Frame

23

14

Retainer

-----

Fig. 10 CENTER JOURNAL PREVIOUS DESIGN

Section 2

Page 18

BI005718

182-M

Propel Shaft Nut

/ 1

'4

II

Bevel Gear

Center Jo urnal Nut 1H"

Running

Clearance

Lock Plate

Shoulder Bushing

24 24

-

Upper Frame

Center Journal

2nd Intermediate

25

Propel Shaft

25

Lnwer Frame

~_ --~-------I ~-

23

Retoiner

14

Fig. 11 CEtr..· ....TER JOURNAL

CURRENT DESIGN Section 2

Page 19

.---------BI005718

FIRST INTERMEDIATE PROPEL SHAFT ASSEMBLY

The propel gear is mounted on the shaft on two anti-friction tapered roller bearings, so it rotates freely around the shaft. The intermediate propel gear meshes with the helical gear on the hoist drum shaft. The propel gear has on integral gear type clutch with internal teeth which mesh with external teeth on the sliding clutch.

The sliding clutch has internal splines which slide on the shaft.

When the clutch is engaged with the intermediate propel gear, the first intermediate propel shaft turns. The bevel gear, splinedto the shaft, meshes with the bevel gear at the top of the center journal.

Power to propel is suppl ied by the hoist motor. The clutch is moved by a shifter lever actuated by an air cylinder. The clutch adjustment is factory set. To prevent the cylinder from acting too fast, a restricting nipple is provided between valve and cylinder to restrict air flow.

Keep this opening clean.

Shifter Lever

\I~ I

1

Air Cylinder

Limit Switch

Fig. 12 SHIFTER ASSEMBL-,

Section 2

Page 20

.

----+-----.

BI005718

,.-

Anti-Friction Bearings

64

68

) Ii,,,,,,,~ I t

\

~0:''',\''W ~'/////b

67

~

'\

~ ~"////'" // ~/~,~~,,~ ~,~~.

,X:'i~T-'

/mmw-r~ ~ - --

l ' I L

~

-

..-1-

-

<t;,: ,....., ~~

:

~J JJJ>

~

~ 63

- -

If

65

;;.L

w

-

~

'=;

~

~

~

66

Helical Gear

Sliding Clutch Collar

Bevel Gear

Fig. 13 FIRST INTERMEDIATE PROPEL SHAFT ASSEMBLY

LUBRICATION OF FIRST INTERMEDIATE PROPEL SHAFT Location No.

Ne me of Part

Type

63

Intermec iote Propel Shaft Suppa t Bearing (Right)

AntiFriction

64

Intermec iote Propel Shaft Suppa t Bearing (Left)

AntiFriction

No. of Fittings

Location of Fittings

1

In Bearing Retainer

--- -f-

65

Lub Period in Houri

MPG

500 .~--

- - _ . _ - _ . _ ~ ~

In Bearing Housing

P;~;~I ( ear (Helical)

AntiFriction

1 ---

Clutch ~ hifter Collar

Plain

1

500

MPG

~-

_ ...._ 66

1

Lub Sym

-_.-._---.~~.-

In R.H. End of Shaft

500

MPG

---'~---'---~~-~-_.

-

_

.

_

-

~

~

-

In Shifter Collar

MPG

4-8

Apply to Splines

MO

Keep Coated

OGL

Keep Coated

~--_.--

67

Clutch ~ pline - -

68

-

I----~~---_._--

-

Bevel G or Teeth

~

~

~

~

.. - f--

-~.

1----

~ ~ . _ -

Pins onc Links

Apply to Teeth -~~---'--~.-

-

-

Apply to Port

-'

--

~~--

MO

Section 2

Keep Coated

Page 21

.-------------BI005718

MAIN COLLECTOR

RINGS

The main callector rings provide connection of the power supply between the upper and lower frame. These rings are concentric. with the center journal and are connected by insulators to the underside of the upper frame.

The brushes are anchored to the lower frame and are connected to the trail cable. The brushes are spring-loaded and replaceable.

The rings pick up power from the brushes and transfer it to the upper frame electrical equipment. Each ri'ng has two brushes located 180 0 apart to ensure contact at all times.

With power OFF, inspect rings and brushes every 30 days. Keep clean and free of grease and oil.

WARNING Due to the dangers inherent in the operation of any high voltage electrical equipment, a safe grounding system should be used. Such a 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. We suggest that you contact your electrical supplier in regard to the above equipment; Marion will be glad to assist you if you so desire.

Upper Frame

Brush Steel Rings

Brush Support

Fig. 14 MAIN COLLECTOR RINGS Section 2

Page 22

BI005718

182 M

-

Steel

Collector Rings

ing

Brush

Brush Support

Fig. lS COLLECTOR RINGS (Propel Broke & Steering)

The collec or rings provide the electrical connection between the upper and I wer frames for the control circuits that operate the hydraulic sys em for the propel broke and steering clutches.

Six large iameter brass rings ore bolted to a steel ring which is welded to he top of the lower frame. These rings are concentric with the cen er journal. Two sets of six brushes each are bolted to the undersid of the upper frame. A set is installed on each side of the mach ne to ensure electrical connection at all times. (See Electrical Se tion for core of brushes.)

COLLECTOR

RINGS (Propel Brake and Steering)

Section 2

Page 23

BI005718

•

----------------..I. t--MAIN ROTATING GIAR CASI'

Rotation of the machine is powered by two vertical mill-type motors mounted on identical gear cases at the front of the upper frame. The first intermediate rotating shaft, mounted in two antlfriction bearings inside the gear case, has a large diameter gear on the top which meshes with the motor pinion and on integral pinion at the bottom.

The integral pinion of the first intermediate rotating shaft meshes with the gear on top of the main rotating shaft. The main rotating shaft is mounted in two anti-friction bearings. A pinion, splined and bolted to the bottom of the main rotating shaft, meshes with the main rotating gear bolted to the lower frame weldment.

The direction of rototion is determined by the rotating direction of the motors.

The bottom anti-friction bearing for the intermediate rotating shaft and the top anti-friction bearing for the main rotating shaft are lubricated by the gear oil bath. A double oil seal is provided under the top bearing of the main rotating shaft to retain oil in gear case. Oil capacity of gear case is 51 V2 gallons checked by dipstick. A globe valve, located near the rotating pinion below the frome, is provided to drain the lubricant from the gear case.

MAIN ROTATING GEAR

The main rotating gear is. bolted to the top of the lower frame weldment. The lower roller circle rail is welded to the gear.

The pinions on the bottom of the main rotating shafts mesh with the main rotating gear cQusing the upper frame to rotate about the lower frame.

The main rotating gear is lubricated by the Automatic Spray Lubricating System.

LUBRICATION OF ROTATING GEAR CASE Location Ho.

Ham. of 'art

Type

Ho. of "ttln..

-

30

Main Ratatfng Shaft (Top Bearing)

AntiFriction

31

Main Rotating Shaft (Lower Bearing)

AntiFriction

32

Intermediate Rotating Shaft (Top Bearing)

AntiFriction

33

Intermediate Rotating Shaft (Lower Bearing)

AntiFriction

Rotating Gear Case Main Rotating Pinion

--

34

Lub Location of Fitting.

----

36

Section 2

~-

Rotating Pedals (Not Shown)

Page 24

Lult ,.'""'

III Heu..

Gear Case Oil

Oil Both

-

2

Pipe to Deck Between Gear Cases

MPG

500

2

I" Top of Gear Case

MPG

500

-

Gear Case Oil

Oil Both

-

-

-

Fill Through Breather Pipe

51 Y2 Gal. Change

-

-

Automatic Lube System #2

AntiFriction

-

In End of Pin

GL

Seasonal

Capacity

-- - - - -

35

Sym

-

-

MpG

500

!'..>

10 lb

o

"'0

IV

:J

n.....

0"

VI lb

30

31

,/

Shaft Pinion

Main Rotating

Shaft

Main Rotating

O,i Seal

Double

Gear

Shoft

Rotating

Main

.---'-

I

~

j

,

~

~L

----=-7

.

7

j

'

,

[I

I',! I ii,

,

" ,

".-

l

r-

I'

,

-J

35

"J~r

33

Vi

t~

"

i'

.....

_L

Drain

PREVIOUS DESIGN

Pinion

Intermediate Rotating

17

Oil Level

H~------- Gear Case

/ ' Dip Stick

Intermediate Rotating Shaft

;J :d

'e

-=-t

._ _

f

Main Rotatina Gear

~" - .~."''''"-~~~

'_ ..f=C~-'-

I

,ra.",

.ic~j ! . - . .-~ ~-i'l ..

Fig. 16 ROTATING GEAR CASE

-

".--1f',

~

Breather

·F -" . __

J----'-ftt 1. ).1. -,'-, -,-,~~,.~.'. --i.----,'_-----==--==11 \_=-~_~_ "

r:~----J" I il:if---'. ,/ I III:. . .', ,._~-., ',1 11 'll

' -ffL__ : F-

/ ,

'

!

, -l IhftTI,j'4 ":! ~ ~~"d_~

II-rjL : rl,HTI '

~ J

'

I

- -~AS/.:

-'--~ ~--/l~Fi' ~" ~

r~~

--.,.:J

Rototing Motor Shaft Pinion

BI005718

0-

IV

10 III

o

"U

Main

31

Shaft Pinion

Main Rotating

Shaft

/'

~'j

Main Rotating

Oil Seal

Double

30

Gear

Shaft

Rotating

.. ~

.1

. -l

'.1 .~

~---

y/ /~

~

""., fi"

"

-1

35

";

~,:F :t~·

'

~x~

C. ._ '

r.; .

'

33

'"

f

/'

Drain

Intermediate Rotating Shaft

CURRENT DESIGN

Pinion

Intermediate Ratating

17

Oil Level

Gear Case

Dip Stick

Intermediate Rotating Gear

Breather

Main Rotating Gear

....,.:;.}-

1

-.

n ~\,.uc4

. r'.""·:fj

C.~ t; ,::;.'

·'1·"'

j1J

-.=.,c•.)"

~'l'·! \ .

34

32

Fig. 17 ROTATING GEAR CASE

"":F~:

i

Shaft Pinion

IV

r:

Rotating Motor

J

n .... o·

v.

III

BI005718

BI005718 · /.'

NOTES-+---

_

~_____.;

Section 2

Page 27

.------

BI005718

MAIN ROTATING BRAKES

Main rotating brakes are mounted on each rotating motor. These brakes are not to be used to stop or retard rotating motion. Rotation is stopped by plugging or reversing the rotating motors. (See Operation Section for details.) The brake is released by an air cylinder and set by a double compression spring assembly. Each brake consists of two brake shoes with friction blocks, an air cylinder, a double compression spring rod, a support rod, and the brake housing which is keyed to the extended shaft of the rotating motor. Each brake is supported by a notched ong Ie iron attached to a base plate bolted to the top housing of the rotating motor.

Adjustment of Main Rotating Brakes 1. Set brakes.

2. Turn piston rod adjusting screw (A) until friction blocks barely touch brake housing.

3. Loosen locknuts (B) on each end of spring rod and adjust nuts (E) until each spring measures 4 and 25/32 inches.

4. Tighten locknuts (Bl. The assembly will automatically balance tension between the two springs.

5. Push and hold piston in against end of cylinder.

6. Tighten locknut (F).

7.

Release brake and loosen locknuts (G) on support rod.

8. Adjust sleeves (e) until friction blocks are evenly spaced around housing with Va inch minimum clearance. There should be 1/.1 inch clearance between washer (0) and the guide block at spring end of support rod.

9. Tighten locknuts (G) on support rod.

These brake assemblies do not require lubrication and should not require additional adjustment to compensate for wear.

Replacement of Friction Blocks 1. Disconnect air line and remove complete brake assembly.

2. Remove support and spring rod assemblies.

3. Lift brake shoe assembly from around housing.

4. Remove snap rings from pivot pin of brake shoes, and remove pin.

5. Remove old rivets and blocks and install new ones.

6. Put brake shoe assembly together and return to housing.

7. Install support and spring rod assemblies and connect air line.

8. Test brake.

LUBRICATiON OF ROTATING BRAKE on Name of Part , Links & Pins

ction 2

Page 28

Type

No. of Fittings

-

-

Location of Fittings

---

Lub $ym

Lub Period in Hours

MO

Keep Coated

---..-.-----..--_---.

BI005718

Air Line

Cylinder

Spring

B A

E

Spring

ad

E B

Support

R d 3fl

FrictIOn

B/o k

G

c Broke Hou:;ing Broke Sha

'0· ..

