CAT Dragline Marion 7800 Operation & Maintenance Instruction Manual

BI116002 © Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI116002

(

OPERATION AND MAINTENANCE INSTRUCTION MANUAL

NO. 1004

MARION 7800 WALKING DRAG LINE

(

Manufactured By MARION POWER SHOVEL CO. MARION, OHIO, U.S. A.

BI116002

CONTENTS

SECTION

PAGE

I

Erection Instructions

II

Adjustments ...................

III

Operating Instructions ............... .

IV

Lubrication Instructions . . . . . . . . . . .. .

V

Wire Rope Reeving .................. .

VI

Electrical Instructions .............. .

VII

Appendix ........................... .

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•••

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\

i

1' f

100 - 2/53

- 2 -

No. 1004

BI116002

SECTION I

ERECTING INSTRUCTIONS

MARlON 7800 WALKING DRAGLlNE

( Required Material· . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . .

5

Er.ecting Procedure ..... ~ . . . . . . . . . . . . . . . . . . .

6

c - 3 -

BI116002

(

/" ,/

/

/

I

/

/

I f

\ -\ to cIIod _

on t.Yt1 9I'0Il00,

\

\

"

~

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In cow 9'Ound

IS not Ieotl, dead ""'" will hoy. to b4t plcclll ..., turlhe, '''''''

indic.1Id to pro.1de

boom

o"'o,ance

Doitod men ""'" 3' wide • 6' 10 8' dtt!> • 'ii Doitod _ 109 20" olio .• 7'10 II' kln9 lid.

R.R. I•• , Dead mon c<lbk> 1-112" clio, • 1r:J 10"'3 IIcIuIIIM 0,""00 IoQ and 'o.!HId,

Of"

Loe<r'IM .f "10 ton, 110'-0' boOII\ ....tid< !Or ....:lIon of Tyl>' 1Il00 WaIIoItr

CR-4564

BI116002 ERECTING INSTRUCTIONS FOR MARION 7800

(

These instructions have been prepared to aid in erecting a MARION 7800 WLE Walking Dragline; a guide for th~ operator, the groundman, and the oiler in their operatioJil, maint~na~te and lubrication. The engineering drawings which ac:compa!ny the machine give the exact location of all parts. all necessary dimensions, etc. It is very important that extreme care be taken in assembly because improper erection may cause unnecessary wear and faulty operation of the machine.

When the machine is shipped from the factory. the partsarematchmarked throughout. Care should be taken to follow these match marks when the machine is assembled.

All finished surfaces and bearings are protected against corrosion and should be thoroughly cleaned just before assembly. When assembling. all bearings should be lubricated. Ball and roller bearings are to be filled only 1/2 full of the proper g~ease. Also lubricate all gears and put the proper oil in gear cases up to the correct level before the machme is run. All air and electrical equipment, bearings and finished surfaces should be protected from the weather until the machine is fully assembled.

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

It is important that the derrick be placed so that the greate st loads can be lifted without interfering with the erection of the machine. The recommended position of this derrick is mdicated on drawlng CR-4564. If the ground is not level, place the dead men out further than the 425' indicated for boom clearance.

REQUIRED MATERIAL Following is a list of materials required to aid in the erection of the machine.

They are to be furnished by the purchaser.

24 12 90 200 60 1000 1000 8

(

2 x 10 or 12" Planks x 20' long 2 x 10 or 12" Planks 10' to 12' long 2 x 10 or 12" Planks 14' to 16 1 long 2 x 4 - 16 1 to 18 1 long 2x 4 - 8 1 to 10' long Standard railroad ties Miscellaneous flat blocking 2" x 6" x 12" Dead men logs for anchoring derrick guys. 20 tl diam. x 7' or 8 1 long. or can use 32 standard railroad ties TOOLS AND EQUIPMENT

It is recommended that a small tool room be erected at the erection site for the protection of the tools, dri;lwings. etc No. 1004/1

- 5 -

(Rev. 9/1954)

BI116002 One electric welding machine is required to be used throughout the erecting period. Also, four electric welding machines are recommended for use in the tub assembly.

Consult Marion Power Shovel Company regarding derricks, tools and other equipment for use when erecting the machine.

(

ERECTING PROCEDURE It is recommended that the following procedure be used in erecting the machine.

1.

Assemble sections of lower frame or tub. (Refer to erecting prints for a detailed "Field Assembly Procedure lt or consult Marion Power Shovel Co. engineers). a.

Tub consists of three center sections and four outer sections.

First, place center sections and bolt together.

b.

Install center journal.

c.

Place outer sections, bolt to center section, level entire tub and then weld.

Caution:

d.

Remove all manhole covers during assembly to allow weld fumes to escape.

Tub should be rechecked for level and circle rail bearing surfaces checked for levelness with transit.

2.

Install main swing gear segments, accurately tram, bolt down and weld, according to assembly instructions.

3.

Install lower circle rail, accurately tram, and bolt to tub.

4.

As semble roller circle, making certain that the small diameter of the roller is to the inside of the circle.

5.

Install upper circle rails on the roller circle in such a position that boom end of upper frame will be pointed toward derrick. (See CR-4564) .

6.

Burn off lifting lugs and grind smooth.

7.

Assemble sections of rotating frame. a.

b.

No. 1004/1

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

Place center section of upper frame. Be sure center journal is well greased and shear blocks welded in place before placing center section over it.

- 6 -

(Revised 9/1954)

(

)

BI116002 c.

Place cribbing under both front and rear of center section and- front section so that there is approximately 3'-01t between the tub and the upper frame. This will allow room to work on the underside of the upper frame. Be sure center section is level.

d.

Assemble main swing shafts and swing gear cases, on front section of upper frame. (When upper frame is lowered onto tub, the pinions on main swing shafts must be meshed with main swing rack on the tub. This is best accomplished by turning main gear in gear cases).

e.

Place right and left side sections in position, align and bolt for riveting.

f.

Place lower superstructure in position. 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 section and bolt for riveting.

1.

Ream where necessary and rivet rotating frame complete.

j.

Place jacks under frame, remove cribbing and call'efully lower the frame onto the roller circle on tub. Fasten upper rails to rotating frame.

(

8.

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

9.

L. P. 255 (Page 10) shows method of distributing the ballast so that the machine will be properly balanced when in operation. During this operation care should be taken so as not to damage the electrical conduit.

10.

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

Place main propel gears and install main propel shafts.

b.

Bolt on hoist and drag machinery frames and install hoist and drag drum.

c.

Install swing motors and oil pumps for swing gear cases.

(

- 7 -

BI116002 d.

Install main drive g~ar cases, 2nd intermediate extension shaft, hoist and drag motors.

e.

Install air compressor.

(

11.

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

12.

Install fairlead.

13.

Install walking towers and stub shafts. Align, bolt and rivet. It is particularly important that the matchmarks be followed exactly during this installation.

14.

Assemble boom complete. This can be a simultaneous operation with other phases of erection. (See 22).

15.

Install front and rear of house.

16.

Place roof trusses and eave angles.

17.

Place operator's cab.

18.

Assemble upper structure.

19.

Install gantry cap.

20.

Install front and rear gantry bracing and all 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 braces,

No t e :

Place boom hoist machinery on gantry.

Before roof of house is installed, keep machinery and electrical equipment well covered.

21.

Install and weld house roof.

22.

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. .

23.

Reeve cables. Reeve boom hoist cables first. Reeving is more easily accomplished by welding or brazing 7/ 8 u x 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 still on ground) and reeve boom safety cables in same manner as boom hoist cables. See section for cable reeving diagrams.

24.

Install air piping.

No. 1004/1

- 8 -

Rev. 9/1954

(~

BI116002 25.

Complete house.

26.

Install walking cranks and walking shoes.

27.

Raise boom and remove all cribbing.

28.

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

29.

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. that they are filled.

Make sure

After painting is completed, the Il,lachine is ready {or testing and making electrical settings.

C \

'~,

... '

- 9 -

BI116002

BALLAST

DIAGRAM

(

D

D

.A

B

D

D

Capacity Wi. in lba.

Pocket 100 % 85°/0 at 85°/0 COl).

269 228 A 269 228 Aa 178 151 38,000 B 178 15 I 38~OOO BI

G

D

C

D

D J

o

c.

B

D

D 01 E

E6 F F'I

G Ga H

95 95 59 59

e.

8.

50 50

12,,500

82.S00

·123 123

104 104

16 76 14 14

64 64 65 63 250

16,,000 16.000 _

155

58400 15 000

J

294 182

K

7_0_

6Q

Total 2294-

1941

15 ~800 15.800

2. la.obo 486.000

NOTE - Fill pockets (1j~ indicated on table any additional ballast required to be in pockets 0, C" E.

Ee, H, A

a

AI.

Capacity figures are based 250-/cu. ft.

-/0-

on

l. P. 255

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BI116002

c· SECTION II ADJ USTMENTS

MARION 7800

WALKING DRAGLINE

Swivel Return Mechanism - - - - - - - - - -

15

Swing Lock Brake

17

Propel Brake- - -

(

- - - - - - - -

21

Hoist or Drag Check Brake - - - - - - -

21

Boom Hoist Brake

21

Propel Clutche s -

21

Couplings on Hoist and Drag Motors

- - - -

21

Lock Brake for Jib Crane - -

21

Swing Gear Case Oil Pumps

21

( - 13 -

BI116002

SWIVEL RETUR.N MECHANISM ( 0 0

o o o

0 0 0

o o o

0

0

0

0

o 0 o 0 o 0 o 0 o 0 o 0 o 0 0 0

0

0

I

J

~

8

I

-i

N

!III

:;;

..

:;;:

z0

.

II!

( L.P.256

BI116002 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 footing and the other will sink in or slip back. This would tend to rotate the entire machine around the shoe which is holding. Such a condition imposes excessive stresses in the walking mechanism.

Illustration 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. l' shows ,the shoe in its normal or starting position, which is parallel with the center line of the machine. This position is brought about automatically when the shoes 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 is 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) is mounted. Journal bearing,",(5) is cast integral with the swivel casting while journal bearing (6) is ca'st separate and is bolted to the swivel casting. This type d~sign is necessary for assembly, purposes. The walking arm yoke casting (7) is 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 sli9.e blocks which are made of special composition having a low coefficient of friction, so that they will sl1de readily under pressure. These slide blocks bear on finished slide plates (8) welded to the top of the shoe, the contact surfaces being greased packed. The lubricant is prevented from espaping by means of a grease retainer entirely surrounding the slide plate s ,on the shoe. The slide plate covers (9) protect the slide plates preventing dirt and moisture accumulating on the bearing surface s.

Extending forward on the shoe swivel pin (3) is a part of the swivel assembly known as the Swivel Return Mechanism. This return mes;:hanism consists of an adjusting screw (10), a spring (11), 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 automafically 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 No. 1004/II

- 15 -

(Rev. 9/1954)

BI116002

a

SWING BRAKE - TYPES 5323, 5561, 7400 (ALSO SPRING

TYPE

5560

WITH

VERTICAL

7800

(

SWING MOTORS)

SET, AIR RELEASED, ELECTRIC CONTROL USING MAGNET VALVE To RELEASE qRAKE, OPERATOR TURNS SWITCH

SKETCH SHOWS BRAKE IN SET POSITION

"OFF",

To

OPENING MAG-

NET VALVE AL.LOWING AIR

I,

TO ENTER CYL I NDER

2

COMPRESS I NG SPR I Nt;

o

AND FOROING PISTON ROD

3

10 MOVE OUT.

ROD

PISTON

IS BUSHED AND

IS

OONNECTED TO TWO LEVER BARS

4

ON tHE OUTSIDE,

5, WHIOH

AND TO OLEVIS

IS BUSHED, ON THE

IN-

SIDE,

CLEVIS

5

BY A BOLT.

IS OONNECTED TO

OLEVIS 6 BY ROO 7 HAVING R. H. A.ND L.H. THREADS.

CLEVIS

6

IS

OONNECTED, ON NEAR SIDE OF BRAKE, TO ONE END OF BRAKE SHOE BUSHED.

8 WHICH IS

OTHER END OF

BRAKE SHOE

8

IS BUSHED

AND PIN OONNECTED TO BASE STRUCTURE. SHOE

BRAKE

8 I ,ON THE FAR S I DE

IS BUSHED AND BOLTED TO LEVER BARS 4 AT ONE END, WHEN PISTON ROD

3

BUSHED AND PIN OONNECTED TO BASE AT OTHER END.

MOVES OUT,

ON FAR SIDE.

8 HAV I NG R I VETEO LIN I NG 9; 8' PUSHES AWAY FROM BRAKE WHEEL

BRAKE SHOE

PULLS AWAY FROM BRAKE WHEEL AND BRAKE SHOE WHEN OPERATOR TURNS SWITOH ~o

"SET",

SPRING

2

IN OYLINDER

RETURNS BRAKE SHOES TO SET POSITION AS AIR IS RELEASED FROM CYLINDER. ADJUSTMENTS: AND

6

TURN HEX ON ROD

7 TO MAINTAIN DISTANCE BETWEEN CLEVISEs 5

TO SECURE PROPER CONTACT WITH BRAKE WHEEL.

ADJUSTING BOLTS 10

ARE STOPS FOR BRAKE SHOES. NOTE:

BRAKE

IS

N~RMALLY

MACHINE WHEN OPERATING

OFF EXCEPT WHEN PROPELLING; AS SWINGING OF THE

IS STOPpED BY PLUGGING THE MOTORS.

NOTE: DESCRIPTION AND OPERATION THE SAME FOR ALL TYPES, PARTS MAY VARY 1N DETAIL.

MARION POWER SHOVEL COMPANY MARION, OHIO

CI-582 ReVised 11-15- 51

C'

BI116002

(

low point or center of the cam (14). When in 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.

View No. 2 shows the walking shoe partially pivoted out of the normal position. This may be caused by the shoe being pressed against ground of sui£iclent uneveness to force the roller toward one of the high sides of the cam (14), thus compressmg the spring (11) The energy thus stored in the spring will return the shoe to the normal posltion when it is lifted from the ground for the next step. The direction and amount of sWlveling depends on the directlon and magnitude of ground slope or unevene s s, the maximum position bemg when the roller (13) is stopped by the cam end plate (15).

(

The spring (11) requires an initial compression of 5-1/4 inches (equal to 24 turns of the adjusting screw (10) for proper functioning of the swivel return mechanism. This adjustment 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). If the shoes are mounted on the machine, back off the adjusting screw till the spring is just free (or if the shoe s are being assembled, tighten the adjusting screw till the spring just ceases being free) then tlghten the adjusting screw exactly 24 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 travel is fairly level and that the shoe s or tub do not rest on any sharp obstructions. The machine should not be propelled along the slde of a steep hlll where there lS considerable danger of slipping. If possible, ground over which the machine is walking should be such that both shoes make contact with the ground at approximately the same time. When the machine reaches 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 digging. It is very desirable that the shoes when making contact with the ground have 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 spoil in the line of travel and leveling with the dozer.

SWING LOCK BRAKE - CI-582 The swing lock brake used fo'r Type 7800 dragline is spring set, air released and electrically controlled through a magnet valve.

c

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.

- 17 -

BI116002

( PROPEL BRAKE (BAND TYPE) 7400 8 7800 SPRING SET AIR RELEASED, ELECTRICAL CONTROL USING MAGNET VALVE ONE USED ON 740Q-TWO ON 7800 SKETCH SHOWS BRAKE IN SET POSITION To

RELEASE BRAKE OPERATOR THROWS

AL~OW'NG

INTO RAM OYLINDER IN,

I

COI>IPRESSING SPRING

AND PUSHING PISTON ROO

2

PIN CONNECTED TO LEVER CRANK

:3

SWITOH

AIR TO ENTER THROUGH MAGNET VALVE

A,

HAS A FULCRUM PO I NT

THERE

OUT, WHICH

:3.

IS

LEVER CRANK

BE 1 NG PIN CONNECT-

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

4

:3

IS PIN CONNECTED TO LINKS

5;

WH I CH ARE PIN CONNECTED TO LEVER ARM

5

LEVER ARM

8,

HAS A FULCRUM PO I NT

BE I NG PIN

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

IS TO LUG

CONNECTED TO BOSS ON BRACKET. PARTS ON,

8, 9,

6

ON THE LIVE

7

IS PIN

BAND IS

IN TWO

DEAD END OF BAND

AND CONNECTED TOGETHER WITK SPLICE BARS.

BAND IS PROV IDEO WITH TWO SPR I NG LIFTERS ANOHOREO TO THE BAND, BAND AWAY FROM THE

BRAKE WHEEL, AS THE COWP-

10

IN

8,

2

MOVES OUT,

CONNECTING LINKS

4

LEVER ORANK

I

:3

CAUSE LEVER ARM

THUS PUSHING BAND AWAY FROM BRAKE WHEEL,

RELEASED FROM CYLINDER ADJUSTMENTS:

DUE TO

WHIOH PREVENTS THE

COMPRESSION SPRING

NUTS ON SPR I NG LIFTERS

to

MOVES AND FULCRUMS ABOUT POINT

5

THE LINING.

AIDED BY SPRING LIFTERS

TO COMPRESS SPR I NG.

6

ADJUSTING NUT ON CYLINDER

BRAKE WHEELS ARE ON THE DRAG DRUM SHAFT.

A

WHICH

TO MOVE, WHICH FULCRUMS ABOUT POINT

IN CYLINDER RETURNS

HAND AND L. HAND THREADS BETWEEN LUG

NOTE:

ONLY PULL OUT,

II

IN.

WHEN PISTON ROD IS ANCHORED.

10

AND TEND TO PULL TH

RESSION SPRINGS

BAND LIFTER SUPPORTS SPRINGS FROM MOVING

to.

ADJUST I NG BOLT

AND LIVE END OF BAND,

I

WHEN AIR

12

WITH R.

FOR WEAR OF

TO COMPRESS SPRING.

THE PROPEL SHAFT

IS DRIVEN BY PINIONS

ARE ENGAGED BY POSITIVE JAW CLUTCHES.

A

IMPOSSIBLE TO RELEASE BRAKE UNLESS

SWITCH

IS PROVIDED THAT MAKES

CLUTCHES ARE ENGAGED. W~IL[

¥~C~INE

IT

IS

BAND TO THE SET POSITION.

ON THE DRAG DRUM SHAFT, WHEN THE PINIONS ll~IT

C'

EACH HAVING WOVEN LINING RIVETED

THE BRAKES ARE USED TO HOLD THE SHOES OFF THE GROUND

IS DIGGING OR ROTATING.

MARION POWER SHOVEL COMPANY MARION, OHIO

CI-587 4-/-46

(

BI116002

HOIST OR

DRAG CHECK BRAKE (BAND TVPE)-7800

SPRING SET # AIR RELEASED ELECTRICAL CONTROL USING MAGNET VALVE (SEE NOTE) SKETCH SHOWS BRAKE IN SET POSITION To RELE~SE BRAKE THROW SWITOH AT OONTROL STATION TO

"OFF"

ALLOWING AIR TO ENTER

THRU MAGNET VALVE

I

INTO CYLINDER

2

CAUSING PisTON ROD

OUT.

TO MOVE

PISTON ROD HAS A THREADED

CONNEOTION:3 WHIOH

IS BUSHED

AND PIN CONNECTED TO LEVER ARM

4,

WHICH IS PIN CONNEOTED TO

CONNEOT I NG BARS

5;

BARS ARE

BUSHED, PIN CONNEOTED AT POINT

A

TO ANCHOR OASTING

6

AND

PIN

OONNEOTED AT TOP TO LEVER ARM

7

WHICH IS BUSHED; OTHER END

7

Of LEVER

IS KEYED TO A SHAfT

WHICH PASSES THRU BUSHED ANOHOR O~STING

8

AND KEYED TO LEVER ARM

AT POINT

LEVER ARM

(

8

B ;

OTHER END Of

IS BUSHED AND PIN

9

OONNECTED TO CONNEOTING LUG ON LIVE END OF BRAKE BAND. BAND CONNEOTION

10 ON DEAD END

OF BAND IS PIN OONNEOTED TO ANOHOR OAST I NG BAND IS

II

IN TWO PARTS

AND

12

AND OONNECTED TOI)ETHER WITH SPLICE BARS; EAOH

PART HAS FRICTION BLOCKS BOLTED TO BAND.

13

6.

