Cat Dragline MARION 7400 ELECTRIC WALKING DRAGLINE Operation & Maintenance Instruction Manual

BI005692

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI005692

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI005692

MARION 7400 ELECTRIC OPERATION & MAINTENANCE MANUAL SIN 22084 MANUAL NO. 1017

060694

MARION Division of INDRESCO Inc. 617 West Center Street • Marion, Ohio 43302 USA

BI005692

BI005692

OPERA TION AND MAINTENANCE INSTRUCTION MANUAL

MARION 7400 ELECTRIC WALKING DRAGLINE

No. 1017

Manufactured by

MARION POWER SHOVEL COMPANY MARION, OHIO, U.S. A.

)

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CONTENTS

No. 1017

I

Erection Instructions

1 - 14

II

Adjustments

1 - 12

III

Operating Instructions

1 - 11

IV

Lubdcation Instructions

1 - 22

V

Wire Rope Reeving

1

VI

Electrical Instructions

1 - 26

VII

Miscellaneous

- 2 -

-

6

9/1955

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SECTION I

ERECTION INSTRUCTIONS

MARION 7400 ELECTRIC WALKING DRAGLINE

No. 1017/1

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9/1955

GENERAL

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The.e in.truction. haTe been prepared to aid in erecting a Marion 7400 Electric Walking Dragline, a. a guide for the operator, the groundman, and the oller in their operation, maintenance and lubrication. The engineering drawinl. whick accompany the machine, give the exact location of all part., all nec•••ary dimen.ion., etc. It ia Tery important that extreme care b. taken in a ••embly becalise improper erection may cause unnecessary wear and faulty operation of the machine.

When the machine is shipped from the factory. the parts are match marked throughout. Care ahould be taken to follow these match marks when the machine ia assembled.

All finished surface. and bearings are protected against corrosion and ahould be thoroughly cleaned just before assembly. When a.sembling, all bearings should be lubricated. Ball and roller bearing. are to be filled only 1/1. full of the proper grease. Alao lubricate all gears and put the proper oU in gear cases up to the correct leTel before the machine ia run. All air and electrical equipment, bearings and fini.hed surfaces should be protected from the weather until the machine ia fully as sembled.

Select a level assembling area adjacent to the unloading point approxbnately 300' x 300 ' preferably made up of solid material and with good drainage. It may be adYisable to place gravel or cinders in the immediate erection area.

It is important that the derrick be placed so that the greatest loads can be lUted without interferring with the erection of the machine. The recommended podtion of this derrick ia indicated on drawing CR-4585. U the ground ia not level, place the dead men out further than the 300' indicated for boom clearance.

MA TERIAL REQUIRED

(For Domestic Shipment) Following is a list of materials required to aid in the erection of the machine.

They are to be furnished by the purchaser.

zoo - Standard rails 48 - 2 x 10 or 11. 11 plank 12 to 14 feet long 100 - 2 x 4 - 16 to 20 feet long 8 - Dead men logs 1.0" dia. x 7' to 8' long or can use 31. standard raUroad ties for anchoring derrick guys.

1 - 310 cubic foot air compressor I - Electric welding machine 2 - 25 to 30 ton low lift jacks 1. - 15 ton track jacks 1 - 15 ton chain, hoist MA TERIAL REQUIRED

(For Export Shipment) The following is in addition to the above.

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1 2 1 1 8 12 12 4

-

6 3 4 -

6 4 4 -

2 2 1 1 2 2 I 1 2 2 1 6 3 3 6 2 2 2

-

1 2 6 Z Z 2 2 1 1 I 6 6 6 24 24 18 6

-

6 No. 1017/1

14 11 Stilson wrench 24" Stilson wrenches 48" Stilson wrench 12 11 Monkey wrench 5/8" construction wrenches 3 / 4" construction wrenches 7 /8 11 construction wrenches 1" construction wrenches 1-1/4 11 aingle end wrenches 3/4 11 socket wrenches' 7/8 11 aocket wrenchea 1" socket wrenchea 1-1/8 11 aocket wrenchea 1-1/4" aocket wrenchea 1-1/2 11 socket wrenches C Plate clamp s Set stock and Dies for threading pipe up to and including 3/4" Set stock and Dies for threading pipe 111 up to and including 2" 0 to 3/4 Positive plate clamps 6 lb. sledge hammer.

8 lb. sledge hammer 12 lb. sledge hammer 2 lb. hand hammers Flat file s Half round file 12 11 Mill filea Gouges Cold chisels Pinch bar s 1/2 11 chain 10'_0" leng hook each end 3/4" chain 15' -0" long hook each end 1" cable sling. consisting of 1" x 38'-0" cables. 1 link, 2 hooks.

32 cable clamp and 10 cable thimbles each Burning torch including gouges, 100 feet of hose. 3 tip. and 3 cutting tip s Adaptors for acetylene gas tank Hose connectors with clamps for acetylene gas hose 3/4 Rope double gate block (for snatch block) 3/4 Rope double blocks (for snatch block) 3/4 x 150'-0" Rope 3/4 x 75'-0" Rope for tag line Portable pipe vice 2' -0" Steel carpenter square Cross cut .aw 7/16" Barrel drift pins 9/16 11 Barrel drift pins 5/8" Barrel drift piu.

25/32 11 Barrel drift pins 3/4" Barrel drift pins 7/8" Barrel drift pina 1" Barrel drift pins 1-1/8" Barrel drift pins - 5 -

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MA TERIAL REQUIRED (Cont'd. ) 1Z 6 Z4 lZ 1 1 1 1 1 -

1-1/4" Barrel drift pins 1-1/ Z" Barrel drift pins 13/16" Barrel drift pins 15/16" Barrel drift pins 3/4" U. S. Std. Taper Tap 7/8" U. S. Std. Taper Tap 1" U. S. Std. Taper Tap 1-1/4" U. S. Std. Taper Tap 1-1/Z" U. S. Std. Taper Tap AIR TOOLS

1 1 1 1 1 Z Z 4 Z Z Z 1 1

-

6 1 Z1 6 4 1 8 8 lZ 6 ZZZ Z15 1 5 6 6 6 ZZZ-

Corner air machine with *4 Morse Chuck No. 3 air machine with '3 Morse Chuck No. 4 air machine with 13 Morse Chuck Small one man air drill Air surface grinder Stone. for above surface grinder 6" Air buckers lZ" Air buckers '80 Air hammers Chipping hammers #90 Air hammers '60 Air hammer '46 Portable air grinding machine Carborundum Wheela 8" Dia. (to fit above machine) Oil burning rivE!: forge Z lb. hand hammers Old man to back up 1-1/4 11 drill Flat chisels for air gun Gouge. for air gun Chisel bar 3' _0" long 5/8" backing out punches (without handles) 3/4" backing out punches (without handles) 7/8" backing out punches (without handles) H&ndles for backing out punches Side cuts with handle.

Cold cuts with handles Heating tongs Z'-6" long Pick up tongs I' _6" long Rivet set clips Extension Z' -0" long with No. 3 Morse Chuck (for air machine) 5/8 button head rivet sets 3/4 button head rivet sets 7/8 button head rivet sets 1 button head rivet seta 5/8" button head rivet seta (to fit abort bucker) 3/4" button head rivet set. (to fit short bucker) 7/8" button head rivet seta (to fit short bucker)

No. 1017/1

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AIR TOOLS (Cout'd. ) 2 1 1 2 1 2 6 6 6 6 1 6 6 6

-

6 6 2 2 4 2 2 1 2 4 4 3 3 2 2 1 2 1 1 1 4 8 450 75 75 75 75 75 50 35 800 400 50 12 450 450 No. 1017/1

-

1" button head rivet sets (to fit short bucker) Taper rivet set 7 /8" rivet set to fit large air bucket (to be 10" under shoulder) 3/4" flush rivet sets Sleeve 6100 for taper shank drill 62 to 63 Taper shank sleeves 63 to 64 3 /4 jack sets 7 /8 jack sets length 3 / 4" air hose 50 feet long length 1/2 11 air hose 50 feet long Lightening hose clamping tool 3/4 never slip hose clamps 1/2 never slip hose clamps 9 / 32 Drill straight shank 13/32 Drill 63 Morse taper shank 17/32 Drill 63 Morse taper shank 21/32 Drill 63 Morse taper shank 25/32 Drill 63 Morse taper shank 29/32 Drill 63 Morse taper shank 1-1/32 Drill 63 Morse taper shank 1-9/32 Drill 63 Morse taper shank 17/32 Bridge Reamer 63 Morse taper shank 21/32 Bridge Reamer 63 Morse taper shank 25/32 Bridge Reamer 63 Morse taper shank 29/32 Bridge Reamer 63 Morse taper shank 1-1/8 Bridge Reamer 63 Morse taper shank 1-1/4 Bridge Reamer 63 Morse taper shank 1-1/32 Bridge Reamer 63 Morse taper shank 1-5/32 Bridge Reamer 63 Morse taper shank 1-1/4 1400 chucking reamer 1-1/4 Rose reamer 63 Morse taper shank 1-1/2 Dowel pin reamer 3/4" Drill 63 Morse taper shank 1" Rose Reamer 63 Morse taper shank 15/16" Bridge- Reamer 113 Morse taper shank 13/16" Bridge Reamer #3 Morse taper shank 5/8 x 2-1/2 Bolts 3/4x2 Bolts 3/4 x 2-1/2 Bolts 3/4 x 3 Bolts 3/4 x 3-1/2 Bolts 3/4 x 4-1/2 Bolts 3/4 x 5-1/2 Bolts 3/4 x 6 Bolts 7}8 x 3-1/2 Bolts 7/8 x 4 Bolts 1" x 3-1/2 Bolts 1" x 12 Bolts 5/8" Cut Washers 3/4" Cut Washers

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AIR TOOLS (Cont'd. ) 1500 100 50 Z 30 30 ZO 40

-

6 lZ Z ZO 1 Z

-

6 Z-

6 Z 50 4 4 40 40 15 1 24 100 1 Z 19

-

1 -

Z 24 lZ lZ

-

7/8" Cut washers I" Cut washers 1-1/4'· Cut washers 1-1/2" Globe valves 1/4 x 4 Nipples 3/8 x 4 Nipples l/Z x 3 Nipples 1 /Z x 4 Nipples l/Z x 6 Nipples 3/8" Close Nipples 1-1/Z" Close Nipples 3/4 x 4 Nipples 1-1/2" Union Elbow 1-1 / Z" Union 1 / 4" Elbows 1-I/Z" Elbows l/Z" Elbows 1-1/2 x 6 Nipples I/Z to 3/8 Bushing Z to l-l/Z Reducing Bush 1-1/2 Coupling I/Z to 3/4 Reducing Coupling 1/ Z" Coupling 3/4" Coupling 1-I/Z x 1-1/Z x l/Z" Tee I/Z to 3/8 Reducing Coupling Feet l-l/Z I1 Pipe Manifold 4 11 pipe 4'_0" long 4" Pipe Cap l/Z" Globe Valve 3/811 Pipe Plug 1/4" Globe Valve 3/8 to 1/4 Reducing Valve 3/4 to lIZ Reducing Bushing.

Feet /#Z Annealed Wire ELECTRICAL TOOLS

Z - 4'· Screw Drivers Z - 8" Screw Drivers Z - 8 11 Pliers (side cutting) 1 - 6" Long Nosed Pliers Z - 10" Gas Pliers 1 - 8 11 Mill File 1 - 1ZIt Mill File 1 - 1Z" Double Cut File 1 - 1Z Half Round File 1 - 8" Round File 5 - File Handle B No. 1017/1

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ELECTRICAL TOOLS (<Aut'd.)

1 1 1 1 1 1 1 1 1

-

1 2 2 2 1 I 1 1 1 1 1 1 48 1 1 1 1 1 2 1 1 1 1 1 100 100 Z 1 1 8 8 12

-

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6" Crescent Single End Wrench 10" Crescent Single End Wrench 1 /4 to 3/4 Pipe Bender 5/16 X 3/8" Open End Wrench 7 /16 x l/Z Open End Wrench I/Z x 5/8 Open End Wrench 3/4 x 7/8 Open End Wrench 7/8 x 1 Open Ene. Wrench 10" Stilson Wrench 12" Monkey Wrench 18" Pipe Wrench Cold Chisel.

Gouges Center Punch I-lIZ lb. Hanci Hammer 3/16 Straight Shank Drill 1/4" Strai,ht Shank Drill 1/2" Straigat Shank Drill 3/ i" Square Shank Wood Bit Standard Brace 10" Hack Saw Frame Hack Saw BIactes tlZ Soldering Iron 6 ff Melting Pot "," Pouring Ladle Set 3/16" Steel Letters Set 3/16" Steel Figure 8 2" Paint Bru.he.

Gasoline Furnace 1 Quart Blow Torch 25000 OHM Mallleh /12 Pipe Viae 75 Foet Filh Tape Feet l/Z Rope Feet 5/16" Tiller Rope 1/2 Deuale Block Steel Grip for 1/2 Wire Set Pipe Die. l/Z to 2" Copper Terminal. (508,000 CM) Copper Terminal. (250,000 CM) Copper TerIninal. (3/0)

TOOLS AND EQUIPMENT It fa reconunended that a small teo1 room be erected at the erection .ite for the protection of the teela. drawill". etc.

One electric weldin. machine is required to he u.ed throughout the erectien period.

Conault Marion Pewer Shoyel Cempaay re,ardin, derrick., tooll uul other equipment for u.e wilen erectiJa. tlae maclUne.

No. 1017/1

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LOCATION OF DERRICK FOR ERECTION OF TYPE 7400

.....---44' -6·---.....

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I I

I I

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......

.....

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50 ' -0·

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15'-0

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£.

ROT.

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•• OAII IROyND IS NOT LEVEL. DEAD MEN MAY HAV[ TO IE PLAOID OUT ,U.TH[R THAN INDICATED TO PROVIDE 100M CLEAR. DIAD MIN HOLEI - 3'-0· WIDE X 6' TO 8'-0· DEEP X 9'-0· LONI. DEAD MIN LOI - 20· DIA. X 7' TO 8'-0· LONI OR ITO. ReA. Till·. DEAD MIN CAILEI DIA. X 70'-0· LO.'. OOUILI AaQUND LOI AND LOOPED.

1.·

4.

- 10 -

CR-4585

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ERECTION OF MACHINE It i. recommended that the followin« procedure be uaed in erectinl the machine.

1.

Aaaemble sections of lower frame or tub. a.

Build a crib, preferably of railroad ties, approximately 30" high to allow for riveting and bolting underneath tub.

b.

Place center section on crib.

c.

Place outer aectiona and pull sections tosether, alip and bolt.

Tub should be leveled and circle rail bearing au.rface checked fer levelness with transit.

d.

Rivet tub complete.

e.

Bolt on wearing plates and cleata.

f.

Remove cribbing and lower the tub to ground. (U erecting the machine in the winter, it may Be adviaable to lower the tub to a mat of timber, clear of the cleata, under tJae edge of the tub, to prevent freezing the tub to the ground).

z.

Inatall gear segment. being aure to follow matcla markings.

3.

Inatalilower circle rail and bolt to tub uaiag wed«e washers under nut.

4.

Inatall center journal.

5.

Aasemble roller circle, making certain ia to the inside of the circle.

6.

Install upper circle rails on the roller circle in auch a position that boom end of upper frame will be pointed toward derrick.

7.

Burn off lifting luga and grind sm.oth.

8.

Aasemble aectiona of rotating frame.

~at

amall diameter of roller

a.

In assembling the upper frame the electrician ahould install the conduit, wiring and electrical equipment aimultaaeoualy with erectors to avoid being blocked out.

b.

Place center aection of upper frame. Be aure center journal is well greased and shear blocka wehied in place aefore placing center aection over it.

c.

Block up front of center aection on the lear aegments to make eaaier installation of front girder.

d.

Asaemble main swin« ahaft ani swinS sear caae on aide aectiona of upper fra.me.

No. 1017/1

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e.

Place right and left side sections, pull each into center section, align and bolt for riveting. On placing the side sections, pinions on main swing shafts must be me shed with main swing rack on the tub which is best accomplished by turning main gear in gear case.

f.