, \

Shae Support

Pivot Pin

." ~

Base Plate

Hrake Shoe

Fig. l8 MAIN ROTATING BRAKE

Section 2

Page 29

Vl 111

... o

o

W

111

(Q

o

"U

IV

:J

n

"-

..

~.

Intermediate Hoist Pinion

Gear

Intermediate Hoist

41

Shoft

~

~~

40

0

:r="

/'

0

o

t:

...-

0

1/

40 Pinion

Hoist Motor Shaft

Flexible Coupling

Hoist Motor

Hoist Motor Extension Shaft

Fig. 19 INTERMEDIATE HOIST GEAR CASE

41

Hoi"

Intermediate

t

BI005718

--+------.--_-------.

BI005718

INTERMEDIATE HOIST GEAR CASE

Power or hoist and propel is provided by a horizontql mill type motor T e hoist motor shaft is bolt~d to a flexible coupling joining the hoist motor shaft and the hoist motor extension shaft. Integral teeth on he hoist motor extension shaft mesh with the helical gear splined t the intermediate hoist shaft.

The ho st motor extension shaft is mounted in two tapered roller bearings The intermediate hoist shaft is supported by tWQ doublerow taper d roller bearings,. All bearing retainers are bolted to the gear cas The intermediate hoist shaft pinion meshes with the hOist dru gear keyed to the hoist drum shaft. The pinions have been carefully set with proper backlash.

To che k backlash, refer to CI-784, Installation and Operation of Open nd Semi-enclosed Gear Sets, included with this manual.

The hoist motor shaft coupling hub must be seated against the tapered otor shaft as tightly os possible, and the motor extension shaft hub pressed onto the shaft with a key. (Refer to CI-772 in back of t is manual for recommended shrink procedures,) Lubrica e coupling according to manufacturer's specification in this man al.

Check il in gear case weekly. Oil should be kept level with plug in siqe of gear case (35 gallon copacity) To fill ge r (Gse: 1. Remo e breather from gear case cover.

2. Remo e pipe plug from side of gear case.

3 Fill with oil through hole in cover until it begins to overflow from r:;ide hole.

4 Repla e plug and breather.

I-UBRICATION OF INTERMEDIATE HOIST GEAR CASE ..-.----~-+------...,---...._---...._--_r------------....,...,...---r_-location lub No. of No. Nome of Part Sym Type Fitting, Location of Fittings

40

f- oist Motor E¥tension Shaft

AntiFriction

Gear Case Oil

~'--.~-~-~~----~ ~ + , - ~ ~

41

I termediate HOISt Shaft

42

(ear Case

----~-

-

---~--~

Anti.

Friction

--

2

-

Oil Both

-,~----~-

4 - - - ~-,

MPG 500 - ---~ ~- e----GL Seasol 35 Gal Chan

In Top of Bearing Boss

,-~-

Fill through Breather Pipe See Manufacturer'$ Specifications See Manufacturer's Sper;ificotions

\

Section 2

Page 31

/1)

..

Vl

IV

W

/1)

(Q

o

-0

IV

:J

0'

n

11

/L

I

.

.

i\\L

'

"]

)l=JU

49

Brake

Drum Lagging

51

Fig. 20 HOIST DRUM SHAFT ASSEMBLY

50

Clutch

Drum Shaft

Drum Lagging Hub

48

Rotary Air

Spur Drive Gear

Air Cylinder

Helical Gear

Seal

BI005718

BI005718

The hoist drum shaft assembly consists of the shaft, a helical gear, the d um clutch, two spur geors, a drum lagging, and the drum hub. Irhe assembly is mounted on two double-row tapered roller bearings. The bearing housings are bolted to support pedestals.

The hel ic pi gear is keyed to the right end of the drum shaft. A spur drive g or is bolted to a flange ~f the helical gear. The drum hub, mounte~ on bushings, is next to the large gear. Thrust washers are doweled on each end of the hub A spur driven gear is bolted to the nght dn m hub flange. The drum lagging is in two pieces for easy remova and bolts to the drum hub. The drum check brake housing is bc Ited to the left flange of the drum hub The hoist wi re rope IS anchpred with five "U" bolts to each flange of the drum fogging.

The hoist drum clutch is used only to release the drum while operating pre pel mechanism. The drum check brake wi II set when clutch is relepsed. The drum clutch is a sliding collar activated by two double-a ting air cylinders. Internal teeth on the sliding collar mesh with -ex ernal teeth on both spur gears.

The clutch is adjusted by changing the position of the air cylinder piston rod CIE vis until the edge of the clutch, in released position, IS flush with he edge of the spur drive gear. Keep all sliding surfaces lightly ooted with oil.

HOIST DRUM SHAFT ASSEMILl

LUBRICATION OF HOIST DRUM SHAFT Location No.

48 - -

49

-

-_..

51

Lub Perle hi Houn

1

In top of Bearing Housing

MPG

500

Anti· Friction

1

In top of Bearing Housing

Bushing

2

In Hub of Drum

Fittl"g~

Ho st Drum Shaft Support eo ring (Right)

Anti.

Friction

Lub

-- -----.--

---

Ho st Drum Shaft Support eoring (Left)

--- f------.--- - .

La . ging Hub Support Bearings ._~-

f-----

.

-.

. ..

__

-, ..

--'--'

_.~-_.--.'--

Ho st Drum Drive Gear ~"---

52

$ym

Type

...

50

LOCCltion of Fitting.

No. of

Name of Part

._-,._------

Dn m Shaft Clutch Teeth

"'r-_

~.

- ._--_ ..

~-

-

I·

MPG

500

MPG

4-8

OGL

Keep Coate,

MO

Keep Coote

Section 2

Page 33

-------- .._..

.---.--._--_.~~--~

Appl\! to Gear Teeth -.

Apply to Teeth _T'

.~---

-f----

BI005718

.~-------~-------------Check Bond Support

Spring

Check Adjusting Nut

Bond Check Bond

Spring Rod

Support

/

/

Stop Bolt

. Check

~~

Bond Dead End

~

-

Friction

57

Live

Lever Arm.~

End

55

..~ ~.

///

56

58

~~/ ,

Block

~'\

tz~

!

Retaining Bar

<\

" Y":

,,\,

,J

"'

Keeper

.~ Check Bond

Air

1-/'

Cylinder Set Spring

--I'

/ 2' -

~-11 /16_"I -

59 \.- Friction Blocks

Fig. 21 HOIST CHECK BAND

)

Section 2

Page 34

BI005718

LUBRICATION OF HOIST CHECK BRAKE Lull P.rl

No. of

LocatiOll

No.

Type

Nome of Part

55

C evis & Pins

56

H ist Check Band Anchor (Dead End)

57

H ist Check Band Anchor (Live End)

hI Hou~

Location of Fitting.

FItting.

Apply to Parts

MO

Ploin

In Eye of Anchor

MPG

Ploin

In Eye of Anchor

MPG"

Keep Cootl

40

- ---~----~ .---~~---f-------f~-~-

58

Br ke Lever

Oilite

No Lubrication Required

59

R lIer

Oilite

No Lubrication Required

HOIST

The hoist heck brake consists ot the band, friction blocks, brake housings, spr ng rod, air cylinder ond the set spring.

The releCJs cylinder and set spring are mounted on the deck inside the Ie t hoist drum shaft support frame The dead end of check ba!1d is pinned to the or'll:hor weldment. A, spring rod connects the two piece of the check band The live end of the band is secured to a lever ar , which pivots around a pin in the weldment. The other end of he lever arm is connected to the air cylinder and set spring. The c eck bond tightens around the brake housing, which is bolted to th hoist drum hub. Eighteen friction blocks are attached to the check and by bolted keepers The hoist check brake is air released and pring set. The brake is operated by a solenoid valve controlled at he operator's station.

CHECK BRAKE

~I

--.-

Dead End

..__-

li ve End

Fig. 22 HOIST CHECK BAND LEVER & SPRING Section 2

Page 35

.-........---_---------BI005718

CHECK lAND ADJUSTMINT

IMPORTANT: Rest bucket on ground before making adjustment.

1. Tum adjusting nut on the spring rod until band is tight enough to hold the load under all conditions. Be sure that the spring is not so tight that it cannot be overcome by the air cylinder. The initial tension of the set spring is correct when spring measures 2 feet and 9-11/16 inches. (See illustration.)

2. Adjust piston rod clevis so piston will not "bottom" in released or set position.

3. With check broke in released position, adjust band lifter springs. until clearance is even all around brake housing. Do not allow band to drag when in released position.

4. Adjust stop bolts to contact the check bond.

FRICTION ILOCK REPLACEMENT

1.

2.

3.

4.

5.

6.

7.

Section 2

Page 36

Remove nuts from retaining bors and lift off bars.

Loosen all remaining nuts on friction block keepers.

Slide friction blocks off keepers.

Insert new friction blocks.

Replace retaining bars.

Tighten all nuts.

Adjust check bond. (See above'>

-~------------------------.

BI005718

SECTION 3 FRONT END

Shovel Front End

,

, Page 3

Shipper Shaft Assembly .......................•......... Page 5 Crowd Clutqh

,.......... Page 8

Intermediate Crowd Assembly. . . . . . . . . . . . . . . . . . . . . . . . • . . .. Page 9 Intermediate Crowd Brake ..•.......... ,................. Page 10 Boom Point Assembly ..... , ..............•....•...... , .. Page 10 Raising the Boom

...........................•....•.... Page 14

Boom Support Ropes Hoist Rope

~

, . . . . . . .. Page 14

, .• ,................. Page 15

Dipper Trip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • .. Page 17 Dipper Door I..atch .................•.•...••..•......... Page 19 Dipper Door Snubbers. . . . . . . . . . • . . . . . . . . . . . . • . . . . . . . . . .

Dipper T~th .

Page 21

. . . . . . . . . . . . . . . . . . . . . . . • . • . .. Page 21

Care of Wire Rope .................•............... ,... Page 21

Section 3

Page 1

.-~~~---------------

BI005718

Holst Rope

Boom Support Rope,;

, Point Sheaves 71

72

73

78

Dipper Handle

I'

74

84

Dipper Trip Motor

76

Shipper Shaft Dipper

/ 82

Intermediate Crowd Shaft

83

Fig. 23 SHOVEL FRONT END

/

ion

3

Page 2

------~-~.........-------.

BI005718

SHOVEL FRONT END Location No.

Name of Part

7)

Bpom Point Sheaves

72

E uolizer Sheove E uolizer Boil Pin Connection B il Pin o or Hinge Pins R ck and Pinion Sf ipper Shoft Yoke Block Sf ipper Shoft Bearings Irtermediate Crowd Shaft

73 74

75 76 77 78

80 8)

82 83

Ir termediate Crowd Gea. ond Pinion Teeth In ermediote Crowd Gear 8< om Foot Pins

LuI».

Location of Fitti..,.

Sy....

LuI». Perie i.. Hrs,

MPG MPG MPG MPG MPG

500

2

In sleeve End of shaft End of pin End of eoch pin End of each pin Automotic Lube System Two on eoch block Top of boom

MPG MPG

4-8 4-8

2

Top of boom

MPG

500

1

Avtqmpti, Lube System # 2 H\-lp of gear Both emds of each pin

MPG MPG

4-8

Type AntiFriction Bushing Bushing Bushing Bushing Bushing Bushing AntiFriction

Bushing Bushing

2 1 1

2 2 4

4

4-8 4-8 4-8 4-8

#2

Section 3

40

Page 3

(1)

VI

Jlo,.

(1)

10

Q

"

w

g"

~

n

~

78 79

77

Name of Part

Yoke Block

!

I

L

/ Yoke Block

/"

-=-----~--~~

t.

78

.>Jllms---/

CI..·

Lock ---'Pin

Shipper Shaft Gear

-

Bushing Bushing

Type

-

2

4

No. of Fittings

Two in each yoke Top of boom Automatic Lube System #2

Location of Fittings

SHIPPER SHAFT ASSEMBLY

Collar

Shims

'-- Pinion

Fig. 24 SHIPPER SHAFT ASSEMBLY

Shipper Shaft

Shipper Shaft Yoke Block Shipper Shaft Bearing Gear and Pinion Teeth

Pinion __ J

Location No.

Collar

Shims --~.

Thrust Washer

79

MPG MPG -

Lub. Sym.

c

-

4-8 4-8

Lllb.P.riocI in Hn.

B

A

BI005718

~--+-------.

BI005718

The shi per shaft assembly consists of the shiPPeJ" Sihaft, two yoke blocks, tw pinions, and the shipper shaft gear. The shipper shaft IS the hOri ontal shaft mounted neQr the mid-point of the boom.