BAND

IS PROVIDED .ITH SIX SPRING LIFTERS

ANCHORED TO TH£ BAND, AND TEND TO PULL THE BAND AWAY FRO~ THE HOUSING, AS THE

OOMPRESSION SPRINGS

IN

13,

ONLY PULL OUT, DUE TO A BAND SPRING LIFTER SUPPORT

WHIOH PREVENTS THE SPRING fROM MOVING WHEN PISTON ROD

2

TO PIVOT AND LEVER ARM

4

MOVES OUT LEVER ARM

8

MOVES OUT, OAUSING OONNEOTING BARS

B,

TO MOVE UP FROM POINT

WHEN AIR IS RELEASED fROM CYLINDER

11

PISTON ROD BAOK, AND RETURNS BRAKE TO THE

5

THUS PUSHING THE BAND AWAY

13.

FROM BRAKE HOVS I NO A IDEO BY SPR I NO' LIFTERS

ADJUSTMENTS:

14

IN.

OOMPRESSION SPRINGS' THERE-IN MOVE

S~T

POSIT10N.

NUTS ON PISTON ROD IN OYLINDER TO OOMPRESS SPRINGS THERE-IN.

(NOT

SHOWN) TURNBUOKLE LIFTERS NOTE:

13

15

ON LIVE END OF BAND FOR WEAR OF BLOOKS.

NUTS ON SPRING

TO COMPRESS SPRING.

HOIST BRAKE HAS ELECTRIO SWITCH TO CONTROL THE AIR ENTERING THE CYLINDER. DRAG BRAKE HAS ELECTRIC SWITOH TO OONTROL THE AIR ENTERING THE OYLINDER, ALSO A FOOT OPERATED AIR VALVE WHIOH IS USED WHEN THE DRAG DRUM IS FREE FROM THE DRAG GEAR.

MARION POWER SHOVEL COMPANY MARION. OHIO

CI-588 4-1-46

BI116002

a

TYPE - 7400

BRAKE

7800 BOOM HOIST

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

(

2 4

i

( 01-589

To

:3

AND

LIVE

RELEASE

END

SPR I NG

3 •

8.

BAR

5

EXCEPT

BAND

POWER WHICH

BOLT

BAR

5

THUS

IS

APPLIED HOLDS

FOR

DEAD END OF

PUSHING TO

LEVER

ON

BOLT

NUTS

ON

BOLT

1 9

TYPE

IS' KEYED BAR

5

BAND,

S'UPPORT

e,A,ND ,I.S

:"WflY;-'F'~O~

I , CA~4

2,

TO PIN

I S WELDED

L1NING".'IO • .

BAND

BRAKE OPEN.

ADJUSTMENTS: NUTS

SAME

STO'P

TO ,eAND;' PASSES THP-U

OPEN.

-7400

'fIHIQH

A'NDCOMPRESSED

THEN BRAKE

9

I

END.

LEVER THE

IS HELD

TYPE -

WHEN

ON

I S WELDED

PADDLE

STOP

MOVE

WELDED

BAND HAS'1?OLDED

CONTACTS ENOUGH

OF

BRAKE,

4

HAS CAM

TO

3,

BRflKE

W·II.(·M-OVE

LEVER

2 IS 6.

SP:.RING B,AND

FOR WEAR

LININ'G.

OPERATION

OF

AND

DESCRIPTION

FOR

AS

IS

'~OVED,

CAM

F'OR

AND

SPRING

8;

FL.AT SPOT' ON ,OAM OO,.,tACTS BAND

IF

S.TOP

TO's'~:f,PO!HTION

WEAR OF' LINING,

7800

POWER SHOVEL COMPANY MARION, OHIO

7

4'M~VES

BUT'PARTS

W'I.I.

1I.I\R:Y:-I,.

CI-589 MARION

SUPPORT

OOM~RESS I ON

WHEELAND COMPRESSING UNTlt.

II

eOl T

BAND. AND PASSES >TH'/'lu"SUP'PORT

I

COMPRESSION ,SPRING 8'WILI. RETURN

TO COMPRESS

HtRU

RuN

PADDLE

AND OaNTA I NS

WELDED TO

As

P'IN BAND

4-1-46

DETAIL.

(

BI116002

PROPEL BRAKE CI-S87 The propel brake 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-S8.7.

HOIST OR DRAG CHECK BRAKEChS88 The hoist and drag check brakes are equipped with air operated brake banda ..

Each of these bands has a sepa.rate and independent control system. The adjustments and operations of this brake are fully .explained in CI-588.

BOOM HOIST BRAKE CI-S89 The boom hoist brake is the band type and is spring set and manually released. The .operation and· adjus tme nts of this brake are fully explained in CI-589.

PROPEL CLUTCHES L. P. 257

(

These are a jaw type clutch on each end of the drag drum shaft and are air engaged. spring disengaged. The springs (1) should be compressed by the adjusting nuts (2) sufficiently to assure prompt and complete disengagement of the clutches when the air is released from the ram cylinders.

Caution: The springs should not be initially compressed so much that they will be compressed solid before the clutches are fully engaged. The stop screws (3) should be set to stop the shifter yokes (4) at one halito three quarters inch after full disengagement. Note: The stop screws must always be kept properly adjusted so that the ends of the clutch jaws will not strike one another while the hoist drum shaft is turning.

COUPLINGS ON HOIST AND DRAG MOTORS See Falk Corporation instruction bulletin in Appendix.

LOCK BRAKE FOR JIB CRANE WINCH INSIDE HOUSE See CI-674.

SWING GEAR CASE OIL PUMPS See Tuthill pump instructions in Appendix.

No. l004/II

- 21 -

(Rev. 9/1954)

BI116002

PROPEL

CLUTCH

(

(

.....

II"'OIII!"_

BI116002

LOCK BAND BRAKE FOR JIB CRANE (ON DECK) 5561 B 7800 SPRIN G SET, AIR RELEASE D SKETCH SHOWS BAND IN SET POSITION

7

6

5

SKETCH SHOWS BAND ON L.H. SIDE

AIR RELEASED:

VIEW OF WORKING PARTS - AIR MACHINE

R. HAND OR L. HAND SIDE.

BAND MAY BE ON EITHER

To RELEASE BAND, ~PERATE THE FOOT VALVE WHIOH ALLOWS AIR TO ENTER THE AIR OYLINDER

I, FORCING PISTON ROD 2 INTO CYLINDER.

PISTON ROD

2

AND

IS

KEYED

CONNECTED TO CLEVIS END OF ROD

7.

SPRING

AND RESTS

CONNEOTING BARS

8

4.

TO SHArT

6

LEVER 10

2MqVES

IS

KEYED TO SHAFT

4

KEYED TO SHAFT

I.

SHAFT

EVE BOLT

9

AND PIN

LEVER

5

4

RUNS THRU

LIVE END OF BAND

WHIOH IS PIN OONNEOTED TO LEVER

BETWEEN OONNECTING BARS

8.

IT PULLS LEVER .3 WHIOH BEING KEYED

THE SHAFT TURNS,

4,

WHICH HAS FULL AND HALF NUT AND COMPRESSION

WHIOH ARE PIN OONNECTED TO DEAD END OF BAND.

INTO OYLINDER

THE SHAFT; AS

IS

IN BOSS ON R.H. MACHINERV SIDE FRAME.

HAS A WELDED OONNECTION WHIOH HOLDS

10.

5

LEVER

LEVER.3 IS PIN OONNECTED TO-

WHEN PISTON ROD

TO SHAFT

MOVES, OOMP~ESSINQ SPRING

7;

4

TURNS

ALSO LEVER

/0 MoiES UP, PUSHINI BAND I~, WHIOH HAS RIVETED WOVEN LINING, 'AWAY FROM BRAKE HOUSING; SPRING

7

THUS RELEASINI BRAKE. CAUSES

ADJUSTMENTS:

LEVER

5

WHEN AIR

TO MOVE SHAFT

NUTS ON ROD

6

4

IS NO LONGER ADMITTED BACK TO

TO OOMPRESS SPRING

NUTS ON EYE BOLT

9

INTO CYLINDER

ITS POSITION SETTING THE BRAKE.

7.

FOR WEAR OF LINING.

eI - 674 MARION

POWER SHOVEL COMPANY MARION. OHIO

I.

4 - I-53

BI116002

(

SECTION III

OPERATING INSTRUCTIONS

MARION 7800

WALKING DRAGLINE

(

...

- 25 -

BI116002 OPERATOR'S CONTROL,PANEL (L. P. 326) MAIN A-C CABINET (L. P. 325)

(

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 sets, thereby causing serious damage. When starting for the first time, all rototrol, blower, filter fan, air compressor and motor generator units must be checked for proper rotation. Once these rotations are correctly determined, they need not be checked again until electrical connections to the motors have been disturbed. When trail cable connections are changed. only one unit need be checked fO,r rotation. Use the blowers, vent fans or filter fans for this rotation check rather than one of the M. G. sets. Also when starting for the first time or after repairs, turn the motor generator sets by hand to make certain they rotate freely and are clear of all obstructions. Fol .. lowing procedure is used in starting the machine:

1:

Start the blowers, rototrols and filter fans (if used) by pressing their re spectivc "Start'l buttons located on starting panel of the main AC cabjrll:>.

(See drawing L. P. 325).

2.

Start the auxiliary motor generator set. On some machines, this is started by pre s sing the "Sta!'t" button. On this machine, this set is started by lifting tht.) handle of the oil circuit breaker (0. C. B.) marked "Aux. Set" all the way up so that the lever mechanism engages. Now grasp tht' handle and in one motion quickly push it all the way down. Do not he sHate with handle only partially down as this subjects the contacts within the O. C. B. to burning.

3.

Repeat the above procedure for the main M. G. sets, starting No. 1 set first, then No. 2 set. The auxiliary M. G. set must be running before the others can be started. After one main set is started, it is necessary to wait until this set is up to speed and the field contactor is closed before the other main set may be started. The set being started is up to speed and field contactor is closed when the A. C. ammeter on the front of the panel shows near zero current.

NOTE: On some machines a switch is used to select the main set to be started fir st. The switch has a pistol grip handle and is located near the center of the main A. C. panel. The switch must be turned to the position corresponding to the set to be started fir st. On machine s that do not have this switch, the M. G. set on which the exciter is mounted must be started next after the auxiliary set. This is normally the #1 M. G. set.

When the M. G. sets are checked for rotation, the O. C. B. is closed only momentarily by pushing the O. C. B. handle all the way down, then immediately raising the handle. Here again care No. I004/III

- 26 -

(Rev. 9/1954)

(,

BI116002

MAIN AC CABINET

(

----I

r------------------------------------~

Ii ~!~ I I I I I

I

I I

!I I

I

I I I I

[~~

~?S~.

Mlr1 R

BLOWERS

~ROTOTROL.

EXCITER

~SET S:;~~R, 1f

I ,

I I I I I I I

I

I I

II II

I

I I

I I I I

I I

I I I I I I I I

!i

I I I I ' I I I

I I

(

I

II

I, III I

---I

MG SET NO . .I

I I

I I I I

MG SET NO.2

I I

I

I

I I

I I I :

II I i

I I

I I I I

I I

I I

I I

I I I

I

II I I

I I

I I I I

I

I

I I I 1 I ,

'I

I I

I I

I

I

I J I IL I----:------------------,-----------------------' '/I ------------------------------~ I

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

L.P. 360

BI116002 should be taken so that there is no he sitahon during the downward or upward motion of the handle. It is important that this momentary closing and opening of the O. C. B. be done as few times as possible as this sq.bjects the contacts to severe burning. The only time it is necessary to do this is for initial rotation check or rotation check after connections to one of the M. G. set motors have been changed. As mentioned before, use blowers, vent fans or air filters for rotation check after trail cable or other supply lines have been changed.

DESCRIPTION OF CONTROLS The hoist,' drag and swing motions of this machine are controlled by their own individual lTIaster switch, each independent of the other. When the operator is in position in the operator f s seat, the hoist lTIaster switch is on his right, the drag on his left, and the swing at,his feet. The lTIachine is propelled by the drag lTIotors and consequently the l:'l"opellTIotion is controlled by the drag lTIastel" switch. To the operator's right is the Operator's Control Box, the face of which is shown on drawing L. P. 326. Attached to the drag lTIaster switch is the "Drag RalTI lt lTIagnet valve control switch.

OPERA TION OF MACHINE Before attelTIpting to operate the rnachine, start the air compressor (see switch on operator's control box) and see that frolTI 95 to 115 pounds pressure is built up. Pressure can be read £rOlTI gauge that is lTIounted to the right of the operator. Also set the "Hoist H and "Drag" lTIaster switche s in their middle or "NeutraP' position. The "Swing" master switch is self-centering and with no pressure on either pedal will be in the "Neutral" position. Turn the "Hoist Brake", "Drag Brake" and "Swing Brake!! switches to their II set" position and turn pistol grip handle of "Drag-Prope'iJ Tran rlt switch to "Drag" position. (See switches on drawing L. p. '326.)

('"

HOIST OPERATION Press the "Start" button of the "Exciter Emergencyt, push button station. This puts control power to all master switches and control switches. Turn the tlHoist Brake" switch to "Offff. Now the bucket may be raised by pulling the "Hoistff master switch handle toward operator. To lower, the !'Hoist!! master switch handle is moved forward from the center position. There are five points of graduated control in each direction, hoist or lower, each successive point giving increased power. The hoist brake is used only to hold the bucket while propelling or to hold the bucket and machinery in position while not operating.

At all times the bucket is positioned by proper manipulation of the "Hoist!! master switch.

DRAG OPERATION The drag motion is controlled by the "Drag!! master switch. Turn the I'Drag Brake!! switch to the 1I0ff" position. The bucket is pulled in by pulling the "Drag" rnaster switch handle toward the operator frOlTI its center position, - 28 -

r

"""

BI116002

e 0 0 0 I

I

DRAG BRAKE

HOIST 8RAKE

PROPEL. CLUTCH

I

I

I

I EXCITER EMER.

0 0

I I

0 0 0

e

PANEL

(

/], r-_....1 _ -1. -

".R••-PROPEI!' ~I TRANSfER SWITCH .\ II . 'r-T

CONTROL

PROPEL

I

'I

AIR COMRI

OAB FAN

IOA8 LIGHT

I

I

I

OPERATOR1S

I I BRAKE

SWING

I

...,

BI116002 The bucket is let out by moving the handle of the "Drag" master switch forwa.rd from center. As on the hoist, there are five graduated steps of power provided. A thumb latch on the "Drag" master switch handle, when depressed, allows a somewhat higher speed for .pulling in the drag cable. If it is desired to cast the bucket beyond the point of the boom, the "Drag Ram" switch is moved to release the drag drum from the drag machinery, allowing the bucket to swing out farther than is possible when drag motion remains under power.

(Care must be taken when attempting this as the drum must be caught with the friction to keep from tangling the drag cable). The "Drag Ram" switch must be restored to original position before dragging operation can be accomplished.

SWING OPERATION 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 if!! automatically set when the shoes are on the ground.

The swing motion is controlled with the "Swingtl master switch, located at the operator I s feet and operated by two pedals which are spring centered. Depressing the right pedal swings machine to the right, depressing the left pedal swings machine to the left. Each successive point of the master switch gives increased power, there being five graduated points of control.

When swinging the machine, the operator must be certain that the bucket has been raillied to clear all obstructions. The master switch pedal should be moved gradually to the end of its travel. To stop the swing motion, the master switch pedal 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 t;he machine to a stop is known as "Plugging". When the machine comes to rest, the master switch pedal should be brought immediately to the neutral position or the machine will start to swing in the opposite direction.

Intermediate swing speeds can hI;! obtained by moving the "Swing" master switch pedal to the intermediate points.

By applying the power gradually so that swinging motion accelerates and decelerates smoothly, the operator can eliminate excessive swinging of the bucket and cable.

PROPELLING The propelling on a walkhlg dragline ill accomplished by a series of "Steps".

Each step repre ments iii. complete revolution of the main propel shaft which runs across the machine. On each end of this shaft there ill attached the walking mechanism. (See CR-3634).

Before starting to propel, be certain -chat the "Drag-Propel" trandel' switch. is turned to the "Propel" position.

- 30 -

(

BI116002

:( SKETCH A

SK ETCH B

SKETCH C

( SKETCH 0

BI116002 The prope~ clutches are of the jaw type and it is necessary that the two ha.lve. of the clutches be lined up before the clutches will engage. The dragging l'!l&chinery should be turned very slowly until the clutch halves engage.

A limit switch on each clutch has one contact that controls the signal light markedliPropel Clutch" on the Operator's Control Box (See L. P. 326) and another contact controls the propel brake. Both clutches must be fully engaged - befox:e this signal will light and the propel brake is released. When this light is lit, the operator is ready to proceed with the propelling motion.

the propel control is

so arranged that the ma.xunUin. ~peed of walking is controlled automatically throughout a.ll parts of the cycle. Intermediate speeds can be obtained by various positions of the master switch.

Before starting to propel or wa.lk. the operator muat awing the ma.chine so that the rear end of the machine is pointing in the direction in which he whhe s to travel. As long as the propel clutch. is engaged. the awing power is limited so. the :machine, therefo're, will not respond as readily to the movement of the , swing controller as in normal operation. As soon as the shoe s are moved off· top center. the swing brakes are set so that swinging is impossible until the shoes are again brought to top center.

To propel, the operator moves the "Drag" master switch in the same direction as for dra.gging, which means pulling it towards operator. The entire walking cycle is automatically controlled and the :master switch may be left in full on position until desired number of steps have been taken, at which time the mastel' switch is returned to neutral as the shoes near top center.

( '"

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

The walking cycle is accomplished in four steps, each step representing 90 de':' grees 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 CR-3634 shoes these four positions in sketches "A", liB", "C", and "D" 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.

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 op~rator find that the shoes have traveled beyond this point, he may move the shoes back to the proper position by moving the "Drag" master sv,.itchhandle in the forward direction. The forward position of the· master 6witch allows only minimum power for moving the shoes in reverse and not sufficient to raise the tub. After taking the final step. the operator should be careful in bringing the -shoes to the normal raised position to avoid rever sing.

- 32 -

( '>..,.

BI116002

TYPICAL CYCLE OF OPERATION

I(

We will start the cycle with the bucket on the ground under the point of the boom. The "Drag ll znaster switch is pulled toward the operator to start dragging in the bucket, the desired speed and power determining the position of the master switC'h. Tension is held on the hoist cable by znanipulation of the "Hoist" master switch; pulling the handle toward operator from center raises the bucket, moving it forward from center lowers the bucket. (As no brake is employed on the hoist while diggiIlg, the [mcket will actually lower when master switch is in neutral or center position as the motors are exerting no pull to hold weight of bucket in air). The bucket is pulled in until it is full.

Then, by proper movement of the znaster switch handle, power on the hoist is increased and power on the drag is decreased. Only enough tension is kept on the drag cable to keep the bucket from dumping. if too much tension is held on the drag cable, the bucket is carried up near the boom, which causes undue strain on the boom,. and as this added drag tension must be overcome by the hoist, there is a decided slowing down of the hoisting speed. As the bucket clears the ground, the swing pedal, corresponding to the direction in which it is desired to swing, is slowly depressed. While swinging, the hoist is raising the bucket higher and the swing and hoist should be coordinated so dumping height and position over dump are reached together. If the swing is long and the dumping height is low, the loaded bucket is carried by selecting the prc>per point of power on the "Hoist" master switch. (Note: Do not hold heavy loads longer than necessary to complete regular digging cycle).

As the desired position is approached, the swing pedals are slowly reversed, bringing the swing motion to a sznooth stop. At the same tizne, the tension on the drag cable is released, allowing the bucket to dUznp. As the bucket dumps, the "Hoist" znaster switch is returned to a point of less power and care should be taken that an excess of drag cable is not allowed to run out as it znight tangle on the drag drum. By znaintaining the reversal of the swing pedals mentioned above, the mac.hine will start its return swing to pit. The bucket is lowered by forward movement of the handle on the "Hoist" master switch, the slack in the drag cable is taken up by pulling the "Drag" master switch handle toward the operator, and swing power is applied as desired to bring the bucket back to the point where it is to be filled again.

(

Whenever the operator leaves the operator's seat, he should ·make all contTcls inoperative and set all brakes. This is done by pressing the "Stopl! button of the "Exciter Emergency" push button on Operator's Control Box or pressing the mushroom head push button that is on top of the "Drag" master switch.

To again make controls operative, the "Start" button of the "Exciter Emergencyll push button station must be pressed. If it is desired to shut down all three motor-generator sets, this may be done by pressing mushroom head push button located on top of the "Hoist" master switch. This latter button stops blowers and rototrols also and machine must be started as explained in the opening paragraphs of these instructions.

- 33 -

BI116002

(

SECTION IV

LUBRICATION INSTRUCTIONS

MARION 7800 ELECTRIC WALKING DRAGLINE

(

..... - ..