Place lower superstructure and front and rear girders. This will not include any of the cross members for they will interfere with lowering the machinery from above. Align all members and bolt for riveting.

g.

Install right and left wing sections and bolt for riveting.

h.

Install rear ballast box and bolt for riveting.

i.

Ream where necessary and rivet rotating frame complete.

9.

Build secure crib under rear of machine to support ballast and machinery.

10.

Install ballast as indicated in print L. P. 287 supplied by our Engineers.

Ballast should be distributed in accordance with these instructions so that the machine will be properly balanced when in operation. During this operation care should be taken that electrical conduit is not iamaged.

11.

Place all machinery on upper frame including electrical equipment and necessary wiring in the order outlined below. The electrical cabinets, motor generator set, and transformers may be placed at any convenient time while machinery is being installed. a.

Bolt on hoist and drag machinery frame and install hoist and drag drum. NOTE: Slip rings should be installed before the hoht drum is placed.

b.

Install swing motors and oil pumps for swing gear cases.

c.

Place main propel gear and install main propel shafts.

d.

Install boom hoist machinery.

e.

Install main drive gear case, 2nd, intermediate extension shaft, and hoist motor.

f.

Install air compressor.

12.

Install lower cross beams of superstructure. Bolt and rivet. (Be sure crane trolley girders are installed before cross beams are placed).

13.

Install fairlead.

14.

Install walking towers and stub shafts. Align, bolt, and rivet. It fa particularly important that match marks be followed exactly during thfa installation.

No. 1017/1

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15.

Assemble boom complete.

16.

Install house front and rear.

17.

Place roof trusses and eave angles.

18.

Place operator's cab.

19.

Assemble upper structure.

20.

Install gantry cap.

21.

Install front and rear gantry bracing and ¥1 other connecting beams.

Ream, bolt, and rivet. Gantry braces are assembled and riveted before placing and welding on the upper structure. Weld stiff legs top and bottom first and then insert the assembled and riveted brace s.

22.

Install house roof. (Before roof is installed, keep machinery and electrical equipment well covered).

23.

Connect boom to rotating frame. (Boom may be connected as a complete unit or foot section may be assembled first on upper frame and the rest of the boom built from foot section).

24.

Reeve cables. Reeve boom hoist cables first. Reeving is more easily accomplished by welding or brazing a 7/8" by 300' (or longer) cable to one end of the boom hoist cable. After threading this smaller cable by hand as far as it will go, pull boom cable through with the 7 / 8" cable.

After connecting boom hoist cable to the boom hoist, pull up taut (with boom sUll on ground) and reeve boom safety cables in the same manner aa boom hoist cables. See Cable Reeving Section.

25.

Install air piping.

26.

Complete house.

27.

Install walking cranks and walking shoes.

28.

Raise boom and remove cribbing at rear of machine.

29.

Make all necessary adjustments and completely recheck the machine for any loose bolts, nuts, cotters or errors in assembly. Remeve all tools and equipment. Check all moving parts for obstructions which may cause damage.

30.

Install the proper type and amount of oil in all gear cases and completely lubricate the machine with type of lubricant recommended in the Lubrication Section.

Caution: Machine is shipped less fluid lubricant in gear cases. sure that they are filled.

Make

After painting is completed, the machine is ready for testing and making electrical settings.

No. 1017/1

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9/1955

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BALLAST BOXES

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I--

rrl

G

D

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~

0

~

~

~

0

[V

~

POCKET

10M CAP. CU. F'T.

A A'

B B

c c

D D' E E F' F' G H

J

TOTAL

61.65 61.65 47.67 47.67 '7.71 '7.~1

9'. 9 9,.89 103.45 10' 5 50. 5 5°.15 117.49 12 6 .,

:'t

3.4,

1104 .'2

~

~

~

CAP.

CU.F'T.

5~t~ ~.90

42.90

" .94

~.94 .50 84.50 93.10 ~'5.14 .10 45.14 10~ .74 11 .51 61.51 99,.88

- 14 -

-~ [b

~ ~

AT 2-;0 LBS. PER CU. F'T.

1'900 1'agO 10 0 10800 ~oo

8500 21200 21200 23'00 23300 11'00 11'00 26500 29200 15400 249100

L.F! 287

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SECTION II

ADJUSTMENTS

MARION 7400 ELECTRIC WALKING DRAGLINE

No. 1017/II

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9/1955

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SWIVEL RETURN MECHANISM (L. P. 256) The machine is equipped with swiveling devices on each walking shoe. The purpose of these swivels is to protect the walking mechanism. When the greater part of the shoes is on firm dry level ground, slippage is not noticeable but conditions will arise when one shoe may be on solid fotting and the other will sink in or slip back.

This would tend to rotate the entire machine around the shoe which h holding.

Such a condition imposes excessive stresses in the walking mechanism. nlustration of walking shoe swivel assembly view No. 1 and 2, L. P. 256, shows the swiveling device installed on the shoes and its operation is described in the following paragraphs.

View No. 1 shows the shoe in its normal or starting position, which 18 parallel with the center line of the machine. This position is brought about automatically when the Ihoes are raised off the ground through the action of the swivel return mechanism which is described in detail as follows: The walking shoe (1) has mounted on its upper side, a swivel assembly (2) which 11 attached to the shoe by pin (3), allowing the shoe to rotate in either direction.

The other end of the swivel assembly is prevented from lifting off the shoe by a keeper casting (4) which is bolted to the shoe and has a projecting flange or lip which hooks over the swivel assembly. The swivel assembly is provided with two journal bearings (5) and (6) in which the walking arm yoke casting (7) 11 mounted. Journal bearing (5) is cast integral with the swivel casting, while journal bearing (6) is cast separate, and is bolted to the swivel casting. Thil type design is necessary for assembly purposes. The walking arm yoke casting (7) 11 also made with two journal bearings in which the walking arm is mounted.

These two sets of journal bearings form a universal joint which allows the shoe to tilt both sidewise and lengthwise.

Attached to the underside of the swivel casting are two slide blocks which are made of special composition having a low coefficient of friction, 10 that they will slide readily under pressure. These slide blocks bear on finished slide plates (8) welded to the top of the shoe, the contact surfaces being grease packed. The lubricant is prevented from escaping by means of a grease retainer entirely surrounding the slide plates on the shoe. The slide plate covers (9) protect the slide plates, preventing dirt and moisture accumulating on the bearing surfaces.

Extending forward on the shoe swivel pin (3) is a part of the swivel assembly known as the Swivel Return Mechanism. This return mechanism consists of an adjusting screw (10), a spring (II), a plunger (12), a roller (13), and a roller track or cam (14).

View No. 1 shows the walking shoe in the normal position, which is brought about automatically when the shoe is raised off the ground. This is accomplished by the action of the spring (11), causing the roller (13) to seek the low point or center of the cam (14). When 1.1 the normal position, the center line of the shoe coincides with the center line of the swivel assembly which is always held parallel to the upper frame by the walking arm.

No. 1017 III

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SWIVEL RETURN MECHANISM

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L.~256 - 3 -

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View No. 2 shows the walking shoe partially pivoted out of the normal position.

Thia may be caused by the shoe being pressed against ground of sufficient uneyenneas to force the roller toward one of the high sides of the cam (14) thus compressing the spring (11). The energy thus stored in the spring will return the ahoe to the normal position when it is lifted from the ground for the next atep. The direction and amount of swiveling depends on the direction and magnitude of ground slope or unevenness, the maximum position being when the roller (13) is stopped by the cam end plate (15).

The apring (11) requires an initial compression of 5-1/4 inches (equal to 24 turns of the adjusting acrew (10) for proper functioning of the swivel return mechan18m. This adjuatment must be made with the shoe s off the ground (if the shoes are mounted on the machine), and the roller (13) centered on the cam (14). U the shoes are mounted on the machine, back off the adjusting screw till the apring 18 juat free (or if the shoes are being assembled, tighten the adjusting screw till the spring just ceases being free) then tighten the adjusting screw exactly Z4 full turns. A paint spot or a punch mark on the adjusting screw head will aid in counting the full turns of the adjusting screw. Never tighten the spring more than shown above, since the shoe must be capable of swiveling to the limit of the cam end plate (13) without any interference within the return mechanism.

When propelling the machine, the operator must be sure that the ground over which the machine is to trayel is fairly level and that the shoes or tu~ do not rest on any sharp obstructions. The machine should not be propelled along the aide of a steep hill where there is considerable danger of slipping. U posalble, ground over which the machine is walking should be such that both ahoe s make contact with the ground at approximately the same time. When the machine reachea its digging position, the operator must be certain that the machine does not set on top of a small knoll, as this will cause the machine to rock while dig-" ging. It is very dellrable that the shoes when making contact with the ground haye bearing their entire length in order to prevent excessive strains. When the ground is extremely uneven -a dozer may be required to push large rocks out of the way, and level the ground. Filling may be done by dumping some of the spoll in the line of travel and leveling with the dozer.

SWING LOCK BRAKE (CI-58Z) The swing lock brake used for Marion 7400 Electric Dragline is spring set, air released, and electrically controlled through a magnet valve.

Caution:

This brake is intended only to hold the machine when not operating and should not be used to stop the machine when rotating. The brake must be released before the machine is operated.

PROPEL BRAKE (CI-587)

The propel br~ke is the band type and is spring set, air released, and with electric control using a magnet valve. The operation and adjustments are fully explained in CI-587.

No. 1017 III

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SW9NG BRAKE -TYPES 5323, 5561, 1400 • (ALSO TYPE

1800

5560 WITH VERTICAL SWING 11010"

SPRING SET, AIR RELEASED, ELECTRIC CONTROL USING MMNET VALVE To RELEASE ~RAKE, OPERATOR TURNS SWITCH

SKETCH SHOWS BRAKE IN SET POSITION

TO

·OFF-,

OPENING MAGA~LO.fNG

NET VALVE

AIR

I, Sl

TO ENTER CYLINDER COMPRESS I NG SPR. NQ

AND rORCING PISTON ROO

3

10 MOVE OUT

ROO

PISION

IS 8USHED AND

IS

CONNECTED TO TWO LEVER

4

BARS

ON THE OUTSJDE, ~,

AND TO CLEVIS BU~HED,

IS

SIDE, ~

WHICH

ON THr

IN-

BY A BOLTe

CLEVIS

IS CONNECTED TO

CLEvl S ING

6 BY ROO 7 HAV-

R. H.

L.H. C(EVI~ 6 AND

THREADS.

CONNECTED, ON

N~AR

is

SIDE

or BRAKE, TO ONE END or BRAKE SHOE 8 BUSHED.

WHnCH

OTHER

IS

NO or

BRAKE SHOE 8"IS BUSHED AND PIN CONNECTED TO BASE STRUCTURE.

BRAKE

SHOE 8' ON THE rAR SIDE IS BUSHED AND BOLTED TO LEVER BARS

4

AT ONE END,

WHEN PISTON ROO

3

BUSHED AND PIN CONNECTED TO BASE AT OTHER END.

MOVES OUT,

BRAKE SHOE 8

HAV I NG RiVETED LIN I NG

9,

PULLS AWAY rROM BRAKE WHEEL AND BRAKE SHOE 8' PUSHES AWAY rROM BRAKE WHEEL ON rAR SIDE.

WHEN OPERATOR TURNS SWITCH TO

RETURNS BRAKE SHOES TO SET POSITION AS AIR AD~USTMENTS:

AND

6

TURN HEx ON ROO

7

"SET",

SPRING

2

IN CYLINDER

IS RELEASED rROM CYLINDER.

TO MAINTAIN DISTANCE BETWEEN CLEViSES ~

TO SECURE PROPER CONTACT WITH BRAKE WHEEL.

AD~USTING BOLTS

10

ARE STOPS rOR BRAKE SHOES. NOTE'

BRAKE

IS NORMALLY orr EXCEPT WHEN PROPELLING; AS SWINGING or THE

MACHINE WHEN OPERATING'S STOPPED BY PLUGGING THE MOTORS. NOYE: DESCRIPTION AND OPERATION THE SAME rOR ALL TYPES, PARTS MAY VARY IN DETAIL.

CI-582 - 5 -

ReVised 11-15-51

BI005692

PROPEL BRAKE (BAND TYPE) 7400

a

7800

SPRING SET AIR RELEASED, ELECTRICAL CONTROL USING MAGNET VALVE ONE USED ON 7400-TWO ON 7800 SKETCH

SHOWS BRAKE IN SET To

RELEASE

BRAKE OPERATOR

INTO RAM CYLINDER IN,

I

SWITCH

COMPRESSING SPRING

AND PUSHING PISTON ROD

2

A,

HAS A FULCRUM PO I NT

THERE

OUT, WHICH

3.

PIN CONNECTED TO LEvER CRANK

3

TH~OWS

AIR TO ENTER THROUGH MAGNET VALVE

ALLOWING

..

POSITION

IS

LEVER CRANK

BE I NG PIN CONNECT-

ED TO BOSSEs ON BRACKET AT THAT POINT, OTHER END OF CRANK LEVER

- - - - -Hil---

4

3

II PIN CONNECTED TO LINKS

5;

WH' CH ARE PIN CONNECTED TO LEVER ARM

5

LEVER ARM

B,

HAS A FULCRUM POINT

BEING PIN

CONNECTED TO BOSSES ON BRACKET AT THAT POINT, AND OTHER CONNECTION END OF BRAKE BAND.

IS TO LUG

ON,

8, 9,

ON THE LiVE

7

IS PIN

BAND IS

IN TWO

DEAD END OF BAND

CONNECTED TO BOSS ON BRACKET. PARTS

6

EACH HAVING wOvEN LINING RIVETED

AND CONNECTED TOGETHER WITH

S~LICE

BARS.

BAND IS PROVIDED WITH TWO SPRING LIFTERS

."N'

ANCHORED TO THE BAND,

BAND AWAY FROM THE BREAK WHEEL, RESSION SPRINGS

IN

10

BAND LI FTER SUPPORTS I~~INGS

F~OM

MOVING

8,

2

MOVEI OUT, LEVER CRANK

4

CONNECTING LINKI

I

~ELEA'ID '~OM CYLINDE~

WHEEL,

COM~~EIIION S~RING

NUTI ON 'P~ING

3

CAUSE LEvER A~M

THUI ~UIH I NG BAND AwAY FROM B~AKE

ADJUITMINT . .

THI· LINING.

D~AG

WHICH ltREVENTS THE

•. IF'T£RS

10

5

D~UM

A LIMIT IWITCH

TO CO",jI,UIS IP~ING.

IHAFT, WHIN THI

~INION'

.1 lt~OVIDED THAT MAKII

6

IT

ADJUITING 10LT

O~

WHEN AI R I I

12

WITH ~.

AND LIVE IND 0' lAND, 'O~ WIA~ 0'

I

TO COM~~III

Ilt~ING.

THI lt~O~IL IHA'T II D~IYEN IY ltlNIONI A~I

IN8AGID IT ltOllTIVI JAW CLUTCHEI.

IM~OI'IILE TO ~ILIAII

THI B~AKII A~I UIED TO HOLD THE IHOll 0"

II DI80lN8

10.

A WHICH

AIOUT ~OINT

IN CYLINDER ~ETU~NI BAND TO THE lET ~OSITIDN.

ADJUSTING NUT ON CTLINDE~

CLUTCHII A~I INGAGED. WHILI MAOMINI

TO MOVE, WHICH FULC~UMS

AI DID BY I~~ I NG L I FTE~'

B~AKI WHIILS A~I D~ THI DRAG D~UM IHA'T.

ON THI

CO~~­

ONLY ~ULL OUT, DUE TO

II

MOVES AND FULCRUMI AIOUT ~OINT

HAND AND L. HAND THREADS IETwlEN LUG

NOTII

AS THE

IN.

WHIN ~IITON ~OD II ANCHO~ED.

10

A'D TEND TO PULL THE

I~AKI

UNLIII

THI G~OU.D

~OTATINO.

CI-587 - 6 -

4-/-46

BOOM HOIST BRAKE (CI-589)

BI005692

Tile boom boist brake is the band type and is spring set and manually released.

The operation and adjustments of this brake are explained in CI-589.