The shaft s assembled with split collars at each end of the shaft.

Between t e collars and the yoke block is a bronze thrust washer fastened t the collar by four studs with nuts and jam nuts. If excessive sid play develops between the yoke block and the thrust washers, s lit shims are provided to eliminate the side play. Do not allow the y ke block to bind between the thrust washers.

The shi per shaft gear is splined to the shipper shaft, and is driven by t e pinion on the intermediate crowd shaft. The shipper shaft pinio sore splined to the shipper shaft and mesh with the rack gears n the bottom of the dipper handles. For proper timing, each pinio has a "king" tooth which must be aligned. These can be identifle by three punch marks in the top of the tooth, When reassemblin the shaft or replacing the pinions, the punch marks on both the L. H. and R. H. "king" teeth must be aligned.

The dlpp r handle racks are held in mesh with the pinions by yoke blocks. The yoke blocks pivot about the shipper shaft to allow the handles to ave freely in any position. Inside the yoke blocks, at the top sur ace of the dipper handle, are wear shoes. The proper clearance b tween the handle and the weor shoes must be maintained to i sure no binding olong the entire length of the handle.

The clearan e between top wear shoes and handle should not exceed Va inch. W en the clearance becomes greater, shims must be inserted betw en the wear shoes and yoke block. When more than Y.l inch of hlms is required to maintain the proper clearance, the wear shoes ust be replaced.

SHIPPER SHAFT ASSEMBLY

To Inse t split shims ot the ends of shipper shaft: Back a t four studs.

Hold sl tted stud while loosening nut and jam nut 50 stud does not bac out of thrust washer.

3. Insert sims between thrust washer and collor, 4. Install s t screws to hold shims in place.

5. Tighten nuts on studs.

6. Tighten nuts on set screw jam nuts.

7.' Install ual amount of shims on each end of shipper shaft 1.

2.

Do not drive set screw tightly against yoke casting.

The thr st washers must be replaced when Ya inch of shims is necessary a eliminate side play.

Section 3

Page 5

.-_-....--_---------BI005718

To ins~rt shims between the yoke block slide plate and the wear shoes.

1.

2.

3.

4.

5.

6.

1.

2.

3.

4.

5.

6.

7.

8.

While this adjustment is made, the handle should be in a horizontal position.

Remove cap screws (A) and shim retainers (Bl. Insert shims, taking care to insert the same number and kind in each end of the yoke block.

Replace the shim retainers and cap screws.

After proper adj ustment of the wear shoes, remove the retainer bolt (C) on top of the shipper shaft yoke block and add the same (total measurement) amount of 3 inch cut washers as shims.

(For example, if 1/16 inch of shims were necessary, then add 1/16 inch of washers).

Replace the retainer bolt and nut.

To replace the wear shoes: Remove bolt (C) and thread it into the tapped hole in the lock pin. Remove the pin.

Remove cap screws (A) and shim retainers (8).

Remov~ the worn shoe and shims.

Insert new w~ar shoe.

Insert the lock pin in the top until it ,ests on the top of the dipper handle. If necessary, add shims until the distance betw~en the handle top and the shoe is Va inch or less.

Fill space with washers.

Replace cqp ~crews and shim retainers.

Insert bolt .(C) and secure with nut.

I NTERMEDIATE CROWD ASSEMBLY

..ocation No.

No. of Fittings

Name of Part

Type

Gear and Pinion Teeth Intermediate Crawd Shaft

AntiFriction

-

80 81 82

Gear and Pinion Teeth Gear Crowd

-

-

79

Section 3

Page 6

Bushing

2 1

Lub. Sym.

Lub. Period in Hrs.

Automatic Lube System #2

-

-

Top of boom Automatic Lube System #2 Hub of gear

MPG MPG

500

Location of Fittings

500

'...I

III

to

o

"U

W

:J

n ....

O·

Vl III

""h

Ro'my Ai, 5<01 1

Ai, (I

!§ '---

'-

~

I1

'

,_________

81

Crowd Gear.

1__1

79 .

I

___

II

I

Crowd Pinion'

L __ JlJ

I

N ,- -

~

I

--J

I

: ... -tY

~ - - - - ~'-'

"

I

I

I

II

I

1I 1

I

I r- 1 ;

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l~%~ i ~:/?Z2Z21 ZZ 71-

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Fl

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. Fig. 2S INTERMEDIATE CROWD SHAFT ASSEMBLY

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~

~

BI005718

.------------------

BI005718

~'~ Mo • ....-+,-+-+c-.,.,--F-+riC---,tion Discs Air Tl,lbe

o :