'

- 37 -

BI116002 GENERAL LUBRICATION 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, extreme s of heat or cold, etc. Lubrication periods indicated are actual operating hour s.

(

It is important to make sure every rotating or movable part is properly lubric:ated. All gears and 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 recomm:ended 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 hours 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 re suIt. 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 - REGD LAR 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. 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 uses other than in Air Compressor, any good grade of motor ,oil may be used.

SYMBOL

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. l004/IV

- 38 -

(Rev. 9/1954)

(

BI116002

ROLLER

CIRCLE

(

L.P. 27

BI116002 MISCELLANEa 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 5#1449556. for Ball and Roller Bearings on equipment built by Westinghouse Elec~ric Corporation.

General Electric Grease #D6A2.A3, for Ball and Roller Bearl'" OIl equipment built by General Electric Company •

iligs

.AlR CONTROL VALVES AND .AlR CYLINDERS

Air Valves are lubricated with Fi,ske Bros. #110 Lubriplate at assembly. After every 8 to 12 months of ordinary service the valves should be disassembled and coated with this lubricant. (FiSke Bros. #110 Lubriplate may 'be purchased from Fiske Bros. Refining COn::Lpany at New York"N~'w York; Toledo, Ohio, or Newark. New Jersey). If the lubricant specified a.bove is not obtainable, use Borne 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 ordmary conditions.

Air Cylinders are lubricated with Elco *158-LOgrease at assembly. Every mon~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 lists which show 'necessary parts to be lubricated on all valves and cylinders.

LUB. PERIOD TYPE NO. LOC. LUB. SYM. IN HOURS _N_A_M_E_O_F_P_A_R_T~_..;;;B;....E...;;A..;;;.RI,;.;;;;;;;..N.;..;G~___F....;I;;.;:T;.,;;T;:..:IN::..;..;;G;;,...LOCATION FTGS. NO. II

ROLLER CIRCLE

L. P. 27

Roller Circle Track

Two rails below rol- Brush lers. Two rails a-

MO

24

'co

Z4

CO

168

CO

168

boveroll~r s

Roller Circle R.ollers

In end of each rol:ler pih

WALKING SHOE SWIVEL MECHANISM

108

1

L. P. 28

Cam Roller for Spring Return

Bush

In top o'f anchor pin

2.

Plunger in Return Mec'hanism

Bush

On f'orwarCl end of cover plate

2.

Plunger in Return Mechanism

Bush

On rear end of cover plate

z

- 40 -

,6

( 7

CG

168

CD

N

:-0

r

BI116002

5

-

~

WALK IN G SHOE SWI VE L MEC HA!N ISM

n:

-

0

0

0

0

0

0

0

0

0

0

0

0

000

o o o o

000

BI116002 NAME OF PART

TYPE BEARING

NO. LOC. FITTING LOCATION FTGS. NO.

LUB. SYM.

LUB. PERIOD IN HOURS

WALKING SHOE SWIVEL MECHANISM (Cont'd.)

",

(

Factory packed, no lube reqld.

Spring Inside Plunger

8

Bearing in Swivel for Shoe

Bush

In top of swivel anchor pins

4

9

CG

24

Front Journal Bearing

Bush

In front end ann of yoke casting

2

10

CG

24

Rear, Journal Bearing

Bush

In rear end arm of yoke' casting

2

11

CG

24

Slide Block Shoe

On' top of each slide block cover

8

13

CG

24

Rear Yoke Casting

On each sid'e of keeper casting

4

14

CG

24

Slide Block Shoe Front

Below and in front of boss on swivel support casting

2

15

CG

24

Slide Block Shoe Rear

Below and back of yoke conn. bearing on swivel support casting

2

16

CG

24

PROPEL LINKAGE

L. P. 29

Walker Arm Bearing Bush Connection

On boss at bottom of walker arm

2

17

CG

24

Stabilizer Arm Bearing

Bush

On boss at upper end of stabilizer arm

2

18

CG

24

Walker Arm and Stabilizer Conn.

Bush

On boss at lower end of stabilizer arm

2

19

,CG

24

Bearing for Crank

Bush

In top of walker arm

4

20

CG

24

On outside of collar, each end of propel shaft

4

21

CG

24

Propel Crank Pin Collar Bearing

(

UPPER FRAME DECK MACHINERY

L. P. 30

Main Swing Gear and Pinions

Apply to teeth

(

"

Brush

45

GC -j---.~

8

BI116002

PROPEL

(

(

LINKAGE

BI116002 NAME OF PART

TYPE BEARING

NO. LOC. FITTING LOCATION FTGS. NO.

LUB. SYM.

LUB. PERIOD IN HOURS

DECK MACHINERY (Cont'd.)

Outboard Bearings Propel Shaft

Bush

Mab Drive (Hoist) Inter. Shaft

AntiFriction

Two in each bearing cap and two in each bearing

8

46

CG

4

One in retainer on each side of case and ofie-inretainer- atLH end of inter. shaft

3

47

WB

500

Flexible Couplings

See Falk Instructions

Split Collar s

One in each collar

Gears Inside Drive Gear Case (Main Hoist)

Hoist Drum Shaft Bearings

Bush

Hoist Gear and Pinion Teeth Main Drive (Drag) Inter. Shaft

2

8

50

CG

8

Pour thru breather s in top of case, capacity 28 gallons

51

GL

Check daily with dip stick gauge

Piped from each cap 4 down sides of bearings

54

CG

4

Brush

55

GC

24

3

57

WB

500

. Apply to teeth thru opening in guard AntiFriction

48

One in retainer on each side of case and one in retainer at RH end of inter. shaft

Flexible Coupling s

See Falk Instructions

58

Gears Inside Main Drive Gear Case (Drag)

Pour thru breather s in top of case, capacity 25 gallons

59

GL

Drag Gear and Pinion Teeth

Apply to teeth thru opening in guard

Brush

60,

GC

24

('

Check daily with dip stick gauge

Drag Drum Shaft Bearings (Main)

Bush

Piped from each cap down side s of bearing

4

61

CG

4

Drag Drum Shaft Bearings (in Propel Pinions)

Bush

Two on each brake wheel and one on end of each pinion in clutch tooth

6

62

CG

4

Three, on outside of clutch, each end of shaft

6

Propel Jaw Clutch Splines

(

( 64

CG

8

BI116002

DECK

MACHINERY

( L.P. 30

BI116002 LUB. NAME OF PART

TYPE BEARING

NO. LOC. FITTING LOCATION FTGS. NO.

LUB. SYM.

PERIOD IN HOURS

DECK MACHINERY (Cont'd.)

Two on outside of collar i both ends of shaft

4

65

CG

8

Piped to drum hubs from fitting s on LH .. bandhousirig-

2

66

CG

4

Piped from cap down . side s of main bearing

4

67

CG

4

Propel Shaft Bearings

Two in each bearing

8

68

CG

4

Propel Gears and Pinions (Two Sets)

Apply to teeth thru opening in guards

69

GC

2.4

Propel Jaw Clutch Shiite r Collar

Drag Drum Bearirlgs

Bush

Propel Machinery Bearings

Bush

Center J o'urnal Bearings

Bush

On deck in front of propel shaft

6

72

CG

4

Swing Shaft Bearing - Top

Bush

In front of each gear case, near deck

4

73

CG

8

Swing Shaft Bearing - Bottom

Bush

. Two for each shaft, piped to deck level

8

74

CG

8

Gears an<;l. Bearings in Swing Gear Cases

Add oil thru breather pipe on top of .case.

Capacity 75 gal. each

75

Swing Motor s

See Elect. Instructions

76

Oil Circulating Pump (Tuthill Pump)

See Elect. Instructions

Top Fairlead Swivel AntiCasting Bearing Friction

Piped to inside of house, at extreme front, center

Drag Motors

See Elect. Instructions

79

Hoist Motors

See Elect. Instructions

80

M. G. Sets

See Elect. Instructions

81

Swing Generator

See Elect. Instructions

82

Air Compressor

See Elect. Instructions

83

1

78

(

Check GL daily SAE 90 with dip at all times stick gauge

WB

500

(.

BI116002

NAME OF PART

(

'.

NO. LOC. FITTlt'iG LOCATION FTG5. NO.

TYPE BEARING

LUB. SYM.

LUB. PERIOD IN HOURS

L. P. 302

DECK WINCH Deck Winch Drum Shaft Bearings

Bush

In each end of d.rwn a haft

Z

86

CO

24

Deck Winch Worm _ ~f~]3.e~r~JlgfJ .

Bush

In each, end of worm shaft

2

87

CO

24

88

GL

Check weekly

-

-

-

-

-

-

-

---- ---- -- -

--

-

Deck Wisch Worm and 'Worm Gear

Add. oil thru opeaiag in top .f case. Capacity 1 ~allon

SWING LOCK BRAKE

L. P. 16

--

---

Pivot Pins

Bush

In shoe boss

8

100

CO

24

Toggle Pins

Bush

In shoe bos8

a

101

CO

24

Bearings in Clevis Connection

Bush

In both sides of clevis

8

102·

CO

24

Piston Rod Bearing

Bush

In bo s s on end of pis-

4

103

CO

24

4:

ton rod

(

...

DRAG FRIC TION BAND

L. P. 31

Crank Pin Bearing

Bush

In outsid.e end. of crank pill

1

11e

CO

Friction Band LiveEnd Connection

Bush

In live eDd cGJlnectiGn boss

1

111

Co

Piston Rod and Lever Bush Connection

In end of piston rod

1

112

CO

4-

Piston Rod and Piston Connection

Bush

In end of piston rod

1

113

CO

4

Cylinder Bearing

Bush

On outside of special nut

1

114-

CG

PROPEL CLUTCH SHIFTER

L. p. 18

Shifter Yoke Bearing Bush

On top bo Slil of .hifte r yoke

a

117

CO

24

Lever Connection

On center boss of shUte r yoke

2

118

CO

24-

Clevis Comtection

On bottom bo s s of shiite r yoke

2

119

CO

24

(,

- 47 -

BI116002

DECK

WINCH

(

( L. P. 302

BI116002

5WI·NG

LOCK BRAKE

-- I

L.P. 16

BI116002

DRAG FRICTION BAND

c.

L.P. 31

BI116002

PROPEL

CLUTCH SHIFTER

(

( ".

(

..

-.~

BI116002

NAME OF PART

TYPE BEARlNG

NO. LOC. FITTING LOCATION FTGS. NO.

LUB. SYM.

LUB. PERIOD IN HOURS

L. P. 32

DRAG CHECK BAND Live End Toggle Bearing

Bush

Two in top of anchor casting boss

2

120

CG

4

Piston Rod and Lever Connection

Bush

In connection on end of piston rod

1

121

CG

4

CG. ___

4

CG

4

Plston Rod Bearing

In piston head

HOIST CHECK BAND

(Same as drag check band)

PROPEL BRAKE BANDS

L. P. 33

Piston Rod and Lever Connections

In top of boss on end of piston rods

Bush

. L.

.. 122

4

2

125

CG

8

(

L. P. 34

BOOM HOIST Worm Shaft Bearings

Bush

In top of boss at each end of shaft

4

128

CG

Before Using

Drum Shaft Bearings

Bush

In top of frame on each side of drum

4

129

CG

Before Using

Inter. Shaft Bearings

Bush

In top of bearing caps

4

130

CG

Before Using

Spur Gear on Inter.

Shaft

Remove guard to apply lube

131

. GC

Before Using

Worm and Worm Gear Teeth

Remove guard to apply lube

132

GC

Before Using

Spur Gear on Worm Shaft and Pinion on Inter, Shaft

Remove guard to apply lube

133

GC

Before Using

Boom Hoist Motor

See Elect. Instructions

2

135

WB

500

On both sides of sheave hub

2

140

WB

500

In side s of bearing bracket at bottom

2

141

WB

500

L. P. 35 In top of each lever arm boss

('

FOOT', PEDALS - SWING CONTROL Lever Arm Bearing

AiltiFriction

FAIRLEAD Sheave Bearings

Fairlead'Swivel Bearings

L. P. AntiFriction

Anii'Friction

T RAVE IrING CRANE Roller, Shaft Bearing!3 ·l'I.T~

11'lI'lA/T"T

36

(

L. P. 37 Bush

In top of each roller

8

145

CG

Before Using

bearing bos s _

I"&.

_r-

A\.

BI116002

( HOIST and DRAG

. CHECK BANDS

I I -I-rr---H+--_._- --- - - - - - - ----

I NOTE: DI'GIJ ChecII land AI Shown.

Hoi,t Chick Bond" RMrte.

(

'~."

.

L.P'32

BI116002

PROPEL

BRAKE

BAND

(

-+--4l--+I- -

--" -

- - --

-

-t- - - -

/

L.P33

BOOM

BI116002

HO I 5T

h II

II 'I... ______ t..t- -

A

~-------

, or,,

f.'\ " , ..

I

-

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

--'-- -;...---

,

II tI II

10.....

L.P. 34 Q . II;) A

_ 1':\4

FOOT PEDALS FOR SWING CONTROL

BI116002

(

c

BI116002

FAI R'L EA D

(

Section A'" A

L.P. 36 Rev. 9 28'" 54 0

BI116002 LU.t>.

NAME OF PART

TYPE BEARlNG

NO. LOC. FITTING LOCATION FTGS. NO.

LUB. SYM.

PERIOD IN HOURS

TRA VELING CRANE (Cont'd. ) Chain Wheel Shaft Bearing

Bush

In end of bearing bo s s, 2 both ends. of shaft

146

C

Before Using

Center Shaft Bearing

Bush

In end of bearing boss, I center of crane

147

CG

Before Using

. -Crane Track -.

Apply· to track- -

MO

Keep Coated

JIB CRANE (ON GANTRY)

L,P. 38

Sheave Bearings

Bush

One in end of each sheave pin

4

150

CG

Before Using

Top Mast Journal Bearing

Bush

In side of bearing boss 1

151

CG

Before· Using

Sheave Bearing on Gantry

Bush

In endoi sheave pin

1

152

CG

Before Using

FRONT END EQ UIPMENT

L.

Boom Hoist Point Sheave Bearings

Bush

Two in each sheave 4 pin, both side s of boom

175

CG

168

Safety Cable Point .Sheave Bearings

Bush

4 Two in each sheave pin, both sides of boom

176

CG

168

40

Front Swivel Casting Bush Bearing

On end of boom

1

177

ce

168

Rear Swivel Casting Bearing

Bush

Piped to bottom flange of casting

1

178

CG

168

Point Sheave Bearing

AntiFriction

·2

179

WB

500

Pipe to LH ·side of . boom

1

180

. CO

168

SWlvel Casting Bearing

Bush

(

On hub of sheave·

Drag Deflecting.

Sheave Bearing

Anti"Friction

On hub of sheave

2

181

WB

500

Hoist Deflecting Sheave Bearing

AntiFriction

On hub of sheave

2

182

WB

500

(

( ~"

Hoist Cable

Apply to cable

Drag Cable

Do not lubricate

No.

lOO4/IV

- 58 -

Brush

183

GC

184 (Rev. 9/1954)

Keep Coated

. ".

BI116002

TRAVELING

CRANE

Sym. about

( L.P. 37

BI116002

JIB CRANE GANTRY

ON

BI116002

FRONT

END EQUIPMENT

Boom Safety Cable.

See L.P. 324 Boom Hoist Cable

St. L.P. 323 I

BI116002

:-0

r ()J f\) ()J

BOOM

HOIST CABLES

- - - . - - - - - - - - - - - - - - - - - - _ _ - l_ _ _ _

--i-~ ------------~=~--------T----T----- ----------------~.: .--tI ---1-________________________ ~

BI116002

800M

GABLES

---------

'SAFETY

I

I

'---------'--

c(:f:""---.. . .-::- ------'-- ---,- , - - - -.- , .'-;, )-.-------------________ 1 ___ ~ _ ---~--- -=- - ~ --------~--

BI116002

I

I

// ---

I

\\

-~\

--~

---~

BI116002

(

Oil should be added to gear ca..ses as needed. ;/

Maintain a. da.ily inspection.

.

Lubricate all gear teeth as indlcated unless inspection shows more frequent or less lubrication is reqUired. All other pins and moving parts not shown, to be lubricated u often a8 needed.

(

(,

- ·65 ..

BI116002

SECTION V WIRE ROPE REEVING

MARION 7800 WALKING DRAGLINE

(

Drag Cable - - - - - -

- - -- -

-- Gantry Jib Crane - - -

L. P. 407

Hoist Cable - -

L. P. 260

---- -

L. P. 261

- - --- - -

L. P. 262

Boom Safety Cable - Boom Hoist Cable

L. P. 258

( '"

- 69 -

CD

(J1

N

:u

r

BI116002

To 0 r a

Bue ke '

~------===---­

DRAG CABLE REEVING

Sheave

Drag Deflecting . Sheave·

I---Fa irlead

Drag!

Drum~'- - I

r.

,~

o

...:v

BI116002

To Drag Bucket

t

HOIST CABLE REEVING

Boom Point Sheave

.

I

Sheave

Hoi. t_--'4I Drum

.

en o

:t1 ro

..

BI116002

GANTRY

JIB

Sheave At Point

CRA-NE

REEVING

Sheave At Top Of Most

Sheave' At Bottom Of Mast 1:---

Drum---II

Sheave On Gantry

.r

I I

I 1

{t I -

. StaIN.:'

........

-

t.-....R

IIIDCOO'a

REEVING

.:----T-~-T-----------------

at

BOOM SAFETY CABLE

------

-

I

I ,

I

I

I

I

___ ~

----------_l_--.-L __ -------------------~

+-< ......H... H;;-f---.-~-$MIUWI!-... -.....

en

:0 Nl

BI116002

U

Ll

I

,..

...

l.

I

---~

--~

\\

.-t\

~c

u-

...0

I

/i --

~

.....

BOOM HOIST CAS'LE REEVING

---------1-___

~________

..~..

_________________

I

('J

QU _

(J

1

6c

.U

f-.

...--...,.

-------~~,~~~~~ !

--------____ ~

"

{a~====~~~~======================~~~~====================~~~~;l~~JO~~

-----------~---------T----T-----

r...".--......,.,'-··

~~--~--------------------------_4------+_-----------------__ I

--

BI116002

__

BI116002

( SECTION VI ELECTRICAL INSTRUCTIONS MARION 7800 RO,TOTROL CONTROLLED GENERATORS

Part I

-

Introduction

77

Part II

-

Operation -

77

Part III -

Adjustments A. B. C.

IntroductionPreparationProcedure - - 1.

Z. 3.

4.

5.

D. Part IV

-- ---

82.

...

- - ---

.;.

82

--

Preliminary No-Load Voltage Adjustment Stall Current Adjustment- Motor Field Adjustment Final Adjustments

90 97

- -.

97 99 101 102 105

Condensed Procedure -

107

Maintenance- - -- - - - -

113

- 76 -

BI116002 PART I - INTRODUCTION The Marion 7800 is a large sized walking dragline using a direct current WardLeonard system with individual exciter control for powering all motions. The machines to be covered by these instructions use Westinghouse Electric Corp.

"Rototrols" as the individual exciters.

The motor generator sets (M. G. sets) are mounted along the side of the ml'+chine at the rear. The two main M. G. sets are driven by synchronous motors and contain the hoist, drag and swing generators and, on some machines, the ---exciter~-A--smaller· M;;6.·setis-drivenby-aninduG-tion-motor· andcontains-theexciter or a swing generator, or both.

The exciter iurnishesexcitation for the Rototrol pattern fields$ the main motor shunt fields, the synchronous motor fields and the control circuits. The generators furnish power for the 'main D. C. driving motor armature circuits.

The hoist, drag and swing Rototrols, which furnish the excitation for the main generator separately excited fields, are located in the base of one of the synchronous M. G. sets.

The hoist drum, located at the back of the machine, is driven by two horizontal, mill type, direct current motors. Two motors of the same type are used to drive the drag drum. The drag motors are also used for pr.opelling. The swing motors are vertical, mill type, direct current motors.

PART II - OPERATION After the electrical adjustments have been made as de scribed in Part III, the general sequence of operation is as follows: A.

St arting Start the blower, rototrol and oil pump motors by pressing the "Start" buttons mounted on theA. C. cabinet.

Start the exciter M. G. set first. On some machines, this is done by pressing the "Start" button located on the A. C. cabinet. On other machines, this set is started by pulling the Oil Circuit Breaker (0. C. B.) handle all the way up and then quickly pushing it down.

After the exciter M. G. set is started, the other sets may be started as given above. On machines which have the exciter on the auxiliary set. a selector switch is provided to select which main set is to be started first. This switch has a pistol grip handle and is located near the center of the main A. C. panel. The switch must be turned to the position corresponding to the set to be started first.