HOIST OR DRAG CHECK BRAKE (CI-590) The hoist and drag check brakes are equipped with air operated brake bands. Each of these bands has a separate and independent control system. The adjustments and operations of these brakes are fully explained in CI-590.

PROPEL CLUTCH (L p. 288) This is a jaw type clutcl1 on the left end of the drag drum shaft and is au engaged and spring disengaged. The sprina (1) should be compre8sed by the adjusting nuts (2) sufficiently to assure prompt and complete disengagement of the clutch when the air is released from the ram cylinder.

Caution The spring should not be initially compressed 80 much that it will be compressed solid before the clutch is fully engaged. The stop screw (3) should be set to stop the shifter yoke (4) at one half to three quarters inch after full disengagement.

Note: The stop screw must alway8 be kept properly adjusted so that the ends of tlle clutch Jaws will not strike one another while the drag drum shaft is turning.

When setting the poppet valve adjus ing screw. care should he exercised since only 3/16 inch travel is reqUlred to open the poppet valve and over travel may damage the valve. The adjusting screw should be set 80 that the valve will be full open when the propel clutch is fully engaged, This poppet valve will release the propel brake when the propel clutch 18 engaged. and will set the propel brake when the propel clutch is diseniaaed if the propel brake control is at "Off"

HOIST AND DRAG CLU CHES (L. p. 189) These clutches are the same except for s ,ze and will be discussed together. The clutches are air set and spring released. When air is adm'tted into the air cylinder (1). the crank pin (2) rotates. Lever arm 3) and link (4) CQnnectIJ the crank pin and the air cyhnder. Thia action tightens the frIction band (5) en the housing (6) cau8ina the drum to turn. When air is exhausted from tae air cylinder. the spring (7) will return the band to the released position. The band lifter springs lift and hold Ute band off the clutch housing when the band is released Acijustment of the frictien clutches is accomplished by means of an eye bolt (9).

Tae bands should he adjusted so that they will not require all the air cylinder travel to 'set them. aIlci atill will not slip during the meat severe service. At the same time, the eye. bolt muat be set so that the friction bands will be free and not drag on the clutch housing in the released position The spring (7) should be adjustei by means of the adjusting nut (10) 80 taat the friction band will be pr(tmptly and fully released from the housing when the air is exhausted frem the air cylinder. This sprina s.ould not be adjusted tighter thatl necessary to acceJl1.plish its purpose since the power required to compress the spring will reduce tlle power availahle to aet the friction banel.

No. l017/II

- 7 -

BI005692

TYPE - 7400

a

7800 BOOM HOIST BRAKE

BAND TYPE - SPRING SET, MANUALLY RELEASED SKETCH SHOWS BRAKE IN SET POSITION

I

4

or-51'

I

To RELEAIE BRAKE, MOVE LEVER

3

4

WELDED ON THE END.

LiVE END or BAND

II WELDED TO BAND,

AND HAl CAM

IPRING

3 •

8.

PADDLE 10LT

ENOUGH POWER

5

5

5

I,

.HICH THEN HOLDS BRAKE OPEN.

IS RUN THRO A SUPPORT

6.

PADDLE 10LT

CAM

4

7

rOR

AND CONTAINI COMPRllalON

IS WELDED TO BAND AND PAIIES THRU SUPPORT

10.

As LEVER

I

IS MOVED, CAM

4

MOVES AND

8;

IF'

WILL MOVE UNTIL rLAT SPOT ON CAM CONTACTS STOP

COMPRESSION SPRING

8

WILL RETURN BAND TO lET POSITION

IS HELD OPEN.

7

TO COMPRESS SPRING

NUTS ON BOLT

9

rOR WEAR or LINING.

7400

3.

2

THUS PUSHING BAND AWAY F'ROM BRAKE WHEEL AND COMPRESSING SPRING

ADJUSTMENTS: NUTS ON BOLT

TYPE -

PIN

IS WELDED TO BAND

PAIIEI THRU SUPPORT

rOR DEAD END or lAND

IS APPLIED TO LEVER

ExCEPT WHEN BRAKE

2,

IS KEYED TO PIN

STaP BAR

BAND HAl "OLDED AND COMPRESSED LINING

CONTACTS STOP BAR

BAR

9

WHICH

SAME TYPE

BAND.

8

AND rOR WEAR or LINING.

OPERATION AND DESCRIPTION AS

7800

BUT PAATS WILL VARY

CI-589 - 8 -

4-1-46

IN DETAIL.

BI005692

HOIST CHECK BAND DRAG CHECK BAND

TYPE-7400 HOIST CHECK SAtC>-AIR SET- SPRING RELEASE-FOOT OPERATED SKETCH SHOWS SAND IN SET POSITION

I

A R II ALLOWED TO INTEft CTLINDEft RI.ULA 'T

~LOW.

NG TNI AIR

I'

3,

O"NIoTI' TO OLlv11

OOIl~RI,

I~R'"

'10"

AR.AN.IIIEliT

~RA"E

AIIC,lOlhD TO IIAeMIIIII" TRUII.',-II TO

AI THE AIM

7 ,.

WHICH

aT

A

I"~,'T

~

I'

5 r.

I,

4

6,

rwo IEARINOll

IU~~OftTI ftOIl ~AIIEI THftU L I \'E

AND

TKAT ALia

6 I,

2,

ftOD

4

N OONNECTED "'0 LEVEft AftM

ATTACHE' TO LEvEft Aftll

~OlNT ~'.

NTWIUI .EAft I NG.

t,

EV;,1 ARII

AT

8T ACTION or F10T ~EDAL WHICN CONTftOLI THE

IS ADMITTED TO CTLINDEft

THlftE

Alft VALVE,

IN MOVES OUT,

J A CLEVIS, ftOD, AND

4,

AND lOll ON LEVEft

II

'4.

AftE C;;ONNECTED TO AftMI LEVEft IH 10M' HAS A OLEV I SEND THA

10.

fND OF lAND

r

0

9

LEvEft AftM

NNE' T' II

IS· • [)cAD EN' OF lAND II , I ' ~ I N CONNECTED TO MACH I NER" 12. 13, EAOH HAV'NG Fft ICT I ON ILOOK. 10L iED ON, AND OO)lNECTEI BANI II ~ftOVIDED WIT" S~R'N. LIFTERI 14, WHIOH TEND TO ~ULL ~HE AI THE OOIl~REI'lo" I~RING' til 14J O"LY ~ULL OUT, DUE TO 'A"D LIFTER

AN'PHOft" 0 TO MAOH,"IIY FRAIII AT ~O' NT FRf"III.

BAND

II

I II TWO

'~LIOE

TO.fTMIR W'TN

~ARTI

'ARI.

lAND AIAT 'ROII 'HE "OUI'N',

IU~~ORT

~OINT

15

WHIOM

2,

WHEIi ROI ... ,

~REV["TI

TO

~IIIH

IA,";;

'~RIN.'

FROM IIOVI'"

1I0VII OUT, LEVER ARII

OAUSINO RO' •

10, THU' 5 .. ULLI LEVIII A.II 9,

IND OF IA"D 10" .... IN.

TMI

IN

4

TO "uLL L:"vIR Altll

.ITTI N. THE IRAKE. Llvr" ARII

4,

1I0VI.,

9

I".

OOIl~Rr'"I1• • ~ftl".

5 "A'"

"ft,

10,

2,

~ULCRUIII

AND TO

WHIII A1ft . . E ~MAu,Tr, FROII "C'L I "IIR

THUI IIEITOIILN. 1101

A"D LIVE END 0' lAND

III

WNION '"LO.UII. AT "Ol"T

I,

~ULL

.O... ~"I ••-

INTO O'''t.IIR A.' CAUIII ROI

AND WITH THE Ai.

O~

AT

Llvl

8

14,

'''.'N' LI'TIII.

II RELIAIII FROII IIIAKI MO"II I " .

ADJUITIIENTI' NUTI 0"

I

OOIl~REI'

TO

NUTI 0" ROI . .

1 .. IIING.

NUTI."

I~R'''O L'~TI'"

14

TO 00-.11111

'~III"GI.

rOil wEAR or L N'" ILOCKI.

OftA. CHIOK BAN,-Alft SIT-S~.I". RELrAI~-FooT OPERATII SKITOH SHOWI BAli' IN SET POIITIQ"

O.. ERATIOII

AND AIIIIAIIOlllrll' IAur .1 '011 HOIIT .HICK IA~D IXor~T, LIVEII ARII II D,REOTL'

CONNECTED TO LIVI END or lAND, OF lAND

II IIIED '011 AD.lUITIIE"T

ANI ADJUI,ING 10LT liT

R.H.

All'

l.H.

THllrAII, all LivE E",

-, L ' . ' . 'Loo•• WIA ••

CI-590 - 9 -

4-1-41

BI005692

PROPEL

- 10 -

CLUTCH

L.F? 288 -

BI005692

HOIST and DRAG CLUTCHES

- 11 -

L.F? 289

BI005692

AIR COMPRESSOR

The air compressor and motor will be operated and maintained according to the instructions of their respective manufacturer's.

MAIN DRIVE COUPLINGS

See the Fast's Flexible Coupling Co. bulletins in Miscellaneous Section.

SWING GEAR CASE OIL PUMPS

See Tuthill Pump Instructions in Miscellaneous Section.

No. l017/U

- 12 -

9/1955

BI005692

CONTROL FOR TYPE 7400 HOIST AND DRAG BRAKES

TME TY~l

I

I I I

d ~~~$'":.:>

7400

·WALKING

DRAGLINE

IS EQUI~~ED WITH A'~

O~ERATED

eRAKE eANDS ON THE

HOIST DRUM AND ON THE DRAG DRUM. A

EACH or THESE BANDS HAS

SE~ARATE

AND

I NDE~ENDENT

CONTROL SYSTEM. CONSISTING OF A FOOT ~EDAL AT THE O~ERATOR'S STATION. DIRECTLY CONNECTED TO AN AIR

CONTR~L

VALVE. WHICH

IN,

TURN GOVERNS THE ACTION OF THE COM~RESSED

AIR

CYLINDER

~OWER

THAT SETS THE BRAKE.

By MAIN-

TAINING THE CONTROL SYSTEM IN ~RO~ER

ADJUSTMENT. THE

ION OF THE FOOT

O~ERAT­

GivES

~EDAL

THE OPERATOR T~E tt FEEL" ~RESSURE ~OWER

OF THE

BEING DELIVERED TO THE

CYLINDER,

AS THE FOOT

TRAVEL AND FORCE ARE DIRECTLY ~RO~ORTIONAL

TO THE AIR

~RES­

SURE DELIVERED BY THE VALVE. THE O~ERATION OF THE FOOT ~EDAL

RESEMBLES ORDINARY DIRECT

MECHANICAL CONTROL BUT THE RESULTS ARE OBTAINED WITH A GREATLY REDUCED DRAWING SHOWS THE GENERAL ARRANG~MENT OF THE TWO FOOT ~EDALS TOGETHER WITH THEIR RES~ECTIVE CONTROL VALVES AND CONNECTIONS. IS ~ART OF AIR VALVE ~EDAL

THE FOOT

3

~OINTS.

5

THE VERTICAL LEVER

4

7

U~

AIR CONTROL VALVE O~ERATES.

5

2.

IN THE VALVE LEVER ARM

2

AND THE VALVE LEVER ARM

VARIED AS DESIRED.

~EDAL

6.

ROCK SHAFT

FURTHER VARIATIONS

THE CONNECTING ROD

IT ~OSSleLE

4

4

B

IS

IN THE LOWER HOLE

HOLE OF THE VALVE LEVER

IS ALWAYS DESIRABLE TO

KEE~

IS OBTAINED CONSISTENT WITH

FROM ONE

BETWEEN THE FOOT ~EDAL

I S ADJUSTABLE AT EACH END, SO THAT THE LENGTH CAN aE

IN THE VALVE LEVER ARM.

SOFTEST O~ERATION OF THE BRAKE IS OBTAINED WHEN ~IN TO~

AS TWO ARMS

IN THE O~ERATION OF THE

THE MAXIMUM SPEED AND SEVERITY OF THE eRAKE IS OBTAINED WHEN ~IN

TO~ OF THE SLOTS AND ~IN

IS IN THE

FROM

OR DOWN TO VARY THE LENGTH OF TRAVEL OF THE

AIR CONTROL VALVE CAN BE OBTAINED BY SHIFTING THE ATTACHMENT OF THE CONNECTING ROD

LEVER ARM

4

IN RELATION TO THE TRAVEL OF THE FOOT ~EDAL. THEREey CHANGING THE RELATIVE

S~EED WITH WHICH THE

HOLE TO ANOTHER

W~ICH

2

ALTHOUGH THE HOLE AT THE END OF THE LEVER

ATTACHED TO THEtFOOT

WHICH ARE SLOTTED TO ~ERMIT MOVING THE ~IN CONNECTING ROD

AT THE O~ERATOR'S STATION

,

THE CURVED LEVER ARM

IS ~ROVIDED WITH A SERIES OF HOLES SO TH,AT THE CONN~CTING ROD

CAN BE ATTACHED AT VARIOUS

IS GENERALLY USED.

EFFORT.

~HYSICAL

7

7

IS AT THE

THE SLOWEST S~EED AND

IS AT THE BOTTOM OF THE SLOTS AND ~IN

8

A~M.

THE BRAKES ADJUSTED ~ROPER

IN SUCH A WAY THAT THE SOFTEST

CONTROL AND SAFE

MARION

POWER SHOVEL COMPANY MARION. OHIO

O~ERATION

O~ERATION.

CI -591 4-/-46

BI005692

BI005692

a

PROPEL BRAKE (BAND TYPE) 7400

7800

SPRING SET AIR RELEASED, ELECTRICAL CONTROL USING MAGNET VALVE ONE USED ON 7400-TWO ON 7800 SKETCH SHOWS BRAKE IN SET POSITION To RELEASE

BRAKE OPERATOR TH~OWS SWITCH

ALLOWING AIR TO ENTER THROUGH MAGNET VALVE

..

INTO RAM CYLINDER IN,

I

COMPRESSING SPRING

2

AND PUSHING PISTON ROO

PIN CONNECTED T(I LEVER CRANK

3

A,

HAS A F'ULC~UM POINT

THERE

OUT, WHICH

IS

LEVE~ CRANK

3.

BEINO PIN CONN,ECT-

ED TO BOSSES ON BRACKET AT THAT POINT, OTHER END OF' CRANK LEVER

-----+++--

4

3

II PIN CONNECTED TO LINKS

5;

WH I CH ARE PIN CONNECTED TO LEVER ARM

5

LEVER ARM

B,

HAS A F'ULCRUM POINT

BEING PIN

CONNECTED TO BOSSES ON BRACKET AT THAT POINT, AND OTHER CONNECTION END OF BRAKE BAND.

6

IS TO LUG

CONNECTED TO BOSS ON B~ACKET.

8, 9,

PARTS ON,

IN

10

BAND LIF'TER SUPPORTS

2

WOvEI OUT,

CONNECTING LINKI

4

LEvER CRANK

I

COMP~ESSION IPRING

NUTI ON I"~INO

3

CAUSE LEVER A~M

THUI "UIHING BAND AWAY F'ROM BRAKE WHEEL,

~ELEAIEO '~OM CYLINDER

AOJUITMENTII

THE'LINING. B~AKI WHEELI

ON THI

A

D~AG

10

TEND TO PULL THE AS THE COWP-

ONLY PULL OUT, DUE TO

II

WHICH P~EvENTS

•. I!'"TERS

10

WOVES AND F'ULCRUWS AIOUT POINT

5

THE

TO WOVE, WHICH F'ULC~UMS

;dDEO BY IPRING LIF'TE~I

TO CO!llp!tUS IP~ING.

6

ADJUSTING NuT ON CYLINDER

A~I O~ THE

O~AG

D~UM

10.

A

WHICH

AIOUT POINT WHEN All'

IHA'T.

AOJUITING 10LT

12

WITH ~.

AND LiVE END 0' lAND, 'O~ WEA~ 0'

I

TO COM"~EII

IPRING.

THE P~OPEL IHA'T II D~IYEN IY "INIONI

DRUM IHAF'T, WHEN THE PINIONI ARE INGAGID IY POIITIVI JAW CLUTCHEI.