Plate

/

~~~i~l3firlii~~- Return Springs r - __

:0

:tion 3

~~

__ I

0:

Plate

Friction

Fig. 26

Page 8

CROWD

Di~cs

CLUTCH

-"

Drive Ring

-------------.

BI005718

i

The inte~iediate crowd shaft assembly consists of the shaft, mounted in anti-friction bearings, crowd pinion, crowd gear, air clutch and rake.

The inter1ediate crowd shaft gear meshes with the pinion on the motor shaft. When the clutch is disengaged, the gear turns freely on the shaft, but when the clutch is engaged, the clutch drive ring, mounted on ~he gear, turns. This turns the interhal member of the clutch, keye~ to the shaft, and thus, the crowd motor turns the intermediate cfowd shaft.

The crowdl pinion is splined to the shaft, and as the shaft turns, the pinion tutns This pinion meshes with the shipper shaft gear.

The air cl~tch is a friction drive clutch, installed to pr<;>tect the crowd machi ery as well a5 rhe dipper arid dipper handle. The ~Iutch, when properl adjusted, will transmit full stall torque, but will slip when a shoc or overload is imposed. The air pressure determines the slip point of the clutch and can be adjusted by the operotor to suit the dlggi 9 conditions. The regulator valve is loc<;lted in the operator's cab. nd 45 psi should be used as an initial setting,

INTERMEDIATE C~ ASSEMBLY

Replaceme t of the air tube: 1. Disconn ct the air hose and spud fittings.

2. Remove the six socket head screws holding the plate.

3. Remove the plate and air tube.

4. Replace the air tube.

5. Reasse ble.

If the air t be does not leak and the clutch doesn't deliver full torque, then t e friction discs have worn down and the return springs are bottoming These discs must be replaced Replaceme t of the friction disc: 1. Shut off air supply by turning pressure regulator valve in operator's ab to O. 2. Remove ir tube holding plate 3. Remove ressure plate 4. Remove looting plate.

5. Remove riction plate 6. Remove enter plate.

7. Remove riction disc.

8. Replace riction discs and reassemble clutch, taking carE;! to properly osition return springs, center the discs and align the serration Adjustment f the clutch When the c utch has new friction discs, and the air tube has to expand further than 9 16 inch, the shim must be removed. When the air tube expan s 9 16 inch or more with the shim removed, the air tube must be r placed.

1.

2.

3.

4.

5.

Remove t e rotary air seal.

Disconne t air hose and fitting.

Remove ap screws, plate and air tube.

Replace ir tube.

Reassem Ie.

Section 3

Page 9

.------------------------

BI005718

fERMEDIATE OWD BRAKE

Maintenonce/ Operation and Ll,.Ibrication of the crowd brake is the some as the rotating brakes. See page 28 : Section 2

OM POINT ASSEMBLY

At the boom point are two large diameter sheaves. The sheaves minimize wire rope distortion and prolong rope life. Each sheave turns independently on two tapered roller bearings. A sleeve, mounted between the side members of the boom is supported by a fixed shaft.

The sleeve is threaded at each end and an adjustable nut on each end of the sleeve secures the bearing assembly. (See Fig. 27). The boom support rope anchors are attached to the ends of the boom point sheave shoft.

To take up the bearing of the point sheave, loosen the pinch bolt and turn the lock collar nut to the right until a slight bind is noticed when turning the sheave by hand. Tighten the collar nut bolt to lock the assembly.

To replace bearings, heat bearing cones in oil to 250 0 F. and clamp in place. Use fixture J-14077.

1 - - - - - - Sheave

Benring

~

,..-..

Fixture

FIXTURE J-14077 IS AVAILABLE FROM THE MARION POWER SHOVEL CO. Fig. 29 FIXTURE J-14077

Section 3

Page 10

BI005718

/

Boom Point Shea"es

/\

~.~~I,):.•~.IV/ \1 !

i

JI~

I! Rope

Rpe nchor

Adjustable Nut

Roller

Bearing

Fig.21

BOOM POINT SHi;AVE ASSEMBLY

Section 3

Poge 11

BI005718

.-~----

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CD .>Iu 0

--l

D:

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Section 3

Page 12

UJ

.... llJ

d

>

llJ ~

BI005718

182-M

Boom Support Ropes

~7Zn:ZZZZZ;ZZZZ;:

/-~- f ~-~i

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87

/

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8 6 ' - , , .'

Gantry

Fig. 30

BOOM SUPPORT ROPES

BOOM SUPPORT ROPES Location 1'40.

1'40...0 of 'A rt

Type

1'40. of Fitting.

Lub.

Location of Fitting.

5y....

Lub. Period in Hi'll.

86

Li ks and Pins

Boom Point and Gantry

MO

Weekly

87

Wire Ropes

Hoist and support

MO

Coated

Section 3

Keep

Page 13

.-------------BI005718

Fig. 31 HOIST REEVING DIAGRAM

~ISING

THE BOOM

10M SUPPORT ROPES

ction 3

Page 14

To install boom support ropes, the boom must be raised into working position. This is done by using the hoist rope, equalizer sheave, boom point sheaves and hoist drum.

Anchor one end of the hoist rope to the right hand drum flange "U" bolts. Reeve the other end up and over the right side of the sheave at the center of the gantry. From the gantry sheave reeve through the eq\-la1izer sheave, attached by a link (furnished with machine) to the rope anchor near the boom point. Reeve the rope over the left side of the gantry sheave and attach to the left hand fl<;mge anchor an the hoist drum shaft.

Slowly operate ti1e drum shaft until the boom is pulled into working position. .

The boom i.s supported at a fixed angle by four boom support ropes.

The wire ropes are identical and are pinned to links on the gantry and to anchors on the boom point shaft.

---r----------.-The shov I is reeved with a double hoist rope using a one-port hitch.

That is, bot ends of the hoist rope are anchored to the drum, and there is no echanical advantage in the reeving. An equalizer sheave at the bail nsures an even line pull on both hoist lines at all times.

The rope is anchored at the sides of the rope drum and is wrapped to lead off t e bottom of the drum.

BI005718

•

HOIST ROPE

The shov I hoist rope is reeved as follows: 1. From he bottom of the drum to the top of the left hand point shea v 2. Over t e left hand point sheave to the left hqnd side of the equali er sheave.

3. Under and around the equalizer sheave to the front of the right h nd point sheave.

4. Over t e right hand point sheave and down to the bottom of the right s de of the drum.

S. The ro e is ended at the right side of the drum.

Section 3

Page 15

BI005718

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Section 3

Page 16

BI005718

The dipp r trip assembly unlatches the dipper door to empty the

DIPPER TRIP ASSEMB

dipper. This assembly consists of a geor-driven cable drum and an electric mot r, located on the gantry. A wire rope, from the dipper trip drum, i reeved through a fairlead on the lower flange of the R. H. yoke bl ck of the sl ipper shaft. The wi re rope is attached to the dipper trip cain, which is fastened to the dipper door latch bar lever.

While the m chine is in operation, the dipper trip motor is energized at all times y enough voltage to keep the dipper trip rope taut, but without with rawing the latch bar from the latch plate. When the dipper is era ded out, the cable wi!1 unreel, and as the dipper is retracted, the otor will rewind the wire rope.

The opera or may unlatch the dipper door at any time by pressing the dipper trip switch located on the crowd retract control lever. This will direct ad itional voltage to the dipper trip motor, whiCh will withdraw the do r latch and allow the dipper door to swing open.

No adjust ent of the dipper trip is required. However, be certain the latch ha enough slack between the rope attachment and the dead end of he chain to avoid restricting the movement of the wire rope.

DIPPER TRIP ASSEMBLY Locetion No.

Nome of Port

84

Dipp r Trip Motor

88

Dipp r Trip Drum Shaft

89 90

Type AntiFriction

r Trip Fairlead

2

L.,b.

Sym.

Location of Fittings See

Ele~trical

Bushing

BeQring rousings

Oilite

L.,b. Period In Hrs.

Section

Apply to teeth

Dipp r Trip Gear and Pinion Dip

No. at Fittings

MPG

500

OGL

Keep Coo ted

Nane Reqliired

Section

3

Page 17

.---------_

BI005718

_----------------

..........

Trip Choin

Lev..r Arm

Trip Clevis Lever

II ,

I I

I II ,

A

B-:---

,9 1

Fig. 33

Section 3

Page 18

DIPPER DOOR

BI005718

182-M

The dip er door latch bar must extend into the latch plate far enough to eep the dipper door closed until the dipper is tripped, but not so far s to require excessive movement of the dipper trip mechanism. E cessive movement of the latch will cause delay in dumping the dipper. The latch bar should bear on the latch plate approximately % inch, so a movement of 1 inch will trip the door. Make certain th latch bar is free in the guides.

To adju t the latch bar: The latc bar is adjusted by changing the position of the eye bolt (A), attach d to the trip clevis lever, and locking the bolt in position with the n ts (8) .

DIPPER DOOR LATC

DIPPER DOOR Locntion No. QI

Home of Port L tch Bar and Guides Links and Pins

Type -

Ho. of Fittings

-

Locotion of Fittings

--

Lub. Sym.

Lub. Perio in Hrs.

Light

MO

As Req'(

Section 3

Page 1~

.

BI005718

.------------------------r-'

A'

I I Spring.

I I

I

Pin Bond

I

I I I

II

Plfl

ction

~----.;:"....----:'-----Lining

Dipper

Hinqe

,, Broke Drum

I I

3

Page

20

I I

Fig. 34 DIPPER DOOR SNUBBER

Pin

BI005718

---.-----+-----~.

Two dipp r door snubbers are Installed to retard the free swing of the dipper oar. The snubbers must be properly adjusted to prevent damage to t e door and latch. Each snubber consists of (] brake drum welded to t e door hinge. The snubber band is anchored to the dipper back. The s ubber offers enough resistance to the swinging action to prevent t e door from excessive swing and to eliminate the bounce that might revent the latch bar from engaging in the latch plate.

DIPPER DOOR SNUE

To adjust the dipper door snubber 1. Adjus the nuts (A) on the spring rod until both bands are in close ontact with the drum.

2. Turn he nuts on both bands the same amount until the bonds are ti ht enough to prevent the door from latching when the dipper is lowered.

3. Back ff the nuts (both the same amount) Just enough to permit th door to latch. If, while working, one of the drums de, velops more heat than the other, loosen the snubber band slightl To replac linings 1. Back ff nuts (A) until spring compression IS loose.

2. Remo e cotter pins and pins at each end of the friction band 3. Remo e the lining and rivets from bond, and replace with new ones. he grooves In the lining are to miss the rivets.

4. Reass mble and adjust the spring tension as above The dlpp r teeth must be tightly wedged into the dipper lip at all times. Laos or missing teeth will couse excessive wear to the dipper lip. Do not perote the machine with loose or missing teeth.

Each toot is held in place by a wedge pin through the tooth shonk and dipper Ip. Drive the pin in firmly, with the tapered side of the wedge towa d the tooth point Use a new pin when changing teeth.

Dipper teet can and should be reversed for equal wear. Do not allow the tee h to wear too for before reversing. ExceSSive wear will change the ngle entry of the tooth. Worn teeth can be bUilt up to original co tour with hard face weld. Keep ex1 ro sets ot teeth available.

DIPPER TEETH

Wire rop should be kept as clean as rossible by reeving directly from the co I or reel, working from the dead end toward the drum.

Place the coil as near as possible to the sheave closest to the dead end. Mount the coil on a round bar or pipe with supports on each side, so the ope will unspool from the top of the coil when the tree end of the r pe is pulled toward the first sheave to be reeved Never take the ro e off the reel in loops, because the loops will become kinks. A ki k In a rope permanently weakens It at that point. If no facilities or available for unspoollng the rope, the coil may be rolled along the gr und with the rope unwinding from the bottom of the reel.

After the reeving is complete, check all sheaves and the drum. If grooved, ma e certain the rope is laying properly in the grooves.

Clean the wire rope by blOWing off With compressed air, If available, or with a WI e brush. After the rope is cleaned, lubricate throughly, using regul r rope dressing or a light weight motor oil (do not use gear compo nd or any tacky lubricant). Sheaves and logging grooves must be ke t lightly coated with lubricant

CARE OF WIRE ROF

Section 3

Page 21

.--------'-------BI005718

fOTES:

iection 3

_

Page 22

BI005718

SECTION 4 OPERATING INSTRUCTIONS

Operator's Station

'..............................

Page 3

Operator's Control Prlnel

.

Page 4

Operating Controls

,

.

Main Levers

Page 5

, .. '

Page 5

Electrical Control Panel , ..... ,..........................

Page 5

Digging Operation

Page 5

Hoist and Crowd . , Overcrowd and Retract

, . , . . _ ., . . . "

. Page 5

........................•........ Page 6

Rotation

,

Page 6

Dipper Trip .... ,

~

.

~

. ... . . . .... ........

~

.

. Page 6

Return Rotation and Lowp.f

Page 6

Propel

,

............ ,

Steering the Machine

,

. Page 6 --

-

_

""

Page 7

Hoist

........................................... Page 7

Crowd

Page 7

Rotating Propel (Caution)

,

. ,

Page 7 Page 8

S~ction

4

Page 1

BI005718

1. Carefully read this Manual and Parts Book.

2. Do not swing over ground men.

3. Be careful where you park the machine.

4. Do not swing over the cab of a tl'Uck. 5. Avoid all overhead wires.

6. Always watch your clearances.

7. Leave the load suspended in air.

B. Watch the load at all times.

9. Try to lift the whole bank - slice it off.

10. Back away from dangerous banks.

11. Keep your doorsteps clean.

12. Steer while the machine is moving.

13. Keep the walkways clean, clear and free from obstructions.

,ection 4

Page 2

-----+--------.

BI005718

~A

c

~V ~ill

•'I

B~

I, l

E

1,

~'

~'

/

,'-

./,"",.

'/

,~~F

1

/

,

/

,

,

~,

I .,.. I·'· f

\..'

'{.

"

{",/ >~

Fig. 35

OPERATOR'S STATION

Opf'rotor's Station idf''lti ficotlOn

A -'

HOIST

B

Crowd Lever

Lever

C- Whistle D- Dipper Tnp Switch E

Left SWing Pedol

F - Right Swing Pedal

Section 4

Page 3

.---------------BI005718

c=I=:J mJ

o

RED

OD OGR[£N

Fig. 36

~

OPERATOR'S CONTROL PANEL

Indicates contact closed when toggle in this position.

1 2 3 4 -

Hoist Clutch Hoist Brake Propel Brake Swing Brake 5 - Crowd Brake 6 - Cab Light 7 Air Compressor 8 Excitation 9 Steering 10 Propel 11 Hoist 12 - Set 13 _. Off 14 15 16 -