After the first main M. G. set is stat-ted,it is necessary to wait until

No. l004/VI

- 77 -

(Rev. 9/1954)

BI116002 this set is up to speed and the synchronous motor field contactor is closed before the other main M. G. set may be started.

i("

With the M. G. sets running, the "Exciter Emergency-Start" button on the control station may be pressed, energizing the LE contactor. This contactor carries the power for the Rototrol pattern fields, control contactors and magnet valves.· When the "Stop" button is pressed, LE opens, removing excitation from the generator s and setting the hoist, drag and swing brakes .

... ___ .. .___ ..__ When_th.e ..operatorLea'\l:es _the._C:Q.n.t:rQJ.Jl_o;r._th~_m.a~hjn.e__is_t.Q be....S.to.pped.fQr._ . a short time, the "Stop" button should be pressed to set the brakes and deenergize the controllers. To energize the controllers again, the lIStart" button is pressed.

B.

:(

Hoist Operation

1.

The speed and direction of rotation of the hoist drum is controlled by operating the right hand controller in front of the operator. Pulling back on the controller handle will raise 'the bucket and moving the handle forward will lower the bucket. There are five points or positions of the controller for hoisting, five for lowering and one for the neutral point. The speed of the motor is increased as the controller is moved point by point away from the neu:tral or center position.

2.

The hoist Rototrol pattern field is energized, rever sed and strengthened or weakened by the contacts in the hoist controller. Pulling the hoist controller to the first position back will energize the pattern field in one direction while moving the hoist controller to the first position out will energize the pattern field in the opposite direction.

Moving the hoist controller to each successive point in either direction will short out resistor HVl-HV2 on the second point, HV2-HV3 on the third point, HV 3 -HV 4 on the fourth point and HV 4 -HV5 on the fifth point. Each step thus increases the current in the Rototrol pat-, tern field by decreasing the resistance in series with the field.

The hoist controller also energizes the hoist motor field contactor, HMF2, in the hoisting direction only. This contactor shorts out part of the resistance in series with the hoist motor shunt field and thus increases the field strength. The field is not· strengthened for lowering so that a higher motor speed may be obtained.

Another hoist motor field contactor, HMF 1, energized by the hoist motor field relay, HMFR, is also used. The HMFR relay is energized by the hoist generator armature so that when the hoist motor speed (and thus the armature voltage) increases to a specific value. the HMFR relay will close and allow the HMFI contactor to open.

When HMF 1 opens, the motor field will be weakened, allowing the motor speed to increase. The effect of this system is similar to that of overdrive on an automobile.

- 78 -

BI116002 3.

The hoist drum can be held from turning by setting the hoist brake.

This brake is spring set, air released. Tht:! air pressure is controlled by means of a magnet operated valve which is clo£ed when the magnet valve is deenergized.

Tht! hoist brake magnet valve is energized through the Hoist Brake switch. When the Hoist Brake switch is moved to "Set", the magnet valve will be deenergized and the brake will set. With the Hoist Brake switch moved to "Off ll , the hoist brake will be released.

.~

c.

The hoist brake is used only to hold the drum while propelling or .. whfHl-tntnnachine-isstopped-;-------- -~------~-~,

Drag Operation 1.

The direction and speed of dragging is controlled by operating the left hand controller. Pulling back on the controller handle will pull the bucket in and pushing the handle out will allow the bucket to move out.

2.

The electrical operation of the drag controller is the same as the operation of the hoist controller.

The drag controller also energizes the drag motor field contactor, DMF, in the drag in direction only. This contactor inci-eases the drag motor field strength by shorting out part of the resistance in series with the field. The contactor is not energized in the paying out direction so that a higher motor speed may be obtained.

If the operator wishes to have a higher speed dragging in. he may press the thumb operated latch on the drag controller which will open the DMF contactor, weaken the motor field, .and give a higher speed.

3.

The drag machi.11ery can be held from moving by setting the drag brake. This brake is spring set, air released and may be released by rrloving the Drag Brake switch in the operator's control station to the "OHI! position. The drag brake magnet valve will then be energized, the valve will open, and the air pressure will release the brake. By rnoving the selector awitch to "Set", the magnet valve will be deenergized, the valve will close o.nd the spring will <:let the brake.

The drag brake is used only to hold the drag machinery while propelling or when stopped.

4.

The drag motors are coupled to the drag drum through the drag clutch. (Note:. The drag clutch is sometimes referred to as the drag ram). This clutch is air engaged and spring released. The air pressure used to engage the clutch is controlled by a magnet operated valve which is open when the magnet is deenergized. The

- 79 -

(

BI116002 clutch is engaged while digging but when the operator wishes to release the clutch for casting, he may close the drag ram magnet valve control switch, which will energize the magnet valve, clo se the valve and allow the spring to release the clutch.

The drag clutch magnet valve is also energized by the Drag-Propel transfer switch in the "Propel" position so that the clutch will be released while propelling.

D.

Swing Operation 1.

The direction and speed of swinging is controlled by operating the foot pedals in front of the operator. Pushing, on the right hand.pedal will cause the machine to swing to the right, and pushing on the left pedal will swing the machine to the left. A spring is used to hold the peda.1s and controller in the neutral position.

There are five points of control in each direction. As the pedals are pushed dQwn point by point, the speed will increase. When the machine is swinging in one direction, to stop or reverse the rotation, allow the pedal to return to neutral and push on the opposite pedal. This operation is called "plugging". When the controller is in neutral, the machine may drift slowly. To stop the drift, it is only necessary to plug the swing to a standstill.

2.

The electrical operation of the swing controller is the same as the operation of the hoist controller.

The swing controller also energizes the swing motor field contactor, SMF, through the swing motor field SMFR. When the operator opens the controller, SMF will be energized to give a strong motor field for accelerating. When the motors reach a high enough speed, the armature voltage will cause SMFR to close, opening the SMF contactor. When SMF opens, the motor field will be weakened, allowi'hg the motors to reach a higher speed.

3.

The machine can be held from swinging by setting the swing brake.

Thisbrake is spring set, air released and may be, r'eleased by moving the Swing Brake switch on the control station to the, "Off n position. The swing brake magnet valve will then be' energized, the valve will open, and the air pressure will release'th~ brake. 'By moving the switch to "Set',', the magnet valve will be deenergized, the valve will close and the spring will set the erake.

The swing brake is used only to hold the machiri'e while propelling or when stopped. A contact on the propel shaft limit switch is used to s~t the swing brakes when the shoes are on the ground; to prevent damaging the propel levers.

( \'"

E.

Propel Operation l.

Since the drag motors are used for propelling as well as for driving - 80 -

BI116002 the drag drum, the drag clutch mu,st be released and the propel clutch engaged when propelling.

The change from drag to propel operation is made by moving the Drag-Propel transfer switch to the "Propel" position. This will energize the d:rag clutch magnet valve, close the valve and allow the spring to release the clutch.

The propel clutch is air engag~d and spring released. The air pressure for operating the propel clutch is supplied through a magnet . operatedvalvewhich~isopen~whentbem.a.gm:~tjs Ell}e:rg:i~El'Cl.~~WhEll} the Drag-Propel transfer switch is moved to the ItPropel" position the magnet valve will be energized, the valve will open and the air pressure will engage the clutch. Turning the transfer switch to "Drag" will deenergize the magnet, close the valve and the spring will disengage the clutch.

2.

Two limit switches are used. to prevent releasing the propel brakes until the propel clutch is fully engaged. One limit switch is located on each propel clutch so that the limit switch contacts will close when the clutch is fully engaged. With the propel clutches engaged, th~ propel brake will be released when the controller is opened.

Another set of contacts on the propel clutch limit switches is used to energlze the Propel Clutch mdicating light to tell the operator that the c1utche s are fully engaged.

The Propel indicating light is energized by a limit switch operated by a cam on the propel shaft. When the propelling shoes are at their highest point, the Propel indicating light will be deenergized. When the shoes are,.. lowered to the ground, the light will be energized. Another contact on this limit switch is used to set the swing brakes when the shoes~are close to the ground, so that the machine cannot swing and damage the propel levers.

3.

The drag controller is used for propelling and its operation is the same as the hoist controller.

The Drag-Propel transfer switch is used to change the control circuits for propelling. When this transfer switch is turned to the Propel position, the group of contactors will be energized to change the settings on the drag rototrol for the required characterlstics

4.

When the machine is lowered at the completion of a step, the weight of the machine will drive the motors so that they will act as generators. The current generated by the motors will be opposite in direction to the current flowing when raising the machine. This reversal in current causes the Rototrol series field to reverse If the same circuit were used as for drag, the series field would becorne cumulative in respect to the shunt field when lowenng the machine, the generator voltage would increase, and the motor speed vr.ould lncrease.

- 81 -

(

BI116002 For the above reasons, the circuits are changed so that the series field will be cumulative when raising the machine and differential when lowering the machine. This is accomplished by reversing' the generator separately e:-.:cited shunt field when propelling. The shunt and series fields will then be in the same direction when raising the tub.

( F.

Boom Hoist Operation

~. -~-

The boom hoist and safety cable hoist drums are driven by separate alternating current motors. In order to operate the drums, ~-thep-rop-erpush-butto xl -sh-o p-r e e cr-to--e-ner-gize-the- d riving--

uld-b-e-

-ss

motor.

G.

Auxiliary Controls 1.

Air Compres'sor The air compressor is used to provide. air pressure for the operation of the various brakes and clutches. The compressor is driven by a three phase motor which is controlled by a pressure switch.

The pressure switch energizes the coil of the compressor magnetic switch to automatically start the motor when the air pre ssure is low and to stop the motor when the pressure is built up. A switch is provided at the operator I s control station to be used for stopping the compressor for servicing or when the machine is shut down.

2.

Blower and Oil Pump Motors The hoist, swing and drag motors are forced-air cooled by means of fans driven by three phase motors. Three phase motors are used to drive the swing gear case lubricating oil pumps. These motors are energized through a magnetic switch which is controlled by the blower push buttons.

3.

Cab Ventilating Fan Motors Three phase motors drive fans used to exhaust air from the cab for cooling. The fan motors are controlled by starting switches located at the rear of the cab.

4.

Lights The lights are controlled by switches mounted on the left wall of the cab. - These switches are of thelno-fuze" type designed to open automatically under overload. To reset the switches after an overload, throw the handle to the -"Off" position and then to the "On l' position.

PART III - ELECTRICAL ADJUSTMENTS

( 'I., ••.

A.

Introduction Before outlining the procedure to be followed in te sting and adjusting - 82 -

BI116002 the electrical apparatus on this machine, a brief description of the equipment and diagrams will be helpful.

1.

Ward-Leonard Control

The Ward-Leonard controlled electric shovel or dragline haa a separate motor geared to each motion with each motor of the proper size for its pa,rticular job. These motors are individually powered by specially designed excavator,generators. The power ' and speed of each motion is controlled by varying the output of . ------each-genel"atorthrough smalLmaster_switchesmanipulate.d__by_tbe __ _ operator.

Z.

Generators The generators used for W~rd-Leonard control of the various motions of shovels or draglines are specially designed for excavator service. The generators used with Ro,totrol control have two main fields, called the series field (denoted 51-52),· and the separatelyexcited shunt field (denoted FI-F2.). ~he

t;leries field is excited by the armature ourrent and serves to limit the maximum current flowing from the generator. The series field is connected differentially to the separate shunt field. The separately excited shunt field is excited by the Rototrol armature current. The various Rototrol fields are used to control the Rototrol output and thus the main generator output. The operation of the Rototrol is covered in the following section.

The Ward-Leonard excavator generator has a drooping voltage characteristic shaped somewhat as shown by Curve A on page 84.

On Curve A, the No-load or open circuit voltage is shown at point C and the Stall Current is shown at point D. The graph of power output in kilowatts is shown by Curve B. (This power curve is the product of volts times amperes). The maximum power delivered by the generator is at point E.

3.

Rototrols The Rototrolsused to excite the excavator generators have fields sp3ciallydesigned for this purpose. These fields are the seri~s field (denoted 51-52), the self field (FI-F2), the pattern field (F5-F6). and the voltage field (F1-F8). The series field is connected differentially to the self and pattern fields. The voltage field iaa differential field on the hoist and drag motions, but is connected cumulatively on the swing motion.

Since the armatu,re voltage of the Rototrol is applied directly to the generator separate field, it follows that the Rototrol fields can be used to control the generator output. These fields, then, are used to obtain the desired values of main generator no-load voltage, stall current and peak power.

- 83 -

'e

BI116002

c -

TYPICAL GENERATOR CURVES

-

------ - -

-

- --

---- -

----- - -

-

-----

-

-

--

-- -

---

-

-

-

------- --

-

-

-

-

-

-

-- -

-

-

-- -

-

--

(/)

lI-

•o e(

-' ~

2 0lil(

w (!) e(

I-

...J

o

> w a: :::>

le(

2.

a:: 0lil(

ARMATURE CURRENT

- 84 -

BI116002 The Rototrol pattern field (F5 -F6) is excited by the exciter voltage, through resistors, and is controlled by the master switch manipulated by the operator. The current in this field call be varied in both direction and strength, thus determining the output of tb.e Rototrol.

The Rototrol self field (Fl-F2) is excited, through resistors, by the Rototrol armature voltage and current. This field serves to increase the total. field strength, as set up by the pattern field • . The connections for the self field can best be explained by refer___________ ..!"J.ng_tQ tl!Et ty:p.l..c; a.L~j~c.J~it.JLIlhQYiILi.IL1.'j.gur~s_l_a...n.g~2..Il:Ra.g~~_ 8.6 __ and 87.

Figure 1 shows a typical circuit for the hoist or drag motions. As shown, the Rototrol self field, with its resistor, is connected from HG3 to HRA2, so that the excitation for the self field is equal to the Rototrol armature voltage minus the drop across HG1-HG3. When the Rototrol pattern field is excited, the armature voltage will rise rapidly. At the first instant, the inductance, of the main generator shunt field will keep the Rototrol armature· current from flowing, so the full Rototrolarmature voltage will be applied to the Rototrol self field. As the armature current builds up, the self field excitation will be reduced to the desired steady state value. This action is called forcing, and is used to speed up the response of the generator to the changes made in the controller position.

The swing Rototrol self field is connected across the resistor 5015G3 as shown in Figure 2. Its excitation depends solely on the Rototrol armature current. With this connection, there is no forcing action. This results in a much smoother action, as desired for the swing.

The Rototrol voltage field is excited, through resistors, by the generator armature voltage. This field is connected differential to the pattern and self fields on the hoist and drag motions and it is connected cumulative on the swing motion.

4.

Wiring Diagram A wiring diagram applying to this type machine is included with these instructions. TI e diagram may not apply in all respects, (such as incoming voltage and frequency) but the control circuits will be correct. The particular diagram for the machine to be tested should be studied and any differences noted.

Certain abbreviations in notations are used on the diagram. The prefixes H, 5, and D refer to the hoist, swing and drag motions, ret::pectively. The notation G refers to "Generator", M refers to "Motor " , E refers to "Exciter", and R refers to "Rototrol".

Al and A2 are the armature terminals; 51 and 52 are series field terminals; Fl, F2, F5, F6, F7 and F8 are shunt field terminals.

- 85 -

('

BI116002

ROT.

FIELD

VOLTAGE

~S2

H\S1

FIELD

SER I (5

ROTOTROL

FIELD

HD1

ROTOTROl PATTERN'

RES ..

TO .

SfI ITCH

MASTER

~:

?"",--.

,

..

FIGURE 'I

HGA1

HGA2

5ER IES

GENERATOR

FIELD

TYPtCAl HOIST OR CROWD ROTOTROL CIRCUIT

i

i

MOTOR

.... A1

COMMa !

I

FIELD i

I·'

-J

00

BI116002

ROT ..

VOLTAGE Fl ELO SRF7

S01

ROTOTROl SER I ES FIELD

SRA2

SRA1

SRS2

SRF5 ROTOTROL PATTERN . FI ELO

SG1

S05

GEN. SHUNT F I ELO .

TO MASTER SWITCH

GF

SGA1 GENERATOR SER I ES FIELD

GENERATOR

SG

FIGURE 2 .

TYPICAL SWING ROTOTROL CIRCUIT

SMA

MOTOR

~IELO

COMM.

BI116002 The following notations are used:

c

LE - line energizing contactor used to energize control circuits.

Operated by push buttons in the operator's control station.

HMFI - hoist motor field contactor used to strengthen motor field. Operated by HMFR. HMF2 - hoist motor field contactor used to strengthen motor field. Operated by the hoist controller. '.

HMFR - hoist motor field relay used to open HMF 1 after hoist motors have accelerated to nearly full speed. Energized by hoist generator voltage.

HR - hoist 'relay in rototrol differential voltage field circuit used to provide better stepping of generator voltage. Operated by the hoist controller.

DMF - drag motor field contactor used to strengthen motor field.

Operated by the drag controller.

DR - drag relay in rototrol differential voltage field circuit used to provide better stepping of generator voltage. Operated by the drag controller.

I(

SMF - swing motor field contactor used to strengthen the motor fields. Operated by swing controller and SMFR. SMFR - swing motor field relay used to weaken the swing motor fields after the motors have accelerated to nearly full speed. Energized by the swing generator voltage.

PCl, PC2, PC3, PC4, pes - propel control contactors used to change circuits for propelling. Operated by the Drag-Propel transfer switch.

The following notations applying to other devices are used: Gen. I, Mtr. I, etc. - the generators and motors for each motion are numbered 1, 2, 3 or 4. The lower numbers are on the left side and the higher numbers on the right side of the machine, as seen ·from the back facing the boom.

O. C. B. sets.

(

- oil circuit breakers used to start the motor generator

Propel Clutch Limit Switches - switches ope;rated by the propel clutch levers. Used to insure that the clutches are fully engaged before the propel brakes are released and to energize the propel clutch indicating light.

- 88 -

BI116002 Propel Shaft Limit Switch - switch operated by a cam on the propel shaft. Used to energize the propel indicating light and to set the swing brake s when the shoe s are on the ground.

Propel Clutch Indicating Light - indicating light in the operator's control station. Energized by the propel <:lutch limit switches when the propel clutche s are fully engaged.

Propel Indicating Light - indicating light in the operator's control station. Energized by the propel shaft limit switch wh~n the shoes -- ------ ---a-re- on-the-g-round-.---------------- ----- - ----------------~------ -Drag-Propel TranBier Switch - manual Bwitch in the operator's control station, used to change the controls for digging or propelling ..

Operator's Control Station - the panel containing the various control switches and push buttons, mounted to the right of the operator.

5.

Instruments The following is a complete list of meters required to make the desired electrical adjustments: 1 -

625 -0 -625 volt D. C. voltmeter

1

300-0-300 volt D. C. voltmeter

1 -

0-600 volt A. C. voltmeter

4

-

100 -0 -1 00 scale, 60 milli-voltmeters.

2

-

10 amp, 60 milli-volt shunts.

1 -

30 amp, 60 milli-volt shunt

1 -

75 amp, 60 milli-volt shunt

1 -

100 amp, 60 milli-volt shunt

1 -

300 milE- ampere meter

3

Sets of voltmeter leads

4

-

Sets of milli-voltmeter leads

1 -

Ta.chometer

1 -

Thermometer.

Shunts will not be required for the generator armature circuits as· one is provided for each generator, mounted on the generator frame.

- 89 -

i

(

BI116002 The above list of meters and shunts is an ideal list which permits making the tests in the quickest possible time. It is entirely possible to make these test with fewer instruments, but this means a rather slow process as the meters must be moved from circuit to circuit. In case a complete set of meters is not available, it is our suggestion that a minimum of two voltmeters, two milli-voltmeters and the shunts listed be used.

(

It must be remembered that electrical instruments are rather deli________ cate an_c.Ll!lu~t'l:l~k~p~i_~!l_C!j,!~!Oe!l-~.i!~ey_a.~e tOB!!t!50~re~t _________ _ readings.

6.

Desired Electrical Settings The desired values of the various voltages and currents are given on the test sheet or list of recommended settings. The important settings and the ones that must be set as called for are: a. b. c.

Stall Amperes No-load Voltages Motor Field Voltages

The value s of generator and Rototrol field currents are given for reference, but are reasonably close. If these values should be found to vary to any great extent, the Marion Power Shovel Company should be consulted.

( B.

Preparations for Making Adjustments 1.

Preliminary Before energizing any part of the machine, the following outline should be followed: a.

Check wiring as farae possible to see that it is according to the diagram.

b.

Check trail cable connections to be sure they are tight and well insulated.

c.