LIMIT IWITCH II "ROVIDED THAT MAKEI

CLUTCHII ARE ENGAGED.

IS

IN CYLINDER ~ETU~NI BAND TO THE lET POIITION.

HAND AND L. HAND THREADS IETwEEN LUG

NOTEI

IN TWO

IN.

WHEN PilTON ~OD

8,

A~D

FROM THE BREAK WHEEL,

RESSION SPRINGS

ANOHORED.

IS

IS PROVIDED WITH TWO SPRING LIFTERS

BAND AWAY

.1

IS PIN

EACH HAVING WOVEN LINING RiVETED

ANCHORED TO THE BAND,

FROM WOVING

BAND

7

AND CONNECTED TOGETHER WITH SPLICE BARS.

BAND

SP~INGS

ON THE LiVE

DEAD END OF BAND

IT

IMPOIIIILE TO RILE All IRAKE UNLIII

THE BRAKEI ARE UIED TO HOLD THE IHOEI 0"

WHILI MACWINI II DIGGING 0 .... OTATING.

- 6 -

THI GROUNO

BI005692

BI005692

SECTION III

OPERATING INSTRUCTIONS

MARION 7400 ELECTRIC WALKING DRAGLINE

No. 1017/111

- 1-

9/1955

BI005692

OPERATOR'S CONTROL PANEL (L. P. 290) MAIN A-C CABINET (L. P. 291) STARTING Before starting the machine, a careful inspection should be made of all movable parts to make sure no loose bolts, nuts or tools of any kind have been left laying loose which might become engaged in the gear teeth, in the motors or in the generator set thereby causing serious damage.

1.

Turn the M-G set by hand to make sure that it rotates freely and that it is clear from all obstructions. (Only necessary when starting for the first time, or after making repairs).

2.

Start the blowers by pressing the blower pushbutton, located on starting panel of the main AC cabinet.

3.

Turn the selector switch mounted in operator's cab to the "ON" position to close the circuit to the undervoltage device.

4.

Press the plunger of the undervoltage device by hand and close the "Starting" lever (left hand) on the oil circuit breaker momentarily to start the M-G set. The direction of rotation should be in the direction shown by indicating arrow on name plate of M-G set.

5.

After the direction of rotation has been ascertained to be correct, start the M-G set by closing the "Starting" lever on the oil circuit breaker and bring the set up to speed. When the set is up to speed, the AC ammeter on front of panel will show minimum amount of current.

* 6.

After the set has reached full speed, drop the "Starting" lever and immediately close the "Running" lever with the right hand. The "Starting" lever must be clear out before attempting to close the "Running" lever.

* 7.

Turn the "Field Switch" mounted to the right of the starting levers to "Closed" position to apply the field to the synchronous motor.

* For G. E.

machines produced after January I, 1965 See Addendum Sheet I, paragraph 1 and 2.

HOIST AND DRAG WITH SYNCHRONIZED CONTROL

First the operation of the hoist and drag motions will be described using synchronized control which is standard for all type 7400 electric draglines, and will be included on all such machines sold unless specifically requested otherwise. Briefly, synchronized control consists of an arrangement whereby, when the hoist and drag drums are engaged at the same time, the drag cable pays out automatically as the bucket is hoisted and the hoist cable pays out automatically as the bucket is dragged in, which, in effect, makes a continuous or closed circuit of the hoist and drag cables.

No. 101 7/ III

-2-

9/1955

BI005692

ADDENDUM SHEET 1 For all G. E. Machines produced after January 1, 1965 with manual voltage starting the following applies:

l'l~,illCt·ti

1.

After the set has reached full speed, close the run oil cirellI, f,l crtker thereby shorting out the starting reactor. The start O. ( . h. n"llst remain closed at all times while the sync motor is running.

2.

Apply the field to the synchronous motor by depressing the tJush button "START".

No. 101 7/ III

- 2A-

5/1968

BI005692

BI005692

OPERATOR'S

CONTROL BOX

I

r-

I

MG

SET

II

0

lAIR COMp.1

I

ISWI~G BRAKE

- 3 -

I

EXCITER EMER. _ .........

(5

L.P.290

BI005692

MAIN A-C

AC VOLT

METER

DC VOLT

AC

AMMETER

START

BLOWER

CABINET

METER

RUN

[;]

FIELD

~

SWITCH

o o o

00 00

-"-

L.P 291

BI005692

The use of synchronized control should be limited to operations where normal depths of digging are encountered, as in the bituminous coal fields or for other work of a like nature. It is not desirable for extremely deep digging such as is encountered in the anthracite coal fields. On the Type 7400 there is little difference in the equipment for synchronized and conventional control and the conversion can be made from one type of control to the other. The changes necessary for this conversion will be discussed in the Electrical Section.

Before attempting to operate the hoist and drag motions, set the "Hoist-Propel" selector switch in the "Hoist" position; set the "Hoist-Drag" ram controller in the middle or "Neutral" position; move the "Hoist-Drag" master switch (right of operator) and the "Swing" master switch (left of operator) to their neutral positions; start the air compressor and build the air pressure to 115 pounds. Press the "Start" button of the "Emergency" pushbutton station to obtain excitation for the control.

The hoist and drag motions are both controlled by means of the "Hoist'Drag" master switch. The latch on the master switch handle when pressed will speed up the lowering of the bucket when swinging into the pit. The "Hoist-Drag" master switch provides five points of graduated control, each successive point giving increased power. This master switch controls the dragging in of the bucket and the hoisting of the bucket. Two foot brakes are provided, one for the hoist and the other for the drag drum. These brakes are used to control the paying out of the drag cable and the lowering of the bucket.

To describe a cycle of operation, assume that the bucket is in the pit under the boom point and ready to be dragged in for loading. The "Hoist-Drag" ram controller has already been set in the middle position so that both the hoist and drag rams are engaged to connect both drums to the motor, the gear ratios being such that the speed of the hoist cable is about 10% faster than the speed of the drag cable. The "Hoist-Drag" master switch handle is then moved over to the "Drag" position and as the bucket is dragged in the hoist cable pays out automatically.

This is the normal method of operating and both rams are kept engaged during the dragging part of the cycle.

If the hoist cable pays out too fast or if it is desired to drag with the hoist drum disengaged, the operator throws the ram controller to the "Drag" position which disengages the hoist ram, and he then holds the hoist drum with the foot brake.

Or if the operator wants to reduce the depth of the bucket cut, he simply disengages the hoist ram as above and holds the hoist drum with the foot brake until the hoist cable slightly lifts the bucket as it is being dragged in. The hoist cable should payout gradually so that the hoist cable does not become too slack. By keeping the hoist cable taut, the depth of digging can be controlled.

When the bucket is filled and with the "Hoist-Drag" ram controller in the middle position, the operator moves the "Hoist-Drag" master switch handle to the opposite or "Hoisting" position which reverses the motor, causing the hoist cable to be pulled up and the drag cable to payout simultaneously.

In normal operation, the bucket is hoisted to the dumping position with both drums engaged, and, when a high height of dump is required, the bucket dumps itself No. 1017 /III

- 5 -

9/1955

BI005692

automatically. If, with the synchronized control, the drag cable pays out too fast and there is not sufficient pull on the drag cable to keep the bucket from dumping as it is being hoisted, the operator throws the "Hoist-Drag" ram controller to the "Hoist" position to disengage the drag drum and then he holds the drag drum with the foot brake until the desired pull is obtained from the drag cable to prevent the bucket from dumping. When proper tension has been obtained from the drag cable, the "Hoist-Drag" ram controller switch is thrown to the middle position so that both hoist and drag drums are again engaged as the bucket is hoisted to the dump point. When it is desired to dump the bucket below the point at which it would dump automatically, the operator throws the "Hoist-Drag" ram controller to the "Hoist" position to disengage the drag drum and the bucket swings out and dumps. This also enables the operator to dump the bucket beyond the point of the boom when a greater bucket throw is desired. By controlling the drag drum with the foot brake, the operator can prevent too much drag cable from paying out under such conditions. The longer the hoist cable between the bucket and the point sheave, the further the bucket may swing out and dump beyond the point of the boom.

During the hoisting and dragging periods, it is important to avoid having too much tension on the drag cable to prevent pulling the bucket up near the boom as this will cause undue strain on the boom. When paying out on the drag just enough pull should be applied to prevent the bucket from dumping. More pull tha.n this simply slows up the hoist and adds excessive strain on the boom.

To complete the cycle, the bucket must be lowered into the pit. The bucket is designed so that it will dump forward with teeth down. Ordinarily, the bucket is left hanging with the teeth down until it is lowered. It can be righted, if desired, by pulling in on the drag cable with power. To lower the bucket, the usual practice is to set the "Hoist-Drag lt ram controller in the "Hoist" position to disengage the drag drum, reverse the "Hoist-Drag" master switch handle and lower the bucket regeneratively with only the hoist drum engaged; in which event the bucket lands in the pit immediately under the boom point. In case the operator wants to spot the bucket nearer the machine or if he desires to begin dragging part way up the face on the next cycle, he may lower the bucket by synchronized control with both the hoist a.nd drag drums engaged. In this way, the bucket wil~ be pulled in automatically as it is being lowered into the pit.

If desired, the bucket can be lowered by disengaging the hoist drum (by squeezing the latch on the "Hoist" master switch) and allowing the bucket to fall using only the hoist foot brake to control the fall. However, this method of lowering is not recommended unless the machine is equipped with oversize hoist brakes, for it causes excessive wear on the hoist brake.

HOIST AND DRAG WITH CONVENTIONAL CONTROL The operation of the hoist and drag motions using the conventional control differ s little from that already described for the synchronized control. It is only for the middle or "neutral" position of the "Hoist-Drag" ram controller that the action is entirely changed. The main difference to keep in mind is that for the conventional control, when the "Hoist-Drag" ram controller is in the middle position,

No. 1017 lIn

- 6 -

9/1955

BI005692

both the hoist and drag cables payout at the same time or take up at the same time, depending on the direction of rotation of the drum. With this arrangement, it is possible to operate the hoist and drag so that the operator may hoist at the same time he is dragging.

As pointed out above, a great many of the operations are the same for synchronized and conventional control, but to clearly define the differences a complete cycle of operation will again be explained, this time using the conventional control.

We will assume that the bucket is on the ground directly beneath the point sheaves, the hoist and drag brakes set and the machine otherwise ready to operate ("HoistPropel" selector switch in the "Hoist" position; the "Hoist-Drag" master switch and the "Swing" master switch in their neutral positions; and the "Hoist-Drag" ram cont roller in the "Drag" position). The operator should, simultaneously, release the drag drum brake and apply power gradually by slowly opening the master switch for dragging. This will start the bucket moving in toward the machine. As the bucket progresses, it will be necessary to allow the hoist cable to payout by releasing the hoist drum brake, however, the cable should be paid out gradually so that the hoist cable does not become too slack. As soon as the bucket is filled the drag brake should be set and the tlHoist-Drag" ram controller moved to the "Hoist" position. In order to avoid engaging the hoist drum with a jerk, the "Hoist-Drag" master switch should be moved to slow up the hoist motor. After the hoist drum is engaged, the "Hoist-Drag" master switch should again be moved to the wide open position to hoist at full speed. As the operator becomes more experienced, he will be able to make the change from drag to hoist by taking advantage of the reduction in speed resulting from the heavy pull just before the bucket is completely filled. As the bucket hoists, the drag cable should be allowed to payout gradually by partially releasing the drag brake so that the tension will be maintained on the drag cable at all times to prevent the bucket from dumping. To dump the bucket, release all tension on the drag cable by fully releasing the drag brake. After the bucket is emptied, the operator should begin to lower the bucket by releasing the hoist foot brake and reversing the "Hoist-Drag" master switch handle and lowering the bucket regeneratively with only the hoist drum engaged; in which event the bucket lands in the pit immediately under the boom point. In case the operator wants to spot the bucket nearer the machine or if he desires to begin digging part way up the face on the next cycle, it will be necessary to release the hoist drum by moving the "HoistDrag" ram controller to the "Drag" position and reverse the "Hoist-Drag" master switch to apply power in the direction for dragging and by use of the foot brake, allow the hoist cable to payout as necessary.

If desired, the bucket can be lowered by disengaging the hoist drum (by squeezing the latch on the "Hoist" master switch) allowing the bucket to fall, using only the hoist foot brake to control the fall. However, this method of lowering is recommended only when the machine is equipped with oversize hoist brakes.

The middle position on the "Hoist-Drag" ram controller may be used at any time it is desired to operate the hoist and drag simultaneously. This procedure is often necessary when the machine is sitting on top of a bank with a rather steep No. lOI7/III

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9/1955

BI005692

incline. When moving the "Hoist-Drag" ram controller to the middle position to engage both drums, the operator must be very careful not to engage the other drum while the bucket is coming in fast.

SWINGING

When it is desired to operate the swing motion, the "Swing Brake" selector switch must be turned to the "Off" position, thereby releasing the swing brake. The swing lock brake is used only to hold the machine from swinging while the machine is not operating or when the shoes are on the ground. (The swing brake is automatically set when the shoes are on the ground).

The swing motion is controlled by means of the "Swing" master switch located to the left of the operator. This master switch provides four points of graduated control in each direction. Each successive point of the master switch gives increased power. The "Swing" master switch is so connected that when the master switch handle is moved forward the machine will swing to the right, and when the handle is moved backward the machine will swing to the left.

When swinging the machine the operator must be certain that the bucket has been raised to clear all obstructions. The master switch handle should be moved gradually to the end of its travel. To stop the swing motion the master switch handle should be brought to the neutral position and then moved slowly to apply power for swinging in the opposite direction. This procedure of applying reverse power to the swing motor to bring the machine to a stop is known as "Plugging". When the machine comes to rest, the master switch handle should be brought immediately to the neutral position or the machine will start to swing in the opposite direction.

Intermediate swing speeds can be obtained by moving the "Swing" master switch handle to the intermediate points.

The operator should start swinging the machine in the direction of the place where he is to dump as soon as the bucket has cleared the ground and at the same time continue hoisting and paying out on the drag cable as described previously. Dragging the bucket through the ground after it is filled is a waste of power and time.

On a dragline, it is essential that the operator start swinging and stop swinging smoothly so that the bucket will not swing like a pendulum. This is very important especially when it is necessary to dump the bucket into cars or trucks. When dumping on to a spoil bank, a certain amount of swing in the bucket can be tolerated. After the bucket is emptied, the operator should begin to lower the bucket by releasing the hoist foot brake at the same time he swings to return to the digging position provided that no obstructions lie between the dumping position and the digging position.

PROPELLING The propelling on a walking dragline is accomplished by a series of "Steps".

Each step represents a complete revolution of the main propel shaft which runs across the machine. On each end of this shaft there is attached the walking mechanism.

No. 1017 I III

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9/1955

BI005692

Before starting to propel, be certain that the "Hoist-Propel" selector switch is turned to the "Propel" position.

The propel clutch is of the jaw type and it is neces.sary that the two halves of the clutch be lined up before the clutch will engage. The hoisting machinery should be turned very slowly until the clutch halves engage.

The propel control is so arranged that the maximum speed of walking is controlled automatically throughout all parts of the cycle. Intermediate speeds can be obtained for various positions of the master switch.

Before starting to propel or walk, the operator must swing the machine so that the rear end of the machine is pointing in the direction in which he wishes to travel. As long as the propel clutch is engaged the swing is limited so that it is impossible to swing the machine while the shoes are on the ground. The machine, therefore, will not respond as readily to the movement of the swing controller while the propel clutch is engaged.

To propel, the operator moves the "Hoist-Drag" controller handle to the If Drag" position. The control of the propel can be obtained through the master switch by moving the handle to the various points. If it is desired to start propelling at full power. move the master switch to the full "On" position. The control is 80 arranged that the lowering of the tub in the walking cycle is retarded regeneratively to allow the machine to set down gently. Should it be desired to set the tub down more slowly than the automatic control permits, the operator can move the control back to the neutral position to set the propel brake and allow the tub to drift down with the brake engaged. This procedure should not be used except in rare cases for it will cause the propel brake to wear rapidly.