Section 4

Page 4

17 -

On

Left Right M. G. Set

_.....--_----------.

BI005718

Before oper ting this machine, the operator should memorize the position of the controls and switches. Keep in mind that the amount the levers or edals are moved determines the speed of the motion.

The electric otors will turn with the required torque, because the electrical equi ment is designed to compensate for the variety of power requi re ents.

OPERATING CONTRC

The main I vers for operating the rotation, hoist, and crowd mo. tions are as f Ilows: 1. Right pe 01 - Right rotation 2. Left ped I - Left rotation 3. Right ha d lever - Hoist 4. Left han lever - Crowd 5. Switch 0 crowd lever - Dipper trip 6. Switch 0 hoist lever - Whistle

MAIN LEVERS

The electri al control panel, containing switches for the various operations of he machine, is mounted on the right side of the op· erator's cab.

Before any of the controls can be effective, the "start" button must be pres ed. The levers, pedals and switches can then be energized.

When the' stop" button is pressed, all main operating controls ore de-energi ed, the hoist clutch engaged, propel and steering clutches disen aged, and all brakes are "set". A power failure would hove the sam effect as pressing the "stop" button.

ELECTRICAL CONTRO PANEL

1.

2.

3.

4.

\.

Before d gging, start the air compressor, and allow pressure to build up to operating range.

Start M. . set and blowers, and press the excitation "start" button t energize the main levers.

Move th propel brake switch to "set". The red and green indicating lights must be out.

Move th propel hoist clutch switch to "hoist". This engages the hois clutch, disengages the propel clutch, and releases the hoist br ke.

The hoist b ke switch must be "off". The hoist brake is controlled by the propel oist clutch switch when changing from propel to hoist.

(While waitin for long periods, as for trucks, the hoist brake may be used to hoi the dipper and is controlled by the hoist brake switch.

DIGGING OPERATIOI

Section 4

Page 5

.-----BI005718

)15T AND CROWD

iERCROWD ~D RETRACT

To start the digging operation: 1. Slowly pull back on the hoist lever; and carefully move the dipper into the bank.

2. As the dipper moves into the bank, pull the hoist lever to full "on" to fill the dipper.

3. While hoisting, move the left hand (crowd) lever forward (crowd out) just enough so the dipper takes an even cut and the hoist will not run away from crowd.

Do not crowd too hard into the bank. This slows the hoist and reduces production.

1.

When the dipper is filled, move the crowd lever toward the rear (retract) till the dipper clears the bank. Judge the depth of cut required to fill the dipper at a single pass, and avoid the second pass.

1.

When the dipper has cleared the bank, start the rotation. To rotate right, step on the right pedal, and to rotate left, step on the left pedal.

Retard or stop the swing motion by "plugging" or reversing the rotating motors by depressing the opposite pedal. Release both pedals just as the machine comes to rest.

2.

IPER TRIP

rURN ROTATION AND LOWER

To empty the dipper, press the dipper trip switch, mounted on the crowd lever, and the dipper door will open. The door will close itself when the dipper returns to the digging position.

1.

2.

~ction

4

Page 6

After the load is dumped, start the return rotation to the pit, and simultaneously lower the dipper by pushing the hoist lever to the forward position. The dipper should come to the pit bottam at the same time the machine reaches the end of the return rotation.

The lowering is stopped by "plugging" or reversing the hoist motor, by moving the hoist handle to the hoist position. Do not allow dipper to strike floor before rotation is stopped.

)

---+-------------.

BI005718

To propel'the machine, the followil)g steps are taken at the conclusion of t e digging operation.

1.

2.

3.

PROPEL

Raise he dipper off the ground. Place the handle in a vertical positio , so the weight is supported by the shipper shaft rather than t e hoist rope.

Rotate the machine until the upper frame IS centered over the lower fame. a. Mo e the crowd brake switch to "set." b. Swi g brake switch to "set." c. Pro el hoist clutch switch to "propel." This engages the pro el clutch, sets the hoist brake and disengages the hois clutch. d. Mo e the propel brake switch to "off." The red indicating ligh will come on. When the propel brake is fully released, the reen light will came on and the red light will go out.

Wh n the green light is on, it IS safe to propel.

When the ropel brake switch is moved to "set", the green light will go out, a d the red light will come on until the broke is fully set.

The red light il then go out. DO NOT DIG OR PROPEL WHEN THE RED LIGHT IS ON, AS THE PROPEL BRAKE MAY BE DAMAGED.

1.

To steer he machine, return the propel lever to neutral (do nat engage r disengage steering clutches while the machine is in motio ). a. To steer ight, move the steering control to the right b. To steer eft, move the steering control to the left. c. For straight travel, move the steering control to the strolght up and dow position.

STEERING THE MACHINE

Move the lever slowly to permit steering clutch to engage Move the controlle forward or rearward, whichever direction is desired.

Ordinarily t e trail coble is attached to the rear of the machine.

When backi g, it is advisable to rotate the upper frame, so the operator is f cing the rear of the lower frame and con observe his progress 2.

3.

4.

When t e machine is located In the deSired position, move the prop I brake switch to "set" The red light will come on until the brake is fully "set".

When th - red light goes out, move the propel hOist clutch sWitch to "hois ", the hoist clutch will engage, the propel clutch will d,sengag , and the hOist brake will release.

Move th main rotating broke and the crowd broke sWitches to "off", a d the machine is ready to dig.

Section 4

Page 7

.--"""""'-----BI005718

IOTES ON: EVERS AND OPERATION

1.

The master levers are speed regulators. Slight movement gives .almost full torque. Move the handle only for enough to get desired speed. Use smooth movements. Handle jockeying is not required. Excessive handle movements overheat the motors and reduce life.

10lST

2.

Holt the dipper by reversing the hoist lever moderately. Use caution when hoisting the dipper to prevent the equalizer block from striking the boom point sheaves. When lowering the dipper, core should be exercised to prevent striking the crawlers.

1l0WD

3.

Core should be exercised to prevent racking the handle so for as to strike the stop costing on the handle against the pinions on the shipper shaft. Avoid rocking in so for as to couse the handle spreader to strike the underside of the boom. The dipper may be held out, for short periods by applying just enough crowd power to prevent the handle from drifting bock. To hold the dipper for long periods of time the crowd broke should be "set".

OTATING

4.

The rotating pedals will neutralize themselves if both feet are removed. If the machine is not on level ground, it may tend to rotate to one side or the other without applying power. The machine should be held steady while digging by pressing lightly on the pedal opposite the direction of drift. If the machine must be held for longer periods, "set" the rotating broke. Do not attempt to rotate while dipper is on the ground, or while filling the dipper. Make certain the broke is "off" before rotating.

ROPEl

5.

Before propelling begins, the operator should make certain there is sufficient slack in the trai I coble for the move-up and that he does not hit the coble when backing or steering.

)

;ection 4

Page 8

BI005718

182-M

SECTION 5 LUBRICATION

Selection of Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Page 3 Lubrication Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Page 3

Lubrication of Anti-Friction Bearings. . . . . . . . . . . . . . . . . . . . . ..

Page 3

Lubrication of Cylinders

Page 3

__ . . . . . . . . . . . . . . . . . . . . . . . . ..

Lubrication of Gears

Page 3

Extreme Temperature Operation. . . . . . . • . . . . . . . . . . . . . . . . . ..

Page 3

Introduction - Automatic Lubrication System, . . . . . . . . . . . . . . ..

Page 4

Lubrication Specification

Page 4

Lubrication Specifications - Oils

, Page 6

Lubrication Specifications - Greases

Page 6

Lubrication and Maintenance Check List. . . . . . . . . . . . . . . . . . . ..

Page 7

Automatic Lubrication System (Bushings)

Page 10

Automatic Lubrication System (Spray)

Page 14

Section 5

Page 1

.------BI005718

1. Lubricate regularly. Establish a systematic procedure and stick to it.

2. When lubricating, check all bolts, nuts, locknuts and cotter pins.

3. Keep loose objects off the machine.

4. Always replace guards.

5. Do not service or lubricate moving parts.

6. Keep the floor clean and free from oil and grease.

7. Prevent the accumulation of grease and oil around bearings and gears. Grease and oil collect and hold grit and dirt, which work into finely machined parts.

8. A clean machine is easier to operate . easier to inspect· easier to service.

9. Keep hands and clothing away from moving parts.

Section 5

Page 2

BI005718

182-M i

0i

No part the care of your Marion machine is more important than proper lubri ation. WITHOUT PROPER LUBRICATION, the air compressor, anti friction bearings, finished shafts, gears and other important parts 0 the precision-built piece of machinery can be quickly ruined. i For abov I reasons, the lubricants recommended for this machine have been s lected according to the ASTM specification standards.

These stand rds have been compi led through the cooperation of major petroleu suppliers in order that the consumer can be supplied with the ex ct lubricant to fit specific requirements regardless of the source 0 supply.

SELECTION OF LUBRICANTS

This mac ine is fitted with two types of lubrication fittings. The button head itting for plain or bronze bushed bearings, and hydraulic push-on fitti gs for anti-friction bearings. This way the operator can easily distin uish between anti-friction and plain bearings if he wishes to us diferent kinds of lubricant or to determine the frequency of lubricatio .

LUBRICATION FITTINGS

All roller nd ball bearings on the machine should be kept about 1/3 to 1/2 full of the lubricant recommended in the Lubrication Instructions Add only enough lubricant to maintain this level.

These are oil tight bearings, and the lubricant level will usually remain cons ant over a long period of time. Therefore, only very small QUant ties need be added. Unless otherwise specified, we recommend a small amount of lubricant every 500 hours, which will usually aintain the desired level in the bearing of about 1/3 to 1/2 full a all times.

If these b rings should ever become completely filled, the addition of more lub icant would result in pressure bemg built up inside the bearing, and heating would result. If a bearing should run excessively warm, it is a visable to remove the pressure fittings and allow some of the excess lubricant to escape.

LUBRICATION OF ANTI-FRICTION BEARINGS

Air cylind rs are lubricated at assembly with ELCO # 158-LO. Everyone or wo months all air cylinders should be lubricated with a small amoun of Neatsfoot oil or clean Non-detergent motor oil as follows: Release th air pressure in the system. Then, by disconnecting the air line near he cylinders, lubricating oil can be introduced into the cylinder. Pou into each fitting approximately on-half teaspoonful of Neatsfoot oil or motor oil, and replace the air line.

LUBRICATION OF CYLINDERS

It is impo tant to make sure every rotating or movable part is properly lubr cated. The pinions and gears on hoist and crowd machinery, as ell as racking on the dipper handle, and on all other gears and pi ions which are not enclosed should also be kept coated with a good rade of gear lubricant as recommended in Lubrication instructions. il should be kept at the proper level in all enclosed gear cases.

LUBRICATION OF GEARS (Open or Sem i-enclosed)

The lubric tion specifications in this manual cover the lubrication requirements of the machine when operating within an ambient temDerature ran e from -20 degrees to 110 degrees F.

EXTREME TEMpERATURE OPERATION

Section 5

Page 3

.-----BI005718

If this machine is to be operated at temperatures below -20 degrees F. or above 110 degrees F., contact the Marion Power Shovel

Company, Inc., Marion, Ohio or local supplier for special lubrication recommendations. Give full particulars concerning your conditions of operation.

OTE:

Dusty and dirty atmosphere, high humidity and/or extreme temperatures can alter the effective life of a lubricant. Therefore, it shall be the responsibility of the operator and/or owner to determine the most effective lubrication interval in accordance with existing environmental conditions for all components, bearings (plain and antifriction), gears, gear cases, etc.

ITRODUCTION AUTOMATIC LUBRICATION

Automatic lubrication, is usually arranged to lubricate the bronze bushings and plain bearings in the lower frame, crawlers, roller circle, upper frame and front end.

The lower frame and crawlers can be serviced from the upper frame supply, and the roller circle lubricated by means of a Quick Disconnect or Hook-an-System. The upper frame and front end can then be turned on for full automatic lubrication controlled by a timing device.

The machine is equipped with separate control panels and pumps for the lower and upper frame assembl ies. The lower frame system wi II lubricate only when the machine is propelling. If lubrication is desired at other times, the system can be operated manually.

The upper frame and front end system are wired into the digging circuit and only function when not propelling, unless actuated manually.

The roller circle is lubricated from the upper frame system by the Hook-On-arrangement, and only when the upper frame is stopped .

SYSTEM

..

JRICATION SPECIFICATIONS

We recommend that the following information be made available to your petroleum supplier to assist him in selecting the proper product for each application on your machine.