Check the collector or slip rings to see that they are aligned properly, connections made tightly and all foreign objects re ~ moved. Be sure that the brushes move freely and hav.e ample pressure against the rings.

d.

Check brush pressure on all D. C .. motors and generators.

If necessary, carefully sand in the brushes.

(

e,

Blow dirt and dust from all electrical equipment with dry compressed air. .

- 90 -

BI116002 f.

See that the bearings of all motors and generators are properly lubricated.

g.

Rotate the motors and generators by hand to see that they move freely.

h.

Temporarily connect all resistors so that maximum resistance i8 in all circuits.

1.

Open the hoist, swing and drag motor armature and field cir- -- - ----- ------cuitsateachm01:or-an:diemporarIly-inBuliletre-1eadi-:----j.

Open the hoist, swing and drag Rototrol self fields (at RFl), voltage fields (at RF7) and armatures (at RAZ) at the terminal boards near the rototrols.

k.

Open all switches and the transformer disconnects.

1.

Arbitrarily call one of the transformers No. 1 (Refer to the Diagram on the next page). The jumper connected to secondary 'terminal Xl of transformer No. 1 connects to terminalX4 of the transformer which should be called No.2. (This is jumper A on the diagram). Open this jumper which will open one corner of the delta-connected secondaries.

m.See that all connections are properly insulated. n.

Z.

Connect suitable shunts in the two lIynchronous motor field circuits.

Starting Energize the :machine and follow this procedure: a.

Close the transformer cutouts. Referring to the diagram, measure the voltage from secondary terminal Xl of transformer No. I to terminal X4 of transformer No. Z. (The jumper between these points was removed in step 1. above), (1)

If the voltage measured above ill. nearly zero, open the

transformer cutouts and reconnect the Jumper A. (Z)

If the voltage measured above is about two bmes the

rated transformer voltage, open the cutouts and reverse the secondary connections (Xl aDd X4) of tranllformer No. I, leaving terminal X4 disconnected. Close ,the cutouts and measure the volta.ge from terminal X4 of transformer No. 1 to X4 of transformer No. Z. U thiB voltage is now nearly zero, the transformers may be connected, using these last connections.

- 91 -

i,

(

BI116002

THREE PHASE TRANSFORMER CONNECTIONS

( WYE

TO

DELTA

CONNECTION

--- - - - - ---- -------- - -- - --j-O- j-R--R!:--E---P-H-A-S-E---H-(-G-H---VU-L-TA-G-E-----S-U-p-p-L:y---------------------

L3

L2

LI

---- -- flli

H~ ~2

I I TRANS. NO.3 I

TRANS. NO.2

LA

JUMPER-A

LB

I

x~ LX~ _ _ X3

X~_?tIJ

LC

LN

,( '"

DEL TA

TO

DEL TA

CONNECTION

TO THREE PHASE HIGH

L:3

VOLTAGE SUPPLY

L2

LI

fH2 -----Hil'IH2 - - - - H I I IH2 - - - - - Mil

l

'-O---'-~I-. . o(l>oH'. ~A~0

: TRANS. NO. I IL

I I

-

I

I.

TRANS. NO.2 I I

TRANS. NO. 31

~"t:t"~ ~. I .~IJ'LX~~JIIL~~X'J LJUMPER-A LA

CAUTION:

LB

. LC

LN

DO NOT CONNECT JUMPER A UNLESS THE FROM TERMINAL X I OF TRANSFORMER NO. I TERMINAL X4

OF

TRANSFORMER

- 92 -

NO.2

IS

VOLTAGE TO ZERO.

BI116002 (3)

If. the vvltage measured above is about two times the rated secondary voltage, the secondary connections of both No. 1 and No.2 transformers must be reversed.

If the voltage across the open corner is now zero, reconnect the transformers, using these connections.

Finally, measure the secondary voltages of all the transformers and see that they are the same in all three phases and correct according to the transformer nameplate s. b.

Check the operation of the light switches.

c.

Momentarily close the ventilating fan m.otor starting switch and see that the fans turn so as to force air from the machine.

If the rotation is incorrect, reverse any two of the leads.

When an air filtering system is used, the nlain blowers should rotate so as to draw air into the machine. The small blower behind the D. C. control cabinet should rotate so as to draw air from the cab.

d.

Momentarily close the "Air Conlpressor" switch in the control station and see that the air compr(:ssor motor turns as indicated. If the rotation is incorrect, reverse any two leads.

e.

Pushthe blower "Start" button on the A. C. cabinet and then quickly push the "Stup" button to check rotation of the swing gear case lubricating oil pump motor s. If the motor runs backward, reverse any two leads to the motor. Check all of the oil pump motors.

CA UTION:

Do not run this nlOtor backward very long as the pump may be damaged.

When the oil punlp lTIotors are connected for the proper rotation, pres s the Rototrol "Start" button and see that the hoist, swing and drag Rototrols turn in the proper direction. If any of the motors run backward; reverse two of the leads to the motor.

Again push the blower "Start" button and see that the hoist blower motors run so as to blow air into the hoist motors. If rotation is wrong, reverse any two leads to the motor. Repeat this procedure for the swing and drag blower lnotors.

f.

Momentarily start and then stop the exciter motor-generator set (M. G. set), See that the M. G. set runs in the direction indicated on the nameplate. If direction is not correct, reverse any two leads to the main motor.

CA UTION:

No. l004/VI

It is very important that the motor generator set does not run backward for 'any appreciable time.

- 93 -

(Rev. 9/1954)

BI116002

Repeat the above procedure for the main M. G. sets, making certain that they turn in the proper direction.

(

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

g.

Start the auxiliary M. G. set.

Start the No. I main M. G. set, noting the time at which the synchronous motor field contactor closes. This contactor should close shortly after the M. G. set reaches full speed.

(Full speed is reached when the A. C.current, read on the ---------ammeter-on--the-main-A-.-6 ;-panel,-drops-toits-minimum--- value). If the contactor closes too soon, the timing device must be set for a longer time delay. If the contactor closes a long time after the M. G. set is up to speed, a shorter time delay may be used.

~--

Repeat the above procedure for the other main M. G. set. h.

With the motor generator set running which contains the 'exciter, connect the low-reading voltmeter a'cross the main fuses on the D. C. control panel. The exciter on this machine has two shunt fields, the auxiliary shunt field being connected differentially to the main shunt field. The action of the se fields will produce a low voltage when the equipment is cold and normal valtage when the equipment is at normal operating temperature. This is done to keep the motor torque nearly constant for all temperatures.

Set the voltage by adjusting the resistor EXI-EXZ to obtain the correct exciter voltage. as shown on the attached curve. It is necessary to determine the temperature of the main poles on the exciter. Knowing the temperature. the correct exciter voltage can be found from the curve on the next page.

NOTE:

If the exciter has been idle and is at room temperature, the room temperature can be used for making the exciter voltage adjustment.

The settings are all based on 125 volts excitation so it is necessary to check the exciter voltage from time to time while making adjustments and to keep the voltage at 125 volts during the period of adjustments. This can readily be done by periodically changing a temporary jumper, on the exciter resistor.

If the machine is equipped with an air filtering system, the exciter may never get up to its full operating temperature, so the exciter should be adjusted for 125 volts when the exciter h at its normal operating temperature.

(

;- ..

1.

With the M. G. sets running. connect a milli-voltmeter across the shunt in the synchronous motor field circuit. Adjust the synchronous motor field resistor. F to SY8, located in the D. C.

- 94 -

----

BI116002 30v"tl911N30 S33~930 N I 3Jnl 'Y't:l3 dVGl 013 U

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BI116002 control cabinet, for the current given on the motor nameplate.

Repeat the above for the other motor. Record the values of current.

(

j.

Press the "Exciter Emergency-Start" button in the control station and see that contactor LE closes. Press the "Stop" button to make certain the contactor opens. Close the LE contactor and stop the blowers and see that LE opens. Close the LE contactor, stop the Rototrols and see that LE opens.

--------- --- ---- -- -k-.------W-ith-the--LE----contac-to-l!---closed-,---pull---the---hoist--contr-oller--one---- -,- ---- - -------- -------point back and see that the HMF2 contactor closes. This' CODtactor should be open when the controller is moved in the. lowering direction.

With the LE contactor closed, close the HMFR relay by hand and see that HMFI opens.

Pull the ·drag controller one point back an.d see that the DMF contactor closes. The DMF contactor should remain ')pen when the ·.ontroller handle is moved forward.

See that the SMF contactor closes when either swing controller pedal is pressed down. With the controller pedal held down, close the SMFR relay by hand and see that the SMF contactor opens.

({

Turn the Drag-Propel transfer switch to the Drag position and see that contactors PCI, PC4 and PCS are cloaed. Turn the aelector switch to the Propel position and see that contactors PCl, PC4 and PCS open and that contactors PCZ and PC3 close.

With the switch in the Propel position, pull the drag controller handle one point back and see that contactors PCl and PC5 close. Move the controller handle forward and see that only pes closes.

1.

With the LE contactor closed, check these magnet valves by connecting a voltmeter across their terminals. (It may be more convenient to connect a lamp socket with suitable voltage lamp across the magnet valve terminals. The lamp will burn when th~ magnet valve is energized), (1)

The hoist brake magnet valve should be energized when the "Hoist Brake" switch in the control station is moved to "Off".

(2)

The drag brake magnet valve should be energized when the "Drag Brake II switch in the control station is move4 to "Off" and the Drag-Propel transfer switch is in the Drag position. The magnet valve should be deenergized when the transfer switch is in the Propel position.

- 96 -

BI116002

C.

(3)

The swing brake magnet valve should be energized when the 11Sw ing Brake ll switch in the control station is moved to 110ff 11 arid the propel shaft limit switch is closed.

(4)

The two propel clutch ma&net valves sh('luld be energized when the transfe'r switch is turned to the Propel position.

(5)

The drag clutch (or ram) magnet valve should be energized when the drag ram control switch is clo sed or when the transfer switch is turned to the Propel position.

(6)

The propel brake magnet valve should be energized when the Drag-Propel transfer switch is in the Propel position, the two propel clutch limit switches are closed, and the drag controller handle is moved one point in either direction.

Adjustment Procedure 1.

Preliminary Steps a.

The following procedure for adjustments is written for the hoist only, but it will apply to the drag, propel anG: swing excapt that the swing will require a slightly different procedure because of the difference in the rototr01 voltage field connections.

For clarity, these instructions ar~ written for the hoist motion only. In actual practice, time can be saved by checking the polarity of corresponding fields for all three motions at each step. That is, when checking the voltage field polarity, for example, check it for all three motions before checking the self field. Then when cherking the self field, check this for all motions before going to the next step. This, of course, applies only to the field polarity checks.

To save time) the drag and propel settings can be made at the same time since the same circuits are used.

This procedure is condensed on later pages for ease in fol:-lowing the instructions.

b.

Before starting adjustments, stop all units and connect suitable shunts in all of the fields and the armature of the hoist rototrol and connect volt:meters across the :main generator and rototrol arnlatures.

CAUTION:

c.

Do not close any of the circuits opened in paragraphs 1. and j. on Page 91.

Close the hO).8t rototrol ar:mature circuit through the shunt.

Start the roto'crols and M. G. sets and close the LE contactor.

- 97 -

c

BI116002 d.

Open the hoist controlle:r; two or three points and read the voltage across the rototrol armature. Momentarily connect wire HRF7 and again read the voltage. 1£ the first reading was higher than the second, the voltage field is connected correc'tly.

If not correct, reverse RF7 and RF8 at the rototrol.

NOTE:

-

---

The above is correct for the hoist and drag motions only. The swing rototrol voltage field is connected cumulative and the second reading should be higher than the first. If the swing differential voltage field - - - - - - - - - - --RF7-ano.-RF8 -isiiot-correct,-rever-se -irattlieroto':-- - -- ---

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

tral unit.

This check also indicates whether or not the pattern field RFS -RF6 is operating and its circuits properly connected. If this field is open or there is something wrong with the connections, the rototrol armature voltage will not build up at all. e.

With the rototrol voltage field F7 -F8 disconnected and the hoist master switch again on the second or third point, close the rototrol self field circuit with a wiping contact at HRFI and observe the rototrol armature volts.

CAUTION: Do not hold the contact on HRFl for more than just an instant.

i(

If the voltage increases when this field is closed, the polarity is correct; if the voltage decreases, the rototrol self field polarity is incorrect and it must be reversed at the rototrol unit.

CAUTION: ' Do not open the self field with the rototrol running' and controller open, after the self field has been closed for any appreciable length of time. On the swing, with generator armature circuit open, never open the rototrol self field with rototrol running regardless of position of controller because the swing voltage doe s not drop to zero when the controller is bro'l;lght to the neutx.al position since the swing generator is self sustaining.

At this point in the procedure, it is important that the voltmeter connected across the generator armature be observed from time to time to make certain that generator voltage is at zero when it is supposed to be at zero. If it is not zero, refer to step 2-g below.

The rototro! self field for the swing motion is connected somewhat differently than the hoist and drag. In the hoist and drag motions, the self field circuit is connected acrOBS the rototrol armature and the series resistor HGI-HGS (or DGI-DGS), but

- 98 -

BI116002 in the sWIng motion, the self field circuit is connected across

part of the series resistor SGl-SG5 only. With the swing connection, the self field excitation depends upon tLe rototrol armature current flowing .. As this current increases, the self field excitation increases. With the other connections, the self field excitation decreases as the current increases. There is no basic difference in self field adjustments, however.

For the swing motion, the tap SG3 should be set to include 1/ Z to 3/4 the total resistance of SGl-SG5. f.

Move the hoist controller to the neutral position, stop all units and disconnect the rototrol motors so they will not run when the motor generator set runs.

g.

Close the hoist generator armature circuit and make certain the milli-voltmeter is connected to the hoist generator armature shunt.

h.

Start the M. G. sets and observe the milli-voltmeter connected to the armature shunt. If the current remains at practically zero value as the set speeds up, the g~neratol' differential series field is connected properly. If the current tends to increase to an extremely high value, the generator differential series field is reversed. STOP MOTOR GENERATOR SET IMMEDIATELY BEFORE FLASH OVER OCCURS AND REVERSE GENERATOR SERIES FIELD. NOTE:'

1.

Reconnect the leads to the hoist rototrol motor only.

j.

Start the ro.totrol and the M. G. aets and observe the miHi-voltmeter in the hoist armature circuit. If the current is practically zero, a8 in step h .• the series field of the rototrol is properly connected. If the current is high, the rototrol series fields are reversed. STOP THE SET IMMEDIATELY AND REVERSE ROTOTROL SERIES FIELD. NOTE:

Z.

This will also occur if the M. G. set rotation is incorrect.

This will also occur if the rototrol rotation is incorrect.

Preliminary No-Load Adjustments /I..

Stop all units and open the main motor armature circuits. Make certain all hoist rototrol field a.nd armature circuits are closed.

b.

Adjust the pattern field resistor HVO-HV05 to obtain the current in the pattern field F5 -F6 as called for on the data sheet.

c.

With lelf field tap HG3 in the resistance center of HGI to HGS,

- 99 -

I( :)

BI116002

adjust self field resistance HPI-HP5 to obtain self field current in field RF l-RF2 as called for in the data sheet under noload conditions.

Adjust the rototrol armature circuit resishn~e HGI-HG5 to obtain the generator field current listed for no-load volts.

e.

Adjust the current in the rototrol voltage field RF7 -RF8 to value called for by adjusting resistance HD I-HD5.

f.

Make certain the hoist rototrol armature voltage is correct in accordance with the value given in the data sheet. If this voltage is off more than 5 to 10 volts, it is advisable to recheck the pattern field, self field and voltage field currents. If these field currents are reasonably close, but the rototrul armature voltage is too high, reduce the self field current and then readjust resistor HG1-HG5.

g.

After the rototrol fields have been adjusted, bring the hoist controller to neutral and observe the generator voltage. If it drops off to zero immediately or goes back and forth through zero three or four times and finally goes to zero, the self field adjustment is correct. However, if the voltage continues to oscil.,. late or will not stay at zero, it will be necessary to· stop the rototrols and p":'oceed as follows:

( ,

..

d.

,'--

(1)

Move self field tap HG3 toward HGl. In other words. move the self field tap away from the generator field .

.(2)

Start the rototrol.

(3)

With hoist controller wide open, readjust self field current to value calle:i for -in step c. above.

(4)

Bring controller to neutral and again observe generator voltage. Ii voltage dies ttl zero in three or four oscillations,. the adjustment is correct. If not, repeat this procedure.

NOTE:

h.

(.

The oscillating condition may be found· before reaching this step. If so, the same corrective measure as described above can be followed.

Open the hoist controller all the way and observe the hoist generator armature voltage. Check main generator field current to see that it is approximately equal to the value listed on the data sheet. If it is low, decrease the resistance HG1-HC5 to a value such that the generator field current is made to agree with the required value. Note that if any change iG made 10 HG1-HG5, the self field current must be corrected also.

BI116002 1£ the generator field current is correct, then the generator noload voltage should agree very closely with the tabulated value.

If it is necessary to reduce the generator no-load voltage, it should be done by reducing the ma.in gene rator field current.

i.

The voltage field can also be used for adjusting no-load volts.

Increasing resistance HDI-HDS will raise the no-load volts and decreasing the resistance HDI-HDS will lvwer the no-load volts.

This field. however. should not be used if the proper adjustment can be obtained with the other rototrol fields.

The voltage field on the hoist and drag motions can be adjusted for more equal steps by means of contactors HR and DR. Thb contactor is energized and opens its contact on the fourth point of the controller. For the first three points, tap HD3 (or DD3) may be adjusted to reduce the generator VOltage. By moving tap HD3 closer to BDl, the voltage will be reduced. The current in the voltage field with the controller on. the third point should not be higher than the :maximum value given on the list of IU!!Itting s.

NOTE:

j.

3.

The voltage field on the swing is cumulative, therefore. in adjusting this field cutting out resistance in SD 1-8D5 will increase the swing generator voltag" and inserting resistance in SDl-SDS will lower this voltage.

Check to see that the no-load voltage is the same for each generator.

Preliminary Stall Current Adjustments a.

Stop all units and close the hoist motor armature circuit. Make certain the hoist motor field is open and the hoist brake is aet, then restart all unib.

b.

Observe the milli -voltmeter i:q the hoist armature circuit and with LE closed, slowly move the hoist controller to full on po.hion and note atall current. U too high, weaken the pattern field by adding more resistance in Bection RVO-HVOS. If too low, strengthen the pattern field by cutting out more resistance ia aection HVO-HVOS. The stall current must be Bet in accordance with the value liven on the data .heet~

c.Should it be found that the stall current ~ontinue8 to oscillate after the controller iI brought to naut:r.a.l. follow the procedure outlined in step 2.g, sub steps (1) to (4~. In this calle, however. the procedure will be followed under stall conditions, and will

- 101 -

(

BI116002 mean that the self field amperes will be less. The self field under this condition will be deterrrlined by the value noted at the correct stall current.

(

NOTE:

It will be found that the stall current will be affected somewhat by changing the self field current. For small changes in stall current, a change in self field may be advisable, however the self field is primarily used for other purposes.

-----------------------------I-MPGR-T-AN-'I'-:--The-ac-t-ien-of--t-hese1-i-field-of-the-rototrolis--------such that its tuning :materially affects the peak output of the generator or hump of the generator volt-a:mpere curve. Decreasing the value of this field reduce s materially the peak output, while strengthening this field' . increases the peak output of the generator, up to the point of self sustaining on the rototrol. Change s in this self field will :make slight changes in the stall current obtained, but this can be co:mpensated for by changing the pattern field.

4.

5.

('

\'"

Motor Field Adjustments a.

Stop the M. G. sets, open the hoist :motor armature circuit at the :motor and reconnect the :motor iieldcircuit.

b.

Connect a voltmeter across the :motor field terminals, at the motor.

c.

Start the M. G. sets and adjust the hoist motor field voltages.

With the LE contactor open, contactors HMFl and HMF2 should be open. Adjust the hoist :motor field resistor HMI to HM6 for the desired value with the controller on neutral by shorting out resistance starting at the HM6 end.

d.

Close the HMF2 contactor only and adjust tap HM3 for the de ... sired motor field voltage for hoisting, with field weakening.

Moving tap HM3 closer to HMl will increase the voltage while moving the tap closer to HM6 will decrease the voltage.

e.

Close both HMFl and HMF2 and adjust tap HM2 for the desired voltage for hoisting. Do not :move tap HM3 when :making this adjustment.

f.

Check to see that the voltages across each :motor field are the same.