As soon as the shoes start to move down toward the ground a red warning light mounted on top of the control box to the right of the operator will light. This light remains on during all parts of the walking cycle except when the shoes are in the raised position, normal for digging.

The walking cycle is accomplished in four steps, each step representing 90 degrees rotation of the propel shaft; first, lowering the shoes; second, raising one edge of the tub; third, lowering the tub; fourth, raising the shoes. Drawing GR-3634 shows these four positions in sketches "A", "B", "G" and "0" respectively.

The edge of the tub will follow an arc shown in sketch "A". This cycle will be repeated until the machine has traveled or stepped as far as necessary.

The speed of lowering of the machine is controlled by a reverse current relay which will be described fully in the Electrical Instructions.

When the operator wishes to continue digging. he must be certain that the shoes are in their raised position as indicated by the signal light which is out only in this position. Should the operator find that the shoes have traveled beyond this point, he may move the shoes back to the proper position by moving the "HoistDrag" master switch handle in the "hoist" direction. The "Hoist" position of the No. 1017 III!

- 9 -

9/1955

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

SKETCH A

BI005692 ,

I

SKETCH B

,

SKETCH C

,

SKETCH 0

uQ.16,1938

- 10 -

CR-3634

BI005692

master switch allows only minimum power for moving the shoes in reverse and not sufficient to raise the tub. After taking the final step for a move up, the operator should be careful in bringing the shoes to the normal raised position to avoid reversing.

No. 1017 III!

- 11-

9/1955

BI005692

BI005692

SECTION IV

LUBRICATION INSTRUCTIONS

MARION 7400 ELECTRIC WALKING DRAGLINE

No. 1017

-

1 -

9/1955

BI005692

GENERAL L UBRICA TION The lubrication instructions in this manual are intended as a general guide for ordinary operating conditions. Deviations may be required where unusual conditions are encountered, such as excessive dust, excessive moisture, extremes of heat or cold, etc. Lubrication periods indicated are actual operating hours.

It is important to make sure every rotating or movable part is properly lubri-

cated. All gears a.nd pinions which are not enclosed should be kept coated with a good grade of gear compound, as recommended in lubrication instructions.

Oil should be kept at the proper level in all enclosed gear cases.

All roller and ball bearings in the Mechanical Section should be kept about 1/2 full of the lubricant recommended in the Lubrication Instructions, and only enough grease should be added to maintain this level. These are oil tight bearings and the grease level will usually remain constant over a long period of time; therefore, only very small quantities ever need be added. Unless otherwise specified, we recommend a small amount of grease every 500 hour s which will usually maintain the desired level in the bearing of about 1/2 full at all times.

If these bearings should ever become completely filled, the addition of more grease would result in a pressure being built up inside the bearing and heating would result. If a bearing should appear to be running excessively warm, it would be advisable to remove the pressure fittings and allow some of the excess grease to escape. If grease becomes dry and grooved, it must be replaced with new fresh grease.

All bronze or other sleeve bearings should be greased or oiled as indicated in the Lubrication Instructions.

SYMBOL

SPECIFICATIONS - REGULAR OILS

GL

Gear Lubricant. SAE 90, EP, for Winter; SAE 140, EP, for Summer, unless otherwise specified. Non-corrosive, Extreme Pressure Lubricant.

MO

Motor Oil, Good Grade, Non-Detergent, for Air Compressor, SAE 20, for Winter; SAE 30 for Summer. (May also be used for miscellaneous oiling). NOTE: Where "MO" is specified for use other than in Air Compressor, any good grade of motor oil may be used.

SPECIFICATIONS - REGULAR GREASES

CG

Chassis Grease (Lime Base - Water Repellent).

WB

Medium Fibre Wheel Bearing Grease (Soda Base - Heat Resistant).

GC

Gear Compound, Winter or Summer Grade as required.

(Texaco Crater or equivalent).

No. 1017/IV

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9/1955

BI005692

MISCELLANEO US - SPECIAL Neat's-Foot Oil for Air Cylinders with Leather Piston Cups. (If not obtainable, use SAE 30 Motor Oil).

Lubriplate #110 (Fiske Bros. ) for Air Valves.

Westinghouse Grease S#1449556, for Ball and Roller Bearings on equipment built by Westinghouse Corporation.

General Electric Grease ID6A2A3, for Ball and Roller Bearings on equipment built by General Electric Company.

AIR CONTROL VALVES AND AIR CYLINDERS Air Valves are lubrica.ted with Fiske Bros. #110 Lubri-plate a.t assembly. After every 8 to 12 months of ordinary service, the valves should be disassembed and coated with this lubricant. (Fiske Bros. 1110 Lubri-plate may be purchased from Fiske Bros. Refining Company at New York, New York; Toledo, Ohio; or Newark, New Jersey). If the lubricant specified above is not obtainable, use some other good calcium zinc base (waterproof) grease. In case excessive condensation is present or if equipment is operated under extremely dirty or dusty conditions, we suggest checking and lubricating air valves more frequently than for ordinary conditions.

Air cylinders are lubricated with Elco # l58-LO grease at assembly. Every month or two all air cylinders should be lubricated with a small amount of Neat's-Foot Oil. This will keep the cup leather and seal pliable. Refer to repair list sheets which show necessary parts to be lubricated on all valves and cylinders.

No. 1017 /lY

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9/1955

BI005692

NAME OF PART

TYPE BEARING

NO. LOC. LUB. FITTING LOCATION FTGS. NO. SYM.

ROLLER CIRCLE AND TRACK

L. p. 14

Roller Circle Track

2-rails below rollers Brush 2-rails above rollers

Roller Circle Rollers

In end of each roller pin

WALKING SHOE SWIVEL MECHANISM

1

77

LUB. PERIOD IN HOURS

MO

24

CG

24

L. P. 2

Cam Roller for Spring Return

Bush

In top of anchor pin

2

5

CG

168

Plunger in Return Mechanism

Bush

On forward end of cover plate

2

6

CG

168

Plunger in Return Mechanism

Bush

On r ear end of cover plate

2

7

CG

168

Spring Inside Plunger

Factory packed, no lube req'd.

8

Bearing in Swivel for Shoe

Bush

In top of swivel anchor pin

4

9

CG

24

Front Journal Bearing

Bush

In end of arm of yoke casting

2

10

CG

24

Rear Journal Bearing

Bush

In end of arm of yoke casting

11

CG

24

Bearing for Propel Linkage Connection

Bush

In outside end of pin in yoke connection

12

CG

24

Slide Block Shoe

On top of each slide block cover

8

13

CG

24

Rear Yoke Casting Slide Bearing

In each side of keeper casting

4

14

CG

24

PROPEL LINKAGE

L. P. 21 17

CG

24

18

CG

24

Walker Arm Bearing Connection

Bush

On boas at bottom of walker arm

Bearing for Stabilizer Anchor Casting

Bush

On boss at upper end of stabilizer arm

No. 1017/IV

- 4 -

2

9/1955

ROLLER CIRCLE and TRACK

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- 7 -

BI005692

NAME OF PART

TYPE BEARING

LOC. LUB. NO. FITTING LOCATION FTGS. NO. SYM.

LUB. PERIOD IN HOURS

PROPEL LINKAGE (Cont'd.)

Walker Arm and Stabi- Bush Iber Conn. Bearing

On boss at lower end of stabilizer arm

2

19

CG

24

Bearing for Crank

In top of walker arm casting

4

20

CG

24

Brush

21

GC

8

4

40

CG

4

Bush

UPPER FRAME MACHINERY

L. P. 26

Main Swing Gear and Pinion

Apply to gear teeth

Center Journal Bearings

Bush

Two on LH side, on deck at base of hoist drum shaft bearing Two on RH side, on deck at base of drag drum shaft bearing

Hoist Drum Shaft Bearings

Bush

Two in each bearing cap

4

41

CG

4

Hoist Drum Barrel Bearings

Bush

Three in each hub

6

42

CG

4

43

GC

24

Hoist Gear

Apply to gear teeth through opening in guard

Drag Drum Shaft Bearings

Bush

Two in each main bearing cap and two in bearing cap, LH side of propel pinion

6

44

CG

4

Drag Drum BarreI Bearings

Bush

Three in each hub

6

45

CG

4

46

GC

4

47

WB

500

Drag Gear

2nd Intermediate Extension Shaft

No. 1017/IV

Apply to gear teeth through opening in guard AntiFriction

Two in each bearing cap

- 8 -

4

9/1955

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NAME OF PART

TYPE BEARING

LOC. LUB. NO. FITTING LOCATION FTGS. NO. SYM.

LUB. PERIOr: IN HOUR

UPPER FRAME MACHINERY (Cont'd. ) Worm Shaft Bearing (Front)

Bush

At base of gear case on RH side

1

63

CG

When req'd.

Int. Boom Hoist Shaft Bearings

Bush

One in bottom of bear- 2 ing, one in top of bearing

64

CG

When req'd.

Boom Hoist Motor

See Electrical Instructions

65

When req'd.

Worm & Gear in Case

Pour into opening in top of guard. Caply.

4-1/2 gal.

66 GL, SAE 90 at all times

When req'd.

Top Swing Shaft Bearing

Bush

At front of each swing gear case

2

67

CG

8

Bottom Swing Shaft Bearing

Bush

On deck at rear of each swing gear case

2

68

CG

8

Spur Gear Bearing on Top of Main Rotating Shaft

At front of each swing gear case

2

69

CG

8

Oil Circulating Pump

See Electrical Instructions

70

Hoist Check Band Ram Cylinder

On deck, LH side, in 1 front of machinery frame

71

CG

8

Drag Check Band Ram Cylinder

On deck, at center, 1 back of machinery frame

72

CG

8

In boss on end of piston rod

73

CG

8

GC

When Req'd.

Propel Brake Band Ram Cylinder Piston Rod Bearing

Bush

1

M. G. Set

See Elec. Instructions

74

Air Compressor

See Elec. Instructions

75

Hoist Motor

See Elec. Instructions

76

Swing Motors

See Elec. Instructions

81

Boom Hoist Motor Pinion and Gear s

Apply to gear teeth

No. 1017/IY

- 11 -

Brush

82

9/1955

BI005692

NAME OF PART

TYPE BEARING

LOC. LUB. NO. FITTING LOCATION FTGS. NO. SYM.

LUB. PERIOD IN HOURS

UPPER FRAME MACHINERY (Cont'd.)

83

Gears and Bearings in Swing Gear Cases

Pour into opening in top rear of each gear case. Cap'y. 48 gal., each

Fast's Couplings

See Inst. in Miscellaneous Section

SWING LOCK BRAKE

L. p. 16

Pivot Pins

RH in shoe boss

4

100

CG

24

Toggle Pins

LH in shoe boss

4

101

CG

24

GL SAE 90 at all times

When Req'd.

Clevis Connection Bearings

Bush

In both side s of clevis

4

102

CG

24

Piston Rod Bearing

Bush

In boss on end of piston rod

2

103

CG

24

FAIRLEAD

L. p. 161

Vertical Sheave Bearings

Bush

Front of house

2

110

CG

4

Horizontal Sheave Bearings

Bush

Front of house

2

111

CG

4

Bottom Frame Bearing

Bush

Front of house

2

112

CG

4

Top Frame Bearing

Bush

Front of house

2

113

CG

4

PROPEL CLUTCH SHIFTER

L. p. 18

Shifter Yoke Bearing

In boss of shifter yoke 1

111

CG

24

Lever Connection

On middle bo s s of shifter yoke

1

118

CG

24

Clevis Connection

On bottom bo s s of shifter yoke

1

119

CG

24

1

125

WB

500

HOIST &: DRAG CHECK BAND LEVERS Hoist Check Ram Cylinder Link No. 1011 IIV

AntiFriction

L. P. 19

In LH end of shaft

- 12 -

9/1955

BI005692

SWING

LOCK BRAKE

- 13 -

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FAIRLEAD

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- 14 -

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PROPE L

CLUTCH SHIFTER

,.

1\7

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BI005692

NAME OF PART

TYPE BEARING

NO. LOC. LUB. FITTING LOCATION FTGS. NO. SYM.

LUB. PERIO IN HOU

HOIST At DRAG CHECK BAND LEVERS (Cont'd. ) Hoist Lever

AntiFriction

In LH end of shaft

1

126

WB

500

Drag Check Ram Cylinder Link

AntiFriction

In LH end of shaft

1

127

WB

500

HOIST DRUM FRICTION CLUTCH

L. p. 22

Piston Rod Bearing

Bush

In pipe at cylinder head

1

138

CG

4

Crank Pin Bearing

Bush

In outside end of crank pin

1

139

CG

4

Hoist Friction BandLive End

Bush

In live end connection boss

I

140

CG

4

Hoist Friction BandDead End

Bush

In end connection boss

1

141

CG

4

DRAG DRUM FRICTION CLUTCH

L. p. 23

Piston Rod Bearing

Bush

In pipe at cylinder head

1

143

CG

4

Crank Pin Bearing

Bush

In outside end of crank pin

1

144

CG

4

Drag Friction BandLive End

Bush

In live end connection boss

I

145

CG

4

Drag Friction BandDead End

Bush

In end connection boss

1

146

CG

4

8

147

CG

Before Using

148

MO

Keep Coated

TRAVELING CRANE

L. p. 24

Roller Shaft Bearings

In top of each roller bearing

Crane Track

Apply to track

GANTRY AND FRONT END

L. P. 25

Boom Hoist Sheaves

In end of each sheave shaft

No. 1017 IIV

Bush

-17 -

6

150

CG

168

9/1955

BI005692

HOIST DRUM FRICTION CLUTCH

- II -

L.P.22 Rev. 5-l8- 55

BI005692

DRAG DRUM FRICTION CLUTCH

- 19 -

Rev. 5-18-55

L.P. 23

BI005692

TRAVELING CRANE

NOTE: Symmetrical About t ~ I

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BI005692

NAME OF PART

TYPE BEARING

NO. LOC. LUB. FITTING LOCATION FTGS. NO. SYM.

LUB. PERIOD IN HOUR&

GANTRY AND FRONT END (Cont'd. } Boom Safety Sheave s

Bush

In end of each sheave shaft

4

151

CG

168

Sheave Inside House

Bush

In end of shaft

1

152

CG

168

Boom Hoist Sheaves

Bush

Two in end of shaft

4

153

CG

168

Point safety Cable Sheaves

Bush

Two in end of each shaft

4

154

CG

168

Boom Hoist Bridle Sheave s

Bush

In top of each sheave pin

2

155

CG

168

Boom Hoist Bridle Clevis

Bush

In top of each clevis boss

2

156

CG

168

Safety Cable Bridle Sheaves

Bush

In top of each sheave pin

2

157

CG

168

Safety Cable Bridle Clevis

Bush

In top of each clevis boss

2

158

CG

168

Point Sheave

AntiFriction

On both side s of hub

2

159

WB

500

Swivel Casting Bearing

Bush

In top of bearing both ends of swivel

2

160

CG

168

Deflecting Sheave Bearing

Bush,

In hub of sheave

1

161

CG

8

Hours shown in "Lub. Period" column indicate actual operating hours.

All parts of walking mechanism should be lubricated more often than indicated when moving frequently. Boom hoist and motor, gantry sheaves and boom hoist sheaves should be lubricated more often than indicated when boom is raised and lowered frequently.

Oil should be added to gear cases as needed.

Maintain daily inspection.

Lubricate all gear teeth as indicated unless inspection shows more frequent or less lubrication required. All other pins and moving parts not shown to be lubricated as often as needed.

No. 1017/IV

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SECTION V

WIRE ROPE REEVING

MARION 7400 ELECTRIC WALKING DRAGLINE

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PART VI

INSTRUCTIONS FOR MAKING ELECTRICAL ADJUSTMENTS FOR MARION TYPE 7400 WARD-LEONARD ELECTRIC WALKING DRAGLINE

Subjects

Page

l.

General

2

2.

Nomenclature of Wiring Diagram

7

3.

Checking A. C. Auxiliaries

9

4.

Starting the M. G. Set and Checking Rotation

10

5.

Synchronous Motor Field Adjustment

11

6.

D. C. Control Circuit Te st s

11

7.

Hoist Adjustments

15

8.

Swing Adjustments

18

9.