THIS KEY TO LUBRICATION CODE IS APPLIED TO CHARTS COVERING THE ENTIRE MACHINEFAMILIARIZE YOURSELF WITH THE FOLLOWING TABLES: (MPG) MULTI PURPOSE GREASE (Replaces WB & CG) This is a high quality, water resistant grease which has good mechanical and oxidation stability and good pumpability at operating temperatures. The grease may have a lithium or mixed base, must contain no graphite or other fillers and have the properties shown in the table.

USES - Anti-friction Bearings both packed and gun lubricated, Chassis and Plain Bearings and central lubricating systems.

(RGU REGULAR GEAR LUBRICANT . These semi-fluid greases, summer and winter, have just enough body to retain them in a semi-enclosed case. The grease may have C1 sodium or mixed base, have good adhesive, load carrying and nonchanneling properties and meet the specifications in the table.

USES - Semi-enclosed Gear Cases.

Section 5

Page 4

)

BI005718

182-M

(OGU

OP N GEAR LUBRICANTS REPLACE SYMBOL (GO must not rip or sling off while parts are idle or in motion, must be wat r and rust resistant and have extreme pressure characteri tics.

Typ (8) is applied without heat or a diluent by brush, gun or addle.

Typ (H) is an asphaltic type lubricant used in the same applications as (TypeB) and requires heat or a diluent to app y.

USE - Open Gears or sliding surfaces.

(HO)

RAULIC OIL This is a stable, high viscosity index oil oxidation, corrosion, foam, sludge, gum and rust resisroperties with a low pour point and a low carbon residue. oil shall not cause swelling nor deterioration in rubber or I ather. Used in Hydraulic Systems for leveling and power tran mission. See specifications in table.

MO

Mot r Oil-SAE 20 for winter, SAE 30 for summer.

EO

Engi e Crankcase Eng ne.

(MO)

* * A R COMPRESSOR CRANKCASE This is a highly refined .Iow carbon residue oil having rust, foam and oxidation resisti g properties. See Specifications in table.

(Hl)

**H ND LUBRICATION Use Oil (MO) above or a general ma hine oil (S-SAE 30, W-SAE 20W)

(GU

EN LOSED GEAR CASE This is an extreme pressure corrosi n and shock resistant type oi/. See specifications in table.

(PO)

PN UMATIC OIL This is a special oil avaliable thru the Ma ion Power Shovel Company used in the air piping systems.

It i a high detergent oil with good lubricity containing antiwea, clinging and anti-freeze propreties. It will not cause swe ling nor deterioration in rubber or leather.

See instructions by manufacturer of

(EMO) **E ECTRICAL MOTOR OIL Use special lubricant supplied by he manufacturer of the electrical equipment. * *NOTE: All oils are non-detergent except PO and EO.

Section 5

Page 5

.-------------BI005718

- OIU

LUI.ICATION SPECIFICATIONS

!

ASTM Teet No.

Colle ... SY-MI No.

I

MO

Oil, GL

PO

HO

0-97

5 0

10 0

15 15

-25 -25

0-92

450 420

440 410

410 410

390 390

0-446

-

-

150 Min.

150 Min

0-446

60-68 51-55

115-140 80-110

43 43

39 Min.

Viscosity Index, Min.

0-567

90

70

101

100

Rust Test - 48 hrs.

Syn. Sea Water

0-665

None

-

-

None

Pour Point of Max.

S

W Flash

of

Pt.

Min.

S

W Viscosity @ 100° F Sus Viscosity @ 210° F Sus

S

W

S W

-

30 20W

140 90

10 10

-

EP Timken, Min. O. K.

-

-

50 Ibs.

-

-

Copper Corrosion Max.

0-130

-

Oxidation @ 1500 hr: Max

0-943

-

0-611

-

SAE Viscosity

Analine

Pt.

No.

Min.

-

ASTM Test Na.

Penetration

W,nter,

NLG1#

Penetrotion

Worked,

Max.

0-217

<

Change

Dropping Point,

Min.

OF

Bose Oil Viscosity @

190

GREASES Greases RGL

OGL Type B

Type M

-

Worked 60X

Summer, NLG1#

5000X,

MPG

2.0 NN Incr.

215

LUBRiCATION SPECIFICATIONS Code or Symbol

I

-

2

-

2

semi-

1

1

fluid

0

0-217

10%

0-566

350

-

325

325

0-446

75 SUS

140SUS

200SUF

200SUF

0-942

10

0-1264

20%

-

10%

10%

210' F, Min.

Oxidation

Stability

Max. PSI drop - 100 hrs.

Water Resistance Max. Loss

@

100' F

Texture EP Timken, Min. OK

Section 5

Page 6

Visual

Buttery

-

adhesive

Tacky

-

35 Ibs.

-

-

-

BI005718

182-M

MAINTENANCE & LUBRICATION CHECK LIST Kee p Coated

--Location Number

-

Page

Item

Remarks

Specification

--~._,-

7

------

Steering Clutches ~-

--~-----~-----._.

-----

Apply to spline

MO

._-~_._._._---~-

17

Roller Path

Keep rails clean and lightly coated

26

Bevel Gear Teeth (Top)

Apply to part

18

Links and Pins

Diluted OGL

-

OGL

-

-_ ..._-

38

Links and Pins

43

Hoist Motor Coupling

..

~--'---

MO

-_... _----

MO Force through opening in side of coupling. Remove 2nd plug to vent coupling. Keep filled.

OGL or MPG

Apply to gear teeth

OGL

- - - - - - - 1------- - - - - - - - - - - - - ---------- --51

Hoist Drum Drive Gear

.-_... _- -_.-

- - - - - - - - -----------------

55

Clevis and Pins (Hoist Check Brake)

------

--'._-_.

67

Clutch Spline

68

- ---_._--

MO

,,,_.-'

l'q:J 11 Iy 10 part

_.. _--

MO

._----~---

Bevel Gear Teeth ---- ---------------

Ap~)ly to part _.. _._--

OGL

/\n; lJ v to tpcth

OGL

'

Dipper Trip Gear ilnd

89

.

Apply to parts

__._----" - ,-"-------

-----~

----.-

---_.~---_

-- -'----."' -._----

-

Ever y 8 hours:

--_.- ----'._--

-

---'--- ---.------_..

Location Number

Item

-- -- - --"---- --

.-------- -

Pilye ----_._-_._-_.- ._.._-- .-. __ . ._---

Roller Rail~

Remarks -

_. _.. _._- .,----"

Specification

Rotdte upper frame one full turn to change pOSition of the rollers.

-~_.-.

---

~--_

..

~--

1st I nterm!diate Pro[wl Clutch Air Cylinder

~_._-----------

Keep nirplf' opening clean.

-----~-

Section 5

Po 9 e i

.-----BI005718

Every 4 - 8 hours: Location Number,

Item

Page

Remarks

Specification MPG

1

Drive Sprocket and Gear Shaft

Automatic lube system #1

2

5th Intermediate Propel Shaft

Automatic lube system # 2

3

Front Roller

Automatic lube system # 1

4

Bottom Tread Roller

Automatic lube system # 1

11

3rd Intermediate Propel Shaft

Automatic lube system # 1

12

Propel Brake Shaft

Automatic lube system # 1

13

4th Intermediate Propel Shaft

Automatic lube system # 1

16

Steering Clutch Shifter Fork

Automatic lube system # 1

20

Rollers

Automatic lube system # 1

23

Center Journal (Lower frame)

Automatic lube system # 1

24

Center Journal (Upper frame)

Automatic lube system # 1

25

Bevel Gear Thrust Washer

Automatic lube system # 1

50

Lagging Hub Support Bearings

In hub of drum

MPG

66

Clutch Shifter Collar

In shifter collar

MPG

72

Equalizer Sheave

End of shaft

MPG

73

Equalizer Bail Pin Connection

End of pin

MPG

74

Bail Pins

Ends of pins

MPG

75

Door Hinge Pins

Ends of pins

MPG

71

Shipper Shaft Yoke Block

Two on each yoke

MPG

78

Shipper Shaft Bearings

Top of boom

MPG

83

Boom Foot Pins

Both ends of each pin

MPG

..

Section 5

Page 8

)

BI005718

Eve y 24 hours:

---_._-----------------, Location Number

Page

Item

Remarks

Specification

-- ------------6

Drive Sprocket Spur Gear

Check and keep filled to plug in side of gear case.

Hydraulic Ram Cylinders

Check for oil leaks.

GL

Eve~y 40 hours:

_._--- - - - - - - - - - - _ . _ - - ._-_._._--_ .. _----

Location Number

Page

Item

56

Specification

I n eye of anchor

Hoist Check Band Anchor (Dead end)

MPG

_·_··· __·_-_·__· _ - - - - - - - - - - - - - - 1

- - - _..- - - - - j - - - - - - - - - - - - - _ .

57

Remarks

Hoist Check Band Anchor (Live endl

I n eye of anchor

Air Filter in Automatic Lubrication System

Drain

lines and Bearings in Auto·

Check for breaks

MPG

---_._---

;llatic Lubrication System

- - - - - - - - - - . - . - - - - -.-- - ...-... ----- - - - - - _ · _ - - - - - - - - - - - - - - 1

Hydraulic Ram Cylinders

Check tor oil leaks

Intermediate Hoist Gear Case

Chl~d; uil

--- --.------ ---------.-------. ---..----- -----------------------1 42

level

- - - - - . _ ..- . - - - - - - - - - - - - - - - - - - - - - -

82

Intermediate Crowd Shaft

.... ---_._--

86

- -----

_._--_

Links and Pins

- - - - - - - _ . _ - _._----_._-._ ..__.--- .-._

Ever II 320 hours: ._---- -- - -- -_._- - - - Location Number Item ---- - _ . - - - Hydraulic Oil Filter

Side of intermediate crowd gear

MPG

[joom ~UPP()rt

MO

.... _---_.._-----_.. _--------_._--------1

.

__ ._-_.._-

- - - - - - - _._-------Page

Remarks

Specificatio

Clean. If unusually dirty conditions exist, clean more frequently.

- -...---j---------------------------.- - - _ .__._-------------------1 Main Collector Rings and Brushes

Inspect Keep clean and free of grease and oil.

Propel Brake

Check toggle adjustment.

------ ---.---------.-----------------------------J

-----1

Hoist Clutch Air Cylinder

Air lines

Neatsfoot Oil

Section 5

Page 9

.-------------BI005718

Every 500 hours:

--Location Number --_. __ .

-

-

Item

Page

Remarks

Specification

31

Main Rotating Shaft (Lower bearing)

Pipe to deck between gear

MPG

32

Intermediate Rotating Shaft (Top bearing)

In top of gear case

MPG

36

Rotating Pedals

In end of pin

MPG

41

Intermediate Hoist Shaft

Top of bearing boss

MPG

48

Hoist Drum Sh aft Support Bearing (R.H.I

In top of bearing housing

MPG

49

Hoist Drum Shaft Support Bearing (L.H.)

In top of bearing housing

MPG

63

Intermediate Propel Shaft Support Bearing (Right)

In bearing retainer

MPG

64

Intermediate Propel Shaft Support Bearing (Left)

In bearing housing

MPG

65

Propel Helical Gear

In R.H. end of shaft

MPG

Hydraulic Oil

Change oil. If unusually dirty conditions exist, change as necessary.

71

Boom Point Sheaves

In sleeve

MPG

80

Intermediate Crowd Shaft

Top of boom

MPG

88

Dipper Trip Drum Shaft

Bearing housings

MPG

Seasonal Change

Location Number

Item

Page

Remarks

Specification

14

Gear Case at Center of Lower Frame (2nd and 3rd shafts)

Fill at plug in side of case. (Reach from under lower frame.)

GL

15

Gear Case at Rear of Lower Frame (3rd and 4th shafts)

Fill through opening in top of gear case.

GL

34

Rotating Gear Case

Fill through breather pipe.

51 % gal. capacity

GL

42

Intermediate Hoist Gear Case

Fill through breather pipe

GL

----

Section 5

Page 10

BI005718

182-M

Section 5

Page 11

.-------------BI005718

AUTQMATIC LUBRIcATION SYSTEM (BUSHINGS)

The automatic lubrication system for bushings consists of a drum pump, control panel, piping and injectors. The system requires minimum attention. The lubricant is pumped directly from the grease drum. It is important that lubricant be maintained in this drum at all times. The system has an alarm buzzer that signals if the system fails to pump lubricant.

The system is divided into three groups: 1. Upper frame and boom assembly.

2. Lower frame and crawler assembly.

3. Roller ci rcle.

Upper Frame and Boom Assembly

The upper frame and boom are lubricated on a predetermined time cycle, adjustable for varying amounts of lubricant. The lubrication timer should be set at a minimum of one cycle (1 count) every 20 minutes.

Lower Frame and Crawler Assembly

The lower frame and crawlers can be lubricated only when machine is stationary. Attach lubricant hose to the "quick disconnect" at the rear of the lower frame. After hose is connected, press the button to the left of hose reel.

Indicator stems and a pres~ure gauge indicate when grease is being pumped. A counter indicates the number of cycles pumped. Under normal conditions, a working machine should receive 72 "counts" every eight hours and more often when propelling more than normal move-up. When sufficient lubricant has been pumped, relieve valve on hose, detach hose, rewind on hose reel, and resume operation.

, /

Section 5

Page 12

w

(1)

(Q

o

-0

Ln

~

o

n .....

(1)

Vl

WHiG PeuJG2 lJECK

Solenoid VaI....

"

~l

:: =:t1 N.D

jl

,I

"

" ,i

"

-

-

-

-

_

DECK

"

II II

,J

- _::: -=,1

'""IN FRAME

-'--

Center Journal Senter Journal

>lX-

6

-

C.J. Tr..rust Center Journal Center Journal

Push Button

HOB. Connection

Relier ValTe

~

UPPER PlWtE - 12 POINTS

~4

1 2

FL"'.. .00011

0

~

-

~

Reach Block L - 2 .

Fig. 37 UPPER FRAME AND FRONT END LUBRICATION SYSTEM DIAGRAM

1 Count Every 20 Minute.

..ini.... Require. .nt

UPPBR PR.UIB - 12 Pointe

_

' I

-

I..:.J. Thrust

L

&- lIlICR:OSWI~.H

INDICATOR STEl

r----- - - - - - - - - - - - - - - ,

S!:.'T AT 1 SYCLE (l COUNT) EVE.'"iY 20 MIN'UTES

IL ~ - -- ~ f' - - - - -

"

"!,

"

I:

c,, ,

Count Indicator _/Cycle Counter

HC

DltUJI 1,.".. "..1 - - - - , pUJIP

AIR

I

e:- -= .:- _- _-_ ==:.. ~;

,I "

,I jl

:'

=-:;.;; -'" ::' ~

;r:---

e

Shipper Sbaf't L . · Reach Block L-l 2

.

Shipper Sbatt R. Reach Block R-l Reach BloCk R~2

BI005718

~

(1)

to

o

"1J

U1

:J

a

-+

n

(1)

l./1

Sprocket Shaft !nS1ue 5th Propel Outside S9rocket Shaft Center

0procket Shaft OUtside

L~l"T

1

7

nailer 7 Itoller 6 Holler ') Holler 4

'-6

1 12 11 0

11:;(-

CHA\"JLE.f '{lLL.c;J/3 -

---~-

72 Counts hvery 8 HOUTS

;1 1 JilT

DRJV~

,-----

RIGHt fINAL

~

J..-4 Roller 7 ~--_=~. i<'ront rwller 7 ,toller 1 Holler 6 ?

3 0 Holler 2 noller ') ') ,toller 3 doller 4

&linimum nequirement

7

;';rOcKet ..,i..aft Olltsi'le

nr. ;)11r~ft In~l,.e ')t;l ProDel In'lL' .tn i-rop~l, (l1)t·l~e :::ipr. 0[.,. cer;ter~ ,pr. J.:. vcrter ,_

2nd Propel Lower

Steerin£ Clutch W.

)rd Propel OutSloe 4th Propel rt1gat 1 4th Propel "',;llt 2 Propel Brake :{ear

LQd::!l FRAb.J:: - 41 Points

I

u)'ti.m f !{A)'lE

7

1 2

21---

Fig. 38 LOWER FRAME LUBRICATION SYSTEM DIAGRAM

CRAWLER ROLLE}{, - I.t;n

._

'-4

~

Front rloller noller 1 doller 2 doller .3

1

t--'-- Spr: 3h. Cent8r 2

r-- 5th- Propel Insi<ie 1"lI1AL DRIVE

IIX-

2nu Propel Upper

Gear Thrust ,j; C. J.

SteerIng Clutch L.

3rd Propel Im~ide 4th Propel Left 1 4th Propel Left 2 honel Brake Fr.

Lu..JTLR

II

BI005718

BI005718

J82-M

MJ·3

Quick Disconnect

I

MJ·:1 MJ·3

MJ-3

MJ-3

Quick Disconnect

QUick Disconnect (3 Ploces) Any will serve entire Rol er Circle

MJ-3

MJ·3 To show grease flow, all blacks have pin type indicators

Fig. 39 ROLLER CIRCLE LUBRICATION SYSTEM

Roller Circle

All roller c rcle bearings are included in this group. The machine must be stati nary to connect lubricant hose. The hose can be attach· ed to anyone f three "quick disconnects" located on the roller circle.

After con nee ing hose, press and hold the button to the left of hose reel.

Indicator s ms and a pressure gage indicate when grease is being pumped and, a counter indicates the number of cycles pumped. The roller circle s ould receive ten "counts" every eight hours. When suf. ficient lubric nt has been pumped, relieve valve, detach hose, rewind on hose reel, nd resume operation.

Section 5

Page 1:

.----------------BI005718