Swing Adjustments The adjust:ments for the swing circuits should be :made as outlined above for the hoist motion, with the following exceptions: - 102 -

BI116002 ~.

Where the prefix H (for hoist) is used, substitute the prefix 5 (for swing).

b.

Note the difference in the voltage field connection pointed out in step l-d and 2-i.

c.

Note the difference in the self field connection pointed out in step I-c.

d.

When adjusting the pattern field Cl,urent in step 2-l::i, be sure - - ----------thifcontactor PC4 is closed to short out re-sil:itor-5V06~5V57~---~---~

6.

e.

Be sure that the swing rototrol is stopped when opening the rototrol self field.

f.

When checking the stall current, make certain that the stall current is nearly the same for all of the swing generators.

g.

In step 4, when adjusting the motor field voltage with the controller in neub'al, adjust resistance SMl-SM6, starting at the SM6 end, for the desired voltage.

h.

In step 4,when adjusting the motor field voltage with the controller on, close the SMF contactor and adjust tap 5M2 for the desired voltage.

i.

Check to see that the motor field voltages are the same for all motors.

Drag and Propel Adjustments The adjustments for the drag and propel circuits should be made as outlined above for the hoist motion, except as listed below.

NOTE:

Considerable time can be saved by making the adjustments on the drag and propel motions at the same time, since the same circuits are used for these motions.

a.

Where the prefix H is used, substitute the prefix D (for drag).

b.

When adjusting the pattern field current for drag, be sure that contactor PCl is closed and PCl is open. The adjustment is made by means of resistor DVO-DVOS. When propelling, resistor DRF6-l8 is connected in parallel with the pattern field through contactor PCl, and when the controller is in neutral, resistor DV06-DV07 is inserted in series with the field. The pattern field for propel is adjusted by means of resistor DRF6 -18. Decreasing the resistance will decrease the field current and increasing the re sistance will increase the current.

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c

BI116002 c..

The drag rototrol self field adjustment iBmadeby moving tap DP3 and contactor PCZ should be open. Contactor FeZ close. when propelling so the self field current adjustment for propel is made with tap DPZ.

d.

The rototrol armature resistance adjustment for drag is made with the contact on PCZ closed (peZ deenergized) by. using tap DOS. When propelling, this contact on PCZ will open and the' adjustmentis made by 'shorting out part of the resistance, starting at the DG7 end.

(

This field is reversed when propelling so that it will still be differential when the generator fields are reversed,.

(

7.

e.

The differential voltage field adjustment for the drag is made the same as for the hoist. When propelling, contactor DR doe. not operate, so tap DD3 may be adjusted for the desired field cur~ent On propel.

f.

When making the motor field adjustments, the desired value of motor field voltage with the controller in. neutral should be set by shorting out part of resistor DMI-DM6, starting at the DM6 end. With the DMF contactor closed, adjust tap DMZ for the desired voltage with the controller open.

Relay Adjustments a.

With the hoist motor armature circuit open. adjust the HMFR to close at the value given on list of settings. Thisean be done by connecting a voltmeter to read the armature voltage, ' gradually opening the hoist controller, and noting the voltage at which the HMF I contactor is heard to open. The relay should open and energize HMFl at 50 to 75 volts lower than the closing voltage. .

the

The closing voltage may be raised by increasing the resistance in's'eri'es with the coil or by increasing the air gap betweentbe core and the armature. The opening voltage is changed by varying the spring tension. b.

8.

Limit Switch Adjustments a.

(

Repeat the above procedure for the swing motion, adjusting th.e closing voltage of the SMFRrelay to that given on the list of settings.

Two propel clutch limit switches are used. one at each end of the drag drum shaft. These switches are used to insure that the propel clutches are both fully engaged before the propel brakes are released and to energize a signal light in the operator's control station when the clutches are engaged.

- 104 -

BI116002 The limit switches should be adjusted so that the contacts close just as the clutch is fully engaged. The mounting plate has slotted holes so that the switch may be moved into the correct position. The cam plate should then be moved in or out so that the switch is closed atthe prpper time.

With the switch roller on the cam, the arm should be able to turn a few degrees further, to prevent breaking the arm. b.

The propel shaft limit switch is operated by a cam on the left hand end of the main propel shaft. It is used to set the swing -------------br-akes-andenergize-a-si-gna-l-li-ght-in-th e0pe-rat01'-Ls -cont-rol------------------station, when the shoes are on the ground.

The switch may be raised or lowered by sliding the mounting bolts in the slots in the mounting plate. The cam may be rotated to the proper position by loosening the band a'round the propel shaft and turning it as required. When the cam is located, the band should be locked in place by means of the set screw on the top.

9.

Final Adjustments After the preliminary settings have been made for all motions as outlined in steps 2 through 8 above, follow the following procedure for all motions: a.

Stop the M. G. sets again, close the motor armature circuits and make certain all other circuits are closed.

b.

Make certain the hoist, drag and swing motors operate in the proper direction. In case they do not, simply reverse the field leads at the motors.

CAUTION:

(

When reversing leads, make certain there is no voltage on the fields.

The motors should rotate so the controlR operate as follows: Hoist Lower

-

Controller handle pulled in toward operator.

-

Controller handle pushed out.

Swhlg Right

-

Controller right pedal pushed down.

Swing Left- Controller left pedal pushed down.

Drag In -

Controller handle pulled in.

Pay Out -

Controller handled pushed out.

( \,- -

c.

Adjust all brake s, . safety device s and other features on the machine to make it ready for operation.

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BI116002 d.

As soon as poss.ble, the machine should be operated to dig in the regular manner in good d1gging for three or four hour s '30 all equipment 1S up to normal operating temperatures.

e.

Connect the necessary meters in the hoist generator and rototrol circuits. (To avoid too much cooling of the equipment, the instruments can remain connected while digging).

f.

Check the exciter voltage.

(

NOTE:

This value of exciter voltage must be kept throughout the fmal settings. Should exciter voltage tend to drop off temporanly, readjust it to this value. , In case all the equipment gets too cool before the settings are made on all motions, the machine should be operated to heat up the equipment again.

(

g.

Reset the stall current to the correct value called for on the data sheet as explained in Part 3. ThIS will have changed due to equipment temperature change.

h.

Stop the rototrols and move rototrol self field tap HG3 toward the main generator field or toward HG5 approximately one or two inches at a time and each time readjust the self field current by changing re sistance HPI-HP5 to bring the stall current back to the correct value.

i.

After each change, open the hoist controller to the last point and then bring it back to neutral, each time observing the stall current.

j.

Keep repeatmg steps h. and i. until the stall current oscillates by itself.

k.

Finally move tap HG3 away from HG5 until the generator stall current goes to zero in three or four swings of the meter needle.

Keep in mind that each time the position of HG3 is changed, it will be necessary to readjust the self field reSIstor HPI-HP5 for the correct stall current.

1.

Open the hoist armature circuit and reset the no-load volts as covered in Part 2.

m.

After the no-load volts are set, observe the self field current with controller wide open.

n.

If the hoist generator voltage oscillate s and will not stop at zero in three or four swings of the meter needle when controller is brought to neutral, it will be necessary to move self field tap HG3.

- 106 -

BI116002 Every time the tap HG3 is moved, it will be necessary to readjust self field current to obtain the same value noted in step m. proper~y set in step m, the stall current will not change; but to make certain, it must be checked again.

o.

1£ the self field current has been

p.

If the stall current is correct, take point by point readings in both directions of the fallowing currents and voltages:

Generator Stall Armature Amperes _______________________Gene_I"ato_r_ShunLELel~Amp~l" e s ____________________________________________________ _ Rototrol Armature Voltage Rototrol Self Field (F l-FZ) Ampere's Rototrol Pattern Field (F5 -F6) Amperes NOTE:

In case it is desired to change stall current for any step, simply change the taps on the pattern field variable resistance HVl to HV5. For example, if the stall current is too low for step Z, simply move tap HV2 toward HV3, etc.

The stall current should vary in approximately equal steps for each point of control.

q.

Next, open the generator armature circuit and obtain point by point no-load readings in both directions of the following currents and voltages: Generator No-Load Armature Voltage Generator Shunt Field Amperes Rototrol Armature Voltage Rototrol Self Field (Fl-F2) Amperes Rototrol Pattern Field (F5-F6) Amperes Rototrol Voltage Field (F7 -F8) AInpere-a _

D.

r.

Check the motor field volts and hoist mot()i' speeds' and if ne~ ce.sary. change to make them correspoad with values required.

8.

Finally, record exciter volts, motor field v91ts and speed. for all motions to make a complete record.

Condensed Procedure for Making Electrical Adjustments The following is similar to preceding instructions except shortened for ea.se in actually following each step.

1.

Preliminary a..

Before starting any equipment: (1)

Open all armature circuits.

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BI116002

(

(2)

Open all motor fields.

(3)

Open these rototrol circuits for all motions: a. b. c.

Self field at RF 1 Voltage field at RF7 Armature at RAl.

(4) Set resistor taps G3 midway between Gl and G5 for all ---------------- ---------motions.-- - ------(5) b.

2.

iC'

3. .

These precautions should be observed: (1)

Do not open generator armatures with M. G. set running.

(2)

Do not open rototrol self field with rototrol running.

(3)

Do not make settings with motor fields closed. '

Starting a.

Checkrotation of M. G. sets.

b.

Check rotation of rototrols and auxiliaries.

c.

Set exciter voltage.

d.

Check operation of LE Start and Stop buttons.

Field Checks a.

(

Set controller s in neutral.

Connections.

(1)

Close the rototrol armatures for all motions.

(2)

Connect voltmeters across rototrol and generator armatures.

b.

Start. M. G. sets.

c.

Open controller part way and see that generator voltage builds up.

d.

Check rototrol voltage field a.s follewlil: (1)

Open controller part way.

(2)

Watch rototrol voltmeter and close RF7 momentarily.

- 108 -

BI116002 (3)

e.

Voltage should decrease for hoist and drag and increase for swing. If not correct, reverse RF7 -RFS and check.

Check rototrol self field as follows: (1)

Open controller part way.

(2)

Watch rototrol voltmeter and close RFI with a wiping motion.

('

- - - - - - - - - - -(3)--Voltage-should-increa se;--iLiLde cr_ea ses, __ rexerse_REl-"- ______ ._____.___.______ RF2 and check.

f.

Repeat above steps for other motions. noting difference in swing.

g.

Stop rototrols and M. G. sets.

h.

Check rototrol and generator series fields as follows: (1)

Put milli-voltmeter across generator shunt.

(2)

Close generator armature circuit.

(3)

Watching current meter, start M. G. set. If current starts to increase, stop M. G. set and reverse generator series field. Check.

(4)

4.

With M. G. set running. watch current meter and sta-rt rototrols. If current starts to increase, stop M. G. set and . rototrols and reverse rototrol series field.

i.

Repeat steps g. and h. above for other motions.

j.

Stop rototrols and M. G. sets and open generator armature circuits.

Preliminary No-Load Settings a.

Connect the se meters in the hoist circuits; (1)

Generator armature voltmeter.

(2)

Rototrol armature vpltmeter.

(3)

Rototrol armature shunt and MY -meter..

(4)

Rototrcl field shunts and MV -meter. a. b. c.

Self field RFI-RF2 Pattern field RF5-RF6 Voltage field RF7 - RFS - 109 -

BI116002 b.

Start M. G. sets and rototro'is.

c.

Open the controller all the way and adjust these currents to desired values:

(

(

5.

Pattern field RFS-RF6 with aVO-HVOS.

(2)

Self field RFl-RF2 with HPI-HPS.

(3)

Rototrol armature with HGI-HG5.

(4)

Voltage field with HD I-HD5.

d.

Check rototrol armature voltage and if not correct, readjust the field currents. If necessary, change the self field current ..

e.

Watch generator voltmeter and return controller to neutral. If voltage does not return to zero or oscillate s more than 3 or 4: times:

f.

Ie

(1)

(1)

Stop rototrols and move tap HG3 towards HGl.

(2)

Readjust current RFI-RF2 with HPI-HP5.

Repeat step e. above until voltage dies back to zero in less tha.n 4 or 5 swings.

Preliminary Stall Settings a.

Stop M. G. sets and rototrols.

b.

Close hoist armature circuit (hoist only).

C.

Connect a milli-voltmeter across the generator shunt, as well as the meters listed in Part 4a.

d.

Start M. Go sets and rototrols.

e.

Check stall current.

(1)

If too high, decrease pattern field current.

(2)

Ii too low, increase pattern field current.

f.

Return controller to neutral and note generator current. If it does not return to zero in a few swings, adjust tap HG3 as outlined for no -load voltage in Part 4, e. and f. After each change in tap HG3, self field current must be reset.

g.

Repeat Part 5 for other motions.

h.

Stop rototrols and M. G

sets and open all armatures.

- 11 0 -

BI116002 i.

Start M. G. sets and set motor fields.

j.

Check operation of: (1)

Motor field contactors.

(2)

Magnet valves.

(3)

Limit switches.

______. _______(1L_~:h:>eCial rela)"s and contactors.

6.

k.

Stop M. G. sets and reconnect armatures.

1.

Start M. G. sets and: rotations~

(1)

Check direction of motor

(2)

Have machine oper.ated.

(3)

Note characteristic s of machine while operating.

Final Settings a.

Equipment should be up to normal operating temperature.

b.

With the M. G. set and rototrols stopped.

(1)

Open the motor fields.

(2)

Connect in the same meters used in Part 4.

c.

Sta rt rototrols and M. G. set.

d

Make stall settings as follows:

e.

(1)

Readjust rototrol currents as in Part 5e.

(2)

Adjust pattern field with HVO-HV05 to obtain desired stall current.

(3)

Move the tap HG3 as far toward HG5 as possible without getting too much oscillation. After each change in HG3, reset self field current.

(

Make no-load settings as follows: (1)

Open armature circuits.

(2)

Start M. G. sets and rototrols.

- III -

(

( ''\,--

BI116002

(

(3)

Adjust rototrol self field currents with HPl-HPS to desired generator no-load voltage.

(4)

Return controller to neutral and if voltage oscillates; (a)

Move tap HG3 toward HGl..

(b)

Reset HP1-HP5 for desired no-load voltage.

--~--~-----~-~---f-.---When-both-sta-n-a-nd-no-load-are-set.-record--point..by-point----~---­

readings of the currents and voltages listed on. page s. g.

Repeat the above steps for all other motions.

h.

Recormect machine for operation and record: (1)

Mo~or

(2)

Motor speeds.

(3)

Other data required.

field voltages.

(

( - 112 -

BI116002

PART IV - MAINTENANCE A.

Care of D. C. Motors and Generators 1.

. _~__. . . .~~....

(

General One of the most essential points to watch regarding the care of the electrical equipment, especially D. C. equipment, is absolute cleanliness. Too much emphasis cannot be given to pointing out the necessity of keeping the motors and generators clean and free fromdirt; oil or grease . - - - - -~-~ - ~- --~~- --~ -- ~-- - - - -

-~-~

There are a few troubles C()mIDon to both motors and generators which the operator should ~e able to reco¢ze and remedy. 'Normally the D. C. motors and generators give very little trouble, but there are times when something happens tha.t can be taken care of quickly by anyone. The more serious troubles should be handled by a competent electrician. If the conunutation is bad and cannot be corrected by simple remedies. the electrical, equipment manufacturer should beccmsulted.

Z.

Brushes If there is an excessive amount of arcing between the brushes and commutator while the shovel is operating under normal loads and

speeds, the brushes should be inspected and checked for the following: a.

See that they are not sticking in the holders.

h.

Make certain the contact surfaces of the brushes are clean and the brushes are making full r.;ontact on the commutator.

NOTE:

This can be determined by removing the brush and looking at the brush surface. Where the brush has been rubbing, the surface is smooth and polished.

Any portion which is not in contact with the commutator will have a dark, rough appearance.

Excessive arcing may also be caused by loose brushholder stUds, which will throw the brushes out of line. This causes the brushes to ride on the heel or toe, thus moving them out of the normal commutating plane, which usually results in considerable sparking_· This can be corrected by tightening the brushholder in its correct position.

The brushholder yoke set screw may become loosened permitting the brush yoke to rotate and to shift all the '!lrushes. When brushes are moved out of their normal position they will arc badly. The simple correction, of cours-e, is to m.ove the brushholder back into position. _113 _

(

BI116002

(

The spring pressure should be even on all brushes. The exact amount of brush pressure varies with different types of units so' the. factory should be called upon to give definite information on the brush pres.sure required for a given unit. If the brush springs are set originally at a certain point, it is reasonably certain that this ill the correct pressure and the brush pressure should always be kept at this point when installing a new brush. The initial brush pressure should be the same for all brushes on a given generator or motor.

- - --·-----------Al-I--bl"ushe.s-should-be- insp e·c t ~d-:t".egula-r-ly-arid-whe.n-a-brush-ha.s-been---­ worn almost to the point where it is no longer possible to obtain a: good contact, it should be replaced with new ones. Care should be exercised to avoid allowing the brush to wear too far as it may result in improper brush pressure, thereby causing severe arc:ina.

Sometimes too much brush wear may even cut the commutator due to the fact that the pig tail may wear into the commutator proper.

The brush springs should also be inspected to make certain they have not come out of their proper slots. When fairly long brushes are used, it is good practice to increase spring tension after the brushes are partially worn to make up for the loss in brush pressure. "

:(

In replacing the brushes, use the same type of brush as originally' furnished with the motor or genera.tor. Serious trouble can result by using the incorrect brush.

If the commutation or arcing is bad and cannot be corrected, a change in brushes sometimes improves conditions. However, before making such a change the manufacturer should be consulted.

Brushes should be installed as follows: a..

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

b.

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

This can be done as ·follows: After placing the brush in the holder, release the spring and insert a piece of No. 2/0 or 3/0 sandpaper (rough side to brush) between brush and commutator.

The sandpaper should be a little wider than the brush. With. maximum spring pressure exerted on the brush, hold the sandpaper close to the commutator and draw it in the direction of rotation. Then lift the brush, push the paper back and repeat the operation until the brush has been shaped to an even conta:c::t$~ with the commutator. Be sure to raise the brushes before moving the sandpaper back for the next stroke. In removins the sandpaper from the cornmutator, do not raise the sandpaper as so doing will usually ruin the fit on the brush. Brushes should,,,r

- 114 •

BI116002 not be installed and allowed to fit themselves by wear, as this method will usually cause sparking or scoring before the brush wears in. c.

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

-----d-;-Mte-r-grindin-g-i-n-th-e-b-ru-sh-e-s-.-th-e-y-sh-ou-ld-b-e-run-in-una"e"'ri-·- light loads for a short wb,ile. This allows the surface to seat, or wear, itself in better before heavy loads are put on. When the commutator has been used some time. it should present a chocolate brown color; It is preferable to install a complete set of brushes at a time rather than replace them singly.

3.

Commutators I~ is important that the electrician inspect the commutator surfaces at frequent intervals to Inake certain that surface faults are detected in the early stages of formation. :F'aults can be corrected at such :tiJnes with little expense or loss of time but such surface faults as bar burning. high or low bars, high mica or flat spots tend to become more serious with time and often at accelerating rate.

Unless corrected when first observed. they may necessitate a shutdown '0f appreciable duration and involve expensive repairs.

(

If excessive sparking or arcing has taken place for any length of time, the conunutator ~ill become burned and blackened. To smooth the commutator, use a very fine sandpaper. preferably 2/0 or 3/0, fold the paper around a wooden block shaped to the contour of the commutator. and hold it against the commutator with the motor or generator running at no-luau. It is good practice when applying sandpaper to use a slow lateral movem.ent of the sanding block to avoid diagonal scratches.

If the corrunutator is only slightly blackened, it is best to use a piece of canvas wrapped around the block of wood instead of sandpaper.

The canvas leaves the surface clean and does not scratch the copper.

A good commutator surface must be highly poliShed and show a chocolate color. Undue amount of sandpapering destroys this polished surface and results in increased brush wear. Sandpapering should be done as little as possible. In many cases polishing the commutator with a canvas as mentioned above is sufficient to take care of the blackening of the commutator.

Oae of the principa.l objections to the use of sandpaper for cleaning commutators is that it very rart'!ly leaves the bars properly ground.

- .115 -

(

BI116002 On an unslotted cornrnutator. particularly where the mica is high. sandpaper has a tendency to flatten the center of the bars.

(

Should the cOtnrnuta,tor become badly pitted or rough so that sand'paper or canvas cannot clean the commutator or take out the bad spots, it will be necessary to use a hand stone. Sandpapering ,will remove some slight embellishments, but it cannot be depended upon to remove large flat spots. While it may appear to eliminate 'them, the affect is merely to broaden out the spot so it is no longer apparent, due to the flexibility of ~.he paper. The use of a cOtnrnutator stone is therefore recommended in preference to sandpaper where any amount of smoothing is to be. done. The stone presents a rigid contact surface and can be more rigidly held in place while grinding the commutator.