Reverse Current Relay (RCR) Adjustment

22

No. 1017/VI

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GENERAL Before starting up a new machine it is necessary to make careful electrical adjustments and certain tests to insure proper operation of the machine. These adjustments are based on the fact that the machine is completely wired and with all motors and generators connected, is ready for operation. To give a clear understanding of the procedure of the necessary adjustments and tests, the following instructions are written.

In order to make the proper adjustments, it is necessary that suitable meters be available. It is recommended that the following meters and shunts be used.

1 - AC voltmeter, with 0-150/300/600 volt scale 1 - DC voltmeter, with 600-0-600 volt, zero-center Bcale 1 - DC millivoltmeter, with 100-0-100 zero-center scale, suitable for operation with 60 millivolt shunts 1 - 15 ampere, 60 millivolt portable shunt 1 - 50 ampere, 60 millivolt portable shunt The AC voltmeter is used for testing the 440 volt AC auxiliaries.

The DC voltmeter with the 600 volt scale is used for testing and adjusting the generator no-load volts, which range on various machines from 550 to 600 volts. The same meter may also be used when adjusting the exciter voltage to 125 volts.

The DC millivoltmeter is used with the proper shunts to measure the generator armature currents during the stall current adjustment. The shunt to be found for this adjustment will be found mounted on that particular generator.

This millivoltmeter is also used with a suitable shunt to measure the separate and the self field currents of the generator being adjusted and in this case the 50 and 15 ampere ahunts listed above are to be used. The proper shunt is inserted in the circuit where called for in the following instructions.

It should be noted that the 60 millivoltmeter and shunts are standard for all Ward-Leonard generator adjustments.

When adjusting the generator for the stall current and no-load volts, it is necessary that all the readings be taken with the generators hot or the temperature equivalent to normal operating conditions. It has been found from actual field experience that the stall current readings will vary approximately 100/0 from cold to hot conditions.

It is possible to warm the generator to a temperature equivalent to operating conditions by short circuiting the generator armature, opening the controller and keeping 50 to 70 per cent of the stall current on the generator until the desired approximate temperature is reached. This temperature can be easily determined by the feel of the amount of radiation of heat from the generator armature by a competent electrical man. If necessary, the generator can be stopped and the temperature of the armature taken by thermometer. This temperature is suitable if it is between the range of 30 0 to 50 0 rise above ambient temperature.

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It is very difficult to obtain the exact operating temperatures on the generators during test so the recommended procedure is to warm the generators as de scribed above to a suitable temperature and then make the preliminary adjustments. After the machine has been placed in operation and has operated for three or four hours in good fast digging, it is well to stop the machine on a day when all the electrical equipment is at operating temperature and make final adjustments of the stall currents and no load voltages.

At this point, it is well to insert a word of caution as to the application of the short circuit current on the generators when warming the generators and also when making the final stall settings. DO NOT hold the controller in the full on position any longer than necessary to take a quick reading of the meter as serious damage may result due to the overheating of the armature. When applying the 50 to 70% of the stall current to the generator during the warm up period, it is well to keep a close watch on the generator to see that excessive temperature is not reached.

The same might also be said to apply when warming the fields for the no load voltage test.

The motions of the dragline are operated by the hoist-drag controller at the right side of the operator I s cab and the swing controller located at the left of the operator's cab. The hoist-drag controller should be connected so that the machine will hoist when the controller handle is pushed away from the operator and will drag when the handle is pulled toward the operator. The swing controller should be connected so that the machine swings toward the right when the swing controller handle is pushed away from the operator and to the left when the handle is pulled toward the operator.

The hoist and drag brakes are operated by the foot operated air treadles located at a convenient position for the operator's feet. The treadle on the right operates the hoist brake and the treadle on the left operates the drag brake.

Each motion is driven by D-C Motors electrically connected to three field D-C generators in a variable-voltage system. Speed and torque of each motion are changed by varying the resistance in series with the generator fields. Magnetic contactors controlled by five point master switches short out the field resistance as desired.

The same motors, generators, and controls used for hoisting and lowering are also used for propelling. To propel, the hoist-propel transfer switch must be in the propel position. Contactor D It L closes for propelling forward. Contactor H closes for reversing the hoist motor (at low speed and torque only).

With the transfer switch in the propel position the swing cannot be operated when the shoes are down but can be operated at a low speed when shoes are up.

The self excited field of the hoist generator is de-energized during propel to reduce maximum voltage and speed. Relay RCR and limit switch 2LS control the lowering speed of the tub and shoes.

To hoist or lower, the hoist-propel transfer switch must be in the hoist position, and magnet valve control switch in hoist position. The drag ram is No. 1017/VI

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disengaged and hoist ram engaged, so the hoist motor is coupled to the hoist drum only. The self field is energized and the motor field is at medium strength.

Contactor H closes for hoisting and D It L closes for lowering (except see nonsynchronized operation).

To drag, the hoist-propel transfer switch must be in the hoist position and the magnet valve control switch in drag position. Drag ram is engaged and hoist ram is disengaged so hoist motor is coupled to drag drum only. Contactor DMF closes to strengthen motor field. Contactor D 8t L closes for dragging. Contactor H closes to payout cable from the drag drum.

The latch operated switch on hoist master switch is used to engage both the hoist and drag rams when the magnet valve control switch is in either the hoist or drag positions.

Two methods of operation are used, synchronized which is standard, and nonsynchronized.

In synchronized operation the cables are fastened on the hoist and drag drums so that as one cable wraps on one drum the cable on the other drum pays off. One

throw of master switch is for hoist, the other is for drag and lower. Pressing latch (PB I-PBl) on hoist master switch opens contactor HMF to produce high speed lowering.

In non-synchronized operation, the cables are fastened on both drums so that both can be wrapped at the aame time. One throw of master switch is for lowering, the other for drag and hoist. Pressing latch (PBI-PBl) on swing master switch energizes and disengages both hoist and drag rams together providing the magnet valve control switch is in either the hoist or drag positions.

To change the type controls from a synchronized operation to a non-synchronized operation, the following procedure is necessary. All the following changes in connections are to be made on the DC panel terminal board with the exception of changing the normally open contacts on the hoist latch which connections are made in the switch itself.

1.

Disconnect the normally closed contacts of latch on the hoist master switch and connect the leads to the normally open contacts of the latch.

2.

Disconnect PBI and PB2 at the panel terminal board and connect to terminals DI and Dl on the panel terminal board.

3.

Add jumper H8- Y on panel terminal board.

4.

Disconnect jumper Hl3 -H14 on panel terminal board.

The hoist-drag controller is moved in the drag direction when it is desired to walk. If there should be occasion when it has been decided that the machine has walked a half step too far and it is desired to reverse the shoes to pick them up,

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it is necessary to move the hoist-drag controller to the hoist position to back up the shoes. With the hoist-drag controller in the reverse position, the reversing contactor HR and HIA will close, thus giving but very weak reverse walking power so that the shoes only will be able to be picked up.

During the walking operation in the forward direction, the controller is opened wide and is left in that position until the number of steps are completed. The speed of the various parts of the walking cycle is automatically controlled by the device called the "Reverse Current Relay" (RCR). The function of the Reverse Current Relay is to allow full power to be applied to raise and drag the tub and raise the shoes, and reduce the power when lowering the tub and shoes so as to lower the tub and the shoes slowly and lightly to the ground. During the walking cycle, the weight of the shoes when lowering and the weight of the tub when lowering, tend to drive the walking machinery and generate reverse current from the motor to the generator. At the instant that this occurs the Reverse Current Relay opens the circuit to the accelerators, thus cutting off the major part of the walking power and with the generator absorbing the pumpback of current, allows the tub and the shoes to settle slowly to the ground. At the instant the tub or the shoes strike the ground the current again becomes positive and the reverse current relay closes the circuit to the accelerators, thus applying full power to the next part of the cycle. The electrical operation of the RCR relay and the test procedure for adjusting this relay will be explained in a following paragraph entitled, "Rever se Current Relay Adjustment".

When it is desired to propel it is necessary to set the hoist and drag foot brakes, turn the "Swing Brake" selector switch to "On" to set the swing brake and turn the "Hoist-Propel" transfer switch to the "Propel" position. The hoist-propel transfer switch sets up the following circuits.

For those machines equipped with the 2LS limit switch having one set of contacts in series with the RCR relay set of contacts, the following applies instead of the preceding information.

During the walking operation the controller is opened wide and is left in that position until the number of steps are completed. The speed of the motor during the various parts of the walking cycle is automatically controlled by the propel drive shaft cams associated with the 2LS limit switch and the device called the "Reverse Current Relay" (RCR). The function of the cams, the limit switch and the Reverse Current Relay is to allow full power to be applied to raise and drag the tub or raise the shoes and reduce the power when lowering the tub or shoes so as to lower the tub and shoes slowly and lightly to the ground. During the walking cycle, the weight of the shoes when lowering and the weight of the tub when lowering tend to drive the walking machinery and generate reverse current from motor to generator. When the reverse current reaches a sufficiently high value, the Reverse Current Relay opens the circuit to the accelerators, thus cutting off the major part of the walking power and, with the generator absorbing the pump-back of curr-ent, allows the tub and the shoes to settle slowly to the ground. To avoid variations in the point of the cycle at which the Reverse Current Relay opens the circuit to the accelerators due to temperature changes the point at which the accelerators open is controlled by the 2LS limit switch No. 1017 IVI

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through it's associated cams on the main propel shaft. Control of the operation of the accelerators is restored to the RCR relay by making the propel shaft cams of such a length that they keep the 2LS limit switch operated only long enough to be sure that relay RCR operates properly. At the instant the tub or shoes strike the ground the current again becomes positive and relay RCR closes the circuit to the accelerators, thus applying full power to the next part of the cycle. This results in mechanically controlling the point of the walking cycle at which power is reduced and electrically controlling the point of the cycle at which full power is again provided; the reduced power points being controlled by the 2LS cams and the full power points being controlled by the RCR relay. The electrical operation of the RCR relay and the test procedure for adjusting this relay will be explained in a following paragraph entitled, "Reverse Current Relay Adjustment".

The Tl contact of transfer switch T opens, placing the control of the accelerating contactors HlA to H4A under the operation of the RCR contact and the 2LS contact.

The T2 contact of transfer switch permits energizing the propel brake magnet valve and thereby release the propel clutch limit switch is closed and the controller is thrown to the drag position or the hoist position. The hoist position of the controller in propelling is used for positioning the shoes only and is never used for the propelling operation.

The T3 and T4 contacts energize the drag and hoist ram magnet valves, thereby disengaging the drums from the machinery. The operator sets the mechanical brakes to hold these drums and the bucket in the desired position.

The T5 contact energizes three devices as follows: - propel relay P, propel clutch magnet valve, and the potential coil of RCR relay.

Relay P closes its normally open contact to short cut permanent resistance in series with the generator separate field. This gives a strong separate field for propelling. (This is required for hoisting the tub). The normally closed contact of P relay places the circuit for the accelerators H2A to H4A under the influence of the normally closed contact of H. This prevents closing of the accelerating contactors H2A to H4A if the controller is thrown to hoist or reverse position. This provides slow speed reversing for positioning of the shoes.

The propel magnet valve causes the propel clutch to engage.

The RCR potential coil will cause the RCR relay contact to close when the generator current is positive when the tub or shoes are being hoisted. When the generator current approaches zero, or reverses, the contacts of RCR relay will open. The current coil of RCR relay in series with the generator armature circuit serves to measure the direction and magnitude of the armature current.

The T6 Contact is blank.

The T7 Contact opens the generator self field contactor HSF thereby removing the generator self field to reduce the maximum voltage and hence the maximum motor speed for propelling.

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The T8 Contact opens the circuit to the S2A It S3A accelerating contacts, thereby removing all but a small amount of swing power for positioning the shoes when in propel position.

The selector switch S is used to disengage the drag and hoist drum from the machinery for maintenance or adjustment.

Before starting to make any electrical adjustments or tests, it is well to make certain the motor generator set is in the proper condition to run. An inspection of the set should be made to see that all paper has been removed from the commutators and the brushes are free in their holders with the proper spring tension on them, and that there are no loose connections. The armatures should be rotated by hand to make sure that they can turn freely and that they are clear of all obstructions.

NOMENCLATURE OF WIRING DIAGRAM DilL

Drag and Lower Contactor. Also used for propelling forward.

(For nonsynchronized control contacter is used for drag and hoist). Energizes hoist generator separately excited field to rotate hoist drum or drag drum in desired direction.

DMF

Hoist Motor Field Contactor. Produces very strong motor field for dragging and propelling.

H

Hoht Contactor. Also used for propelling backward at slow speed. (For non- synchronized control contactor is used for lowerins). Energizes hoist generator separately excited field.

HIA, H2A,H3A, H4A

Hoist accelerating Contactors. Short hoist generator field resistors to increase speed or torque of hoist motor for hoisting, lowering, dragging and propelling.

HMF

Hoist Motor Field Contactor. Increases motor field strength for hoisting. Decreases field strength for lowering.

HSF

Hoist Generator Self Excited Field Contactor. Opens generator self excited field for propelling to flatten speed-torque curves.

LE

Exciter Line Contactor. Removes excitation from all generators separately excited fields when stop button is pressed or hoist blower motor starter opens.

P

Propel Contactor. Strengthens hoist generator separately excited field for propelling.

RCR

Reverse Current Relay. Reduces speed when lowering the _ .:.shoes or tub in propelling forward. Contact (H 11- Y) closes on motoring (Positive) current and opens on zero or slightly positive current.

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SlA, SZA S3A

Swing Accelerating Contactors. Short resistance in series with swing generator fields to increase speed or torque.

SMF

Swing Motor Field Contactor. motor field strength.

SMFR

Swing Motor Field Relay. Opens contactor SMF to increase omaximum motor speed. Set to pickup with 410 volts on coil a.nd resistor B.

SF, SR

Swing reversing Contactors. cited field.

Shorts resistance to increase

Energize swing separately ex-

MAGNET VALVES DRAG RAM

When valve is energized, drag drum is disengaged from hoist motor.

HOIST RAM

When valve is energized, hoist drum is disengaged from hoist motor.

PROPEL CLUTCH - When valve is energized, hoist motor is clutched to propel shaft.

PROPEL BRAKE -

When valve is energized, propel brake is released.

SWING BRAKE

When valve is energized, swing brake is released.

LIMIT SWITCHES

1LS

-

Actuated by propel clutch. propel clutch is engaged.

Prevents release of propel brake until

ZLS

-

Actuated by cams on propel shaft in parts of propel cycle when P.;);lshoes or tub are being lowered. Contact (HI l- Y) allows RCR relay to reduce propelling speed during parts of cycle mentioned above.

3LS

-

Actuated by propel shaft. Lights indicating light and prevents operation of swing while shoe s are down.

SELEC TOR It CONTROL SWITCHES

HOIST-PROPEL -

No. 1017 /VI

Two position, multi-contact switch. In hoist position shorts relay RCa Contact, energizes contactor HSF to close hoist generator self field circuit and also allows full swing speed. In propel position disengages hoist and drag rams, picks up contactor DMF to strengthen hoist motor field, energizes propel clutch, picks up contactor P, makes relay RCR operative and sets up circuit to energize propel brake magnet valve when propelling.

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MAGNET VALVE CONTROL SWITCH

In drag position energizes and disengages hoist ram, energizes contactor DMF to increase motor field for dragging. In hoist position energizes and disengages drag ram.

SET-PFF

In off position, energizes and disengages both hoist ram and drag ram.

SWING BRAKE

In off position, energizes and releases swing brake.

CHECKING A. C. AUXILIARIES

Before starting the M. G. set for the first time after erecting machines, it is necessary to check all A. C. Auxiliary power circuits and correct rotation of all auxiliary motors. The auxiliary power circuits and motor rotations are checked as follows: 1.

Close the primary high voltage fused cutouts in AC cabinet and the 440 volt safety switch in the AC auxiliary cabinet and check the 440 volt circuits for balanced three phase voltage.

2.

Press the push button for the blowers and then stop immediately. This starts the blowers and the swing gear oil pumps rotating, but the power is cut off before they pick up speed. By visual inspection of the oil pump and of the blowers, the direction of rotation can be determined.