In normal position the three-way solenoid· valve directs flow of lubricant to upper frame. When button to left of the hose reel is pressed, the direction of flow changes automatically to lubricate lower frame or roller circle. When lower frame or roller circle has been lubricated, and the hose disconnected, the solenoid valve automatically returns flow direction to the upper framp-.

If buzzer alarm sounds: 1. Check lubricant ii', drum pump.

2. Check each Trabon block for a blocked line.

3. Check pump for proper operation.

4.

Bleed lines of any air that may have entered, if drum pump runs dry.

To keep lubrication system trouble free: 1. Drain air filter regularly.

2.

Keep regulator set at 60-70 psi.

3. Replace grease drum when required.

4. Check lines and bearings for breaks once a week.

NOTE: The following are exceptions to the automatic lubrication system and must be hand-lubricated.

1. All anti-friction bearings.

2. Miscellaneous points requiring little or infrequent lubrication.

3.

Bushings which cahnot be included due to location: a. Bushings on hoist drum lagging hub. b. Bushings in intermediate crowd shaft gear.

4. All lubrication points on the dipper assembly.

5. All links and pins which receive a light coat of motor oil.

~UTOMATIC

UBRICATION

YSTEM SPRAY)

The automatic spray lubrication system consists of a drum, pump, control panel, piping and necessary spray nozzles. The lubricant (dillJted OGU is pumped directly from the drum. It is important that lubricant be maintained in this drum at all times. The system has an alarm buzzer that signals if the system fails to pump lubricant.

This system is self-contained and requires minimum attention.

The gears covered by this system are lubricated on a pre~ determined setting (a minimum of every 15 minutes). A visual check should be made at regular intervals to make sure that the gears concerned are covered with an even coat of lubricant. The amount pumped can be adjusted as required.

If alarm buzzer sounds: 1. Check lubricant in drum pump.

2. Check each Trabon block for a blocked line.

3. Check pump for proper operation.

4.

Bleed lines of any air that may have entered, if drum pump runs dry.

To keep lubrication system trouble free: The two air regulators should be adjusted to give a 6" wide spray 6 inches from the nozzle. (60-70 psi as an initial setting).

2.

Drain the air filters of all water at regular intervals.

3. Remove all nozzle heads weekly and clean.

4. Visually check gears and crowd handle daily for adequate lubrication.

5.

Replace drum when required.

6. Check lines for breaks at regular intervals.

J.

Section 5

Page 16

'J

III

10

o

-0

lJ1

::J

o

....

n

Vl III

~

o Grease Pane 1

r-

•

g

e.

~

..

'"

c: 'g

'J

AIR RESERVOIR

Oller

o o

I,Ir;G

ALA.RJI

AUDIO

G~A~

OUTSIDE TOP ., STICK

l:lSIDB 1"OP -STICK

L....

8 Counts Every 15 Itlinutee

h'dnlmum J1equirernent

SP.l.AY LUB,tICATION

o o

'" •

~

o

'"'<-g.

g'

~

~

~

!

;U---<>-i=1

To Crowd BrokO....",

RIGII'T YOKE

SIIA" GEAllS

INSIDE TOP - STICK

2 UJ

BOOt!

INTEl!. CROWD GEAllS~SHIPPBll

LEFT y(I(E

I I Deck of ~~por !'nao "'

__::...~:~ 8~:: ~~~~~~~_~~

-=-.-

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I,

I,

II

~I,

~

II 'I

PANEL

Fig. 40 AUTOMATIC SPRAY LUBRICATION SYSTEM

OUtside

~

II

8 COWlta

f'!very 15 m i n u t e s = € )

Jet at

-kOrnTO;' CONTrlOL

'=-="L-~~~

r(cgula. tor

1"11 tp.r

OU'PSIDE TOP -STICE

ll.lCE

BI005718

.---------BI005718

ction 5

Page 18

BI005718

182-M

SECTION 6 AI R CONTROLS

Air System

Page 3

Air Compressor Cooling Fins

. ..•... ...... .....

Page 3

......................................... Page 3

Lubrication ........................................... Page 3 Air Cleaner

Page 3

Air Receiver

. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. Page 3

Rotary Air Seal

Page 3

Anti·Freezer

Page 4

Magnet Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Page 5 Regulator Valve Hoist Clutch Air Cylinders

Page 6 . . . . . . . .. Page 7

Section 6

Page 1

.-----_..-......--_-BI005718

Fig. 41 :AIR SYSTEM

A.

B. C. D. E. F

F F F

F G. H. J. ction 6

Ai r Compressor Assembly K. Solenoid Valve (3-way) L. Filter - Regulator - Oiler Unit M. N. Globe Valve Air Pump O. Magnet Valve (Propel Jaw) P. Magnet Valve (Main Rotating Brake) Q. Magnet Valve (Hoist Brake) R. Magnet Valve (Hoist Jaw) S. Magnet Valve (Crowd Brake) T. Rotary Air Seal U. Hoist Clutch Cylinders W. Hoist Check Brake Cylinder X.

Page 2

Propel Jaw Cylinder Filter - Regulator Unit Main Rotating Brake Cylinder Special Spray Nozzle Solenoid Valve (3-way) Whistle Solenoid Valve Air Gauges Air Pressure Regulator Check Valve Crowd Brake Cylinder Crowd Clutch Air Motor

BI005718

The Mar on air control system is simple in operation, and with reasonable are will give long trouble-free service. The air control system can est be explained by a brief description of its components and their fu ction in the system.

The oper tor must be constantly aware of the air pressure reading of the guag If, at any time, the pressure drops below 90 psi, the operator sh Id shut down the mach me and investigate. Do not operate the mac ine without full tank pressure. If the proper air pressue is not maint med, check the following: 1.

2.

3.

4.

AIR SYSTEM

Is the ompressor operating properly~ Is the pressure switch operating properly~ Is the -belt drive properly adjusted and in good condition~ Are th re leaks in the ai r Iines or fittings~

The com ressor IS a complete unit, including a supply tank, electric motor nd a two-stage compressor with pressure switch. The compressor i driven by a matched set of V-belts.

V-belts tr nsmit power to the compressor pulley through the sides of the belt, at the bottom. Therefore, V-belts mud never be allowed to bottom i the pulley grooves. The proper belt tension must be maintained. belt that is too loose will slip and fail to deliver the required press reo A belt which is too tight will damage bearings through exc sSlve loads. To determine the proper belt tension, push down on the belt with the thumb at the mid-point between the two pulleys. Wh n the belt can be depressed about % inch, the tension IS correct. K ep the belts clean and free from grease and oil at all times

AIR COMPRESSOR

Keep the oolmg fins of the compressor free from dirt and debris to prevent a erheating of the compressor.

COOLING FINS

Check the oil level daily. For grade and kmd of lubricant, see lubrication che k list. Use NON DETERGENT oil only

LUBRICATION

The air cle ner is the air source for the compressor The air cleaner is on oil b th type. It should be disassembled and cleoned once a week uncJer' n rmal operation or daily in dusty and dirty conditions.

Replace oil Ie el indicated by mark on SICIC of cup. Use same kind and grade as used in the compressor crank case Several ti es each day open the air valve under the receiver tank and blowout he condensed moisture. At the end of each day's operation, open th valve and blowout the entire system. When humidity IS high, the cJ ain valve con be "cracked" open to allow the moisture to bleed out s it accumulates.

The rotary air seal forms a connection between the air lmes and the rotating hafts. The rotary seals are lubricated at the factory for the life of th seal. No attention is required. When installing a new rotary air sea, the short piece of flexible hose attached to the seal must be used to prevent any distortion which might c.ause the rotary seol to bind. ake certain the gasket is in place

AIR CLEANER

AIR RECEIVER

ROTARY AIR SEAL

Section 6

Page 3

.--------BI005718

c

~

} J ,11-----11

•,•.

o

Fig. 421 ANTI-FREEZER

ANTI-FREEZER

~

-

The antifreezer unit, installed between the air cleaner and the compressor, prevents icing in the air system in severe weather. This unit introduces alcohol vapor, which mixes with the water vapor in the ai r entering the compressor.

This unit contains an alcohol chamber at the bottom and a vapor chamber at the top. Plug (B), at the top of the unit, is fitted with a central rod. This rod is covered with a tubular wick (D), which carries the alcohol up into the vapor chamber as fast as it evaporates into the air flow. Adjusting sleeve (C) is mounted over the wick. By means of loop (A), the sleeve may be raised or lowered to increase or decrease the amount of wick exposed in the vapor chamber.

Adjustment: In severe weather, the sleeve should be lowered to the maximum depth, leaving the wick completely exposed in the vapor chamber. As the temperature moderates, the sleeve should be raised to reduce the amount of wick exposed, thus vaporizing less alcohol. When the temperature is aobve freezing, the sleeve should be raised to maximum height, which will cut off the alcohol supply to the vapor chamber.

The frequency of refilling depends upcn weather conditiOhs and the hours the machine is operated.

•

CAUTION: Use only methyl alcohol, distilled from wood. Thorough investigations 'prove ethyl alcohol unfit for ute. Do not use radiatot anti-freeze.

Section 6

Page 4

BI005718

182-M

---..,,----~~

1

,I

C -~Jlf{U).'I:.) .!.~. . J

I

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' r~ /

1j~,==i.i~i

~ll~~ L!~ IO~~ JjLv,~-:

Exhaust

Cylinder

r"

",

----41#+~ H

'

r--~d-.:.\

Cylinder

I

Supply Supply

Norm Ily Open

Normally Closed

Fig. 43 MAGNET VALVES

\

Magnet valves are used on this machine to control the air pressure, These valves are normally closed, When de-energized, the valve will shut off air ressure from the supply tonk to the cylinder and open the ports froJil the cyl inder to the exhaust.

When the~j.talve is energized, the plunger moves down to close the exhaust port! to admit air pressure from the supply tonk to the cylinder A normall open magnet valve is used to control the air pressure operating th hoist friction clutch, When energized, this valve will shut off the ir pressure from the supply tonk to the cylinder.

Magnet .valves are rugged and require little attention. If the valve foils to admi the proper volume of air, the valve should be cleaned.

With full to k pressure, open and close the valve several times by means of the and lever on the top of the valve. The valve can usually be cleaned without being disassembled. If not, dismantle the valve, clean and re lace worn or damaged ports.

Apply spa ingly a good grade of zinc-bose waterproof grease to ports before ssembling

MAGNET VALVES

Section 6

Page 5

.-----BI005718

Adjusting Screw - - - '

Adjusting Spring

-

Diaphragm

Inlet----

Valve Pin Valve

Fit. 441 PRESSURE REGULATOR I

,ULATOR VALVE

:tion 6

Page 6

The air tube clutch, located on the intermediate crowd shaft, transmits the crowd torque from the crowd shaft to the shipper shaft. When shock loads are imposed at the dipper, this clutch slips and protects the crowd machinery.

The air pressure for the clutch is controlled by a regulator valve located in the operator's cab. The working elements of the pressure regulator consist of a flexible diaphram, which controls a valve through an interconnecting valve pin, and an adjusting spring, loaded' by means of a T-handle adjusting screw. The pressure side of the diaphram is connected to the outlet port of the regulator, so regulated pressure will be exerted against the diaphram. When the adjusting screw is retracted until no load is applied to the adjusting spring, the regulator valve is closed. As the adjusting screw is turned in, a load is applied to the adjusting spring, which is transmitted to the valve through the diaphram and the valve pin, thus opening the valve.

As the regulated pressure increases, pressure against the diaphram increases and forces the diaphram to compress the adjusting spring until the load exerted by the adjusting spring is equal to the load exerted by the regulated pressure. If there is no flow demand, this state of equilibrium will occur with the valve closed. If. there is a flow demand; this state of equilibrium will occur with the-valve open just enough to compensate for the demand, thus maintaining the desired regulated pressure.

If the valve fails to function properly, it should be cleaned and worn or damaged ports replaced.

The valve can be disassembled without removing the valve body from the piping.

,

BI005718

182-M

To remo e the screen and valve, toke out the plug in the bottom of the valve b y To disas emble the valve, bock out handle to relieve spring tension, and r move bonnet screws. Lift off bonnet, spring assembly and diaphram 0 remove diaphram, hold the spnng rest and unscrew diaphram s rew or relief seat.

Reassem Ie with new ports from kit. Apply a small amount of waterproof gr ase (zinc bose) to the valve "0" nng. Keep screen clean.

Cup Seal Wiper

"'-..

Rod Seal

Fig.4S

~

Follower Seal

HOIST CLUTCH CYLINDER

The hois clutch air cylinders are pinned to the spokes of the hoist drum gear nd to the drum shaft clutch The cylinders are doubleacting (Se. Hoist Drum Shaft Assembly, Section 2).

HOIST CLUTCH AIR CYLINDERS

If the cy inders foil to operate properly: 1. Chec the air pressure to see If there IS a minimum of 90 psi, and that th re are no leaks in the supply lines.

2. Chec the solenoid valve and magnet valves.

If all are orking properly, then the cups and seals in the cylinders may need r placing.

Section 6

Page 7

.----------BI005718

)

Section 6

Page 8

----+------.

BI005718

SECTION 7 ELECTRICAL CONTROLS

Grounding Note (CAUTION) ........................• _ . .. Page 2 Care of D.C. Motors and Generators

Page 3 ,............... Page 3

Brushes In stallation of Brushes

Page 4

Commutators

Page 4

Winter Suggestions

Page 5

Oil Starting Switch

Page 5

Feeder Cable

.....................•................

Page 5

Power Line Grounding Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . .. Page 6 Static Control Test and Trouble Shooting Summary

Page 6

Section 7

Page 1

BI005718

.-------------------------

CAUTION DUE TO THE DANGERS INHERENT IN THE OPERATION OF ANY HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM SHOULD BE USED. SUCH A 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. WE SUGGEST YOU CONTACT YOUR ELECTRICAL SUP. PLiER IN REGARD TO THE ABOVE EQUIPMENT; MARION WILL BE GLAD TO ASSIST YOU IF YOU SO DESIRE.

)

ection 7

Page 2

BI005718

'82-M One of th most important factors in the core of electrical equipment is abso ute cleanliness.

There are few problems common to both motors and generators, which the 0 rotor should be able to recognize. Normally the D.C. motors and enerators give very little trouble, but there are times when somet ing happens that can be token core of quickly.