Although hand stoning will restore a true, cylindrical surface~ it cannot be depended upon to eliminate eccentricity of the commutator or extremely bad spots. Eccentricity is not caused by severe arcing , or poor commutation. but eccentricity may cause excessive arcing or. in other words, poor commutation. Sometimes eccentricity is in the coinmutator initially or it may be caused by the commutator changing shape with heat and age.

In cases where commutator, eccentricity exists or there are extremely ba~

spots. the armature should be removed' and the commutator turned or ground in a lathe , . by som.eone familiar with this type of work.

After turning Or grinding, the commutator mica should be undercut.

Some of the large commutators can be ground in the frame by a skillful mechanic using the proper equipment. This avoids the loss of time and the expense involved in removing a large armature. The speed of commutation while grinding is important, therefore, it is essential that this be handled by experienced :men to prevent damaging the commutator by grinding at the wrong speed. A good cqtnrnutator wili be within only. 0005 to .001" out of round when checked with a dial indicator gauge.

After g.rinding or sanding the commutator, the unit should be brought to rest and all copper or carbon dust blown off with dry compressed air. Also, after grinding or sanding the commutator, the brushes should be run for a short time under a very light load. This will allow the brushes to get a fairly good seat before applying full load.

Whenever the commutator is sanded or stoned, perfect brush contact is destroyed.

(,

Emery paper Or emery cloth should never be used on a commutator, especially when a current is flowing. The reason for this is' that e:mery is an electrical conductor and particles are likely to become imbedded between the segments and cause short circuits. '

If commutation is bad and cannot be corrected by simple re:medies. the electrical equipment manufacturer should be consulted. '

- 116 -

BI116002 4.

Lubrication of Bearings To properly lubricate ball and roller bearings or any other type of anti -friction bearings on electrical equiprnents for shovels or dragline s, the following procedure has been established as suitable for all general conditions.

First of all we want to caution against ~ greasing. Usually rnore darnage can be done to a bearing frorn over greasing than frorn insufficient grease. There is, Of course, a "happy rnediurn" that rnust be established. It also should be kept in rnind that too rnuch lubrication rnay result in electrical failures because of the grease accumulation on comrnutators or windings.

- - - - - - - - -

When the equipment is new, all bearings should be lubricated according to the following chart for the first day of service and then every 250 hours of actual running time thereafter, until a very small amount of grease appear s at the shaft or it starts to corne out at the bottom drain hole (plug rernoved) of the bearing housing. After the first day of service, greasing should be done with the equipment at operating temperature.

An10unt Grease

Shaft Diameter 1I.

1/2 oz.

2 oz.

3 oz.

4-1/2 oz.

6 oz.

8 oz.

10 oz.

12 -1/2 oz.

15-1/2 oz.

18 oz.

2" 2-1/2 11 3" 3-1/2."

4" 4-1/2 11 5" 5 -1 /2"

6"

NOTE: Many srnall moiors use sealed bearings that require no lubrication for two to three years.

The above lubricant should be added with the units at rest and the drain plug rernoved. After the lubricant has been added. the generator or motor should be run with the bottom plug removed for approximately one -half hour to make certain all excess grease flows out.

Do not forget to replace the plug.

In most cases the main hoist, crowd and swing motors; have no plug to be removed. but surplus grease will flow out in a pocket beneath the bearing housing. On vertical motors and some type of horizontal motors plugs' must be removed the same as for the generators.

NOTE:

For oil lubricated anti-friction bearings, check with Marion.

- 117 -

(

BI116002 After the grease appears at the bottom hole or on the shaft, no more grease should be added for the next 1000 hours operating time. After the 1000 hours interval, grease should be added in accordance with the following chart.

(

Amount Grease

Shaft Diameter

1/4 oz.

1 oz.

1-1/Z oZ.

I" Z" Z-l/Z"

3 oz.

4 oz.

5 oz.

6 oz.

3-l/Z"

4" 4-1/2 5" . 5-1/2"

7-liz

oz .

8 oz.

6"

While greasing at the ,1000 hour intervals, care should also be exercised to make certain that grease is not accumulating on the shaft.

If there is an accumulation of grease on the shaft, the greasing inter. val should be increased to 1250 hours.'

(

As mentioned in the Z50 hour interval procedure, the bottom plugs should always be removed before greasing to see that surplus grease escapes. Do ~ forget to replace the plug.

Approximately Ollce every year, or after 7500 hours operating time, the bearing should be "purged" by pumping sufficient grease through the bearing while running so new grease appears either at the shaft or at the bottom plug. If the grease comes out along the shaft, it is very important that this be kept wiped off until new grease appears.

Finally clean off shaft thoroughly again after the machine is run for 15 or ZO minutes. The new grease should appear first at the bottom hole, but sometimes it comes out first along the shaft.

If possible, approximately once every two years the bearings should be disassembled and all old grease ,removed by a thorough cleaning with light lubricating oil.

Each time the bottom plug is removed, a clean Wire should be pushed into the hole to make certain the grease has not hardened to plug the hole.

(,

One measuring tablespoon ful is equal to approximately one ounce of grease. Use General Electric Co. ball bearing grease 'D6AZA3 for General Electric Company equipment. Use Westinghouse Electric Corp. grease" 1449556 for Westinghouse equipment.

CAUTION:

DO NOT MIX GREASES UNLESS THEY ARE OF THE SAME BASE AND WILL MIX. CHECK WITH GREASE MANU F ACTURER IF THERE IS ANY QUESTION •

• 118 -

5.

BI116002

Winter Suggestions

In cold weather, if the machine is shut down long enough to cool off, the motor generator set should be run with no-load. long enough to warm the bearings enough to insure adequate lubrication, when fun load is applied. In extremely cold weather. the motor generator bearings should be warmed with an electric radiant type heater before starting the set.

(

In cold weather. if the machine is shut down long enough to cool off, it is advisable to run the hoist, swing and crowd motors, without digging, to warm them up. and establish lubrication, before --------~--starfing roai~In extremely colcl weath.er, tn-e-m-ot-or-bearings may be warmed up with a radiant type heater. As each set of motors is warmed up. they should be run light to maintain lubrication while the next set of motors is being warmed.

B.

Oil Starting Switch It is important that the operating levers be handled in a snappy and deC1Slve manner. Slow deliberate handling of levers will result in serious bU,rv,i:ag of the contact fingers and jaws. neces!3itating shut downs for frequent renewal of these parts. Burning may be eliminated largely by closing and opening the starting lever quickly as this cuts out the destructive arcs.

C.

Air Magnet Valves The most common trouble experienced with air magnet valves is the gathering of dirt or scale on the valve seat, causing a leaky valve. If the valve is partially opened by means of the lever on top, and the air allowed to blow through. the valve can usually be cleaned without being taken apart. Do not put oil into the air lines as sufficient oil gets by the pistons and piston rings of the air compressor to lubricate valves and other parts.

After the machine has been in service for some time, the brass valve stem may become battered .. This results in a gap which can be corrected by drawing out the valve stem sufficiently to close the gap. The. nut at the bottom should be removed periodically and the dirt blown out.

The magnet valve is very rugged and needs little or no attention: in the course of ordinary operation. The leads to the coil should be kept tight and the coil should be kept free from oil and water.

If a poor grade of air compressor oil is used, a gummy sediment will form in the magnet valve and ram cylinder parts which will eventually cause sticking of these parts in addition to the injury to the air compressor.

In case an air operated ram acts too fast or slow in either direction, its speed of operation can be altered by inserting a drilled plug or drilled

- 119 -

(

BI116002 plug nipple in the intake or exbaust pipe as required. These are furnished with machines for normal operating conditions, but extreme operating conditions may nece s sitate changing the diameter of the drilled hole s.

( D.

Feeder Cable Where 2300 volts and above is used, a feeder cable that contains provision for a ground connection should be used. The power line end must be grounded (see paragraph on ground circuits) to a suitable permanent ground ... Tneend~at tlie~sE.ovel-musr5e securely grounGea.-fnrougna----·---bolted connection to the shovel frame. This will always provide a ground for the shovel and electrical equipment. Failure to do this endangers the life of workmen and equipment.

In making a tempo'rary repair job on a feeder cable after splicing the main and ground conductors, proceed as outlined below:

(

E.

1.

Clean and coat insulation and copper with a good grade of rubber cement.

2.

Allow cement to become tacky, then apply a good' grade of all rubber tape between the scarfs until the diameter over the splice is about the same as the former insulation. Be sure to apply the rubber tape very tightly to exclude all air pockets.

3.

Cover the rubber tape with two layers of 1/2 lap friction tape and then paint with a good quality of waterpr00f paint.

4.

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

Power Line Gr9unding Ci,rcuit The importance of having an adequate grounding system for the machine cannot be over -emphasized. Without a good grounding system, it is possible to have dangerously high voltages between the machine and the ground.

'The portable ca.ble and power lipes supplying the machine should have a ground wire of ample capacity running parallel to the main wire s over the entire distance from the transformer to the machine .. A suitable grounding system should be used at the transformer.

1£ a new power system is to be installed, or if changes are to be made in the present system, the Marion Power Shovel Company should be consulted so that they can assist th'e customer in working with the electrical manufacturer so that satisfactory grounding equipment will be obtained.

c - 120 -

BI116002

(

SECTION VII APPENDIX MARION 7800 WALKING DRAGLINE

Welding Information -

CI-

851

Removing Complete Seal As sembly -

R. L.

5464

Tuthill Industrial Pumps Falk Steel£lex Couplings

-

Service Manual #4801

Falk Installation and Lubrication Bulletin #4800

BI116002 TUTNILL MODIL

A.

CL

PUM' I •• TIIUOTIO.I

RIMO'IAL 0' SUI. To RIMovr TN' .IAL A.II.IL'. OCL1'. OLAMP TNI P~ IN II '1.1 .0 'NA' ONI JAW IRIPe AORO.I TNI TWO ,ul.n. 00 IIOT I.UUH TOO "'NTLY Oil TNI OAI,. .. WILL ,'D.,OllM'D. Rc.ou TNIT OA,. OCL57. "ITN 'N' IPIOIIIL IPAIIIIIII WI"IIION. OL~06.

R'Mo" 'NI 1'111111 IIIUIIlIUI, OCt,41 .ltO 'N' l"IINI OCLn. TM' TNIUI PIIOII 0' RI.' 'AOK' ... OCL~. MAT 'HIli I ' "'MO'IID.

( II.

I."ALL.'IOII 0' SeAL

PLAor TNI .'Rllle. OCL75. 011 TNI IPR'" "IT".ln, OC~, •• 0 ILIDI 'MIM 0,111 TMI 1M." 1L24 U.TlL 'NKY TOUOH TMI .U"NIIII OL71. IIIIU1' TNI PAOK'"1 OCLQk 'MI NOUI'N. PLUI. 8, 'URI 'NA' 'N' OUT. TN' PAON'"I III •• ' '80~ ,,'RT. (Ntw 'ACIIIII• • MOULD ., 'OAIIIO .N 01 L 'OR A' LU" AIIl MOUR 11'0111 INlTALLIIII.) PLAOE THI UUET OL82 0'1111 'Nit OUTlIIDE 0' 'NE NOUIIII. 'LU. OCL11.

- - - - - - - - - - - - - - - - · - 5 ... 10 I-T·H I-A I a, •• L'I'-OO L-,,-oll '"--'HI-' NA '-'-A 1I0-dOIl·I-ILoa L'--•. II·'O-..OI·I-T-IOII-TO-----------.'AII' TH' 'MII'AOI. T.OH"N TMI NOUII ... 111'0 PLAOI alTM 1~ 'P'CIAL IPAII.'" .II'IIION OL506.

,II'

'II

,.'0

'14'

D"'".INI PIIOP[II TAPPID NOLI Oil NDUI' .. PLUI OCL57 'all TH' .IIEAI' '.'T'.I. PLU' OTH'" 'WO NOL!' W'T" PIPI PLU.I. I.I'IIT THI PUMP '" MOTOft IILL AIIO 10LT IIITO POI.TIOII. TH'N '11,,11' II 1/8· x LONI II'PPLE IN'O THI a'LlCTIO HOLI AND ADD COUPL'.I A_D 8.1'1. 'ITT'" '0 'H' 'NO 0' THI II"'L'.

FILL W.TH 10" OUP a~I •• I.

'14'

C.

4·

'H'

'.0

MA '11"11' Il101 BI lUll' 'HAT 'HE NOUB.N. ~Lue.

OCL37

.8 KI"

'ILLIO W"N .O'T OUP 1.,,1'.

DRop-o"

.M OAPAO,TT MAY I' OAUIIO I' ILl •• ' IIIMA.I~r AOTION OF TME 'OR".II MAT.IIIAL IN TN' OIL& OAUIIN. Inc-PLAT 0' TH' MOTOR. TH'I 0.11 I. TAK'II ~P .~ ,II.TALLIII.·A TH'NNIR 8A8KIT, O~4. GA •• IT. ~3 '"ROUIH .009 'HIOK 0.11 II ,UR.IINea.

CAUTIONs

ALWA'. PUT THt PIPI OO.POUN.e OM riMA U IUDe •

'KI'I

'H'

MALI 'ITTI ••• • •• "IR IN '"'

D. 0II0lR PAil'. IT TNr .UMlrR I"IN ON 'HI DRAW ••• AND 81VI TMI 'U.P MODIL ..,MI.R (.UOH AI 1CLX-'79).

MARION

POWER SHOVEL COMPANY 1I ... Il.ON

(

OHIO

BI116002

STEELFLEX COUPLINGS

Instructions for Installation

(

and Maintenance

Type F

SIZES 200 thru 300

Subject to change without notice

4801 SERVICE MANUAL February

1957

Supersedes "·15·52

TYPE F 5TEELFLlEX COUPLING

---------------------~

1. Seal Ring 2. F Cover

3. Gasket 4. F Hub

5. Inner Gridmember, Colored Aluminum 6. Outer Gridmember, Colored Bronze

When ordering spare parts, state coupling size as stamped on coupling cover and hub.

INSTALLATION - The Type F Steelflex Coupling oper~ ates in either the horizontal or vertical position without modification. For best results, folow the detailed instructions on the inside pages of this manual. The following is a summary of the recommended installation procedure.

When this is done, pack lubricant into the spaces around the gridmember. Fill to the absolute limit, but keep flush with the outside diameter of the grid member. Position the gasket and covers centrally on the coupling and bolt the covers together.

Clean all parts thoroughly and then mount coupling covers with seals, hubs, and gasket onto shafts Set the coupling gap within the limits specified on Page 4 and then align units for minimum angular and parallel coupling misalignment. Permanently fasten unit foundation bolts and then recheck alignment.

The lar 'er size couplings in this series have four match marked reamed holes in the cover. Position the covers so that lhe match marked holes male. Tighten the bolts in these holes first and then proceed with the rest.

Pack the coupling with a lubricant recommended bel~w, or an equivalent. The hub grooves are uniformly spaced and do not require matching. Insert. the aluminum colored inner gridmember; then insert the bronze colored outer grid member. NOTE: Do not operate coupling with a partial set of gridmembers. INSTALL ALL SEGMENTS AND BOTH LAYERS OF THE GRIDMEMBER.

RECOMMENDED

DISASSEMBLY -

Whenever it is necessary to disconnect the coupling, draw back the cover halves and remove the grrdmember.

MAINTENANCE -- Adequate lubrication is essential for proper operation of the coupling. Pack with lubricant during assembly and then lubricate periodically at least once every six months. When lubricating, insert a thin screw driver under the seal ring for venting purposes.

LUBRICANTS

The following lubricants are considered suitable for the lubrication of Folk Steelflex Couplings for temperatures up to 150· F. For ambient temperatures above 150· F. consult the Folk Corporation.

Alemite -- No. 339 Continental Oil Co. -- Robalube No. 25 Dow Corning Corp. -- DC44 Silicon Grease E. F. Houghton -- Absorbed Oil No. 042 Esso Standard Oil Co. -- Esso Fibre Grease C Gulf -- Gulf Precisio.n Grease No.2 Imperio! Oit limited -- Imperial Marvolube Grease No. 33 Kendall Refining Co. -- Kendall No. 50 Fibre Grease Keystone -- No. 44 Grease McColl-Frontenac Oil Crl. LtcL _

Mnrfnk Nn

? Hpnvv Dlltv

Phillips Petroleum -- Kyak B Pure Oil Co. -- Poco Fibre Grease No.2 Sinclair Refining Co. -- Since lub Grease No.2 Shell Oil Ca. -- Alvania Grease No.2 Sacony Mobil -- Mobil Grease BRB No. I Standard Oil Co. of Calif. -- Calol Multi-Service Grease No.2 Standard Oil Co. (Indiana) -- Stanolith No. 57 Standard 0'1 Co. (Ohio) -- Sohio 78 Grease Sun Oit Ca. -- Sun 72 X MP Grease The Texas Co. -- Marfak Na. 2 Heavv Dutv

PAGE

BI116002

INSTALLATION OF TYPE F COUPLING COUPLING GAP Maintain the norma! coupling gap shown on Page 4 whenever possible; and to insure optimum performance, do not exceed the minimum and maximum gaps. Consult the Factory if limited axial end float is required.

(

Provide for shaft end play in the coupling gap when sleeve bearing units are used. After mounting the upling~hubsT-position~the~free-unit-··--~··­

CHECK GAP AND

MOUNT COVERS WITH SEALS, HUBS, AND GASKET

ANGULAR ALIGNMENT

Ploce cover with seal ring on shaft before mounting hub. Press or shrink hubs on their respective shafts so Iha! each hub focI' is flush with the end (If ils shaft.

Hang gasket on either hub ne)(t to cover so thai it will not be dpmaged.

For best results, set coupling for normal gop os. described to the righl. Align the shafts b}l p:adng a spacer block whose thiclmess equah the required gap between the hub faces, os shown, and at a position 90· away. Check with feelers.

so that the coupling gap will be within the minimum Clnd maximum limits when both shafts are in their extended or retracted positions. After the gop has been set and the shafts lined up, tighten the unit foundation bolts and then make to final check on the coupling alignment.

(.

CHECi< PARALLEL ALIGNMENT

PACK COUPLING WITH WBIUCANT

INSERT INNER GIUDMEMBER (Aluminum Coloredl

Aligo shafts so thaI a strtlight edgE! will rest squarely on bolh hubs, as shown above, and also ot a position 90" OWCly. Fosten foundation bolls and re-check alignment and 9<lp. Also chec!< to see Ihol gasket has been inserled.

Pack as much lubricant as possible into grOQVE!S, Clnd the side pockets. Muke certain that the side pockets formed by the recess in the hubs Ilre packed solid. The importance of this step is deS(fibed in deh:!iI on Page 3.

The inner gridmember layer consists of several section!> and is ALUMINUM coloree!. Insert the aluminium colored gridmember as instructed on Page 3. Use a plastic, rawhide, or hard rubber mallet to ovoid damaging grid member and hub.

INSERT OUTER GRIDMEMBER

PACK. ALL REMAINING VOIDS WITH LUBRICANT

ASSEMBLE COVERS LUBRICATE SEMI-ANNUALLY

Pack o. much lubricant CIS possible into the spaces (;found the grldmember, but keep lubricant flush with outside diameter of gridmember to permit positioning of gasket and (OVer. Cenler gasket on coupling and lightly lubricotesl'lal rings 10 facilitate assembly.

Draw covers IOClether and bolt. On the IClrger ~izes, mate match marked reamed

ISronze Coloredl The outer 9 ridmember layer (Of'l$ists of

several sections Clnd is BRONZE colored.

Imert the bronze colored I,luter gridmember as instructed on Page 3. Note the positioning of loops and free ends of the griclmemblH. Do no! damage gridmember or hub grooves.

PAGE 2

fhe !:Jap. the hub

holes and tighten bolts in them fint.

Check seal rings for proper seating. Lubricate at least once every six months. When lubricating, insert a thin screw driver under the seal ring for venting purposes.

(

BI116002

INSTALLATION AND REMOVAL OF GRIDMEMBER 'NSTAUAflON -

( "

Gridmember rungs are truly radial, therefore it is necessary to spread the gridmember slightly so that it will pass over the coupling tooth at its outside diameter. To accomplish this with a minimum amount of spreading, start the gridmember at either end and tap the rungs only part way into

REMOVAL - A round rod ._/ ,..,....-

or screw driver that will conveniently fit into the open loop ends of the griclmember is all that is required in the way of tools.