The direction of rotation of the swing gear oil pump motor should be such that the oil drains into the pump through the line from the lower part of the gear case and is forced out the pump through the pipe that leads to the top of the gear case, thus running the oil down through the bearings and over the gears. It is to be emphasized at this point that the swing gear oil pumps should not be run with reverse rotation as severe damage will result to the oil seals of the pump itself.

The rotation of the blowers should be such so that the bla.des of the portion of fan directly over the spout that leads into the mill motor are rotating in the direction toward the motor to which the spout is attached, thus forcing the air into the mill motor. H the rotation of the motion of the blower units should be reversed, it may easily be corrected by reversing any two of the loads at the blower motor itself.

3.

Turn the selector switch marked "AIR COMPRESSOR" in the operator's cab to the "ON" position and the direction of rotation of the motor should conform to the direction of the arrow marked on the flywheel of the air compressor. After the direction of the motor has been checked, the air compressor should be allowed to build up pressure and the setting of the pressure switch adjusted to cutout at 115 pounds and to cut in when the pressure has been reduced to 95 pounds. (See Air Compressor Instructions in Repair Parts Catalog).

4.

The direction of the large cab ventilating fan at the rear of the machine can

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be easily checked by momentarily closing the manually operated motor starting switch located along side the large double doors at the rear of the machine.

If the direction of either the ventilating fan or air compressor motor should be reversed, they may be easily corrected by reversing any two of the leads to that moto r • STARTING THE M-G SET AND CHECKING ROTATIONS The driving motor for the M-G set is a three phase, AC, synchronous motor, arranged for reduced voltage starting.

The procedure for starting the M-G set is as follows: 1.

Turn the M-G set by hand to make sure that it rotates freely and that it is clear of all obstructions. This check is only necessary when set is started for the first time after machine is placed in operation or after a repair job on the M-G set.

2.

Start the blowers by pressing the blower push button, located on starting panel of the AC cabinet near the starting lever of the oil circuit breaker. The holding coil circuit of the under-voltage device is interlocked with the circuit on the magnetic starter for the blower motors so that if the AC supply voltage fails, or if a blower or pump motor should fail, the magnetic starter for the blowers drops out, breaking .the circuit to the under voltage device and thus releasing the oil circuit breaker.

3.

Turn the selector switch mounted in operator's cab to the "ON" position to close the circuitto the undervoltage devices.

4.

Press the plunger of the under-voltage device by hand and close the "Starting" lever (left hand) on the oil circuit breaker momentarily to start the M-G set.

The direction of rotation should be in the direction shown by indicating arrow on name plate of M-G set. If the direction of rotation is wrong, open the oil circuit breaker immediately. If necessary to reverse the direction of rotation of the M-G set, this may be done by interchanging any two leads at the connections to the motor.

5.

After the direction of rotation has been ascertained to be correct, start the M-G set by closing the "Starting" lever on the oil circuit breaker with a firm continuous motion and bring the set up to speed. (It is a matter of good operating procedure to never open the breaker during the period of bringing the set up to speed as this is very severe on the tips of the breaker. The only time it is necessary to open breaker before the set comes up to speed is when checking rotation).

6.

After the set has reached full speed drop out the "Starting" lever and immediately close the "Running' lever with the right hand. The" Starting" lever must be clear out before it is attempted to close the "Running" lever.

7.

Adjust the exciter volts to 125 volts by adjusting the plate rheostat handle

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mounted just above the starting levers and watching the DC voltmeter mounted on the front of oil circuit breaker cabinet.

8.

Turn the "Field Switch" mounted to the right of the starting levers to "closed" position to apply the field to the synchronous motor.

Do not start the M-G set until called for in test procedure if the machine is being placed in operation for the first time.

SYNCHRONOUS MOTOR FIELD ADJUSTMENT After the M-G set has been started and the exciter voltage adjusted to 125 volts, adjust the synchronous motor field current value to rated value given on the motor nameplate by adjusting the field resistor FLD-EX8.

The synchronous motor field resistor is located in the rear of the A. C. Cabinet.

1.

Stop the M-G set.

2.

Disconnect the lead at FLD on the resistor and insert the 50 ampere shunt between the lead FLD and terminal FLD on the resistor and connect the millivoltmeter to the shunt.

3.

Start the M-G set, adjust the exciter voltage to 125 volts and apply the field to the synchronous motor.

4.

Increase the synchronous motor field current to the rated value by shorting out steps of resistance between FLD and EX8 a step at a time.

5.

Stop the M-G set, remove the shunt and reconnect the lead to the terminal FLD. D C CONTROL CIRCUIT TESTS

All of the following tests are for standard synchronized Control. To convert from Synchronized Control to Non-SynchronJ.zed Control, refer to page 4 of these Electrical Instructions. After the exciter voltage has been adjusted to 125 volts and the synchronous motor field current has been adjusted to the rated value, the D C control circuit should be checked in the "Digging" and "Propel" positions for correct sequence of operation of contactors and magnet valve.

Check the "Digging" control circuits as follows after making certain all brakes are set:

1.

Open the hoist and swing motor fields.

2.

Open the hoist and swing armatures at the generators.

3.

Start the M-G set.

Note:

There are times when AC power to the machine is not available when

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the DC control circuit is ready for test. Also, at times during erection it is not desirable to run the M-G set during the DC control test because of men working elsewhere on the machine. Then it is possible to supply the DC control voltage from a separate source such as a DC arc welder instead of running the M-G set. The voltage from the Arc welder will not be 125 volts but will approxim.ate 95 to 100 volts, which is sufficient to operate the contactor s and other equipment.

The method of using the arc welder as a source of exciter voltage is connect the arc welder electrode and ground lead to the panel side of the main line fuses on the DC panel after removing the fuses. Start the arc welder and adjust the voltage to the maximum and then proceed with the DC control circuit test as in step 4 and following steps.

4.

Turn the FRICTION BANDS selector switch to the ON position, turn the SWING BRAKE selector switch to the ON position and turn the pistol-grip handle of the HOIST-PROPEL type SB-l eight point transfer switch to HOIST position. This sets up the digging control circuit and sets the swing brake.

5.

Press the "EMERGENCY" start button and energize the LE contactor.

6.

Note that the HSF contactor closes and is energized through T-7 contact of the transfer switch.

7.

Move the hoist-drag controller one point forward in the hoist direction and note that the H contactor closes and also the HMF contactor. This gives a strong motor field in the hoist direction.

8.

Press the latch on the hoist-drag controller handle and note that HMF drop. out. This weakens the motor field and increases the motor speed. HMF is usually latched out on lowering.

9.

Continue to move the hoist-drag controller in the hoist direction and note that the accelerating contactors HIA. H2A, H3A and H4A close in that order named.

10.

Return the controller to neutral and then move the controller one point in the drag direction. Note that the D &: L contactor closes and also the HMF contactor. This gives a strong motor field in the drag direction also.

11.

Press the latch on the hoist-drag controller handle and note that the HMF drops out.

12.

Continue to move the hoist-drag controller in the drag direction and note that the accelerating contactors HIA, H2A, H3A and H4A close in the order named.

13.

Move the swing controller forward in the swing-right position and note that the SF contactor and SMF contactor close on the first point and accelerating contactors SlA, S2A and S3A close in order on the succeeding points.

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NOTE:

If the SF and accelerating contactor s will not close with the controller wide open, check the normally open contact S8 of the propel limit switch as this contact must be held closed by the cam on the walking shaft with the shoes up.

14.

Return the controller to neutral and then move the controller in the swingleft position and note that the SR contactor and SMF contactor close on the first point and accelerating contactors SIA, S2A and S3A close in order on the succeeding points. Return the controller to neutral.

15.

With the hoist-propel transfer switch still in the hoist position and with the Hoist-Drag Magnet Valve Controller, located to the right of the hoist controller, in the neutral position, turn the "FRICTION BANDS" selector switch to the "OFF" position. Test the voltage across the hoist and drag ram magnet valves with a DC voltmeter and there should be approximately 125 volts applied to each.

16.

Turn the friction bands selector switch to the "ONIf position. There should be zero voltage across each ram magnet valve and both clutches would be engaged if the air is up to pressure.

17.

Turn the hoist-drag magnet valve controller to the 'tHoist tl position and read the voltage on the hoist and drag ram magnet valves. There should be 125 volts on the drag ram MV and zero volts on the hoist ram MY.

18.

Press latch on swing controller and note that there is zero volts on both magnet valves and both clutches are engaged.

19.

Release the latch and turn the hoist-drag magnet valve controller to the "drag" position and read the voltage on the hoist and drag ram magnet valves. There should be 125 volts on the hoist magnet valves. There should be 125 volts on the hoist magnet valve and also on DMF contactor, and zero on the drag magnet valve.

20.

Press the latch on the swing controller and note that there is zero volts on both magnet valve s and also on DMF.

21.

Release the latch and return the hoist-drag magnet valve controller on neutral.

Check the uPropel" control circuits as follows: 22.

Set the hoist and drag brakes to hold the cable drums.

23.

Turn the friction bands selection switch to the "OFF" position and release the hoist and drag clutches so that the hoist and drag cable drums remain stationary while the machinery revolves freely on propel.

24.

Turn the Hoist-Propel transfer switch to "PROPELu. following circuits through the transfer switch.

No. 1017/VI

- 13 -

This sets up the

9/1955

BI005692

25.

Contactora DMF and P, magnet valves Drag Ram, Hoist Ram and Propel Clutch, and RCR voltage coil are energized.

26.

Contactor HSF is deenergized and circuit for S2A, S3A is opened by contact T7.

27.

With a DC voltmeter, test the voltage coil of the RCR relay. be 125 volts across the coil and the resistor.

28.

With a DC voltmeter, test the drag ram, hoist ram and propel clutch magnet valves for voltage. There should be 125 volts on each.

29.

Pull hoist-drag controller one point in the propel (drag) direction. The propel brake magnet valve should now test 125 volts with circuit closed through the limit switch on the propel clutch and T-2 of the transfer switch.

30.

Pull the controller to the full-on propel position and note that the contactors D & L, HlA, H2A, H3A and H4A close in sequence.

31.

With the controller in full-on position, open the H-ll contact of 2LS limit switch at propel shaft by hand and open RCR by hand and note that accelerating contactors HlA, H2A, H4A and H4A drop out.

There should

3lA. For machines having a set of contacts on the 2LS limit switch in series with the RCR relay set of contacts substitute the following in place of paragraph 31.

With the controller at full-on, open the RCR contact by hand and note that accelerating contactors HlA, H2A, H3A and H4A drop out. Repeat this observation when the limit switch 2LS is operated by hand at the propel shaft.

32.

Return the controller to neutral and note that the propel brake magnet valve is deenergized and the propel brake is applied.

33.

Push the controller one point in the hoist, reverse propel, direction, and note that the propel brake magnet valve again becomes energized and the brake is released.

34.

Push the controller to the full-on hoist, reverse propel, position and note that contactors Hand HlA only close. This provides reduced power for positioning shoes only and eliminates the possibility of propelling in the reverse direction by the opening of the normally closed interlock on H contactor. The normally closed interlock on P contactor is already open when in propel position.

35.

Return the hoist-drag controller to the neutral position.

36.

Move the swing controller to the full-on swing-right and swing-left position and note that the swing accelerating contactors S2A and S3A do not close in either direction. The circuit 24 of their operating coils has been opened at T8 of the transfer switch.

No. 1017 IVI

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BI005692

37.

Loosen the straps of the cam under limit switch 3LS and move cam to one side.

38.

Note that signal light 13 is on and swing brake is applied through Swing Brake selector switch may be in the "OFF" position.

39.

Move the swing controller to the full-on swing-right and swing-left positions and note that none of the swing contactors operate because their control circuit has been opened by the S8 contact of the 3LS limit switch.

The purpose of the cam under the 3 LS limit switch is to show an indicating light in the operator's cab and to remove the power from the swing control circuit at any point of the propel cycle except when the shoes are up and in the neutral position.

40.

Return the swing controller to neutral and position the cam so that the propel indicating light is out with the shoes up and in the neutral position, and secure the cam tightly to the propel shaft.

After the control circuits for the digging and propelling po sitions have been checked, the hoist and swing generator s are to be adjusted for stall current and no-load volts; and the motor field volts are to be adjusted to the recommended values specified on the attached test sheet at the rear of these instructions.

HOIST ADJUSTMENTS

STALL CURRENT ADJUSTMENT Adjust the hoist generator stall current to the recommended value by the following procedure:

1.

Short circuit the hoist generator by having the generator armature solidly connected to the hoist motor armature with the hoist motor field disconnected.

z.

Open the self excited generator field circuits at HP1 on the resistor.

3.

Connect the millivoltmeter to the hoist generator armature shunt and also insert a 50 ampere shunt in the separately excited field circuit between lead HVO at the resistor and the terminal HVO.

4.

Start the M. G. set and with all controllers in neutral, press the emergency start push button in the operator's cab to energize the control circuits.

5.

Move the hoist controller slowly to the full-on hoist position by pushing handle forward and watch the armature ammeter carefully to see that the current value increases step by step as the controller is advanced.

Record the maximum value of stall current read.

No. 1017 IVI

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CA UTION: When checking the stall or short-circuit currents do not hold the controller in the full-on position any longer than necessary to take a quick reading of the meters as serious damage may result due to the overheating of the armature.

6.

The hoist stall current should be adjusted to the desired value by regulating the strength of the separately excited field HF3 -HF4, by adjusting the permanent resistor section HVO-HV05 of the separately excited field.

7.

To raise the stall current to the desired value, it is necessary to short out sections of resiatance between HVO and HV05, a step at a time, until the desired stall current is reached.

The resistance should be shorted out by inserting a short jumper between the selected terminals on terminal board, or several jumpers between combinations of terminals. If it is necessary to short out a minimum value of resistance, smaller than any single step value between any two terminals on the terminal board, it is sometimes possible to parallel two of the steps of resistance at the terminals and thus obtain the minimum step of resistance required.

It should not be necessary during any of the tests to make changes in the internal connections of the resistor, but if so, it can be simply

done by loosening the two bolts holding the resistor frame in the rack and sliding the whole frame of resistance out to work on. The change can be made by adding jumpers between the taps on the bars themselves or by paralleling sections of the bars themselves, using the same method explained in paragraph above.

8.

Record the separately excited field amperes when the correct stall current is set. The separately excited field amperes should be approximately as specified on attached test sheet.

9.

Check the value of stall current and the separately excited field amperes in the opposite direction of the control. These should check with the values previously taken in 7 and 8.

10.

Adjust the propel stall by turning the Hoist-Propel transfer switch to Propel and by moving the lead P from the propel contactor toward HVO until the recommended value is reached with the hoist-drag controller in the full-on drag position.

11.

Record the propel stall current and record the separately excited field current at stall.

12.

Return the hoist-drag controller to neutral, turn transfer switch to Hoist and stop the M-G set.

13.

Stop the M. G. set.

No. 1017/VI

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9/1955

BI005692

N~LOAD

VOLTS ADJUSTMENT

Adjust the hoist generator no-load volts to 475 volts by the following procedure: 14.

After the M. G. set has come to a dead stop, open the hoist generator armature circuit a.nd leave on open circuit for the no-load voltage test.

15.

Connect a 0-600 scale voltmeter across a pair of brushholder arms on the hoist generator, disconnect the generator self field and start the M. G. set.

16.

Press Emergency "Start" button and advance hoist controller to full-on hoist position. Read and record the no-load voltage with separately excited field only.

17.

Turn the Hoist-Propel transfer switch to Propel and record the no-load voltage for propel with the separately excited field only.

18.

Return the Hoist-Propel transfer switch to the Hoist position.

19.

With the controller full on, check the polarity of the hoist generator self field, HFl-HF2, by touching the lead HPI to the terminal HPI momentarily and reading the voltage at that time. If the voltage reading is higher than that previously read with the separate field only, the polarity of the self field is O. K. If the voltage reading is lower than that previously read with the separate field only, the polarity of the self field is wrong and the field should be rever sed.

20.

Insert a 15 ampere shunt in the self field circuit between load HPI and terminal HPI and close the self field circuit at HPI.

21.

Press Emergency "Start" button and open the hoist controller to the full-on hoist position.

22.