The more serious problems should be handled by a competent 'electrician I the commutation is bod and cannot be corrected by simple reme ies, the electrical equipment manufacturer should be consulted

CARE OF D.C. MOl AND GENERATO~

If there is n excessive amount of arcing between the brushes and commutator hile the shovel is operating under normal loads and speeds, the bushes should be inspected and checked for the following: 1. See th t the brushes are not sticking in the holders.

2. Make c rtain the contact surfaces of the brushes are clean, and the bru hes are making full contact on the commutator.

NOTE: his can be determined by removing brush and looking at the rush surface The surface where the brush has been rubbln will be smooth and polished. Any surface which is not in cant ct with the commutator will have a dark rough appearan e.

Excessive rcing may also be caused by loose brush holder studs, which will throw the brushes out of line. This can be corrected by tightening th brush holder in its correct position.

The brush holder yoke set screw may become loose and permit the brush yo e to rotate and to shift all the brushes. When brushes are moved 0 t of their normal position, they will arc badly. The simple correc ion is to move the brush holder bock into position.

The sprin pressure should be even on all brushes. The exact amount of bush pressure varies with different types of units, therefore the ma ufacturer will give definite information on the brush pressure for heir unit. If the brush springs are set originally at a certain pain, it is reasonably certain that this is the correct pressure, and th brush pressure should be kept at this point when installing a ne brush. The initial brush pressure should be the some for a II brush s on a given generator or motor.

All brush s should be inspected regularly, and when a brush has been worn to the point where it does not make good contact, it should be replaced. Care should be exercised to avoid allowing the brush to wear too or as it may cause severe arcing. Sometimes too much brush wear may even cut the commutator, because the pig tail may wear i to the commutator proper. The brush springs should be inspected to make certain they have not come out of their proper slots.

When fOlly long brushes are used, increase the spring tension after the b shes are partially worn to make up for the loss in brush press reo In replaci g the brushes, use the some type of brush as originally furnished wth the motor or generator. Serious trouble can result by uSing t e incorrect brush. If the commutation or arcing is bod and co not be corrected, a change in brushes sometimes improves cond hons. However, before making such a change, the manufactur r should be consulted.

BRUSHES

Section 7

Page 3

.-'

BI005718

-------------

NSTALLATION OF

BRUSHES

1.

The brush should properly fit the holder or guide, so it will work up and down freely in the holder.

2. The brush should be ground in with 2/0 or 3/0 sandpaper until the contact surface conforms to the contour of the , commutator.

This can be done as follows: a. After placing the brush in the holder, release the spring, and insert a piece of 2/0 or 3/0 sandpaper (rough side to the brush) between brush and commutator. The sandpaper should be a little wider than the brush. b. With maximum spring pressure exerted on the brush, hold the sandpaper close to the commutator and draw it in the direction of rotation. c. Lift the brush, push the paper back, and repeat the operation until the brush has been shaped to an even contact with the commutator. Be sure to raise the brushes before moving the sandpaper back for the next stroke. In removing the sandpaper from the commutator, do not raise the sandpaper. So doing will usually ruin the fit on the brush.

Brushes should not be installed and allowed to fit themselves by wear, because this will usually cause sparking or scoring before the brush wears in.

3. After the brushes are sanded, the armature, commutator, commutator risers and brush assembly should be thoroughly cleaned with dry compressed air to prevent the possible grounding or short circuiting of these parts. Failure to do this resulted in costly shutdowns due to damaged armatures.

4. After grinding in the brushes, they should be run under light loads for a while. This allows the surface to set, or wear itself before heavy loads are applied. When the commutator has been in use for some time, it should be a chocolate brown color.

Install a complete set of brushes at a time rather than replace them singly.

OMMUTATORS

Section 7

Page 4

The commutator surfaces should be inspected frequently by an electrician. When detected in the early stages, surface faults can be corrected with little expense or loss of time. The commutator will become blackened and burned if excessive sparking or arcing has taken place for any length of time. If the commutator is only blackened, use canvas to clean without scratching.

Fold the canvas over a wooden block, shaped to the contours of the commutator, and hold the block against the commutator with the motor or generator running at no load.

A good commutator surface is a highly polished chocolate color, and unnecessary sandpapering destroys this polished surface and results in increased brush wear. Therefore, sandpapering. should be avoided as much as possible. But, when the surface· has slight blemishes, use a very fine (2/0 to 3/0) sandpaper to smoath it.

Use sandpaper rather than canvas around the block, and use slow lateral movement to avoid diagonal scratches.

One of the principal objections to the use of sandpaper for cleaning commutators is that very rarely are the bars left properly ground.

On an unslotted commutator, particularly where the mica is high,

BI005718

J82-M

sandpaper as a tendency to flatten the center of the bars. Should the comm tator become so badly pitted or rough that canvas or sandpaper annot clean the commutator or take out the bad spots, use a han stone. Sandpapering will remove some blemishes, but cannot be epended upon to remove large flat spots The effect is merely t broaden the spot until it is no longer apparent. Therefore, a co mutator stone is recommended. The stone has a rigid surface an can be firmly held in place while grinding the commutato , Although hand stoning will restore true cylindrical surface, it cannot be epended upon to eliminate eccentricity of the commutator or e tremely bad spots. Sometimes eccentricity is in the commutato initially or may be caused by the commutator changing shape ith heat or age. When commutator eccentricity or bad spots exist, the armature should be removed and the commutator turned or g ound in a lathe by someone familiar with this type of work, After tur ing or grinding, the commutator mica should be undercut, Some f the large commutators can be ground in the frame by a skillful mechanic using the proper equipment. This avoids the loss of tim and' expense involved in removing a large armature.

This must e handled by experienced men to prevent damaging the commu ator by grinding at the wrong speed. A good commutator will e within only .0005 to .001 inch out of round when checked wit a dial indicator gauge.

After gri ding or sanding the commutator, the unit should be brought to rest and all copper or carbon dust blown off with dry compressed air. After grinding or sanding the commutator, the brushes sho Id be run for a short time under a very light load.

This will 1I0w the brushes to get a fairly good seat before applyIng full loa Wheneve the commutator is sanded or stoned, perfect brush contact is dest oyed.

EMERY APER OR EMERY CLOTH SHOULD NOT BE USED ON COMMUTATOR. Emery is an electrical conductor, and particles are likely to become imbe ded between the segments and cause short ci rcuits.

If communi ation is bad and cannot be corrected by simple remedies, the electric I equipment manufacturer should be consulted.

If the m chine is shut down and allowed to cool in cold weather, run the hoi t, rotating and crowd motors to warm them and establish lubrica ion before starting to dig. In extremely cold weather the motor earings may be warmed with a radiant type heater.

Each ~et of motors should be lightly run to maintain lubrication while the n xt set of motors warm.

The star ing switch levers should be handled in a snappy decisive mann r. Slow deliberate handling of levers will cause serious burning of he contact fingers and jaws, resulting in frequent shut downs. Bur ing may be largely eliminated by closing and opening the starting lever quickly

23lo

When volts or more are used, a feeder cable containing provision fOr a ground connection should be used. The power line

WINTER SUGGESTI

OIL STARTING SWITCH

FEEDER CABLE Section 7

i

Page 5

.-----BI005718

end must be grounded (see paragraph on ground circuits) to a suitable permanent ground. The shovel cable end must be securely grounded through a bolted connection to the shovel frame. This will always provide a ground for the shovel and electrical equipment. Failure to do this endangers the equipment and life of the workmen.

When making a temporary repair on a feeder cable after splicing the main and ground conductors, proceed as outlined below: 1. Clean and coat insulation and copper with a good grade of rubber cement.

2. Allow cement to become tacky, then apply a good grade of all rubber taper between the scarfs until the diameter over the splice is about the same as the former insulation. Apply the rubber tape very tightly to exclude C!II air pockets.

3. Cover the rubber tape with two layers of Y2 lap friction tape and paint with a good quality waterproof paint.

4. Remove cable from service and properly repair and vulcanize at earliest opportunity.

IWER LINE tOUNDING CIRCUIT

ATIC CONTROL TEST TROUBLE SHOOTING SUMMARY

The importance of having an adequate grounding system for the machine cannot be overemphasized. Without a good grounding system, dangerously high voltage can exist between the machine and the ground. The portable cable and power lines supplying the machine should have a ground wire of ample capacity running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system should be used at the transformer.

If a new power system is to be installed, or if changes are to be made in the present system, the Marion Power Shovel Company, Inc. should be consulted so they can assist the customer in working with the electrical manufacturer so satisfactory grounding equipment will be obtained ..

A static machine is the same as a standard Ward Leonard or Ward Leonard Amplidyne except that high load switches with no moving parts are used in the system to enable higher acceleration, more accurate control and minimum effort by the operator.

The only major difference between Amplidyne and Static Control are: 1. On static machines two field generators are used in th~ M. G. set instead of three field generators.

2. On static machines, A. C. supplied excitation panels are used to convert SCR's to D. C. for the generator field excitation instead of Amplidyne generators.

When problems occur try to eliminate the possibility of defects in the motors and generators. Also take into consideration the possibility of any mechanical failure which might have overloaded the electrical system or caused the operator to think one motion has an electrical malfunction.

In the case of a weak or dead motion, a simple test procedure taken step by step can determine any malfunction of the Static Panel.

Determine proper reference or control voltage at the panel.

Section 7

Page 6

BI005718

'82.1.1 fhis is the "signal" from the cab controller. If this is correct, the controller nd circuitry from the cab back to panel is functioning properly.

Check th panel "output". This can be obtained at the panel or at some pint preceding the generator field. Test points for the generator f eld or panel output are provided on General Electric equipment. If this voltage is correct, check the wiring from the panel to th generators.

Also, on G t eqUipment, Indicatln<] lights are pfOvlllpd to ab serve the fu lCtionmg of the SCR's In the VOl iOllS lllot,OIlS und dile, tions. For xample: In swinging to the lett at full power, the two indicating I ghts on the left would go black, while the two on the right would be full bright.

Any discr pancy of these lights would indicate either a bad order light, fixtur , or diode in the light circuit. If these are all right, there is a alfunction in one of the SCR packages or its affiliated firing circui In order a double check the "output" circuit with a light discrepancy, c eck the field output test points with a voltmeter for proper volta e.

If there ight be a malfunction in the static panel, make three simple tests or adjustments to determine which ranel section is out of order I. 2 3

Bias V Itage No La d Volts - Both Dlrectiurl', Stall ps - Both Directions

These adjustments, after having been set for specified adjustments, shoul not vary, but sometimes loose connections, open resistors or br ken wires may cause trouble.

The abov three tests are made after making certain the control voltage (Can roller Output) is correct at the panel.

I f there i definite trouble In the panel, the electrician should refer to the applicable instruction book and continue with further testing.

If at any time, there is a complete loss of bias, the SCR's will fire maximu or full output. This usually causes overload conditions in the A C. i put or A C. supply to the excitors. On some machines the A C. h s overload protection and will usually clear itself or "kick out" This pow r will have to be restored and the bios voltage reestablished b fore the unit will function properly. Again, for proper bias adjust ent and procedure, refer to instruction manual for equipment b~ing tested. Anytime the generator or motors show excessive sp rking a complete stall and open circuit test should be made to dete mine the cause of sparking. This condition would indicate possible high stall or possible component failure in the generator or m tor.

Routine w ekly or monthly inspections are recommended on this equipment. a d all dirt and oils should be cleaned out periodically

Section 7

Page 7

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Section 7

Page 8

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BI005718