Begin at the open end of the gridmember section and insert the rod or screw driver into the loop ends. Use the teeth adjacent to each oop_as-a_fulcrum_and_pl'Y_ ;".~"'-'---th"-Clrooves.-After-all-of-the- -------~UJoIII~V,c'_"i. the gridmember out radirungs are partially in their ally in even, gradual respective grooves, tap the "" stages. Proceed alternately gridmember all the way into place. When installing a two-layer from side to side lifting the gridmember about half way out unW gridmember, center the sections of the outer layer over the the end of the gridmember is reached. By following the same free ends of the inner layer, see A above, and extend all free procedure once again, the gridmember will clear the teeth. ends In the same direction, see A and B above.

LUBRICATION OF COUPLING DURING ASSEMBLY

PROPER! Y flUED

.MPROPERI. Y flUED

Coupling has been well fliled with lubricant. Air pockets have been reduced to a minimum by careful packing.

Note the large number of air pockets and the complete absence of lubricant on the interior surfaces o~ the coupling.

Centrifugal force causes the lubricant in the reservoir to flow outward, thus completely lubricating the coupling.

Centrifugal forclit throws the lubricant outward. Surfaces left without lubricant cue thus subject to needless wear.

VOIDS WERE NOT FILleD, TEETH AND OR/DMEMIIEA5

VOIDS WERE WEU FILLED. RfTH .ND GIUOMfMBfllS THOROUGHLY LUIRIC.4TEO.

POOIUY LUBRICATfD,

LUBRICATION FITTINGS AND GUN NOZZLES FOR STEELFLEX COUPLINGS

42030 81459 A·llB4

5700

The 200 thru 260F coupling hubs are fltted with Alemite A-1184 or Lincoln 5700 button head type lubrication flttings. The Alemite gUrf n;)zzle, 42030 and the Lincoln gun nonie, 81459 can be used on either lubrication fltting.

The 270 thru 300F coupling hub. have openings in the hub flange for lubrication. Remove the covering plate, shown at left, and add lubricant with a paddle or open nOl!zle type gun.

LUBRICATE COUPLINGS AT LEAST ONCE EVERY SIX MONTHS Vent coupling cover when lubricating.

4801

STEELFLEltOUPLlN65

PAGE

SERVICE MANUAL

Type F

4

February, 1957

and Maintenance

CLEARANCE FOR REMOVAL OF GRIDMEMBE

, UBRICATION FITTING SIZES 200 a 210F"", "'"~ I -

"

-=--

I+-

Rn1

r-:;===t.H·'flJjd ~

'''''ER

--

!---c-== ~ ~ ~

)

F

_

~

...rr-~. iij~

'1

IJIi

-= ,_

a

~ FVl~

OUTER GRIDMEMBERS

'c!=-:j:.I==::;:-T

/

.~~~

LUBRICATION FITTING I-SIZES 220-260F

- r- GAP

-

11

'--

-+1+1

r--rk GASKET

Max. M n.

Bore Bore

at

A

24Ya 17%

SIZES 270 thru 300 F

210F

1500

675

. 9Y4

4Y1 27Y4 18Y4

9

14

220F

1300

875

10

4Y1 29Y4 18Y4

9

14%

4

230F

1200 1100

II

5

240F

1100 1500

12

6

250F

900 2200

250

13Y1

6Y1 42

800 3400

260 261 262

14% 12Y4 9%

12Y4 9% 46Ya

700 4500

270 271 272

16

270F

280F

600 6000

280 281 282

17Y1

32% 20Y4

10

15h 18

35Y1 25Y1 12Y1 18Y1 21

7

290 291 292

19 16

300F

400 9000

300 301 302

20Y1 17

10

980 200F

21% lY4

5

1%

80/16

WY16

Y16

Y4

Y1

13

1,170 210F

230/16

lY4

5Y16

11%2

80/16

200/16

Y16

Y4

Y1

14

1,380 220F

270/16

m

50/16

1716

813;\6 24

Y16

Y4

Y1

17

1,990 23DF

P;\6

120/16

26%

Ys Ys

Y1

%

27

3,210 240F

32Y1

Y1

%

34

4,300 250F'

30

1%

7Y16 70/16

1.0/16

12Y4

26Y1 13

21% 19Y4 16Y4

2

m

1Ya

12%

36Ya

Va

Y1

%

43

5,540 26DF

2%

7o/s

lY4

12%

43%

Ys

Y1

%

54

7,100 27DF

52

2%

7%

lY1

12%

47Y4

Va

Y1

%

70

8,300 28DF

58

3Va 8%

2%

13%

52Ya

Ys

Y1

%

86

10,850 290F

64

3Va 9716

3Y16

14716

59

Ys'

Y1

%

93

14,650 30DF

2m

40Ya

23Y1 20Y1 34Y4 47Ya 17Y1

17

16

27Y1 12Y1 65% 29Y1 14Y1 23Y1 40 12Y1 8Y1 18Y1

17 13

Y1

2

8

500 7500

Y4

19Y1 25Y4 35%

14Y1 24Y1 1412 11Y1 58% 27Y1 13Y1 21 Y4 37

mr

Y16

K

J

26Y1 13

13Y1 13Y1 11 54% 26Y1 13 11 7Y1

llY1

170/16

E

17Y4

Lubri· Approx. cant wtWith Cau' pIIng Nor· Max. Req'd No Bore Size mal Ib Ib

8Y4

IY4

8%

GAP

4'%2 1%2

19Y1

500

I-l:+==+=======-~

Min.

13Y4

8%

1800

A

N

H

D

F

M*

F

C

N

--K

'-

DIMENSIONS IN INCHES Hub No,

200F

260F

(... r-GASKET -

COVER CONSTRUCTION SIZES 200-220F

SIZES 200 .thru 260 F Cau- Max. Basic piing Speed Rat· Size rpm ing

!

~':i"~

H'

~

E

1

ILJ_--------IHUB-------~I

1--;:::"

1 0

-c--!--c---

E--------------- KEYWAY

NOv

.l---------+---+-f-+,4

GREASE OPENING SIZE;S 270 -300F

HALF COVER----------~_+--~~~.----~--~--,----_.

-

tl~U~gV~ ,,~ ffk' .. '\.~" I

SIZES 200 thru 300

Suble,ct to change without nolice

Supersedes ".15·52

A

Instructions Tor InSTallaTion BI116002

13 9

29 7l%

36Y1 18

24Y1 45 19Y1

All sizes furnished for press lit, without <et screw, unless otherwise specified.

Dimensions for reference only.

t Dimension B is based an normal gap.

*Clearance M is required for installatian and removal of gridmember.

GRIDMEMBER IDENTIFICATION DATA Cau·

I No.

o. S. Dla. o S. Dia. Inner Layer Outer Layer No. Layers Seg· Gridmember .Gridmember Painted Painted ments Bronze Aluminum

pIIng Sile

Gridmember DimenSions

200F 210F 220F

7I,x Yz x6% 0/16x%x6Jt4 3ti.x%x6%

88 96 104

2 2 2

4 4 4

18.063 19.850 21 500

230F 240F 250F

0/1.x%x6%

120 80 96

2 2 2

6 8 8

24.781 27.437 33 000

~.x%xl0¥., ~.x%xl0~.

No. Rungs

Cau· pIIng Sin

Gridmember Dimensions

19 063 21.100 22.750

260F 27DF 280F

¥I,x I o/1.x 10716 o/1.X 1000.X 1071. 'li6xlxl0Y1

112 .

112

26 031 28 687 311.250

290F 300F

0/16xl x1OY1 0/16xlxlOY1

126 140

No. Rungs

96

No. Layers

O. S. Dia. O. S. Dia. No. Inner Layer Outer Layer Gridmember Seg- Gridmember Painted Painted menls BronZe Aluminum

J ; 2 2

8 8 8

37.750 44.250 48000

39.375 45.875 50.000

2 2

9 10

53.750 59.750

55.750 61.750

(

BI116002

SIEELFLEI COUPLlIIG

4800

and Maintenance

Type F

SERVICE MANUAL Nov. 1, 1956,

Sizes 3 thru 190

Sublect to .change without notice

Supersedes 1·1.56

Instructions for Installation

(

TYPE

F 5'1'IELFLEX

fAG.

COUPLING

INSTALLATION Folk Steelflex Couplings operate in either the horizontal or vertical position without modifi_ _ _ _ _ _ _ catio~etailed installation instruction and re~ommended lubricants are given on Pages 2 and 3 of this manual.

Adequate lubrication is essential for proper operation of the coupling. Pack with lubricant during assembly and then lubricate periodically at least once every six months.

For best results, clean all parts thoroughly and align coup· ling for minimum angular and parallel misalignment. Set the coupling gap as recommended; permanently fasten unit foundation bolts and then recheck alignment.

DISCONNECTING Whenever it is necessary to disconnect the coupling, draw back t'1e cover halves and remove the grid member. The hub grooves are uniformly spaced and do not require matching.

When ordering spare parts, state coupling size as stamped on coupling cover and hub.

IMPORTANT Plea.. fallow the Inltallatlnn procedure lIIu.trated In thl' manual for best result ••

(

TYPE F COUPLING PAIIY.

INIT UCTIONS FOR INSTALLING AID LUBRIC:AT••' T'YPE F FAll STEELFLEX COUP....S

Seal Rings are identical.

2

Cover Halves are identical.

3

Hubs are symmetrical but may have different bores or keyways.

4

Gridmember for smaller sizes is in one piece. In larger sizes, the gridmember is in several sections and layers. (See 'Pages 3 and 4.)

5

Gasket fits b~tween the covers end prevents grease leakage.

C.

A. in.." .... ring. in cover halv••.

TYPE F SIIILIII-IX COUPLING

Complete Steps A and Ii; then mount hubs.

Piac. one cover half on . _ shaft.

PARI.

When

Sizes 3 - 11 employ single layer grid member.

Sizes 12 - 190 employ double layer gridmember. ~

~!~~~ Do not apply load unless the complete

~

c.

grid member is installed.

Ordering

(tJ @)

DOUBLE LAYER OR .

SINGLE LAYER

Spare Parts, State Coupling Sin as Stamped

on the Coupling (over and Hub

BI116002 COU PLI NG GAP

-MOUNT-COVER-WITWSEAt-RING AND HUB ON SHAFT Place cover with seal ring on shaft before mounting hub. Press or shrink hubs on their respective shafts so that the hub face is flush with the end of its shaft.

Tighten set screws in bath hubs on coupling sizes 3 through 11.

Maintain the normal coupling gap shown on Page 4 whenever possiblei i and to insure optimum performance, '( do not exceed the minimum Clnd \ maximum gaps.

Provide for shaft end play in the coupling gap when sleeve bearing units are used. After mounting the coupling hubs and temporarily positioning the free unit, set the coupling gap so that the minimum and maximum gaps are not exceeded when .~---- CHECK-GAP-AND,------ootnsnafts are in their extended or ANGULAR ALIGNMENT retracted positions. After the gap has been set and the shafts lined up, For best results, set coupling for normal tighten the unit foundation bolts and gop as described to the right. Align the shafts by placing a spacer block whose then make a final check on the thickness equals the required gap becoupling alignment. tween the hub faces, as shown, and at a position 90° away. Check with feelers.

CHECK PARALLEL ALIGNMENT

INSERT GASKET

INSERT GRID MEMBER

Align shafts so that a straight edge will rest squarely on both hubs as shown above and also at a position 90° away.

Fasten foundation bolts and re-check alignment and gap.

After coupling is aligned, carefully Insert the gasket between hubs and hang it on either hub. 00 not damage gasket. Next force as much lubricant as possible into the gap and gridmember grooves.

Insert gridmember as instructed on top of Page 3. Coupling sizes 3 thru 11 have a single layer gridmember which is painted aluminum. Sizes 12 thru 190 have a two layer gridmember; the inner layer is painted aluminum and the outer, bronze.

PACK WITH LUBRICANT

POSITION COVERS

Pack the spaces between and around the gridmember with as much lubricant as possible. Scrape or wipe excess lubricant off flush with top of gridmember.Lightly oil hubs to facilitate the sliding of covers onto the hubs.

Mount covers so that lubrication fittings are 180 0 aport. Insert a thin screw driver under the seal ring for venting purposes and then tighten cover bolts. Check seals for proper seating and align cover to prevent cover wobble.

PAGE 2

LUBRICATE AT LEAST ONCE EVERY 6 MONTHS Adequate lubrication is essential for pro- ( per functioning of the coupling. Alemite grease fittings are provided for convenient lubrication. Refer to Page 3 for recommended lubricants. When lubricating coupling, vent as described in Step 7.

BI116002

INSTALLATION AND REMOVAL OF GRIDMEMaER INSTALLATION - Gridmember

REMOVAL - A round rod '" rungs are truly fodicl, or screw driver that will therefore' it is necessary conveniently fit inlo the open loop ends of the gridto spread the gridmember "" slightly so that it will pass member is all that is reover the coupling tooth at qui red in the way of tools. its outside diameter. To Begin at the open end of accomplish this with a minthe gridmember section and imum amount of spreading, insert the rod or screw drivstart the gridmember at er into the loop ends. Use the teeth adjacent to each either end and tap the rungs only pari way into' loop as a fulcrum and pry the grid member out radithe grooves. After all of the __ .....__ .~__ .~_ .. _~~~~fk-T:~~:--~~_..........,t!~__':'re_p.artially_in_theiL .. -~---..-~~'\.)O"'-.:.'7'-"JiIo:~- ... ~~.ally-i n-e.v.en,-gradualrespective grooves, tap the stages. Proceed alternately gridmember all the way into place. When installing a two-layer from side to side lifting the gridmember about half way out until the end of the gridmember is reached., By following the same gridmember, center the sections of the outer layer oller the free ends of the inner layer, see A above, and extend all free procedure once again, the gridmember will clear the teeth. ends In' the same direction, see A and B above.

(

LUBRICATION OF COUPLING DURING ASSEMBLY PROPERL Y F'UED

IMPROPERL Y FILLED

Air pockets have been reduced to a minimum by careful packing and Ihe gap between the hubs has been well filled.

Note the large. num~ ber of air pockets and the absence of lubricant in the gap and at the inside diameter of the cover.

The lubricant in the gap acts as a reservoir. Centrifugal force causes it to flow from the gap into the voids and completely lubricate the coupling.

Centrifugal force throws the grease outward leaving the rubbing surfaces unprotected, thus causing excessive wear.

LUBRICATION FITTINGS AND GUN NOZZLES FOR STEElFLEX COUPLINGS

1853 Z·737

Folk Steelflex Coupling,s, sizes 3-18, are fitted with Alemite flush type lubrication fitting, 1853. The Alemite gun nozzle, Z-737, can be used on this fitting. The design of the Alemite lubrication fitting prevents leakage due to centrifugal force.

42030 81459

The size 190 Steelilex Coupling is fitted with Alemite, A-II 84, or Lincoln,. 5700, button head type lubrication fittings, The 'Alemite gun nozzle, 42030 and the Lincoln gun nozzle, 81459, can be used on either lubrication fitting. These nozzles are the pull-on type which provide positive sealing during lubrication.

RECOMMENDED LUBRICANTS

(

For ambient temperature between minus 20 degrees f to 150 degrees F, use sodium or lithium soap type grease, NlGI No. 2 consistency worked penetration of 250-300.

For ambient temperatures between 150 degrees F to 250 degrees F, use lithium soap type grease NLGJ No.3 consistency worked penetration of 200-250. .

BI116002

DIMENSIONS-SIZES 3FTHRU 190F {

( CLEARANCE FOR REMOVAL OF GRIDMEMBER - - - - - ,

G.IDMEMaER DATA

Grldmember Dimensions Inches

No. Runes

.048 x ~ x 11'\ ~x ~x 2 ~x!li x 2 ~x!li x 2

20 24 28 32

Coupling Size

• • •• 4 5

HUB

GRIDMEMBER LUBRICATION FITTING GASKET

x II. x 31'\

~

11

MI x Ii x 3\1 ~ x ~ x 3\1 ~ x~d\1 ~x%x41i

16 18 17 11 liD

~ x % x 41i OM x \" x 41i OM x~. x 4\1 ~ x Va x 41i OMxlix6%

Outsld.

011. Inchl.

Inner LaYlr Grldmemblr Pllnted Aluminum

2.375 2.687 3.125 3.625 2 2 2 2

40 40 40

~x\1x2%

10

No. Layers

36

x2

'til x ~ x 2%

12 11 14

SET SCREW

NEOPRENE _SEAL

~x~

7

Outside Outside Oil. Inches Oil. Inches Sinsle Llyer Grl member No. SellPllnted ments Aluminum

4.250 5.000 5.500 6.125

40 44 52 48

6.750

48 56

2

64

2 2 2

2 2 3 4

2

72 72

7.500 8.750 9.500

6.875 B.125 8.750

9.750 11.250 12.750 14.250 15.750

9.000 10.500 12.000 13.500 14.750

ONE IN EACH HALF' COVER-ISO" APART

Max. Coupling Speed Size rpm

3F 4F SF 6f 7F SF 9f lOf llF 12F 13f 14F lSF l6F l7F 18F 190f

t t

6000 6000 6000 6000

Basic Rating

0.4 0.9 1.5 2

Max. Bore

DIMENSIONS - INCHES

Min·t Bore

A

B

C

D

F

H

J

M*

1 1\-'4 1'l1' 1%

Y1 % % %

3% 4Ya 4Y1 5

3% 4% 4% 4%

1% 2Ys 2Ya 2Ya

10/1.

1'0/1.

2Ya 2'%2

2% 2% 3% 3%

% % % %

% l.Ys Wa IYs

1% 2\-'4 2\-'4 2\-'4

Vi. Vi. Vi. Vi.

'A.

0/1.

0/16

4 6 8 10

Ys Ya

0/1. \-'4 \-'4 %

14 28 33 49

Ya \-'4 \-'4 %

6000 5000 4500 3750

4 8 12 16

IVa 2% 2% 2%

% Va 1\-'4 IY1

5% 7Ya 7% 8\-'4

4% Wa 6% 7' Vi.-

2Ya 3 3\-'4 3%

2'0/1.

3% 3'0/1.

4Y1

4Y1 5\-'4 5% 6%

% % % %

Wa lY1 lY1 1%

2\-'4 3 3 3%

Vi. Vi. Vi. Vi.

Ys Ya Ys Ya Ys. Ys Ya 0/1.

3400 3000 2700 2500

23 35 48 70

3\-'4

IYt 2 2 2Y1

8Va

9% 11 11%

7' Vi. 7'0/1.

7'0/1.

10

3%

3Va

3% 4%

4'0/1.

5% 6Ys 6%

7Ys

4 4%

9Ys

9Va

% % % %

1% 2 2 2Y1

3% 3% 3% 4%

Vi. Vi. Vi. Vi.

0/1.

7\.

7\. \-'4

% % % Y1

60 75 97 145

Y1 % % IY1

2400 2300 2200 2100 2000

100 140 180 230 330

2Y1 2Y1 3 3 4

13% 15\-'4 16% 18% 21Y1

10\-'4 10\-'4 1OY1 11\-'4 15Y4

5 5 5Ys 5Y1 7Y1

7\-'4 8\-'4 90/1.

10' Vi. 12

10Ys 11% 13Ya 14% 16Y4

lYs IYa lYs 1\-'4 IY4

2Y1 2Y1 2Y1 2Y1 3%

4% 4% 4% 4% 7Ys

~~.

\-'4 \-'4 \-'4 Y4 Y4

Yt Y1 Y1 Y1 Y1

175 215 285 365 650

lY1 2 2% 3Y4 7

3~~

4% 5Y1 6 7 8

Slu. 3F thru 8F have rough drilled hole. for minimum bore ••

*

GAP Approx. LubriInches wI With cant Re- Coupling No Bore quired Size NorMin. mal Max. Ib Ib

Dimension B i. bosed on NORMAL GAP. CI~aranc ..

M iI reqvired for installatian and remaval of gridmember.

Dimensions are for reference only.

7Ya

Vi. \Ii.

Vi. Vi.

o/.n

3F 4F SF 6F 7F Sf 9F 10F 1lF l2F 13F 14f l5F l6F 17F l8F 190F

Size, 3F\thru llF are furnl.hed for PUSH or LIGHT TAP FIT with .et screws unless otherwise specified.

Sizes 12F thru 190F are furnished for PRESS FIT without sel Icrews unle .. otherwise specified.

Sizes JF thru 18F are furnished with lubrication fillings in cover.

Size 190F is furnished with lubrication fillings in hubs.

PAGE 4

Vi. Vi.

!