Adjust the hoist-open circuit or no-load voltage value to desired value by regulating the strength of the self field, by adjusting the section HPI-HP5 of the self field permanent resistor.

23.

To raise the no-load voltage value short out sections of resistance between the terminals HP5 a.nd HPI a step at a time until the desired value is reached.

24.

Record the self field amperes when the correct no-load volts is set.

25.

Check the no-load volts and the self field amperes in the opposite direction of the controller. These values should check with those obtained in 23 and 24.

No. 1017/VI

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9/1955

BI005692

26.

Stop the M. G. set and make the jumpers on resistors permanent, remove the shunts in the field circuits and attach the leads to the terminals permanently. This completes the hoist generator stall current and noload voltage tests.

HOIST MOTOR FIELD VOLTS ADJUSTED Adjust the hoist motor field volts to the recommended values specified in the attached test sheet by the following procedure:

27.

With the hoist armature circuit still open, close the hoist motor field.

28.

Start the M. G. set and press the Emergency "Start tt button to energize LE contactor.

29.

With the controller in neutral, adjust the neutral voltage to the required value by shorting out resistance between HM6 and HM4.

30.

Move the controller one point in the hoist direction and with the HMF contactor closed, adjust the hoist motor field volts to the recommended value for hoisting by moving lead HM4 to the proper tap on the resistor.

31.

With the hoist-dra.g controller in the neutral position, move the Ram Magnet Valve Controller to the "drag" position and thus close the DMF contactor at the same time ram magnet valve is energized.

32.

With DMF closed, adjust the drag motor field volts to the recommended value for dragging and propelling by moving the lead HM2 to the proper tap on the resistor.

SWING ADJUSTMENTS

The swing circuit consists of two swing generators connected in series with two swing motors. It will be found that there will be a slight difference in the self and separate field current values and in no-load voltage values between the two swing generators. The adjustments should be set as close as possible to test sheet values and the values recorded for each unit.

STALL CURRENT ADJUSTMENT Adjust the swing generators to the recommended stall current and no-load voltage value by the following procedure which are similar to that used for hoist adjustment, with the following exceptions.

1.

Stall current and no-load values are different from the hoist because of different size swing and hoist generators.

2.

Resistor terminal markings are different.

No. l017/VI

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BI005692

3.

The field resistors for each swing generator are pa.ralleled with the corresponding resistor of the second generator and the resistor adjustment must be made on both resistors at the same time.

4.

There is no propel adjustment to be made.

The stall current adjustment must be made first as follows: 1.

Short circuit the swing generators by having the generator armatures solidly connected to the swing motor armatures, and open the fields of the swing motors. .

2.

Open the self excited field circuits of each of the swing generator s at SPI on the resistor.

3.

Connect the millivoltmeter to the swing generator armature shunt and also insert a 50 ampere shunt in the separately excited field circuit of swing generator /I 1 between lead SVO at the resistor and the terminal SVO.

4.

Start the M. G. set and with all controllers in neutral, press the "EMERGENC y" start push button in the operator's cab to energize the control circuits.

5.

Move the swing controller slowly to the full-on swing-right position by pushing the handle forward, and watch the armature ammeter carefully to see that the current value increases step by step as the controller is advanced. Record the maximum value of stall current read.

6.

The swing stall current should be adjusted to the desired value by regulating the strength of the separately excited fields SF3-SF4, byadjusting the permanent resistor sections SVO-SV05 of the separately excited fields.

7.

To raise the stall current to the desired value, it is necessary to short out sections of resistance between SVO and SV05, a step at a time, until the desired stall current is reached.

8.

Record the separately excited field amperes of generator #1 at the recommended stall current.

9.

Check the value of 8tall current and the separately excited field amperes in the opposite direction of the control. These should check with the values previously taken in 7 and 8.

10.

Remove the 50 ampere shunt from the separately excited field circuit of generator #1 and insert in separately excited field circuit of generator #2 at SVO on the resistor. Close the separately excited field circuit of generator # 1 at SVO.

No. 1017 IVI

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9/1955

BI005692

11.

Repeat steps 8 and 9 to obtain the field currents of generator 12. stall current will be an identical value.

12.

Stop the M. G. set.

The

NO-LOAD VOLTS ADJUSTMENT Adjust the swing generator no -load volts to the reconunended value by the following procedure:

13.

After the M. G. set has come to a dead stop, open the swing generator armature circuit and leave an open circuit for the no-load voltage test.

14.

Connect a 0-600 scale voltmeter across a pair of brushholder arms on swing generator # 1 and start the M. G. set.

15.

Press Emergency "Start" button and advance hoist controller to full-on swin~right position. Read and record the no-load volts with separately excited field only for generator #1.

16.

With the controller full on, check the polarity of the swing generator #1 self field, SFl-SF2, by touching the lead SPI to the terminal SPI momentarily and l·eading the voltage at that time.

If the voltage reading is higher than that previously read with the separate field only, the polarity of the self field is O. K. If the voltage reading is lower than that previously read with the separate field only, the polarity of the self field is wrong and the field should be reversed.

17.

Repeat steps 15 and 16 for generator #2.

18.

Insert a 15 ampere shunt in the self field circuit of generator 11 between lead SPI and terminal SPI and close the self field circuit at SP1. Also close the self field circuit of generator 12 at SPI.

19.

Press Emergency "Start" button and open the swing controller to the full-on swing-right position.

20.

Adjust the swing open-circuit or no-load voltage value to desired value by regulating the strength of the self fields by adjusting the sections SPI-SP5 of the self field permanent resistors of generators 11 and /12.

21.

To raise the no-load voltage value short out sections of resistance between the terminals HP5 and HPI of each of the generators a step at a time until the deaired value is reached. Identical amounts must be taken from each resistor.

No. 1017/vI

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9/1955

BI005692

22.

Record the self field amperes of generator #1 when the correct no-load volts are set.

23.

Check the no-load volts and the self field amperes in the opposite direction of the controller. These values should check with those obtained in 21 and 22.

24.

Remove the 15 ampere shunt from the self excited field circuit of generator # I and insert in the self excited field circuit of generator #2 at SP 1 on the re sistor. Clo se the self excited field circuit of generator 111 at SP1.

25.

Repeat steps 22 and 23 for generator #2.

26.

Stop M. G. set and make the jumpers on resistors permanent, remove the shunts in the field circuits and attach the leads to the terminals permanently. This completes the swing generator stall current and no-load voltage tests.

SMFR RELAY ADJUSTMENT It is desired to start the swing motion with high torque and low speed and as the cab speed gains momentum, to reduce the torque and increase the speed by weakening the swing motor fields. This is accomplished by the use of a swing motor field relay (SMFR) that is operated by the voltage impressed across the motor armature.

The SMFR relay has a normally closed contact through which the swing motor field contactor (SMF) is energized. As the motor increases speed its armature voltage increases. At a selected speed or voltage it is desired, to weaken the motor field and thereby increase the ultimate speed of the motors. At this point the SMFR relay is adjusted to operate and thus de -energize SMF and weaken the motor fields.

The SMFR relay is adjusted to operate at the selected voltage (speed) recommended in attached test sheet, as follows: 21.

Connect the 0-600 volt voltmeter across the brushholders of swing generator #1.

28.

With the swing generators still on open circuit, open the swing controller slowly and note the voltage at which the SMFR relay operates.

29.

If the relay operates at a voltage lower than the recommended value, raise the voltage point at which the relay operates by increasing the spring pressure of the armature.

CA UTION: Do not tighten the spring to the point where it would bind and hinder the free operation of the armature. Keep the No. 1017 IVI

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BI005692

spring pressure within a reasonable range and aid it by adjusting the adjusting screw which limits the air gap of the armature. Do not keep the adjusting screw set so that the armature has little or no travel. This will result in burning of contact tip which is undesirable.

30.

If the relay operates at a voltage higher than the recommended value, lower the voltage point at which the relay operates by reducing the spring pressure of the armature, or by adjusting the resistor in series with the operating coil, if adjustable.

MOTOR FIELD VOLTS ADJUSTMENT Adjust the swing motor field to the recommended values with the controller in the neutral position and also with the controller full-on and SMF contactor closed, using the same procedure as the hoist.

After the swing adjustments have been made, the machine is ready to start digging operations.

However, before it is attempted to propel, the Reverse Current Relay (RCR) that controls the speed of propel must be adjusted. The explanation of operation and the procedure of adjustment of the RCR relay is explained in the following subject "Reverse Current Relay (RCR) Adjustment".

REVERSE CURRENT RELAY (RCR) ADJUSTMENT By referring to the elementary diagram on the wiring print of the subject machine, the circuit of the operating coils of the accelerating contactors should be examined carefully to see the function of the RCR relay during the propel operation. It may be noted when the propel circuit is set up, the P interlock is open, H interlock is closed, Hll contact of limit switch 2LS is closed and the RCR contact points are open, though the voltage of 125 volts is impressed across its operating coil and resistor.

It will be noted that if the operator desires to walk in the reverse direction, the

H interlock will open and thus limit the walking power to a negligible amount, suitable for lifting the shoes only.

For machines using a set of contacts on the 2LS limit switch in parallel with a set of contacts on the RCR relay, the following five paragraphs apply.

The accelerating contactor coils of the hoist motion during propel must be energized either through a normally open contact of RCR relay or through a normally closed limit switch contact. The normally closed limit switch contact is opened by two cams on the main propel shaft. One long cam holds the limit switch open during lowering (regeneration) part of the cycle.

The short cam opens the limit switch contact for a short time just as the shoes No. 1017/VI

- 22 -

9/1955

BI005692

are about to strike the ground when they are lowering. This permits the RCR relay contact to be effective just as the shoes approach the ground. The short cam is adjustable with respect to the long cam.

The RCR relay has a 125 volt potential coil. which is energized from the exciter during propel operation. This coil furnishes almost enough flux to cause the relay contacts to close. The relay is also equipped with a current coil connected in series with the main circuit of the hoist generator. The effect of the series coil is to assist the 125 volt potential coil when the generator is putting out positive power and to oppose the 125 volt potential coil when the generator reverses current (during the regenerative part of the cycle). This means that the relay will close its contacts during hoisting the tub or the shoes and open its contacts during lowering the tub or the shoes. When the relay contacts are open the propel speed tends to be reduced.

The function of the RCR relay is to hold in the accelerators during the hoisting of the tub and to open the accelerators HlA. H2A. H3A. and H4A aa soon as the tub starts lowering. thereby lowering the tub slowly. Also. the relay must h&ve its contacts open when the shoes are lowering so that the accelerators will open when the short cam opens the limit switch contact just before the shoes strike the ground.

The RCR relay should be adjusted so that the contacts close on as small an amount of positive current as possible, but at the same time this amount of positive current should be a bare minimum to insure the contacts open with the small amount of reverse current when the shoes are being lowered. The contacts of the relay must close when the tub starts to raise and they must open when the tub starts to lower. The contacts of the relay must open when the shoes start to lower and remain open until the tub starts to raise.

For machines using the 2LS limit switch having a set of contacts in series with the RCR relay set of contacts apply the following three paragraphs.

The accelerating contactor coils of the hoist motion during propel must be energized through a normally open contact of the RCR relay and through a normally closed 2LS limit switch contact. The normally closed limit switch contact is opened by two cams on the main propel shaft. One long cam holds the limit switch open during the lowering (regeneration) part of the cycle.

The short cam opens the limit switch contact for a short time just before the shoes strike the ground when they are lowering. This assists the RCR relay in reducing the power as the shoes approach the ground. The short cam is adjustable with respect to the long cam.

The function of the RCR relay and the 2LS limit switch contact is to hold in the accelerators during the raising and sliding of the tub and to open the accelerators HlA. H2A. H3A and H4A as soon as the tub starts lowering. thereby. lowering the tub slowly. Also. the relay and the limit switch must open the accelerators just before the shoes strike the ground. The function of the No. 1017/VI

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BI005692

limit switch contact is to assist the RCR relay by opening the accelerators at a mechanically fixed point of the walking cycle, since the point varies because of temperature if controlled by the RCR relay alone. Closing of the accelerators ia controlled entirely by the RCR relay since the limit switch contact is closed at the parts of the walking cycle where hoisting of the tub or shoes takes place.

1.

Adjust the air gap of RCR relay between magnet core and armature to 220 mills, as measured at the center of the magnet core pas8ing through the center of the coil and the armature. This adjustment should be made by turning the adjusting screw at the front of the relay until the armature is at the proper distance and then the screw should be loced in position by its lock nut.

2.

Adjuat the contact tip gap to approximately 63 mills by adjusting the contact tip stud that projects from the panel.

3.

Adjust the spring adju8ting nut that regulates the required pull for the armature to five or six turns of compression on the spring. To make this adju8tment the adjusting nut should be backed off until there i. no compression of the spring. Then, from the point of beginning compression turn nut to five or six turns of compression.

With these settings of the RCR relay, it is possible to get the relay to pick up at approximately 15 amperes positive current and to drop out at zero current. The differential between pick up and drop out increases slightly with spring pressure.

The point at which the relay operates can be varied by varying the spring pressure.

No. 1017 IVI

- 24 -

9/1955

FOR TYPE 7400 W. L. DRAGLINE

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MOTOR FIELD VOLTS, MAXIMUM MOTOR FIELD VOLTS, NEUTRAL *MOTOR FIELD VOLTS, LOWERING *VOLTAGE IS APPROXIMATE AND IS BASED ON MAXIMUM LOWERING SPEED

8 CU. YD. BUCKET

MOTOR FIELD VOLTS, MAXIMUM MOTOR FIELD VOLTS, NEUTRAL *MOTOR FIELD VOLTS, LOWERING

10 CU. YD. BUCKET

STALL CURRENT NO-LOAD VOLTS, BOTH FIELDS NO-LOAD VOLTS, SEPARATE FIELD ONLY APPROXIMATE SEPARATE FIELD CURRENT, STALL SELF FIELD CURRENT, AT NO-LOAD VOLTS MOTOR FIELD VOLTS, MAXIMUM MOTOR FIELD VOLTS, NEUTRAL *MOTOR FIELD VOLTS, LOWERING MOTOR FIELD VOLTS, FIELD WEAKENED FIELD WEAKENING RELAY, OPERATES AT VOLTAGE

80 50 50

90 50 50

110 50 50

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BI005692

BI005692

SECTION VII

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- 1 -

9/1955

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--IMPORTANT-DO NOT FAIL DO NOT FAIL

to put oil in Coupling before putting machines in operation. t() replace the oil plugs tight enough so that the oil' cannot throw out of the coupling when machines are in motion.

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"FAST'S" SELF-ALIGNING COUPLINGS A ftexible Coupling is not II universal joint. The same care should be taken in the alignment of equipment using ftexible couplings as if solid couplings were to be used.

INSTRUCTIONS FOR INSTALLING '11te Support Ring (C) should be entered over shaft end before the Hub (8) is forced on and keyed. The key must fit on its sides for the entire length of the hub and should not bear on top or bottom. The Sleeve (A) is then entered over the Hub (8) and bolted to Support Rinr (C).

US The hubs of this No. ( 6 ) Coupling must be separated ( ! i t '). This dimension will be found stamped on the alignment faces of the hubs. The shafts should then be lined up by use of a straight edge and taper thickness gauge on the alignment faces of the hubs as shown above.

'11te ftanges of the sleeve should be cleaned and gaskets examined to insure an oil seal and then bolted solidly toiether.

Through one of the two holes provided in the body of the coupling, put in ( 2 ) pints of any good fluid lubricant, no lighter than heavy engine oil (S.A.E. 70) or heavie.· than hea,·y gear oil. (1000 seconds Saybolt viscosity at 212°F.) DO NOT USE GREASE. At the point marked "Oil.Level" dn the above sketch, oil will run out when the coupling is at rest if more than the nerellsary amount is put in. Be sure to replace plugs tightly, using wrench provided with the rouplinjf for that purpose.

CouplinK shuuld be checkt.'CI periudicall), to insure that pr0lk'r amount of oil

i~

main-

tained at all times.

"KEEP COUPLINGS OILED" s.w

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Cmntta......... . . ..

KOPFeRS COMPANY BARTLETT HAYWARD DIVISION BALTIMORI!· MD.

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BI005692